User Manual for XL7 OCS
MAN0974-01-EN
HE-XW1E0 / HEXT391C100
HE-XW1E2 / HEXT391C112
HE-XW1E3 / HEXT391C113
HE-XW1E4 / HEXT391C114
HE-XW1E5 / HEXT391C115
XL7 User Manual
PREFACE
This manual explains how to use the XL7 OCS.
Copyright© 2013 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights
reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language or computer language, in any form by any means, electronic,
mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written
permission of Horner APG, Inc.
All software described in this document or media is also copyrighted material subject to the terms and
conditions of the Horner Software License Agreement.
Information in this document is subject to change without notice and does not represent a commitment
on the part of Horner APG.
Ethernet™ is a trademark of Xerox Corporation.
MicroSD™ 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: http://www.heapg.com
Email: techsppt@heapg.com
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Web: http://www.horner-apg.com
Email: tech.support@horner-apg.com
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XL7 User Manual
LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the XL7 (HE-XW/HEXT391) OCS module
manufactured by HE-APG is free from defects in material and workmanship under normal use and
service. The obligation of HE-APG under this warranty shall be limited to the repair or exchange of any
part or parts which may prove defective under normal use and service within two (2) years from the
date of manufacture or eighteen (18) months from the date of installation by the original purchaser
whichever occurs first, such defect to be disclosed to the satisfaction of HE-APG after examination by
HE-APG of the allegedly defective part or parts. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE-APG NEITHER ASSUMES,
NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY OTHER LIABILITY IN CONNECTION
WITH THE SALE OF THIS XL7 OCS module. THIS WARRANTY SHALL NOT APPLY TO THIS XL7 OCS module
OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE, OR
MISUSE. HE-APG MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT
SUPPLIED BY HE-APG. THE TERM "ORIGINAL PURCHASER", AS USED IN THIS WARRANTY, SHALL BE
DEEMED TO MEAN THAT PERSON FOR WHOM THE XL7 OCS module IS ORIGINALLY INSTALLED. THIS
WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES.
In no event, whether as a result of breach of contract, warranty, tort (including negligence) or
otherwise, shall HE-APG or its suppliers be liable of any special, consequential, incidental or penal
damages including, but not limited to, loss of profit or revenues, loss of use of the products or any
associated equipment, damage to associated equipment, cost of capital, cost of substitute products,
facilities, services or replacement power, down time costs, or claims of original purchaser's customers
for such damages.
To obtain warranty service, return the product to your distributor with a description of the problem,
proof of purchase, postpaid, insured and in a suitable package.
ABOUT PROGRAMMING EXAMPLES
Any example programs and program segments in this manual or provided on accompanying 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 XL7 OCS
module to appropriately design the end system, to appropriately integrate the XL7 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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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
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 XL7 OCS ........................................................................................................... 13
2.1.1 Where to Find Information about the XL7 OCS ....................................................................... 13
2.1.2 Four main types of information are covered in the manual. ................................................... 13
2.1.3 Manual Index ........................................................................................................................... 14
2.1.4 Table of Figures ....................................................................................................................... 14
2.2 Connectivity to the XL7 OCS .......................................................................................................... 14
2.3 Features of XL7 OCS ....................................................................................................................... 14
2.4 Required and Suggested Accessories ............................................................................................. 15
2.5 Useful Documents and References ................................................................................................ 15
CHAPTER 3: MECHANICAL INSTALLATION......................................................................................... 16
3.1 Overview ........................................................................................................................................ 16
3.2 Mounting Requirements ................................................................................................................ 16
3.2.1 Mounting Procedures (Installed in a Panel Door) ................................................................... 16
3.3 Mounting Orientation ....................................................................................................................
17
3.3.1 XL7 OCS Mounting Clip ............................................................................................................ 17
3.3.2 XL7 OCS Mounting Orientation ............................................................................................... 17
3.4 Panel Cut-Out ................................................................................................................................. 18
3.5 XL7 Dimensions .............................................................................................................................. 18
3.6 Factors Affecting Panel Layout Design and Clearances ................................................................. 19
3.6.1 Clearance / Adequate Space ................................................................................................... 19
3.6.2 Grounding ................................................................................................................................ 19
3.6.3 Temperature / Ventilation ....................................................................................................... 19
3.6.4 Orientation .............................................................................................................................. 19
3.6.5 Noise ........................................................................................................................................ 20
3.6.6 Shock and Vibration ................................................................................................................ 20
3.6.7 Panel Layout Design and Clearance Checklist ......................................................................... 20
CHAPTER 4: ELECTRICAL INSTALLATION .......................................................................................... 22
4.1 Grounding Definition ..................................................................................................................... 22
4.2 Ground Specifications .................................................................................................................... 22
4.3 How to Test for Good Ground ....................................................................................................... 22
4.4 Primary Power Port ........................................................................................................................ 23
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CHAPTER 5: SERIAL COMMUNICATIONS ........................................................................................... 24
5.1 Overview ........................................................................................................................................ 24
5.2 Port Descriptions ............................................................................................................................ 24
5.3 Wiring and Dip Switches ................................................................................................................ 24
5.4 RS485 Termination ......................................................................................................................... 25
5.5 RS485 Biasing ................................................................................................................................. 25
5.6 Cscape Programming via Serial Port .............................................................................................. 25
5.7 Ladder-Controlled Serial Communication...................................................................................... 25
5.8 Downloadable Serial Communication Protocols ........................................................................... 25
CHAPTER 6: CAN COMMUNICATIONS .............................................................................................. 26
6.1 Overview ........................................................................................................................................ 26
6.2 Port Description ............................................................................................................................. 26
6.3 CAN Port Wiring ............................................................................................................................. 26
6.4 Cscape Programming via CAN ........................................................................................................ 26
6.5 Ladder-Controlled CAN Communication ....................................................................................... 27
6.6 Using CAN for I/O Expansion (Network I/O) .................................................................................. 27
CHAPTER 7: ETHERNET COMMUNICATION ....................................................................................... 28
7.1 Ethernet Module Protocols and Features ..................................................................................... 28
7.2 Ethernet System Requirements .................................................................................................... 28
7.3 Ethernet Module Specifications .................................................................................................... 28
7.4 Ethernet Module Configuration .................................................................................................... 28
CHAPTER 8: COMMUNICATION OPTIONS ......................................................................................... 33
8.1 Overview ........................................................................................................................................ 33
8.2 Modem COM Module (XMC) Option
............................................................................................. 33
CHAPTER 9: REMOVABLE MEDIA ..................................................................................................... 34
9.1 Overview ........................................................................................................................................ 34
9.2 MicroSD Cards ................................................................................................................................ 34
9.3 MicroSD File System....................................................................................................................... 34
9.4 Using the Removable Media Manager .......................................................................................... 35
9.5 Using Removable Media to Log Data ............................................................................................. 35
9.6 Using Removable Media to Load and Save Applications ............................................................... 35
9.7 Using Removable Media to View and Capture Screens ................................................................. 36
9.8 Removable Media (RM) Function Blocks in Cscape ....................................................................... 36
9.9 Filenames used with the Removable Media (RM) Function Blocks ............................................... 36
9.10 System Registers used with RM ................................................................................................... 37
CHAPTER 10: GENERAL I/O .............................................................................................................. 38
10.1 Overview ...................................................................................................................................... 38
10.2 Removing the XL7 OCS I/O Cover ................................................................................................ 38
10.3 Model and I/O Overview .............................................................................................................. 40
10.4 Solid-State Digital Outputs ........................................................................................................... 40
10.5 Relay Outputs ............................................................................................................................... 41
10.6 Digital Inputs ................................................................................................................................ 42
10.7 Analog Inputs ............................................................................................................................... 42
10.7.1 Common cause of analog input tranzorb failure .................................................................. 43
10.8 Universal Analog Inputs ............................................................................................................... 43
10.9 Analog Outputs ............................................................................................................................ 43
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CHAPTER 11: HIGH SPEED I/O (HSC / PWM) ..................................................................................... 44
11.1 Overview ...................................................................................................................................... 44
11.2 Glossary ........................................................................................................................................ 44
11.3 High Speed Counter (HSC) Functions ........................................................................................... 45
11.3.1 Frequency .............................................................................................................................. 45
11.3.2 Totalize .................................................................................................................................. 45
11.3.3 Pulse Width Measurement .................................................................................................... 45
11.3.4 Period Measurement ............................................................................................................. 46
11.3.5 Quadrature ............................................................................................................................ 47
11.3.6 Regsiter Match ...................................................................................................................... 47
11.4 HSC Functions Register Map ........................................................................................................ 47
11.5 High Speed Output Functions ...................................................................................................... 48
11.5.1 Normal ................................................................................................................................... 49
11.5.2 PWM ...................................................................................................................................... 49
11.5.3 HSC Output (High Speed Counter Match).............................................................................. 49
11.5.4 Stepper Function.................................................................................................................... 50
11.6 PWM functions register map ....................................................................................................... 51
11.7 PWM Examples ............................................................................................................................ 51
11.8 STP Examples ............................................................................................................................... 52
CHAPTER 12: SYSTEM SETTINGS AND ADJUSTMENTS ....................................................................... 53
12.1 System Menu - Overview ............................................................................................................. 53
12.2 System Menu – Navigation and Editing ....................................................................................... 53
12.3 System Menu – Details ................................................................................................................ 54
12.4 Touch screen calibration .............................................................................................................. 64
CHAPTER 13: USER INTERFACE.......................................................................................................... 65
13.1 Overview ...................................................................................................................................... 65
13.2 Displaying and entering Data ....................................................................................................... 65
13.3 Alpha-numeric keypad ................................................................................................................. 66
13.4 Screen Navigation ........................................................................................................................ 67
13.5 Ladder Based Screen Navigation ................................................................................................. 68
13.6 Beeper Acknowledgement ........................................................................................................... 68
13.7 Touch (Slip) Sensitivity ................................................................................................................. 68
13.8 Alarms .......................................................................................................................................... 69
13.9 Removable Media ........................................................................................................................ 70
13.10 Screen Saver ................................................................................................................................ 71
13.11 Screen Brightness ........................................................................................................................ 72
CHAPTER 14: REGISTERS ................................................................................................................... 74
14.1 Register Definitions ...................................................................................................................... 74
14.2 Useful %S and %SR registers ........................................................................................................ 74
14.3 Register Map for XL7 OCS I/O ...................................................................................................... 77
14.4 Resource Limits ............................................................................................................................ 77
CHAPTER 15: CSCAPE CONFIGURATION ............................................................................................ 79
15.1 Overview ...................................................................................................................................... 79
15.2 Cscape Status Bar ......................................................................................................................... 79
15.3 Establishing Communications ...................................................................................................... 80
15.3.1 Communicating via MJ1 Serial Port .......................................................................................... 83
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15.3.2 Communicating via On Board Ethernet Port ............................................................................ 84
15.5 Configuration ............................................................................................................................... 85
15.6 Digital Input / HSC Configuration ................................................................................................. 85
15.7 Digital Output / PWM Configuration ........................................................................................... 86
15.8 Analog Input Configuration .......................................................................................................... 87
15.9 Analog Output Configuration ....................................................................................................... 88
CHAPTER 16: FAIL–SAFE SYSTEM ..................................................................................................... 89
16.1 Overview ....................................................................................................................................... 89
16.2 Settings......................................................................................................................................... 89
16.3 Backup / Restore Data ................................................................................................................. 90
16.4 AutoLoad ...................................................................................................................................... 93
16.5 AutoRun ....................................................................................................................................... 95
CHAPTER 17: CLONE UNIT ................................................................................................................ 96
17.1 Overview ...................................................................................................................................... 96
17.2 Clone: ........................................................................................................................................... 96
17.3 Load Clone.................................................................................................................................... 98
CHAPTER 18: MAINTENANCE ........................................................................................................ 100
18.1 Firmware Updates ...................................................................................................................... 100
18.2 Backup Battery ........................................................................................................................... 100
18.2.1 Indications the battery needs replacing .............................................................................. 100
CHAPTER 19: TROUBLESHOOTING / TECHNICAL SUPPORT .............................................................. 102
19.1 Connecting to the XL7 OCS ........................................................................................................ 102
19.1.1 Connecting Troubleshooting Checklist (serial port – MJ1 Programming) ........................... 103
19.1.2 Connecting Troubleshooting Checklist (USB Port - Mini B Programming) .......................... 103
19.1.3 Connecting Troubleshooting Checklist (ETN port programming) ........................................ 103
19.2 Local Controller and Local I/O .................................................................................................... 103
19.2.1 Local I/O Troubleshooting Checklist ....................................................................................
