Horner APG XL6 User Manual
User Manual for
XL6/XL6M/XL6e
(HE-XL/ HEXT350/ HEXT351) OCS
HE-XL100 / HE-XL1M0 / HEXT350C100 / HEXT280C100
HE-XL102 / HE-XL1M2 / HEXT350C112 / HEXT280C112
HE-XL103 / HE-XL1M3 / HEXT350C113 / HEXT280C113
HE-XL104 / HE-XL1M4 / HEXT350C114 / HEXT280C114
HE-XL105 / HE-XL1M5 / HEXT350C115 / HEXT280C115
HE-XL1E0 / HEXT351C100
HE-XL1E2 / HEXT351C112
HE-XL1E3 / HEXT351C113
HE-XL1E4 / HEXT351C114
HE-XL1E5 / HEXT351C115
MAN0883-05-EN
MAN0883-05-EN Preface
PREFACE
This manual explains how to use the XL6/XL6e (HE-XL/HEXT350/HEXT351) OCS Modules.
Copyright (C) 2008 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights
reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language or computer language, in any form by any means, electronic,
mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written
permission of Horner APG, Inc.
All software described in this document or media is also copyrighted material subject to the terms and
conditions of the Horner Software License Agreement.
Information in this document is subject to change without notice and does not represent a commitment on
the part of Horner APG.
Cscape, SmartStack, SmartStix and CsCAN are trademarks of Horner APG.
Ethernet is a trademark of Xerox Corporation.
Micro SD and CompactFlash are registered trademarks of SanDisk Corporation.
For user manual updates, 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
March 4, 2010 Page 3 of 135 #1037
MAN0883-05-EN Limited Warranty and Liability
LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the XL6/XL6e (HE-XL/HEXT350/HEXT351)
module manufactured by HE-APG is free from defects in material and workmanship under normal use and
OCS
service. The obligation of HE-APG under this warranty shal l be limited to the re pair 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. T HIS
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 XL6/XL6e OCS
WARRANTY SHALL NOT APPLY TO THIS XL6/XL6e OCS
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 XL6/XL6e (HE-XL/HEXT350/HEXT351) OCS
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, shal l HEAPG or its suppliers be liable of any special, consequential, incidental or penal damages inclu ding, but not limited to,
loss of profit or revenues, loss of use of the products or any associated equipment, damage to associated equipm ent,
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.
module OR ANY PART THEREOF WHICH HAS BEEN
module IS ORIGINALLY INSTALLED. THIS WARRANTY
ABOUT PROGRAMMING EXAMPLES
Any example programs and program segments in t his 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 diagr ams.
It is the sole responsibility of the system designer utilizin g the XL6/XL6e OCS
end system, to appropriately integrate the XL6/XL6e OCS
equipment as is usual and customary in industrial applications as defined in any codes or standards which apply.
module and to make safety provisions for the end
module to appropriately design the
Note: The programming examples shown in this manual are for illustrative purposes only.
Proper machine operation is the sole responsibility of the system integrator.
module. THIS
March 4, 2010 Page 4 of 135 #1037
MAN0883-05-EN Table of Contents
TABLE OF CONTENTS
PREFACE.....................................................................................................................................................