104
19.3 CsCAN Network .......................................................................................................................... 104
19.3.1 CsCAN Network Troubleshooting Checklist ......................................................................... 104
19.4 Removable Media ...................................................................................................................... 105
19.5 Technical Support Contacts ....................................................................................................... 105
Main Index ............................................................................................................................................. 106
Index of Figures & Tables ...................................................................................................................... 109
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FIRST STEP of ANY TASK: DATASHEET
Each XL7 OCS unit is sent with a datasheet in the box. The datasheet (MAN0971-02-EN) is the first
http://www.horner-apg.com.)
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 16
Serial Communications
page 24
Maintenance
page 100
Electrical Installation
page 22
CAN Communications
page 26
Troubleshooting
page 102
Ethernet
page 28
Communication Options
page 33
Removable Media
page 34
High Speed I/O
page 44
System Settings
page 53
User Interface
page 65
Registers
page 74
Cscape Configuration
page 79
Fail- Safe System
page 89
Clone Unit
page 96
XL7 User Manual
Visual map of major tasks and the key chapters to assist you
document to refer to for model-specific information related to XL7 OCS models such as pin-outs,
jumper settings, and other key installation information. To obtain updates to datasheets, manuals
and user documentation, visit a Horner website (US:
http://www.heapg.com and Europe:
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Warning: Consult user document atio n.
Warning: Electrical Shock Hazard.
Replace fuse with the same type and rating to provide protection against risk of fire and shock hazards.
replace the fuse again as a repeated failure indicates a defective
other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe
XL7 User Manual
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 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:
WARNING: In the event of repeated failure, do not
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
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
larger.
Adhere to the following safety precautions whenever any type of connection is made to the module.
a. Connect the green safety (earth) ground first before making any other connections.
b. When connecting to electric circuits or pulse-initiating equipment, open their related breakers.
Do not make connections to live power lines.
c. Make connections to the module first; then connect to the circuit to be monitored.
d. Route power wires in a safe manner in accordance with good practice and local codes.
e. Wear proper personal protective equipment including safety glasses and insulated gloves when
making connections to power circuits.
f. Ensure hands, shoes, and floors are dry before making any connection to a power line.
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XL7 User Manual
g. Make sure the unit is turned OFF before making connection to terminals. Make sure all circuits
are de-energized before making connections.
h. Before each use, inspect all cables for breaks or cracks in the insulation. Replace immediately if
defective.
1.2 Grounding
Grounding is covered in various chapters within this manual.
1.3 Compliance
To check for compliance and updates, visit the Horner website (US: http://www.heapg.com or
Europe: http://www.horner-apg.com.)
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XL7 User Manual
CHAPTER 2: INTRODUCTION
2.1 Visual Overview of XL7 OCS
Figure 2.1 – Overview of the XL7
2.1.1 Where to Find Information about the XL7 OCS
a) Datasheet - The datasheet is the first document to refer to for key information related to
specific XL7 OCS models.
a. The datasheets for all XL7 OCS models are available on the Horner websites.
b. Datasheets contain pin-outs, jumper settings and other model specific information.
b) User Manual -This manual provides general information that is common to XL7 OCS models
and can be downloaded from our web. Visit the Horner website (US:
http://www.heapg.com or Europe: http://www.horner-apg.com
documentation and updates.
2.1.2 Four main types of information are covered in this manual
a) Safety and Installation guidelines / instructions (Mechanical and Electrical)
b) Descriptions of hardware features
a. (Serial ports, Removable Media, Communication Options, etc.)
c) Configuration and Use of the XL7 OCS
d) Maintenance and Support
) to obtain user
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XL7 OCS
Other OCS Devices
Sensors
Other OCS Devices
Ethernet
Cscape
Modbus TCP Devices
USB
Flash Drive
2.1.3 Manual Index
Major topics of interest may be found in the Index
2.1.4 Table of Figures
Location of important drawing, illustrations (etc.) may be found in the Table of Figures
2.2 Connectivity to the XL7 OCS
The XL7 OCS has excellent capabilities for connecting to a variety of devices. The diagram below shows
some examples of devices that can be used with the XL7 OCS.
2.3 Features of XL7 OCS
The XL7 OCS are all-in-one industrial control devices. They combine control, user interface, I/O and
networking into a single, integrated package. Unique features of the XL7 OCS include:
XL7 User Manual
towards the end of this manual.
.
Smart Stix I/O
RCX116 I/O Base
OPC Server
Indicators
Alarms
Encoders
Pumps
Relays
Solenoids
Figure 2.2 – Visual Overview of Types of Devices that can be connected to XL7 OCS
CAN
I/O
Serial
Cscape
Drives
PLCs
Bar Code Readers
Printers
SCADA
OPC Servers
Serial I/O
OPC Server
- Bright, 65,536 color graphical touch sensing LCD display in all models of XL7.
- Display of complex graphical objects including trends, gauges, meters and animations.
- Very high performance graphic processing
- Advanced control capabilities including floating point, multiple auto-tuning PID loops and string
handling capabilities.
- Removable media for 32GB of storage of programs, data logging or screen captures.
- CsCAN networking port for communication with remote I/O, other controllers or PCs.
- High speed USB port for communication with PCs and programming of controller.
- Configurable serial protocols for communication to drives, PLCs, or other serial peripherals.
- Full featured, built-in I/O including high resolution analog, thermocouple, RTD, high speed
counters, PWM outputs and relays (depending upon the XL7 OCS model used).
- Advanced high speed I/O capabilities
- Cscape programming software that allows all aspects of the XL7 OCS to be programmed and
configured from one integrated application.
- Optional communication add-on modules
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XL7 User Manual
Table 2.1 – XL7 OCS Accessories
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/AL) at 24VDC. Mounts on Standard DIN rail. Designed for X Family products.
Programming cables for all X products including a USB to serial adapter in a travel case.
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.
Manual Description
Manual Number
User Manual for XLe/XLt OCS models
MAN0878
User Manual for XL6/XL6e OCS models
MAN0883
User Manual for XL4 OCS models
MAN0964
User Manual for QX Series models
MAN0798
User Manual for NX Series models
MAN0781
Other Useful References
Manual Number
Supplement for SmartStack Ethernet Modules
SUP0740
CAN Networks
MAN0799
Spark Quenchers for Arc and Noise Suppression (output protection)
MAN0962
Wiring Accessories and Spare Parts Manual
MAN0347
NOTE: The XL7 OCS is not shipped with a programming cable in the box. To obtain a
programming cable, order HE500CBL300.
- 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 XL7 OCS accessories. Visit the Horner
websites to view updates on new products and accessories.
Part Number Description
HE-MC1 Removable Media card - compatible with XL7 OCS. Card capacity is 2GB or larger.
HE-MR1
HE-X24-AS
HE-X24-AL
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
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
Cscape on a reusable USB flash drive.
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 the Horner websites to obtain user
documentation and updates.
Table 2.2 – OCS Reference Document numbers
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XL7 User Manual
CHAPTER 3: MECHANICAL INSTALLATION
Note: The datasheet is the first document to refer to for model-specific information related to XL7
OCS models such as pin-outs, jumper settings, and other key installation information. Visit the Horner
websites to obtain datasheets, user documentation, and updates.
3.1 Overview
The mechanical installation greatly affects the operation, safety and appearance of the system.
Information is provided to mechanically install the unit such as cut-out sizes, mounting procedures and
other recommendations for the proper mechanical installation of the unit.
3.2 Mounting Requirements
3.2.1 Mounting Procedures (Installed in a Panel Door)
Figure 3.1 – Panel Mounting of an XL7 Series OCS
Once the panel design has been completed using the criteria and suggestions in the following sections,
use the following steps to panel mount the XL7 OCS.
1. Remove all connectors from the XL7 OCS unit.
2. Make sure the gasket is installed on the XL7 OCS and is free from dust and debris. Check that the
corners of the gasket are secure.
3. Pass the unit through the panel.
4. Insert each of the four (4) mounting clips into the slots in the XL7 OCS case. One clip should be
installed on each corner. Lightly tighten each screw so the clip is held in place.
5. Tighten the screws on the clips such that the gasket is compressed against the panel. Recommended
torque is 7-10 lb/in (0.8-1.13 Nm.)
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Slots for mounting clips
3.3 Mounting Orientation
3.3.1 XL7 OCS Mounting Clip
Figure 3.2 – XL7 OCS with Mounting Clips
3.3.2 XL7 OCS Mounting Orientation
Figure 3.3 – Orientation of XL7 OCS
NOTE: There are no orientation restrictions on the XL7 OCS. However, the above orientation provides for
optimum readability of the screen and ease of use of the keypad.
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3.4 Panel Cut-Out
For installations requiring NEMA 4X liquid and dust protection the panel cutout should be cut with a
tolerance of ± 0.005” (0.1 mm).
3.5 XL7 Dimensions
Figure 3.4 – Panel Cutout Tolerances
Figure 3.5 – XL7 OCS Dimensions
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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
each device
When door is closed:
door (Be sure to allow enough depth for the OCS.)
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.
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.
2 inches (50.80mm)
1.5 inches (38.10mm)
on door): Minimum Distance between bases of
Minimum distance between device and closed
4 inches between bases of each device (101.60mm)
2 inches (50.80mm)
3.6.2 Grounding
Panel box: The panel box must be properly connected to earth ground to provide a good common
ground reference.
Panel door: Tie a low impedance ground strap between the panel box and the panel door to ensure that
they have the same ground reference.
3.6.3 Temperature / Ventilation
Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient
temperature range. Consider the impact on the design of the panel layout if operating at the extreme
ends of the ambient temperature range. For example, if it is determined that a cooling device is
required, allow adequate space and clearances for the device in the panel box or on the panel door.
3.6.4 Orientation
When panel-mounted, there are no orientation restrictions on the XL7 OCS.
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XL7 User Manual
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 XL7 OCS and noisy devices such as relays, motor starters, etc.
For details on output protection, especially when using contactors, solenoids… see MAN0962-01-EN.
3.6.6 Shock and Vibration
The XL7 OCS has been designed to operate in typical industrial environments that may inflict some shock
and vibration on the unit. For applications that may inflict excessive shock and vibration please use
proper dampening techniques or relocate the XL7 OCS to a location that minimizes shock and/or
vibration.