LIMITED WARRANTY AND LIMITATION OF LIABILITY...........................................................................4
VISUAL MAP OF MAJOR TASKS AND THE KEY CHAPTERS TO ASSIST YOU...................................9
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 XL6/XL6e OCS..............................................................................................13
2.1.1 Where to Find Information about the XL6/XL6e OCS...........................................................14
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 XL6/XL6e OCS ..............................................................................................15
2.3 Features of XL6/XL6M/XL6e OCS ...............................................................................................15
2.4 Required and Suggested Accessories .........................................................................................16
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
3.3.1 XL6/XL6e OCS Mounting Clip.....................................................................................18
3.3.2 XL6/XL6e OCS Mounting Orientation...................................................................................18
3.4 Panel Cut-Out...............................................................................................................................19
3.5 XL6/XL6M/XL6e 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............................................................................................................................................25
5.4 RS-485 Termination......................................................................................................................27
5.5 RS-485 Biasing.............................................................................................................................27
5.6 Cscape Programming via Serial Port ...........................................................................................27
5.7 Ladder-Controlled Serial Communication ....................................................................................27
5.8 Downloadable Serial Communication Protocols ..........................................................................27
March 4, 2010 Page 5 of 135 #1037
Table of Contents MAN0883-05-EN
CHAPTER 6: CAN COMMUNICATIONS................................................................................................. 29
6.1 Overview.......................................................................................................................................29
6.2 Port Description............................................................................................................................29
6.3 CAN (NET1) Port Wiring...............................................................................................................30
6.4 Cscape Programming via CAN.....................................................................................................30
6.5 Ladder-Controlled CAN Communication......................................................................................30
6.6 Using CAN for I/O Expansion (Network I/O) ................................................................................30
CHAPTER 7: ETHERNET COMMUNICATION (XL6E ONLY)................................................................. 31
7.1 Ethernet Module Protocols and Features.....................................................................................31
7.2 Ethernet System Requirements....................................................................................................31
7.3 Ethernet Module Specifications....................................................................................................31
7.4 Ethernet Module Configuration.....................................................................................................31
CHAPTER 8: COMMUNICATION OPTIONS............................................................................................37
8.1 Overview.......................................................................................................................................37
8.2 Ethernet COM Module (XEC) Option ...........................................................................................37
8.3 Modem COM Module (XMC) Option ............................................................................................38
CHAPTER 9: REMOVABLE MEDIA.........................................................................................................39
9.1 Overview.......................................................................................................................................39
9.2 Micro SD Cards ............................................................................................................................39
9.3 Micro SD File System...................................................................................................................40
9.4 Using the Removable Media Manager.........................................................................................40
9.5 Using Removable Media to Log Data...........................................................................................40
9.6 Using Removable Media to Load and Save Applications ............................................................41
9.7 Using Removable Media to View and Capture Screens..............................................................41
9.8 Removable Media (RM) Function Blocks in Cscape....................................................................41
9.9 Filenames used with the Removable Media (RM) Function Blocks.............................................42
9.10 System Registers used with RM...............................................................................................42
CHAPTER 10: GENERAL I/O...................................................................................................................43
10.1 Overview...................................................................................................................................43
10.2 Removing the XL6/XL6e OCS I/O Cover..................................................................................43
10.3 Model and I/O Overview ...........................................................................................................45
10.4 Solid-State Digital Outputs........................................................................................................46
10.5 Relay Outputs ...........................................................................................................................46
10.6 Digital Inputs .............................................................................................................................48
10.7 Analog Inputs............................................................................................................................48
10.8 Universal Analog Inputs............................................................................................................49
10.9 Analog Outputs .........................................................................................................................49
CHAPTER11: HIGH SPEED I/O (HSC / PWM).........................................................................................51
11.1 Overview...................................................................................................................................51
11.2 High Speed Counter (HSC) Functions......................................................................................51
11.2.1 Frequency..............................................................................................................................51
11.2.2 Totalize..................................................................................................................................51
11.2.3 Pulse......................................................................................................................................52
11.2.4 Quadrature ..................................................................................................................... .......53
11.3 HSC Functions Register Map ...................................................................................................56
11.4 Pulse Width Modulation (PWM) Functions...............................................................................56
11.4.1 Normal...................................................................................................................................56
11.4.2 PWM......................................................................................................................................56
11.4.3 HSC (High Speed Counter)...................................................................................................58
11.4.4 Stepper Function...................................................................................................................58
11.5 PWM functions register map.....................................................................................................59
11.6 PWM Examples.........................................................................................................................59
11.7 STP Examples ..........................................................................................................................60
March 4, 2010 Page 6 of 135 #1037
MAN0883-05-EN Table of Contents
CHAPTER 12: SYSTEM SETTINGS AND ADJUSTMENTS....................................................................61
12.1 System Menu - Overview..........................................................................................................61
12.2 System Menu – Navigation and Editing....................................................................................62
12.3 System Menu – Details.............................................................................................................63
12.4 Touch screen calibration...........................................................................................................74
CHAPTER 13: USER INTERFACE............................................................................................................75
13.1 Overview...................................................................................................................................75
13.2 Displaying and entering Data....................................................................................................75
13.3 Alpha-numeric keypad..............................................................................................................76
13.4 Screen Navigation.....................................................................................................................78
13.5 Ladder Based Screen Navigation.............................................................................................79
13.6 Beeper Acknowledgement........................................................................................................79
13.7 Touch (Slip) Sensitivity .............................................................................................................79
13.8 Alarms.......................................................................................................................................80
13.9 Removable Media.....................................................................................................................81
13.10 Screen Saver ............................................................................................................................83
13.11 Screen Brightness.....................................................................................................................83
CHAPTER 14: REGISTERS.......................................................................................................................85
14.1 Register Definitions...................................................................................................................85
14.2 Useful %S and %SR registers..................................................................................................86
14.3 Register Map for XL6/XL6e OCS I/O........................................................................................88
14.4 Resource Limits ........................................................................................................................89
CHAPTER 15: CSCAPE CONFIGURATION............................................................................................ 91
15.1 Overview...................................................................................................................................91
15.2 Cscape Status Bar....................................................................................................................91
15.3 Establishing Communications...................................................................................................92
15.3.1 Communicating via MJ1 Serial Port........................................................................................105
15.3.2 Communicating via On Board Ethernet Port (For XL6e Only)................................................106
15.4 Models supported....................................................................................................................106
15.5 Configuration...........................................................................................................................107
15.6 Digital Input / HSC Configuration............................................................................................107
15.7 Digital Output / PWM Configuration........................................................................................109
15.8 Analog Input Configuration .....................................................................................................110
15.9 Analog Output Configuration...................................................................................................111
CHAPTER 1 6: FAIL – SAFE SYSTEM................................................................................................... 113
16.1 Overview...................................................................................................................................113
16.2 Settings...................................................................................................................................114
16.3 Backup / Restore Data............................................................................................................114
16.4 AutoLoad.................................................................................................................................118
16.5 AutoRun..................................................................................................................................120
CHAPTER 17: CLONE UNIT...................................................................................................................121
17.1 Overview.................................................................................................................................121
17.2 Clone.......................................................................................................................................121
17.3 Load Clone..............................................................................................................................123
CHAPTER 18: MAINTENANCE..............................................................................................................125
18.1 Firmware Updates...................................................................................................................125
18.2 Backup Battery........................................................................................................................125
18.2.1 Indications the battery needs replacing...............................................................................125
18.2.2 Battery Replacement...........................................................................................................126
March 4, 2010 Page 7 of 135 #1037
Table of Contents MAN0883-05-EN
CHAPTER 19: TROUBLESHOOTING / TECHNICAL SUPPORT..........................................................127
19.1 Connecting to the XL6/XL6e OCS..........................................................................................127
19.1.1 Connecting Troubleshooting Checklist (serial port – MJ1 Programming)...........................128
19.1.2 Connecting Troubleshooting Checklist (USB Port - Mini B Programming).........................128
19.1.3 Connecting Troubleshooting Checklist (ETN port programming) [For XL6e only]..............128
19.2 Local Controller and Local I/O ................................................................................................128
19.2.1 Local I/O Troubleshooting Checklist....................................................................................129
19.3 CsCAN Network......................................................................................................................129
19.3.1 CsCAN Network Troubleshooting Checklist........................................................................129
19.4 Removable Media...................................................................................................................130
19.4.1 Basic Troubleshooting.........................................................................................................130
19.5 Technical Support Contacts....................................................................................................130
Index .....................................................................................................................................................131
Table of Figures...................................................................................................................................134
March 4, 2010 Page 8 of 135 #1037
MAN0883-05-EN Visual Map
Visual Map of major tasks and the key chapters to assist you
FIRST STEP of ANY TASK: DATASHEET
Each XL6/XL6e OCS unit is sent with a datasheet in the box. The datasheet is the first
you need to refer to for model-specific information related to XL6/XL6e 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
Introduction
page 13
Safety / Compliance
page 11
Introduction
page 13
Mechanical Installation
page 17
Electrical Installation
page 23
Clone Unit
Safety / Compliance
page 9
Introduction
page 11
Serial Communications
Page 25
CAN Communications
page 29
Ethernet (XL6e only)
Page 31
Communication Options
page 37
Removable Media
page 39
High Speed I/O
page 51
System Settings
page 61
User Interface
page 75
Registers
page 85
Cscape Configuration
page 91
Fail- Safe System
Page 113
Page 121
Safety / Compliance
Troubleshooting
document
page 11
Introduction
page 13
Maintenance
page 125
page 127
March 4, 2010 Page 9 of 135 #1037
Visual Map MAN0883-05-EN
NOTES
March 4, 2010 Page 10 of 135 #1037
MAN0883-05-EN CH.1
CHAPTER 1: SAFETY / COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
WARNING – EXPLOSION HAZARD – Do not disconnect equipment un less 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 pro vide protection against risk of fire and shock
hazards.