3.6.7 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 XL7 OCS?
Is there adequate ventilation? Is the ambient temperature range maintained? Are cooling or
heating devices required?
Are noise suppression devices or isolation transformers required? Is there adequate distance
between the base of the XL7 OCS and noisy devices such as relays or motor starters? Ensure
that power and signal wires are not routed in the same conduit.
Are there other requirements that impact the particular system, which need to be considered?
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NOTES
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METAL WATER PIPE OR
OTHER GOOD GROUND
GROUND ROD
GROUND
DISCONNECTED
FROM SERVICE
GROUND RESISTANCE METER
XL7 User Manual
CHAPTER 4: ELECTRICAL INSTALLATION
Note: The datasheet is the first document to refer to for model-specific information related to XL7
OCS models such as pin-outs, jumper settings, and other key installation information. Visit the Horner
websites to obtain datasheets, user documentation, and updates.
4.1 Grounding Definition
Ground: The term ground is defined as a conductive connection between a circuit or piece of equipment
and the earth. Grounds are fundamentally used to protect an application from harmful interference causing
either physical damage such as by lightning or voltage transients or from circuit disruption often caused by
radio frequency interference (RFI). Grounding is also for the safety of the user.
4.2 Ground Specifications
Ideally, a ground resistance measurement from equipment to earth ground is 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 – Two-Point Ground Connection Test
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XL7 User Manual
Table 4.1 – Primary Power Port Pins
PIN
Signal
Description
1
Frame Ground
PIN 1
PIN 2
PIN 3
+
10-30 VDC
-
+
+
Power Connector
4.4 Primary Power Port
2 0V Input power supply ground
3 +24V Input power supply positive voltage
supply
Figure 4.2 – Power Connector (Primary Power Port)
Figure 4.3 – Primary Power Port as Viewed Looking at the XL7 OCS
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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XL7 User Manual
CHAPTER 5: SERIAL COMMUNICATIONS
5.1 Overview
All XL7 OCS models provide two independent serial ports, on the first 8-pin modular RJ45 connector,
which is labeled MJ1/MJ2. The MJ1 serial port is RS232 while the MJ2 port is RS485. By default, MJ1 can
be connected to the COM port of a PC running Cscape, for OCS programming. In addition, both MJ1 and
MJ2 can be used for application-specific communication, using a variety of standard data exchange
protocols.
The second 8-pin modular RJ45 connector, which is labeled MJ3, provides a multiplexed serial port,
which can be configured for either RS232 or RS485. MJ3 can be optionally set for OCS programming via
the System Menu for connection to the COM port of a PC running Cscape.
5.2 Port Descriptions
The MJ1 serial port contains an RS232 interface with RTS/CTS handshaking. The MJ2 serial port contains
a half-duplex RS485 interface with no handshaking. The MJ3 serial port can be configured as either
RS232 or RS485. The MJ2 and MJ3 RS485 interfaces provide switchable termination and bias resistors
internally, which can be enabled/disabled with DIP switches.
5.3 Wiring and Dip Switches
Figure 5.1 – Wiring & Dip Switches
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5.4 RS485 Termination
Proper RS485 termination minimizes signal reflections and improves reliability.
Both the MJ2 and MJ3 serial ports allow an internal termination resistor to be placed across pins 1 and 2 by DIP
Switch Setting.
Only the two devices physically located at the endpoints of the RS485 network should be terminated.
5.5 RS485 Biasing
RS485 biasing passively asserts a line-idle state when no device is actively transmitting, which is useful for multidrop RS485 networking.
Both the MJ2 and MJ3 serial ports allow internal 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 MJ2 biasing and setting %SR164.2 enables MJ3 biasing.
If biasing is used, it should be enabled in only one of the devices attached to the RS485 network.
5.6 Cscape Programming via Serial Port
The XL7 OCS MJ1 and MJ3 serial ports support CsCAN Programming Protocol. If a PC COM port is
connected to the XL7 OCS MJ1 or MJ3 serial port, Cscape can access the XL7 OCS for programming and
monitoring. Programming can also be done via the CAN port, USB A port or Ethernet.
5.7 Ladder-Controlled Serial Communication
Using Serial Communication function blocks, MJ1, MJ2 and MJ3 serial ports support Generic Modbus
Master and Modbus Slave Protocols. In addition, external modems can be connected and accessed
using Init, Dial and Answer Modem function blocks.
5.8 Downloadable Serial Communication Protocols
MJ1, MJ2 and MJ3 also support downloadable protocols, such as Allen Bradley DF1, CsCAN Master, GE
Fanuc SNP and Modbus Master.
NOTE: Refer to the download section of the Horner websites for the list of latest supported protocols.
Page 25 of 110
CAN and Device Ground -
Black
Positive DC Voltage Input
(10-30VDC) - Red
CAN Connector
Use the CAN Connector when
CAN1
CAN2
CHAPTER 6: CAN COMMUNICATIONS
Note: For additional CAN information, refer to the CAN Networks manual (MAN0799) on the Horner
websites.
6.1 Overview
All XL7 OCS models provide two CAN network ports, which are implemented with 5-pin connectors.
The connectors are labeled CAN1 and CAN2.
Like the MJ1 serial port, the CAN1 port can be used for XL7 OCS programming by connecting it to the
CAN port of a PC running Cscape. The CAN1 port also allows the XL7 OCS to exchange global data with
other OCS/RCS controllers. Both CAN1 and CAN2 support accessing of remote network I/O devices
(SmartStix, SmartBlock and SmartRail Modules.)
CAN2 port supports CsCAN, CANopen, J1939 and DeviceNet Master (layer 3 as a selectable option – one
only)
6.2 Port Description
The XL7 OCS CAN ports implement the ISO 11898-2 physical layer and the CAN 2.0A data link layer
standards. Also, since the CAN ports are powered by an internal isolated power supply, external CAN
power is not required.
6.3 CAN Port Wiring
using CsCAN or other CAN
Torque rating 4.5 – 7 Lb-In
network.
(0.50 – 0.78 N-m)
XL7 User Manual
Figure 6.1 – CAN1 & CAN2 Connector Locations
CAN1 & CAN2 Port Pins
Pin Signal Signal Description Direction
1 V-
2 CN_L CAN Data Low - Blue In/Out
3 SHLD Shield Ground - None
4 CN_H CAN Data High - W hite In/Out
5 V+
Figure 6.2 – CAN1 / CAN2 Port Pins
−
−
−
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6.4 Cscape Programming via CAN
The CAN1 port supports CsCAN Programming Protocol. If a PC has a CAN interface installed (via PCI card
or USB), and the PC CAN port is connected to the XL7 OCS CAN1 port, Cscape can access the XL7 OCS for
programming and monitoring.
In addition, the XL7 OCS supports single-point-programming of all XL7 OCS and other OCS/RCS devices
that are connected to the CAN1 port network. If the PC COM port is connected to the XL7 OCS MJ1
serial port, the XL7 OCS can act as a pass-through gateway allowing Cscape to access all XL7 OCS and
OCS/RCS devices that are attached to the CAN1 port network.
6.5 Ladder-Controlled CAN Communication
Using Put and Get Network Words function blocks, the CAN 1 port can exchange digital and analog
global data with other XL7 OCS or OCS/RCS devices (nodes) attached to the CAN1 port network.
In addition, Put and Get Network Heartbeat function blocks allow nodes on the CAN 1 port network to
regularly announce their presence and to detect the presence (or absence) of other nodes on the
network.
6.6 Using CAN for I/O Expansion (Network I/O)
Connecting Network I/O devices (SmartStix, SmartBlock or SmartRail) to the XL7 OCS CAN1 or CAN2
port, allows the XL7 OCS I/O to be economically expanded and distributed. A variety of modules are
available for this purpose.
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Protocol / Feature
Protocol / Feature Description
ICMP Ping
Internet Control Message Protocol
EGD (Peer)
Ethernet Global Data
SRTP Server
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)
Table 7.1 – Ethernet Module Protocols & Features
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)
Port
Auto MDI/MDI-X (Auto Crossover)
Table 7.2 – Ethernet Module Specifications
XL7 User Manual
CHAPTER 7: ETHERNET COMMUNICATION
7.1 Ethernet Module Protocols and Features
The following table describes the Ethernet Module Protocols and features supported by XL7.
7.2 Ethernet System Requirements
Full Ethernet functionality requires:
- PC running Cscape Programming Software Version 9.3 SP6 or later (for configuration).
- XL7 controller with onboard Ethernet port.
- FTP & HTTP protocols.
7.3 Ethernet Module Specifications
Speeds
CAT5 (or better) UTP
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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XL7 User Manual
Figure 7.1 – I/O Configuration Dialog
3. Click the Config button to the right of LAN1 for LAN 1 or LAN2 for LAN2, revealing the
Ethernet Module Configuration dialog as shown in figure 7.2
Figure 7.2 – Ethernet Module Configuration
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XL7 User Manual
Table 7.3 - Ethernet Status Word Register Format
High Byte
Low Byte
Bit
16
Bit
15
Bit
14
Bit
13
Bit
12
Bit
11
Bit
10
Status Values
Minimum
Maximum
0
Reserved
Always 0
Dup
Link Duplex (Auto-Negotiated)
0 = Half Duplex
1 = Full Duplex
Spd
Link Speed (Auto-Negotiated)
0 = 10 MHz
1 = 100 MHz
Rx
Receive State
0 = Inactive
1 = Active
Tx
Transmit State
0 = Inactive
1 = Active
Link
Link State
0 = Down
1 = Up
Total Number of Active TCP Connections
(CsCAN, SRTP, Modbus, EIP, FTP, HTTP)
4. Configure the Ethernet Module parameters as follows:
IP Address: Enter the static IP Address for the Ethernet Module being configured.
Note: IP Addresses are entered as four numbers, each ranging from 0 to 255. These four
numbers are called octets and they are always separated by decimal points.
Net Mask: Enter the Net Mask (sometimes called Subnet Mask) being used by all nodes on the local
network. Typical local networks use Class C IP Addresses, in which case the low octet (rightmost
number) is used to uniquely identify each node on the local network. In this case, the default Net Mask
value of 255.255.255.0 should be used.
Gateway: Enter the IP Address of a Gateway Server on the local network that allows for communication
outside of the local network. To prevent the Ethernet Module from communicating outside the local
network, set the Default Gateway IP Address to 0.0.0.0 (the default setting).
Status Register: Enter an OCS Register reference (such as %R100) to indicate which 16-bit OCS register
will have the Ethernet Status word written to it. Table 7.1 shows how this register value is formatted and
explains the meaning of each bit in the Status Word.
Bit 9 Bit 8 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1
0 0 Dup Spd 0 Rx Tx Link TCP Connections
Status Bit(s) Status Indication
TCP Connections
0 40
Version Register: Enter an OCS Register reference (such as %R101) to indicate which 16-bit OCS register
will have the Ethernet Firmware Version written to it. The value stored in the Version Register is:
(Ethernet Firmware Version * 100). For example, for Ethernet Firmware Version 4.30, the Version register
will contain 430.
Get Settings From:
“Get settings from” allows the programmer to either configure the IP Address, Net Mask, or Gateway for
2 functions: Configuration or Register
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XL7 User Manual
Configuration – The configuration for the IP Address, Net Mask, or the Gateway will be assigned using
the value in the Default Settings in this window.