WARNING: In the event of repeated failure, do not
defective condition that will not
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.
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
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
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 code s.
e. Wear proper personal protective equipment including safety glasses and insulated gloves when
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
h. Before each use, inspect all cables for breaks or cracks in the insulation. Replace immediately if
Warning: Consult user documentation.
replace the fuse again as a repeated failure indicates a
clear by replacing the fuse.
larger.
make connections to live power lines.
not
making connections to power circuits.
are de-energized before making connections.
defective.
Warning: Electrical Shock Hazard.
March 4, 2010 Page 11 of 135 #1037
CH.1 MAN0883-05-EN
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/Pages/TechSupport/ProductCert.html
March 4, 2010 Page 12 of 135 #1037
MAN0883-05-EN CH.2
CHAPTER 2: INTRODUCTION
2.1 Visual Overview of XL6/XL6e OCS
Figure 2.1 – Visual Overview of XL6/XL6e type OCS - Side and Rear Views
March 4, 2010 Page 13 of 135 #1037
CH.2 MAN0883-05-EN
Figure 2.2 – Front View of XL6/XL6M/XL6e type OCS
2.1.1 Where to Find Information about the XL6/XL6e OCS
a. Datasheets - The datasheets are the first documents you need to refer to
for key information related to specific XL6/XL6e OCS models. (A datasheet is
provided in the box with your unit.)
The datasheets for all XL6/XL6e 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
XL6/XL6e OCS models and can be downloaded from our web. Visit our website
at
http://www.heapg.com to obtain user documentation and updates.
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 XL6/XL6e 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
March 4, 2010 Page 14 of 135 #1037
MAN0883-05-EN CH.2
Table of Figures
Location of important drawing, illustrations (etc) may be found in the Table of Figures .
2.2 Connectivity to the XL6/XL6e OCS
The XL6/XL6e 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 XL6/XL6e OCS.
Other OCS Devices
Smart Stix I/O
RCS116 I/O Base
OPC Server
Sensors
Indicators
Alarms
Encoders
Pumps
Relays
Solenoids
CAN
XL6 / XL6e
OCS
I/O
Serial
Ethernet
USB
Flash Drive
Cscape
Other OCS Devices
Drives
PLCs
Bar Code Readers
Printers
SCADA
OPC Servers
Serial I/O
Cscape
OPC Server
Modbus TCP Devices
(XL6e Models
Only)
Figure 2.3 – Visual Overview of Types of Devices that can be connected to XL6/XL6e OCS
2.3 Features of XL6/XL6M/XL6e OCS
The XL6/XL6e 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 XL6/XL6e OCS include:
• Bright, 32768 color graphical touch sensing LCD display in all models of XL6/XL6e. XL6M has 16
shade grey scale display.
• Display of complex graphical objects including trends, gauges, meters and animations.
• Advanced control capabilities including floating point, multiple auto-tuning PID loops and string
handling capabilities.
• Removable media for up to two gigabytes of storage of programs, data logging or screen
captures.
• CsCAN networking port for communication with remote I/O, other controllers or PCs.
• USB networking 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 XL6/XL6e OCS model used).
• Cscape programming software that allows all aspects of the XL6/XL6e OCS to be programmed
and configured from one integrated application.
• Optional communication add-on modules that allow additional capabilities such as Ethernet or
modems.
• On board Ethernet port (10/100Mbps) for Cscape programming and application defined
communication, with Auto MDI/MDI-X (XL6e only).
March 4, 2010 Page 15 of 135 #1037
CH.2 MAN0883-05-EN
2.4 Required and Suggested Accessories
The following list contains a sampling of required and suggested XL6/XL6e OCS accessories. Visit our
website to view updates on new products and accessories.
Note: The XL6/XL6M/XL6e OCS is not shipped with a programming cable in the box. To obtain
a programming cable, order HE500CBL300.
Table 2.1 – XL6 OCS Accessories
Part Number Description
HE-XEC
HE-XMC
HE-MC1 Removable Media card - compatible with XL6 OCS. Card capacity is 256 MB or larger.
HE-MR1
HE-X24-AS
HE-X24-AL
HE500OSW232
HE500CBL300 OCS Programming Cable, 9-pin female (PC) to RJ-45 (OCS) - 6 feet.
HE500USB600
10/100 Ethernet option kit - field installable. Kit includes all parts necessary for internal installation within the
XL6 OCS case, including a deeper plastic back cover adapted for Ethernet operation.
14.4 k Telephone modem option kit - field installable. Kit includes all parts necessary for internal installation
within the XL6 OCS case, including a deeper plastic back cover adapted for modem operation.
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.
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.
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.
Cscape Software Package. Includes Cscape CD, 9-pin OCS Programming Cable, RJ-45 Programming Cable,
Documentation
USB programming kit. Includes USB to RS-232 adapter, and 6-foot RS-232 cable with D-sub connections.
Requires HE500CBL300 to program the XL6 OCS.
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 Suppor
Controllers Manual Number
HE-XExxx (XLe and XLt) MAN0878
XL6/XL6e MAN0883
QX Series (e.g., HE-QXxxx) MAN0798
NX Series (e.g., HE-NXxxx) MAN0781
LX Series (e.g., LX-xxx; also covers RCS116) MAN0755
Color Touch OCS (e.g., OCSxxx) MAN0465
OCS (Operator Control Station) (e.g., OCS1xx / 2xx; Graphic OCS250)
Remote Control Station (e.g., RCS2x0)
MAN0227
MiniOCS (e.g., HE500OCSxxx, HE500RCSxxx) MAN0305
Other Useful References Manual Number
CAN Networks MAN0799
Cscape Programming and Reference MAN0313
Wiring Accessories and Spare Parts Manual MAN0347
t.
March 4, 2010 Page 16 of 135 #1037
MAN0883-05-EN CH.3
CHAPTER 3: MECHANICAL INSTALLATION
Note: Each XL6/XL6e 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 XL6/XL6e 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)
Once the panel design has been completed using the criteria and suggestions in the
following sections, use the following steps to panel mount the XL6/XL6e OCS.
1. Remove all connectors from the XL6/XL6e OCS unit.
2. Make sure the gasket is installed on the XL6/XL6e 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 XL6/XL6e 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.
001OCS001
Figure 3.1 – Panel Mounting of an XL6/XL6e Series OCS
001OCS002
March 4, 2010 Page 17 of 135 #1037
CH.3 MAN0883-05-EN
3.3 Mounting Orientation
3.3.1 XL6/XL6e OCS Mounting Clip
001OCS004
001XLQX007
Figure 3.2 – XL6/XL6e OCS with Mounting Clips
3.3.2 XL6/XL6e OCS Mounting Orientation
001OCS001
NOTE: There are NO orientation restrictions on the OCS. However, the above orientation provides for optimum
readability of the screen and ease of use of the keypad.
Figure 3.3 – Orientation of XL6/XL6e OCS
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MAN0883-05-EN CH.3
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).
5.156”
[131mm]
R .12 5” [3 mm] TYP.
RADIUS CORNERS
WHEN REQUIRING
DUST OR WATER
TIGHT SEAL PER
NEMA 4, 4X OR 12
6.875”
[175mm]
001OCS003-R1
Figure 3.4 – Panel Cutout Tolerances
3.5 XL6/XL6M/XL6e Dimensions
Figure 3.5 – XL6/XL6e OCS Dimensions
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CH.3 MAN0883-05-EN
3.6 Factors Affecting Panel Layout Design and Clearances
Warning: It is important to follow the requirements of the panel manufacturer and to follow
all applicable electrical codes and standards.
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
Minimum Distance between base of device and
wiring ducts
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
2 inches (50.80mm)
1.5 inches (38.10mm)
(101.60mm)
When door is closed:
Minimum distance between device and closed door
2 inches (50.80mm)
(Be sure to allow enough depth for the XL6 OCS.)
3.6.2 Grounding
Warning: Be sure to meet the ground requirements of the panel manufacturer and also meet
applicable electrical codes and standards.
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.
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MAN0883-05-EN CH.3
3.6.4 Orientation
When panel-mounted, there are no orientation restrictions on the XL6/XL6e 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 XL6/XL6e OCS and
noisy devices such as relays, motor starters, etc.
3.6.6 Shock and Vibration
The XL6 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 XL6/XL6e 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 prope r 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 XL6/XL6e 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 XL6/XL6e 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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CH.3 MAN0883-05-EN
NOTES
March 4, 2010 Page 22 of 135 #1037
MAN0883-05-EN CH.4
CHAPTER 4: ELECTRICAL INSTALLATION
Note: Each XL6/XL6M/XL6e 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 XL6/XL6e 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
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.