Register – The configuration for the IP Address, Net Mask, or the Gateway will be assigned using the
values in the registers assigned.
Ethernet Module Protocol Configuration
The Protocol Support area contains a list of all the protocols supported by the platform being
configured. To activate a protocol, check its checkbox.
For protocols that require additional configuration, click on a listed protocol to select it and then click
the Configure Selected Protocol button. This will open a new dialog with configuration options for the
selected protocol.
For detailed information on individual protocol configuration refer latest version of ETN 300 Manual
SUP0740
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NOTES
Page 32 of 110
Part Number
Description
HE-XDAC007
2-channel Analog Out (mA/V)
HE-XDAC107
4-channel Analog Out (mA/V)
HE-HXSQ
24V Dual High Speed Output
HE-XHSQ-5
5V Dual High Speed Output
HE-XEC
Add-on Ethernet
HE-XPBS
Profibus DP Slave
HE-XRC9
900 MHz I W Radio Modem
HE-GSM04*
GSM/GPRS Cellular Modem
HE-200GPS183**
GPS Receiver
*add ANT suffix to include antenna , **external unit
XL7 User Manual
CHAPTER 8: COMMUNICATION OPTIONS
8.1 Overview
To supplement the built-in MJ1, MJ2 and MJ3 serial ports, additional communication options are
available. This is accomplished by installing a COM module in the XL7 OCS controller.
Previous OCS controllers shared a serial port with the communication options. The XL7 has a separate
serial port which allows using MJ1, MJ2, MJ3 and the communication options simultaneously. Internal
to the XL7 OCS, there is a CPU board, and up to two installed modules. Models HE-XW100 /
HEXT391C100 have no installed I/O or COM modules. All other models have an I/O module in Slot 1 and
could have a user-installed COM module in Slot 2. A blank I/O board kit to support a COM module in
these models is available.
This chapter briefly describes the Modem COM module options. For detailed information regarding
these modules, please refer to the individual documents provided with the modules.
8.2 Modem COM Module (XMC) Option
A Modem COM module can be installed to allow Cscape programming of an XL7 OCS over a dial-up
network. In addition, the application ladder program can take control of the modem for applicationspecific modem communication.
The Modem COM module supports the standard AT command set and can connect to the dial-up
network at speeds up to 14.4 KBaud. Connection speed is auto-negotiated. The Modem COM module
connects to the dial-up network (phone line) via a cable with a standard RJ11 modular plug.
To enable Cscape programming via a dial-up network, the Modem COM module should first be
configured as the Default Programming Port, using the XL7 OCS System Menu. Doing this puts the
Modem COM module in auto-answer mode, so Cscape can call the XL7 OCS via a remote modem.
To program the ladder application to communicate via the Modem COM module, standard Cscape Serial
and Modem function blocks can be used.
Additional XL Series COM options are shown below:
Table 8.1 – XL Series COM Options
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XL7 User Manual
CHAPTER 9: REMOVABLE MEDIA
9.1 Overview
All XL7 OCS models provide a Removable Media slot, labeled Memory Card, which supports standard
MicroSD Flash memory cards. MicroSD cards can be used to save and load applications, to capture
graphics screens and to log data for later retrieval.
Figure 9.1 – Removable MicroSD Memory Card Slot
9.2 MicroSD Cards
When the MicroSD card format was introduced, it was originally called TransFlash. Cards labeled either
MicroSD or TransFlash, with up to 32 GB of Flash memory, are compatible with the XL7 OCS Memory
slot (larger sizes were not tested at time of publication).
The Memory slot is equipped with a “push-in, push-out” connector and a MicroSD card can be safely
inserted into the Memory slot whether the XL7 OCS power is On or Off.
To install a MicroSD card: Align its 8-pin gold edge connector down, facing the front of the XL7 OCS unit
as shown in Figure 9.2; then carefully push it all the way into the Memory slot. Ensure that it clicks into
place.
To remove the MicroSD card: Push in on the top of the card gently to release the spring. The card pops
out for removal.
9.3 MicroSD File System
The MicroSD Memory slot uses the PC-compatible FAT32 File System. This means that a PC, with a
MicroSD-compatible card reader, can read files that have been written by the XL7 OCS and can write
files that can be read by the XL7 OCS.
However, the XL7 OCS does not support long filenames, but instead implements the 8.3 filename
format. This means that all file and directory names must consist of up to 8 characters, followed by an
optional dot, and an optional extension with up to 3 characters.
Directories and sub-directories can be nested up to 16 levels deep as long as each pathname string does
not exceed 147 characters.
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9.4 Using the Removable Media Manager
The Removable Media Manager is an interactive XL7 OCS screen that performs the following functions:
a. Display number of total and free K bytes
b. Browse file and directory lists
c. Delete files and directories
d. Format a MicroSD card
e. Load and save application programs
f. View screen capture bitmaps
The Removable Media Manager can be accessed via the System Menu or by using Cscape to place a
Removable Media Manager object on an application graphics screen.
Figure 9.2 – Removable Media Submenu
9.5 Using Removable Media to Log Data
Using Read and Write Removable Media function blocks, an application ladder program can read and
write XL7 OCS register data in the form of comma-delimited files, with a .CSV extension. These files are
compatible with standard database and spreadsheet PC programs. In addition, an application ladder
program can use Rename and Delete Removable Media function blocks to rename and delete files.
9.6 Using Removable Media to Load and Save Applications
A special file type, with a .PGM extension, is used to store XL7 OCS application programs on MicroSD.
To load an application from MicroSD to the XL7 OCS, use the Removable Media Manager (open the
Removable Media Manager in the System Menu) to find and highlight the desired .PGM file, and then
press the Enter key.
To save an application from the XL7 to MicroSD, open the Removable Media Manager in the System
Menu and press the Save Pgm
function key. The application will be saved in a file called
DEFAULT.PGM in the MicroSD root directory.
NOTE: Saving an application to MicroSD can only be done from the Removable Media System
Menu and is not available on a Removable Media Manager object that was placed on an
application graphics screen by Cscape.
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Read RM csv
Allows reading of a comma-separated value file from the MicroSD interface into
the controller register space.
Write RM csv
Allows writing of a comma-separated value file to the MicroSD interface from
the controller register space.
Rename RM csv
Allows renaming a file on the RM card. The data in the file is not changed.
Delete RM csv
Allows deleting a file on the RM card
Copy RM csv
Allows copying a file on the RM card. The data in the file is not changed.
Cscape can also save an application directly to a MicroSD card, which is plugged into the PC’s MicroSD
compatible card reader by selecting the Export to Removable Media item on the Cscape File menu.
9.7 Using Removable Media to View and Capture Screens
The XL7 OCS File System uses bitmap files with the .BMP extension or JPEG files with the .JPG extension
to store XL7 OCS graphic screen captures.
To view a captured XL7 OCS screen, use the Removable Media Manager to find and highlight the desired
.BMP or .JPG file, and then press Enter.
To capture an XL7 OCS screen, turning On the assigned Screen Capture Control Register will capture the
current XL7 OCS graphics screen and write it to the MicroSD card using the assigned Screen Capture
Filename.
Before capturing an XL7 OCS screen, Cscape must first be used to assign a Screen Capture Control
Register and Filename in the application. To do this, first open the Graphics Editor by selecting the View
/ Edit Screens item on the Cscape Screens menu. Next select the Screen Capture item of the Graphics
Editor Config menu and then enter a Control Register and Filename.
9.8 Removable Media (RM) Function Blocks in Cscape
NOTE: For detailed information regarding RM function blocks and parameters, refer to the help file
in Cscape Software. Refer ‘USB Flash Media support for RM Functions’ for USB flash drive access
details.
The following RM functional blocks are available in Cscape Software. These function blocks will
reference
- MicroSD when filename is prefixed with ‘A:’ or nothing OR
- USB A Flash Drive when filename is prefixed with ‘B:’.
9.9 Filenames used with the Removable Media (RM) Function Blocks
The RM function blocks support the flash with a DOS/Windows standard FAT-16 file system. All names
must be limited to the “8.3” format where the filename contains eight characters a period then a threecharacter extension. The entire filename including any path must be less than or equal to 147
characters.
When creating filenames and directories it is sometimes desirable to include parts of the current date or
time. There are six special symbols that can be entered into a filename that are replaced by the OCS
with current time and date information.
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XL7 User Manual
Table 9.1 – Filename Special Symbols
Symbol
Description
Example
$Y
Substitutes the current 2 digit year
2004 = 04
$M
Substitutes the current month with a 2 digit code
March = 03
$D
Substitutes the current day
22nd = 22
$h
Substitutes the current hour in 24 hour format
4 pm = 16
$m
Substitutes the current minute
45 = 45
$s
Substitutes the current second
34 = 34
Current date and time
= March 1, 2013 3:45:34 PM
Filename: Data$M$D.csv
= Data0301.csv
Filename: Year$Y\Month$M\aa$D_$h.csv
= Year04\Month03\aa01_15.csv
Filename: Month_$M\Day_$D\$h_$m_$s.csv
= Month_03\Day_01\15_45_34.csv
%SR175 Status
This shows the current status of the RM interface
%SR176 Free Space
This 32-bit register shows the free space on the RM card in bytes
%SR178 Card Capacity
This 32-bit register shows the total card capacity in kilobytes
Table 9.2 – RM Status Values
0
RM interface OK
1
Card present but unknown format
2
No card in slot
3
Card present, but not supported
4
Card swapped before operation was complete
5
Unknown error
Note that all the symbols start with the dollar sign ($) character. Date symbols are in upper case, time
symbols are in lower case. The following are examples of the substituted time/date filenames:
9.10 System Registers used with RM
Possible status values are shown in the table:
For additional status information, consult the Cscape help file.
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XL7 User Manual
WARNING: Power, including I/O power must be removed from the unit prior to removing the
back cover. Failure to do so could result i n electrocution and/or damage to equipment
CHAPTER 10: GENERAL I/O
Note: Each XL7 OCS unit is sent with a datasheet in the box. The datasheet is the first document to
refer to for model-specific information related to XL7 OCS models such as pin-outs, jumper settings,
and other key installation information. Visit the Horner websites to obtain datasheets, user
documentation, and updates.
10.1 Overview
The XL7 OCS is a compact unit that contains high density, very versatile I/O. Using the I/O properly
requires wiring to the proper terminals, configuring jumpers inside the XL7 OCS unit and configuring
Cscape properly. This section will offer some tips and suggestions to configure the I/O properly. For the
register mapping of the I/O, refer to the Index
register mapping.
10.2 Removing the XL7 OCS I/O Cover
Some I/O configurations require jumper settings to be changed in the XL7 OCS unit. Examples of these
settings are setting positive or negative logic on digital inputs or setting current or voltage on analog
inputs.
Each XL7 OCS I/O jumper is set to a factory default. Refer to the XL7 datasheet to find the default
setting to determine if a jumper change is necessary for a particular application.
To remove the I/O cover of the XL7 OCS, remove the four (4) Phillips screws from the I/O back. It may
help to place the XL7 OCS unit face down on a clean work surface. Once the four screws are removed
the I/O cover can be lifted straight off.
Figure 10.1 – Removing the I/O Cover
at the end of this manual for the pages referencing
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XL7 User Manual
J1 J2
J3
JP3
JP1
001XLE005-R1
J4
Figure 10.2 – XL7 I/O Cover Removed (sample I/O board)
Once the back is removed the jumper selection can be changed. The jumper settings are documented
on each data sheet using a diagram such as Figure 9.4 below and a description of the jumper settings.
Figure 10.3 – Example Jumper Diagram
To re-install the cover, place the I/O cover back on the unit.
Place the screw back into the hole and turn the screw slowly counter clockwise until it clicks into the
threads. This prevents the screw from being cross-threaded. Now turn the screw clock-wise until the
cover is firmly secured. Repeat this process for all four (4) screws.
Ensure not to exceed the recommended
max torque of 7-10 lb-in. [0.8 – 1.13 Nm.]
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XL7 User Manual
Table 10.1 – I/O and Model Overview
XL7 Models
DC In
DC Out
Relays
HS In
HS Out
mA/V In
mA/V RTD/Tc
mA/V Out
HE-XW1E0 /
HEXT391C100
HE-XW1E2 /
HEXT391C112
HE-XW1E3 /
HEXT391C113
HE-XW1E4 /
HEXT391C114
HE-XW1E5 /
HEXT391C115
Q14
Q15
V+
0V
LOAD
LOAD
10 - 30VDC
Q16
LOAD
J2
J4
10.3 Model and I/O Overview
12 6 4 4
12 12 4 2 2
24 16 4 2 2
12 12 4 2 2 2
Table 10.1 shows the different types of I/O included with the various XL7 OCS models. Specific specifications,
jumper settings and wiring diagrams can be found on the data sheets attached at the end of the manual.
Descriptions and applications of the different type of I/O can be found below.
10.4 Solid-State Digital Outputs
Solid-state digital outputs are generally used to activate lamps, low voltage solenoids, relays and other low
voltage and low current devices.
NOTE: The digital outputs used on the XL7 OCS are “sourcing” outputs. This means the output applies a
positive voltage to the output pin when turned ON. When turned off, the output applies approximately zero
volts with respect to the I/O ground.
Figure 10.4 – Typical Output Wiring
The digital outputs used in the XL7 OCS have electronic short circuit protection and current limiting. While
these electronic protections work in most applications, some application may require external fusing on
these outputs.
The digital outputs in the XL7 OCS are typically controlled via %Q bits in the register mapping. Some of the
outputs are designed for high-speed applications and can be used for PWM or frequency output
applications. Please see the data sheet and the chapter on High Speed I/O for additional information.
Page 40 of 110
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001XLE015
0V ON J1
12-24VDC
R2
C2
R3
C3
R6
C6
R4
C4
R5
C5
R1
C1
H4
H2
H3
LOAD
230VAC
OR
25VDC
N
L
LOAD
230VAC
OR
25VDC
N
L
LOAD
230VAC
OR
25VDC
N
L
LOAD
230VAC
OR
25VDC
N
L
LOAD
230VAC
OR
25VDC
N
L
LOAD
230VAC
OR
25VDC
N
L
Warning: To protect the module and associated wiring from load faults, use external (5
fuse(s) as shown. Fuses of
Warning:
Figure 10.5 – Relay Fusing
When the controller is stopped the operation of each output is configurable. The outputs can hold the state
they were in before the controller stopped or they can go to a predetermined state. By default digital
outputs turn off. For more information on stop state see the Index
The digital outputs feature an output fault bit. %I32 will turn on if any of the outputs experience a short
circuit, over-current or the output driver overheats.
10.5 Relay Outputs
Relay outputs are designed to switch loads that typically have high voltage or current requirements or
require the isolation that relays provide.
NOTE: The design of the XL7 OCS does not require external coil power for the relays to function. The relays
will activate anytime the XL7 OCS is powered.
There are several factors that should be considered when using relays:
Relay Life – Relays are mechanical devices that have a long but limited life. Typically, switching more current
limits the life of relays. Please check the data sheets at the end of this manual for expected relay life.
Current / Temperature De-Rating – Products containing relays often have total current limits based on the
ambient temperature of the application. Please see the product data sheet for current / temperature de-rating
information for relays.
Fusing – External fusing is generally required to protect the relays, devices and wiring from shorts or overloads.
lower current or fusing for the entire system need to be in place to assure the maximum current rating
of the unit is not exceeded.
Connecting high voltage to any I/O pin can cause high voltage to appear at other I/O pins.
to find pages referencing Cscape settings.
A)
Page 41 of 110
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I1
0V
001XLE036
12-24VDC
I1
0V
Positive Logic In Negative Logic In
Positive Logic vs. Negative Logic Wiring
Negative Logic inputs.
Protection for Inductive Loads
Inductive loads can cause reverse currents when they shut off that can shorten the life of relay contacts.
Some protective measures need to be determined by an engineer. If you have questions on protection from
inductive load, consult an application engineer or HEAPG Technical Support. Details on devices that may
protect outputs can be found in MAN0962-01.
Output State on Controller Stop
When the controller is stopped the operation of each output is configurable. The outputs can hold the
state they were in before the controller stopped or they can go to a predetermined state. By default
relay outputs turn off. For more information on stop state see the Index
for Cscape settings pages.
10.6 Digital Inputs
NOTE: Refer to the datasheet for XL7 OCS model being used for details on jumper settings.
Note: The digital inputs on the XL7 OCS are designed for low voltage DC inputs. The inputs are designed
to support both positive and negative input modes. The mode is set by a jumper setting and a
configuration parameter in Cscape. All the inputs on the unit must be configured to the same mode.
The XL SERIES OCS can be wired for Positive Logic inputs or
Figure 10.6 – Positive and Negative Inputs
In positive logic mode a positive voltage applied to the input will turn the input. The internal design of
this mode is basically a resistor from the input to I/O ground. This mode is sometimes called sourcing.
In negative logic mode, connecting the input to the I/O ground or zero volts will turn the input on. The
internal design of this mode is basically a resistor from the input to the positive I/O voltage (usually 12
or 24 volts). This mode is sometime called sinking.
Some of the digital inputs may support high speed input functional such as counting or frequency
measurement.
10.7 Analog Inputs
NOTE: See the data sheet for the XL7 OCS model being used for jumper settings and see the appropriate page
in this manual (see Index) for details on how to use Cscape to configure the digital filtering.
The analog inputs on the XL7 OCS allow voltage or current measurement from a variety of devices. The
voltage or current mode is set though jumpers on the unit and settings in Cscape. Each channel can be
separately configured for voltage or current mode.
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The analog inputs have a digital filter that can be used to filter electrical noise that may be unavoidable
in some installations. The downside to digital filtering is the inputs will respond more slowly to sudden
changes in the actual input.
10.7.1 Common cause of analog input tranzorb failure, Models 2,3 & 4
If a 4-20mA circuit is initially wired with loop power but without a load, the analog input could see 24Vdc. This is
higher than the rating of the tranzorb.
This can be solved by not connecting loop power prior to load connection or by installing a low-cost PTC in series
between the load and the analog input.
Figure 10.7 – Analog input tranzorb - troubleshooting
10.8 Universal Analog Inputs
Note: See the data sheet for the XL7 OCS model being used for jumper settings and see the appropriate
pages in this manual (see Index
) for details on how to use Cscape to configure the digital filtering.
The universal analog inputs provide a high resolution, very flexible interface for a variety of analog
inputs. These inputs include voltage, current, thermocouple, RTD and millivolt. Each channel can be
configured separately using jumpers and configuration settings in Cscape.
Like the standard analog inputs, these inputs have a digital filter that can be used to filter electrical noise
that may be unavoidable in some installations. The downside to digital filtering is the inputs will
respond more slowly to sudden changes in the actual input.
10.9 Analog Outputs
Note: Refer to the datasheet for XL7 OCS model being used for details on jumper settings.
The analog outputs on XL7 OCS devices provide high resolution voltage or current outputs. The voltage
or current selection is controlled with jumpers and configuration settings in Cscape. Note that each
channel can be separately configured for voltage or current mode.
When the controller is stopped the operation of each output is configurable. The outputs can hold the
state they were in before the controller stopped or they can go to a predetermined value. By default
analog outputs are set to a value of zero. For more information on Stop State, refer to the appropriate
pages (see Index
) for the configuration chapter for Cscape settings.
Page 43 of 110
Table 11.1 – Glossary of High Speed I/O Terms
XL7 User Manual
CHAPTER 11: HIGH SPEED I/O (HSC / PWM)
11.1 Overview
In addition to the compliment of simple analog and digital I/O, several of the XL7 OCS I/O modules
support High Speed Counting (HSC) I/O functions and may also support Pulse Width Modulation (PWM)
Output functions (non-relay modules). The HSC functions include: internal timing, frequency, totalizing,
pulse width/period and quadrature measurement. The PWM functions include: traditional PWM (with
variable rate and duty cycle) and a stepper (limited functionality) with variable acceleration and
deceleration rates. To determine function availability, refer to the associated model’s
Specification/Installation sheet (Digital DC Input / Output sections.)
This chapter describes the operation of these high level I/O functions. For configuration details of these
functions, see Cscape Configuration.
11.2 Glossary
Accumulator Register used to accumulate or store up a sum or count of many items or events.
Clear
Disable A special function to prevent the counter from running.
A special function to zero out the value in a specific register. (Not used with Frequency or
Period Measurement.)
Encoder A sensor or transducer for converting rotary motion or position to a series of electronic pulses
Frequency
Input
Latch (strobe)
Marker
Polarity
Preload
(load)
Quadrature
Totalizer A counter that sums the total number of cycles applied to its input.
The number of times an electromagnetic signal repeats an identical cycle in a unit of time,
usually one second.
A special function that uses a digital logic circuit to store one or more bits. A latch has a data
input, a clock input and an output. When the clock input is active, data on the input is "latched"
or stored and transferred to the output register either immediately or when the clock input
goes inactive. The output retains its value until the clock goes active again.
Input into the OCS that indicates a particular position. Typically an encoder has a marker
output that represents a specific point in the rotation.
A Polarity pull-down box is associated with each function and indicates the manner in which
the trigger happens (e.g., High level, Low Level, Falling Edge, Rising Edge).
A special function used to trigger loading of a value into a register upon an event. (Not used
with Frequency or Period Measurement.)
A high speed device that expresses the phase relationship between two periodic quantities of
the same period when the phase difference between them is one fourth of a period. A coupler
in which the two output signals are 90° out of phase.
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Internal
This mode ties the input to the counter to an internal 10MHz or 1MHz clock.
The special functions can be used to accurately time events.
Count Up
This increments the accumulator when the input is enabled. Note that two
The second input can also be disabled.
Count Down
This decrements the accumulator when the input is enabled. Note that two
The second input can also be disabled.
Up/Down
In this mode, input 1 (assigned to any of the four inputs) increments the
counter.
Clk/Dir
This mode uses input 1 as a clock signal to increment or decrement the
increments the counter, while input 2 enabled decrements the counter.
11.3 High Speed Counter (HSC) Functions
The XL7 supports two very high speed, configurable counters. There are four dedicated inputs that can
be configures to a number of different options. Each of the two counters can run in one of five modes.
Those modes are Totalizer, Frequency Counter, Pulse Width Measurement, Period Measurement and
Quadrature measurement. For some modes, more than one HSC input may be consumed. The
measurement values are provided to ladder in a %AI register (see page 49).