GROUND RESISTANCE METER
GROUND
DISCONNECTED
FROM SERVICE
GROUND ROD
METAL WATER PIPE OR
OTHER GOOD GROUN D
Figure 4.1 – Two-Point Ground Connection Test
exceed
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CH.4 MAN0883-05-EN
(
)
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
+
-
10-30 VDC
supply
+
-
Figure 4.2 – Power Connector (Primary Power Port)
+
-
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
PIN 1
PIN 2
PIN 3
Figure 4.3 – Primary Power Port as Viewed Looking at the XL6/XL6e OCS
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MAN0883-05-EN CH.5
CHAPTER 5: SERIAL COMMUNICATIONS
5.1 Overview
All XL6/XL6M/XL6e OCS models provide two serial ports, which are implemented with 8-pin modular
RJ45 connectors, and are labeled MJ1 and MJ2. The MJ1 serial port is normally used (although MJ2 can
also be used) for XL6/XL6M/XL6e 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 both a half-duplex RS-485 interface and an RS-232 interface with RTS/CTS
handshaking. Note: MJ1 shares its serial port with the optional COM module, so when an optional
Ethernet or Modem COM module is installed and active, the MJ1 connector is inactive.
The MJ2 serial port contains both a full-duplex RS-485 interface and an RS-232 interface with no
handshaking. Both the MJ1 and MJ2 RS-485 interfaces provide switchable termination and bias resistors
internally.
5.3 Wiring
Figure 5.1 along with
assigned.
Pin Signal Signal Description Direction
1
Signals are labeled for connection to a DTE device
Table 5.1 – MJ1 Serial Port Pin Assignments
1 RX/TX+ RS-485 Receive/Transmit Positive In/Out
2
RX/TX−
3 CTS
4 RTS1 RS-232 Request to Send In
5 +5* +5 VDC 60mA max Out
6 0V Ground
7 TD1 RS-232 Transmit Data In
8 RD1 RS-232 Receive Data Out
• * +5 on XLe Rev E and later
• * +5 on all revisions XLt and XL6 and QX351
RS-485 Receive/Transmit Negative
1
RS-232 Clear to Send Out
Table 5.1 and Table 5.2 show how the MJ1 and MJ2 serial port pins are
Note: MJ1 and MJ2 look the
same but have different pin
assignments and functions.
8
1
Figure 5.1 – MJ Serial Port Connector
8
In/Out
1
−
Pin MJ1 Pins
Signal Direction
TXD OUT
8
RXD IN
7
0 V Ground
6
+5 60mA OUT
5*
RTS OUT
4
CTS IN
3
RX- / TX- IN / OUT
2
RX+ / TX+ IN / OUT
1
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CH.5 MAN0883-05-EN
8
8
Table 5.2 – – MJ2 Serial Port Pin Assignments
Pin Signal Signal Description Direction
1 RX+ RS-485 Receive Positive In
2
RX−
3 TX+ RS-485 Transmit Positive Out
4
TX−
5 +5* +5 VDC 60mA max Out
6 0V Ground
7 TD1 RS-232 Transmit Data In
8 RD1 RS-232 Receive Data Out
RS-485 Receive Negative In
RS-485 Transmit Negative Out
−
1
Pin MJ2 Pins
8
7
6
5*
4
3
2
1
Signal Direction
TXD OUT
RXD IN
0 V Ground
+5 60mA OUT
TX- OUT
TX+ OUT
RX- IN
RX+ IN
MJ2 Full Duplex Mode
* +5Vdc 60mA Max
Pin MJ2 Pins
1
Signal Direction
TXD OUT
8
RXD IN
7
0 V Ground
6
+5 60mA OUT
5*
TX- OUT
4
TX+ OUT
3
TX-/RX- IN/OUT
2
TX+/RX+ IN/OUT
1
MJ2 Half Duplex Mode
* +5Vdc 60mA Max
Switch
On
Position
Figure 5.2 – MJ Serial Port Connectors and DIP Switches for RS-485 Port Termination
March 4, 2010 Page 26 of 135 #1037
MAN0883-05-EN CH. 5
r
The DIP Switches are used fo
termination of the RS-485 ports. The
XL6 is shipped un-terminated.
To terminate, select one of the DIP
Switches and configure it based upon
the option that is desired.
SW1 - ON enables MJ2 RS485 port
termination (121 Ohms).