11.3.1 Frequency
In frequency mode, the frequency of the input signal is written to the accumulator in terms of Hertz
(cycles/second). When using frequency mode, four update selections are provided which specify the
width of the sample window. Note that selecting a shorter sample window provides a quicker
measurement (faster response) but lowers the frequency accuracy (resolution) and increases the
minimum frequency measurement limit. In this mode the Disable and Latch special functions are
allowed. Please see section 11.2 for a description of these functions.
11.3.2 Totalize
In totalize mode, the accumulator is simply incremented or decremented each time the input transitions
in a specific direction.
The totalizer supports the following modes:
inputs can be assigned. Either input can cause the counter to increment.
inputs can be assigned. Either input can cause the counter to decrement.
(Input 1 Up/Input 2 Down)
(Input 1 Clk, Input 2 Dir)
counter, while input 2 (also assigned to any of the 4 inputs) decrements the
counter and then uses input 2 to decide the direction. Input 2 disabled
NOTE: the totalize mode enables the Disable, Latch, Preload, and Clear special functions. Please see
section 11.2 for details.
11.3.3 Pulse Width Measurement
In pulse width measurement mode, the high-speed input can measure the width of a pulse stream in
one of two modes and provides a continuous indication of the last sampled value. In this mode the
Disable and Latch special functions are allowed. Please see section 11.2 for a description of these
functions.
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Width High
Width Low
Period from Rising Edge
Period from Falling Edge
Width High 1 µs Counts – In this sub-mode the accumulator value will contain the number of 1 µs counts
the pulse is high.
Width Low 1 µs Counts - In this sub-mode the accumulator value will contain the number of 1 µs counts
the pulse is low.
Figures 11.1-11.2 - Pulse Width Measurements, High & Low
11.3.4 Period Measurement
In period measurement mode, the high-speed input can measure the period of a pulse stream in one of
two modes and provides a continuous indication of the last sampled value. In this mode the Disable and
Latch special functions are allowed. Please see section 11.2 for a description of these functions.
Period Rising Edges 1 µs Counts – In this sub-mode the period of the input signal is reported in one (1)
µs units. The period measurement will start on the rising edge of the input.
Period Falling Edges 1 µs Counts – In this sub-mode the period of the input signal is reported in one (1)
µs units. The period measurement will start on the falling edge of the input.
Figures 11.3-11.4 – Period Measurement, Rising Edges & Falling Edges
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90°
1 (leading)
2 (lagging)
11.3.5 Quadrature
Quadrature mode uses two HSC inputs, any of the four HSC inputs can be assigned for this purpose.
Quadrature mode works much like the totalizer except the accumulator will automatically increment or
decrement based on the rotation phase of the two inputs. See the following example for more details.
Quadrature inputs are typically used for reporting the value of an encoder.
Two modes are available for quadrature that select whether the accumulator counts up or down when
the phase of input 1 leads input 2. Check your encoder’s documentation to determine the output form
it uses or try both modes to determine if the encoder counts up when expected.
phase
Figures 11.5 – Quadrature
Using the above waveforms and a HSC input configuration of “Quadrature” - “1 leads 2, count up,” the
accumulator will count up when 1 is rising and 2 is low, 1 is high and 2 is rising, 1 is falling and 2 is high,
and when 1 is low and 2 is falling. This results in 4 counts per revolution. So in order to determine the
number of cycles, the accumulator would have to be divided by 4.
Marker reset operation is configured in the special operations and can be assigned to any of the 4 high
speed iputs or can be assigned to be controlled by a “Q” bit in ladder.
Note, the quadrature mode enables the Disable, Latch, Preload, Clear and Marker special functions.
Please see section 11.2 for details.
11.3.6 Register Match
All counter modes support a register match function. When the accumulator value matches the Match
1 or Match 2 value setup in %AQ registers a high speed output with either turn on, turn off or toggle
based on settings in Cscape.
11.4 HSC Functions Register Map
The register assignments for the high speed I/O can be moved via a setting in Cscape. The values shown
are the DEFAULT values and may not match the same starting point as the values shown below.
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Table 11.2 – HSC Functions Register Map
Register
Frequency
Pulse
Totalize
Quad
%AI401-402
Accumulator - Counter 1
%AI403-404
Latch Value – Counter 1
AI405-406
Accumulator – Counter 2
%AI11-12
Latch Value – Counter 2
%AQ401-402
Preload – Counter 1
%AQ403-404
Match1 – Counter 1
%AQ405-406
Match2 – Counter 1
%AQ401-402
Preload – Counter 2
%AQ403-404
Match1 – Counter 2
%AQ405-406
Match2 – Counter 2
%Q1601
Latch – Counter 1
%Q1602
Preload – Counter 1
%Q1603
Clear – Counter 1
%Q1604
Disable – Counter 1
%Q1605
Direction – Cnt 1
%Q1606
Output Reset – Counter 1
%Q1607
Preload Disable – Counter 1
%Q1608
Latch Disable – Counter 1
%Q1609
Disable Marker – C1
%Q1610
Latch Marker – C1
%Q1611
Preload Marker – C1
%Q1612
Clear Marker – C1
%Q1613-1616
Reserved
%Q1617
Latch – Counter 2
%Q1618
Preload – Counter 2
%Q1619
Clear – Counter 2
%Q1620
Disable – Counter 2
%Q1621
Direction – C2
%Q1622
Output Reset – Counter 2
%Q1623
Preload Disable – Counter 2
%Q1624
Latch Disable – Counter 2
%Q1625
Disable Marker – C2
%Q1626
Latch Marker – C2
%Q1627
Preload Marker – C2
%Q1628
Clear Marker – C2
%I1601
Overflow Flag – Counter 1
%I1602
Underflow Flag – Counter 1
%I1603
High Speed Out 1
%I1604
Reserved
%I1605
Overflow Flag – Counter 2
%I1606
Underflow Flag – Counter 2
%I1607
High Speed Out 2
%I1608
Reserved
11.5 High Speed Output Functions
On units that support the PWM, two dedicated outputs are available that can be configured for one of four
modes of operation. Those modes are Normal, PWM, HSC Match and Stepper.
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Period
Duty Cycl e
11.5.1 Normal
When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives
that respective output.
11.5.2 PWM
When either Q1 or Q2 is configured for PWM, the PWM function drives that respective output. Both PWM
channels may be individually enabled and can have independent frequency and duty cycles.
The PWMs require two parameters (%AQs) to be set for operation. These parameters may be set at runtime.
Duty Cycle - The Duty Cycle is a 32 bit value from 0 to 32,000 indicating the relative duty cycle of the
output. For example a value of 8000 would indicate a 25% duty cycle, a value of 16,000 would indicate a
50% duty cycle. 0 turns the output off, 32,000 turns the output on.
Frequency - The Frequency is a 32 bit value indicating the output frequency in Hertz. One over the
frequency is the period.
Figures 11.6 & 11.7 – PWM, two parameters, Duty Cycle & Frequency
At controller power-up or during a download, the PWM output is maintained at zero until both the
Frequency and the Duty cycle are loaded with non-zero values. When the controller is placed in stop mode,
the state of the PWM outputs is dependent on the PWM State on Controller Stop configuration. This
configuration allows for either hold-last-state or specific frequency and duty cycle counts. Specifying zero
for either the period or duty causes the PWM output to remain low during stop mode.
NOTE: for standard I/O modules (1E3, 1E4 and 1E5 models,) the nominal output driver turn-on-time delay
(to reach 50% output) is 25 microseconds. Therefore, this limitation should be considered when
determining both the minimum pulse width and the duty cycle accuracy of the application. Special high
speed output options will be available.
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frequency of the cycles within this mode is constant at the specified Run
error is
A high indication on this register indicates the stepper sequence can be started
(i.e. not currently busy).
A high indication on this register indicates that one of the analog parameters
was corrected.
11.5.3 HSC Output (High Speed Counter Match)
When either Q1 or Q2 is configured for HSC Output operation, HSC1 or HSC2 turns on, off or toggles
based on a comparison between the counter accumulator and match registers. See details above in the
high speed input section.
11.5.4 Stepper Function
The XL7 supports two stepper functions, one on each high speed output.
The Stepper requires five parameters (%AQs) to be set for operation. These parameters may be set at
run-time but are ‘latched’ when the stepper is commanded to start:
This value sets the frequency for the first cycle during the acceleration phase and
Start Frequency
(cycles per second)
the frequency of the last cycle during the deceleration phase. When an
acceleration or deceleration count is specified, the Start Frequency must be
greater than 0 and must not exceed the run frequency or an error is generated.
This value sets the frequency for the last cycle during the acceleration phase, the
Run Frequency
(cycles per second)
consistent frequency during the run phase, and the frequency of the first cycle
during the deceleration mode. The Run Frequency must be greater than 0 and
must not exceed 5000 cycles/sec. or an error is generated.
This value sets the number of cycles to occur within the acceleration phase. The
Acceleration Count
frequency of the cycles within this mode will vary linearly between the specified
Start and Run frequency. The Accel count must not equal 1 or an error is
generated. Setting this value to zero disables this phase.
This value sets the number of cycles to occur within the run phase. The
Run Count
frequency. The Run count may be any value. Setting this value to zero disables
this phase.
This value sets the number of cycles to occur within the deceleration phase. The
Deceleration Count
frequency of the cycles within this phase will vary linearly between the specified
Run and Stop frequency. The Decel count must not equal 1 or an
generated. Setting this value to zero disables this phase.
The stepper provides two Boolean registers to provide stepper status:
Ready/Done
Error
specified above is invalid or the stepper action was aborted before the operation
was complete. This register is cleared on the next start command if the error
The stepper requires one discrete register to control the stepper action. Setting this register starts the
stepper cycle. This register must remain set to complete the entire cycle. Clearing this register before
the cycle is complete aborts the step sequence and sets the error bit.
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Table 11.3 – PWM Functions Register Map
Register
PWM
Stepper
%AQ421-422
PWM 1 Duty Cycle (32-bit)
Start Frequency – Stepper 1
%AQ423-424
PWM 1 Frequency
Run Frequency – Stepper 1
%AQ425-426
Acceleration Count – Stepper 1
%AQ427-428
Run Count – Stepper 1
%AQ429-430
Deceleration Count – Stepper 1
%AQ431-432
PWM 2 Duty Cycle (32-bit)
Start Frequency – Stepper 2
%AQ433-434
PWM 2 Frequency
Run Frequency – Stepper 2
%AQ435-436
Acceleration Count – Stepper 2
%AQ437-438
Run Count – Stepper 2
%AQ439-440
Deceleration Count – Stepper 2
%Q1 Digital Out – Stepper 1
%Q2
Digital Out – Stepper 2
%I1617 Ready/Done – Stepper 1
%I618
Error – Stepper 1
%I1619
Ready/Done – Stepper 2
%I620
Error – Stepper 2
Example 1
Duty Cycle
Frequency
To get a 50% Duty Cycle @ 10 kHz
waveform on PWM1:
Example 2
Duty Cycle
Frequency
Example 3
Duty Cycle
Frequency
To turn PWM 1 output ON all the time
Set %AQ421-422 = 32,000
Set %AQ423-424 = Any Value
Example 4
Duty Cycle
Frequency
To turn PWM 1 output OFF all the
time
NOTE: Setting the PLC mode to stop while the stepper is in operation causes the stepper output to
immediately drop to zero and the current stepper count to be lost.
NOTE: The stepper output level may cause damage or be incompatible with some motor drive inputs.
Consult drive documentation to determine if output level and type is compatible.
11.6 PWM Functions Register Map
The register assignments for the high speed I/O can be moved via a setting in Cscape. The values shown
are the DEFAULT values and may not match the same starting point as the values shown below.
11.7 PWM Examples
To get a 50% Duty Cycle on PW1 and
90 % Duty Cycle on PWM2 @ 1 kHz
waveform:
Set %AQ421-422 = 16,000 Set %AQ423-424 = 10,000
Set %AQ421-422 = 16,000
Set %AQ431-432 = 28,800
(duty cycle (32000 * 0.9))
Set %AQ423-424 = 1,000
Set %AQ433-434 = 1,000
Set %AQ421-422 = 0 Set %AQ423-424 = Any Value
Page 51 of 110
11.8 STP Examples
Example 1
Start Frequency
Run Frequency
Accel Count
Run Count
Decel Count
10,000,000
sequence
Example 2
Start Frequency
Run Frequency
Accel Count
Run Count
Decel Count
5,000,000
sequence
Example 3
Start Frequency
Run Frequency
Accel Count
Run Count
Decel Count
6,000,000
sequence
XL7 User Manual
steps control
Then, it runs at 5 kHz for the next 8,000,000 steps. Finally during the last 1,000,000 steps it slows to a stop.
Set %AQ1 =
2500 (Hz)
The example starts at 2.5 kHz and ramps up to 5 kHz during the first 1,000,000 steps.
Set %AQ2 =
5000 (Hz)
Set %AQ3-4 =
1,000,000 (Steps)
Set %AQ5-6 =
8,000,000 (Steps)
1,0000,000 (Steps)
steps control
Then, it runs at 1 kHz for the next 2,000,000 steps. Finally during the last 1,000,000 steps it slows to a stop.
Set %AQ1 =
500 (Hz)
The example starts at 0.5 kHz and ramps up to 1 kHz during the first 2,000,000 steps.
Set %AQ2 =
1000 (Hz )
Set %AQ3-4 =
2,000,000 (Steps)
Set %AQ5-6 =
2,000,000 (Steps)
1,000,000 (Steps)
steps control
Then, it runs at 250 Hz for the next 5,500,000 steps. Finally during the last 350,000 steps it slows to a stop.
Set %AQ1 =
50 (Hz)
The following example starts at 50 Hz and ramps up to 250 Hz during the first 150,000 steps.
Set %AQ2 =
250 (Hz)
Set %AQ3-4 =
150,000 (Steps)
Set %AQ5-6 =
5,500,000 (Steps)
350,000 (Steps)
Set %AQ7-8 =
Set %AQ7-8 =
Set %AQ7-8 =
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↓
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XL7 User Manual
CHAPTER 12: SYSTEM SETTINGS AND ADJUSTMENTS
12.1 System Menu - Overview
The XL7 has a built-in System Menu, which lets the user view System Settings and makes adjustments.
To start the System Menu, press the SYSTEM key (or set %SR3 to 1), which will display the Main Menu.
Then use the ↓ and ↑ (Up Arrow or Down Arrow) keys to select a Main Menu item and press Enter
(Return Arrow) to display the item’s Sub-Menu.
Figure 12.1 – System Menu (XL7) Screenshot
12.2 System Menu – Navigation and Editing
As mentioned above, the System Menu is started by pressing the System key on the XL7. Next press ESC
to exit the System Menu, or use
Sub-Menu.
A Sub-Menu generally shows a list of System Settings and their values. After opening a Sub-Menu, if any
of its System Settings are editable, the first System Setting that can be edited is highlighted. If desired,
the
and ↑ keys can be used to select a different System Setting to be edited.
At this point, either press ESC to exit the Sub-Menu (returning to the Main Menu) or press Enter to edit
the highlighted System Setting. If Enter is pressed, the System Setting’s value will be highlighted,
indicating that it is ready to be modified.
When modifying a System Setting’s value, use either the arrow keys (← → ↓ ↑) or the
numeric keys, or the appropriate touch screen icons to select a new value.
The arrow keys are used to edit System Settings that have just a few possible values. Each time the
arrow key is pressed, a new possible value is displayed. When the desired value appears, press the
Enter key to save it; otherwise press the ESC key to cancel the edit.
The numeric keys are normally used to enter numeric System Settings.
In addition, to edit a single numeric digit, use the ← or → key to select the digit and then either press a
numeric key or use
or ↑ to modify the digit. In any case, after entering the new desired value, press
the Enter key to save it; otherwise press the ESC key to cancel the edit.
and ↑ to select an item and press Enter to display the item’s
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Yes= CAN1 connected to a CAN network and functioning properly
No= Not ready to communicate on CAN network
CAN ID
1 to 253 = This node’s CsCAN Network ID; must be unique on network
125 KB = 125 KBaud CAN network
250 KB = 250 KBaud CAN network
500 KB = 500 KBaud CAN network
1 MB = 1 MBaud CAN network
MAC ID
Displays the Ethernet MAC ID of the unit
IP
Displays the Ethernet IP address of the unit
NetM
Displays the Ethernet net mask of the unit
GatWy
Displays the Ethernet gateway of the unit
XW1yz= Model number of this XL7 OCS unit
00 = no I/O module
Idle = XL7 OCS is in Idle mode
Run = XL7 OCS is in Run mode
0.0 = XL7 OCS is not in Run mode
0.1 to 999.9= Average number of mS for each ladder scan
OCS Net Use %
0.0 to 100.0 = CAN network bandwidth % used by this XL7 OCS node
All Net Use %
0.0 to 100.0 = CAN network bandwidth % used by all nodes
Ladder Size
x = Number of bytes in application ladder program
Config Size
x = Number of bytes in application I/O configuration
Graphics Size
x = Number of bytes in application graphic screens
String Size
x = Number of bytes in application string table
Bitmap Size
x = Number of bytes in application bitmaps
12.3 System Menu – Details
The following sections describe each of the Sub-Menus in detail.
Set Networks
This sub menu allows setting for the CAN and Ethernet network to be viewed or changed.
CAN Ok?
CAN Baud
NOTE: The IP address, Net Mask and Gateway can be changed from the system menu. This is designed
for commissioning or temporary field changes. The actual parameters are defined in Cscape under the
Ethernet configuration and are reverted to whenever the unit goes from idle to run mode.
View Status
The View Status Sub-Menu displays up to 19 System Settings. Only the OCS Mode System Setting is editable.
Model
OCS Mode
Scan Rate(mS)
1yz = indicates the installed I/O module
DoIO = XL7 OCS is in Do I/O mode
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Text Tbl Size
x = Number of bytes in application text tables
Font Tbl Size
x = Number of bytes in application font tables
Protocol Size
x = Number of bytes in application downloaded protocols
SMS File Size
x = Number of bytes in application SMS protocol configuration
Firmware Rev
xx.yy = Current firmware version
OS Ver
a.b.cd.yz = Current Operating System version
FPGA Rev
x.y = Current FPGA version (High Speed IO Sub System)
InitRD Rev
x.yz = Bootloader version
Self-Test
Ok = All power-on self-tests passed
Fault = One or more power-on self-tests failed
Ok = Application graphics objects loaded successfully
Fault = Application graphics objects not loaded or load failed
0 = Watchdog timer has not tripped since the last power-up
x = Number of times watchdog timer has tripped
0 = No CAN network bus-off errors have occurred
x = Number of CAN network bus-off errors that have occurred
Ok = At least one other node was found on the CAN network
Warning = No other nodes were found on the CAN network
Ok = This node’s CAN Network ID is in the range 1 to 253
Warning = This node’s CAN Network ID was out of range at power-up
Ok = This node’s Network ID is unique on the CAN network
Warning = This node’s Network ID is duplicated in another node
Clock Error
Ok = Time and date have been set
View Diags
XL7 User Manual
The View Diags Sub-Menu displays up to 11 System Diagnostics, none of which are editable.
The first two System Diagnostics are critical. If either of these indicate a Fault condition, the XL7 OCS
will not enter or remain in Run mode, and the problem must be investigated and corrected.
Logic Error:
User Program:
Ok = All executed ladder instructions are legal for loaded firmware
Fault = A ladder instruction not supported by firmware was found
Ok = Ladder program and I/O configuration loaded successfully
Fault = Ladder program or I/O configuration not loaded or load failed
The last nine System Diagnostics are informational. If any of these indicate a warning condition, the XL7
OCS can still enter and remain in Run mode, but the problem should be investigated and corrected.
User Graphics
W-Dog Trips
Net Errors
Network State
Network ID
Dup Net ID
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Warning = Time and date need to be set
Ok = I/O configuration matches the installed I/O and COM modules
Warning = I/O configuration needs updating to match installed modules
Ok = Backup battery operating properly
Warning = Backup battery needs to be replaced
Slot 1: I/O: Empty
= No I/O module installed or configured
Slot 1:*Unsupported
= Unsupported I/O module installed
Slot 1:-I/O Missing
= No I/O module installed but an I/O module is configured
Slot 1:+I/O: XExyy
= yy I/O module installed but no I/O module configured
Slot 1:?I/O: XExyy
= yy I/O module installed but another I/O module configured
Slot 1: I/O: XExyy
= yy I/O module installed and configured properly
Slot 2: I/O: Empty
= No COM module installed or configured
Slot 2:*Unsupported
= Unsupported COM module installed
Slot 2:-I/O Missing
= No COM module installed but a COM module is configured
Slot 2:+I/O: XzC
= z COM module installed but no COM module configured
Slot 2:?I/O: XzC
= z COM module installed but another COM module configured
Slot 2: I/O: XzC
= z COM module installed and configured properly
Slot 3: I/O: ETN300
= ETN300 has been configured through Cscape
I/O System
Battery
View I/O Slots
The View I/O Slots Sub-Menu displays three System Settings, none of which may be edited.
Internal to the XL7 OCS, there is a CPU board, and up to two installed modules. Model XW100 has no
installed I/O or COM modules. All other models have an I/O module and can have a user-installed COM
module.
Depending on which I/O module is installed and which I/O module has been configured by Cscape, one
of the following six System Settings should appear for Slot 1:
Depending on the COM module that is installed and the COM module that has been configured by
Cscape, one of the following six System Settings appears for Slot 2:
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Momentary= %K1-5 bits go On & Off as F1-F5 are pressed & released
Toggle= %K1-5 bits toggle each time F1-F4 are pressed
Yes = Reset and all clear system functions enabled
No = Reset and all clear system functions disabled
View Protocols
The View Protocols Sub-Menu displays two System Settings, neither of which may be edited.
As mentioned in
0, both the MJ1/MJ2 (Port 1) and MJ3 (Port 2) serial ports support downloadable
protocols. To assign a downloadable protocol to an XL7 OCS serial port, select the Protocol Config item
in Cscape’s Program menu and then set up a protocol for Port 1 or Port 2 (or both).
In the View Protocols Sub-Menu, the currently downloaded protocol, if any, and its version number are
displayed for each of MJ1, MJ2 COM board and MJ3.
Set Fkeys Mode
The Set Fkeys Sub-Menu displays two System Settings, both of which may be edited.