OFF disables MJ2 RS485 port
termination.
SW2 & SW3 - ON places MJ2 RS485 port in
half-duplex mode.
OFF places MJ2 RS485 port in full-
duplex mode.
SW4 - ON enables MJ1 RS485 port
termination (121 Ohms).
OFF disables MJ1 RS485 port
termination.
5.4 RS-485 Termination
Proper RS-485 termination minimizes reflections and improves reliability.
Both serial ports allow an internal RS-485 termination resistor to be placed across pins 1 and 2 by DIP
Switch Setting.
the two devices physically located at the endpoints of the RS-485 network should be terminated.
Only
5.5 RS-485 Biasing
RS-485 biasing passively asserts a line-idle state when no device is actively transmitting, which is useful
for multi-drop RS-485 networking.
Both serial ports allow internal 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 RS-485
biasing. Also, an application graphics screen that writes to %SR164 can do the same thing. Setting
%SR164.1 enables MJ1 biasing and setting %SR164.2 enables MJ2 biasing.
If biasing is used, it should be enabled in only one of the devices attached to the RS-485 network.
5.6 Cscape Programming via Serial Port
The XL6/XL6e OCS MJ1 serial port supports CsCAN Programming Protocol, but MJ2 does not. If a PC
COM port is connected to the XL6/XL6e OCS MJ1 serial port, Cscape can access the XL6/XL6e OCS for
programming and monitoring.
5.7 Ladder-Controlled Serial Communication
Using Serial Communication function blocks, both MJ1 and MJ2 support Generic, Modbus Master and
Modbus Slave Protocols. In addition, external modems can be connected and accessed using Init, Dial
and Answer Modem function blocks.
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.
March 4, 2010 Page 27 of 135 #1037
CH.5 MAN0883-05-EN
Note: Refer download section of website for the list of latest supported protocols
http://www.heapg.com/Pages/TechSupport/Downloads.html)
(
March 4, 2010 Page 28 of 135 #1037
MAN0883-05-EN CH.6
CHAPTER 6: CAN COMMUNICATIONS
Note: For additional CAN information, refer to the CAN Networks manual (
6.1 Overview
All XL6/XL6M/XL6e OCS models provide a CAN networking port, which is implemented with a 5-pin
connector. The connector is labeled NET1.
MAN0799) on our website.
Figure 6.1 – NET 1 Connector
Like the MJ1 serial port, the NET1 port can be used for XL6/XL6e OCS programming by connecting it to
the CAN port of a PC running Cscape. The NET1 port also allows the XL6/XL6e OCS to exchange global
data with other OCS/RCS controllers and to access remote Network I/O devices (SmartStix Modules).
6.2 Port Description
The XL6/XL6e OCS NET1 port implements the ISO 11898-2 physical layer and the CAN 2.0A data link
layer standards. Also, since the NET1 port is powered by an internal isolated power supply, external
CAN power is not required.
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CH.6 MAN0883-05-EN
6.3 CAN (NET1) Port Wiring
CAN Connector
Use the CAN Connector
when using CsCAN network.
Torque rating 4.5 – 7 Lb-In
(0.50 – 0.78 N-m)
Note: The V+ connection is not
required on the XL6/XL6e OCS.
The XL6/XL6e OCS network port
is self-powered. Supporting
devices can require this
connection, and this pin can be
used to land the extra wire
required for those devices.
Figure 6.2 – NET1 Port Connector
Table 6.1 – NET1 Port Pin Assignments
Pin Signal Signal Description Direction
1 V- CAN Ground
−
2 CN_L CAN Data Low In/Out
3 SHLD Shield Ground
−
4 CN_H CAN Data High In/Out
5 NC No Connect
−
6.4 Cscape Programming via CAN
The NET1 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 XL6/XL6e OCS NET1 port, Cscape can access
the XL6/XL6e OCS for programming and monitoring.
In addition, the XL6/XL6e OCS supports single-point-programming of all XL6/XL6e OCS and other
OCS/RCS devices that are connected to a CAN network. If the PC COM port is connected to the
XL6/XL6e OCS MJ1 serial port, the XL6/XL6e OCS can act as a pass-through gateway allowing Cscape
to access all XL6/XL6e 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 XL6/XL6e 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 Modules) to the XL6/XL6e OCS NET1 port, allows the
XL6/XL6e OCS I/O to be economically expanded and distributed. A variety of SmartStix Modules is
available for this purpose.
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