Fkeys
SYS_Fn enable
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MJ1-232= MJ1 RS232 port is the default programming port
Modem= Modem COM module is the default programming port
No = MJ2 RS485 bias resistors are not switched in
Yes = MJ2 RS485 bias resistors are switched in
No = MJ3 R5485 bias resistors are not switched in
Yes = MJ3 R5485 bias resistors are switched in
Time
16:09:49 = Current time (hours:minutes:seconds in 24-hour format)
Date
10-Jun-2013 = Current date (day-month-year)
Day
Monday = Current day of week calculated from the Date setting
Set Serial Ports
The Set Serial Ports Sub-Menu displays three System Settings, all of which may be edited, and one
optional item. For the Dflt Pgm Port System setting, only MJ1-232 can be selected, unless a Modem
(XMC) COM module is installed.
Dflt Pgm Port
MJ2 RS485 Bias
MJ3 RS485 Bias
Set Time/Date
The Set Time/Date Sub-Menu displays three System Settings. Time and Date may be edited, and Day is
automatically calculated from the Date setting. Note that Time and Date are split into three fields each,
all of which may be edited. Use ← or → to select a field and then use ↓ or ↑ to edit the field.
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Yes (default) = Enables beeper
No = Disables beeper (does NOT affect ladder access)
Yes = Enable screen saver
No (default) = Disable screen saver
5 - 1200 = Amount of time in minutes to expire with NO touch activity
before activating screen saver (black screen)
Off (default) = Disable popup status
On = Display popup status on any controller status change.
Update Time (mS)
2 - 50 = Maximum amount of time to allow for graphics update per scan
Set Beeper
The Set Beeper Sub-Menu displays one System Setting, which may be edited.
Beeper enable
Set Screen
The Set Screen Sub-Menu displays four System Settings, all of which may be edited.
Saver enable
Timeout (min)
Popup Status
Warning = Display popup status only if controller status changes to
NOT Ok or NOT Run mode.
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Media Directory
Media Directory
Media Directory
Shows size of highlighted file or shows <DIR> if directory is highlighted
= MicroSD card is installed and initialized, and it contains files
Removable Media
The Removable Media Sub-Menu displays the Removable Media Manager. Having selected Removable
Media from the Main Menu, one of four Sub-Menu screens will appear:
No Card
= No MicroSD card has been installed in the Memory slot
Initializing
= MicroSD card is installed, but it is still initializing
Dir Empty
= MicroSD card is installed and initialized, but contains no files
Shows the date file or directory was created or last modified
Shows the time file or directory was created or last modified
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Backup
= Copies Battery Backed RAM contents on to the onboard FLASH memory of the OCS.
Restore
= Copies the backed up data from onboard FLASH to the battery backed RAM.
Clear Backup
= The backup data will be erased from the onboard FLASH.
Exit
= Goes back to previous menu
If a directory name is highlighted, pressing Enter will switch to that directory showing its files and subdirectories. In a sub-directory, highlighting “..” (dot dot) and pressing Enter will move up one directory.
Fail – Safe System
The Fail-Safe System is a set of features that allow an application to continue running in the event of
certain types of "soft" failures. These "soft" failures include:
• Battery power loss
• Battery-Backed Register RAM or Application Flash corruption due to, for example, an excessive
EMI event.
Selecting “Fail-Safe System” menu will open the following menu screen:
Selecting Backup/Restore Data displays the following screen in:
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No = OCS will be in IDLE mode after AutoLoad or Automatic Restore.
Automatic Restore.
No = Does not load AUTOLOAD.PGM automatically when application program
program is absent or corrupted.
“Enable AutoRun” displays the following options which can be selected:
Enable AutoRun
Yes = OCS will automatically be placed into RUN mode after AutoLoad or
“Enable AutoLoad” displays the following options which can be selected:
Enable AutoLoad
is absent or corrupted.
Yes = Loads AUTOLOAD.PGM file automatically from RM when application
Clone Unit
‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones”
application program and unit settings stored in Battery backed RAM of an OCS into the RM (refer
Removable Media Chapter 9
for details on using RM). It can then be used to clone a different OCS (exact
same model).
This feature can be used when:
- Replacing an OCS by another unit of the same model.
- Duplicating or “clone” units without a PC.
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AUTOLOAD.PGM
Application file
CLONE.DAT
File having all unit settings and register values from Battery Backed RAM
Clone
Selecting “Clone Unit” menu will open the following menu screen:
Note: Free/Total – displays number of free and total bytes in Removable Media.
Selecting Make Clone brings up the confirmation screen. Upon confirmation, the OCS will create two
new files in the root directory of the Removable Media Drive as shown below:
Load Clone
Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”.
NOTE: For security enabled files, Load clone asks for password validation before loading the application.
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12.4 Touch screen calibration
The touch screen is calibrated at the factory and rarely needs modification. However, if actual touch
locations do not appear to correspond with responding objects on the display, field adjustment is
available. To access the field adjustable touch screen calibration dialog, press and hold both the SYS and
F1 key for longer than 2 seconds and a dialog similar to figure 9.2 should appear. Thereafter, use a
plastic tip stylus and follow the dialog instructions.
Note that special system keys may be locked out from user access. If the SYS-F1 combination does NOT
respond, verify that the system menu’s Set Fkeys sub-menu’s parameter SYS_Fn is enabled.
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• Displaying and entering data
Touch (slip) sensitivity
• Alarm log dialog
XL7 User Manual
CHAPTER 13: USER INTERFACE
13.1 Overview
This chapter presents the user interface (or operator view) of the XL7 and some of the model specific
characteristics of the XL7 as compared to the rest of the OCS line. This chapter does NOT cover building
screens or using the Cscape graphics editor. For instructions on creating screens and using the graphics
editor, refer to the graphics editor help file.
The following aspects are discussed:
• Alpha-numeric data entry
• Navigating around screens
• Beeper acknowledgement
• RM dialog
• Screen Saver
• Dimmer
•
13.2 Displaying and entering Data
Figure 13.1 – Example Screen
Multiple objects are provided for displaying data such as virtual panel lights, push buttons, numeric value
displays, bar graphs, meters, graphs and animated bitmaps. On the XL7, these graphical objects (through
ladder manipulation of attribute bits) can change color, flash or change visibility to attract operator
attention.
On objects that accept user input, the input is provided by touching the object or alternately changing an
OCS register (i.e. Function key registers). Objects that allow input generally have a raised 3D appearance.
An exception is the binary type objects, such as buttons, which are shown in a depressed 3D appearance
when in the ON state. Objects that normally accept touch input may be disabled through program control
(through ladder manipulation of an attribute bit). If an object is disabled, the object’s representation
changes to a 2D appearance.
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On objects that represent non-discrete information, more action may be required beyond that of simply
touching the object. For example, the slider object requires the operator to touch and slide the control in
the direction desired. Alternately, alpha-numeric entry objects invoke a pop-up alpha-numeric keypad for
additional user input. The alpha-numeric keypad is discussed below.
Note that if the numeric entry object displays >>>>>>>, the value is too big to display in the field or is above
the maximum for an editable field. Likewise, if the numeric entry object displays <<<<<<< in a numeric field,
the value is too small to display or is below the minimum for an editable field.
13.3 Alpha-numeric keypad
To allow entry of a specific number or text, several of the input objects invoke a pop-up alpha-numeric
keypad when the object is touched. An example of the alpha-numeric keypad invoked from a numeric input
object is shown in Figure 13.2. Once invoked, the operator may touch the appropriate keys to enter a
specific value. When entering a value, the alpha-numeric keypad is in one of two modes [new-value or editvalue].
New-value mode
Generally, when the alpha-numeric keypad is first invoked, it is placed in new-value mode. Initially, the
alpha-numeric keypad displays the current value with all the digits being highlighted. Once the first digit is
entered, the current value is erased from the display and the new digit is placed in the first location.
Thereafter, no digits are highlighted and new digits are added to the rightmost position while the other
digits are shifted left.
Edit-value mode
Edit-value mode may be entered from the initial new-value mode by pressing either the left or right arrow
key before any digit key is pressed. The result will be a single character highlighted. The user may then
either touch a key to change the digit at the selected position or the up and down arrows may be used to
add or subtract (respectively) from the selected digit. The user may then use the left or right arrow keys to
select a new position.
Figure 13.2 – Alpha-numeric Keypad and ASCII Keypad
Once the desired value is entered, pressing the Enter key moves that value into the object (and the
corresponding OCS register) and the alpha-numeric keypad disappears. Alternately, pressing the ESC
key any time before the Enter key cancels the operation, leaves the objects current value unchanged,
and the alpha-numeric keypad disappears.
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Numeric Object
When editing a numeric value, the [+/-] or the [.] key are disabled (grayed) if the object
is NOT configured for floating-point value or a signed value.
Password Object
When editing a password value, the arrow keys, [+/-], and the [.] keys are disabled.
up keypad
hides the value by displaying ‘*’ alternately for each digit.
ASCII Object
When editing an ASCII value, an ASCII keypad is displayed as shown figure 13.2. The
button may be pressed to access capital letters. When you first enter this editor typing
pressing ESC will cancel the edit and return the string to the previous value.
Text Table Object
When editing a Text Table Object, all the keys except the Up and Down arrow keys are
grayed and disabled. The next text selection is made by pressing either the Up or Down
arrow.
Time/Date Object
When editing a Time/Date Table Object, all the keys except the Up, Down, Left and
selected using the Left and Right arrows. The value in the selected field is changed by
pressing either the Up or Down arrow.
Screen jumps can also be triggered on other keys
NOTE: Each numeric entry object has a configured minimum and maximum value. If the operator
enters a value outside of the configured range, the new value is ignored when Enter is pressed and the
current object value is NOT changed.
Since the alpha-numeric keypad services several different graphical objects, certain keys on the alphanumeric keypad may be disabled (grayed) when the keypad is invoked for certain objects. The following
describes the alpha-numeric keypad variation based on object.
Additionally, overwrite mode is disabled. When entering digits, the pop-
ASCII keypad has 3 modes, numeric, symbols and alpha. In Alpha mode the Caps Lock
a character will overwite the entire old string and start a new entry. You may press the
back space arrow to delete the previous character. Pressing Enter will save the entry,
Right arrow keys are grayed and disabled. The specific field (i.e. hour or minutes) is
13.4 Screen Navigation
To allow the operator to change screens, a screen jump object is generally used. This object may be
visually represented as a 3-D button (responding to touch) or remain invisible and logically tied to an
OCS register. An optional system ICON may be configured for display along with the legend, which aids
in identifying the object as one that causes a screen change (shown below in figure 13.3)
Figure 13.3 – Typical Screen Jump Object
or based on control logic for more advanced
applications. To allow the operator to change
screens, a screen jump object is generally used.
This object may be visually represented as a
button (responding to touch) or remain invisible
and logically tied to an OCS register. An optional
system ICON may be configured for display along
with the legend, which aids in identifying the
object as one that causes a screen change.
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13.5 Ladder Based Screen Navigation
Ladder logic can use several techniques to control screen navigation. Coils can be tied to %D registers to
make them screen coils. These coils have two modes, switch and alarm. If the ladder program energizes
an alarm display coil, the screen associated with this coil is displayed and overrides the normal user
screens. This is designed to show alarm conditions or to display other ladder-detected events. When
the text coil is de-energized, the previous screen that was being viewed before the alarm is returned.
The switch display coil switches to the associated screen when it is energized. Once it is de-energized
the screen remains until it is switched by the user or ladder
Figure 13.4 – Force and Switch Coils in Ladder Programming
There is also a system register that can be used to for control based screen navigation. %SR1 can be
read to determine the current screen or written to change the current screen.
Refer to the on-line help in Cscape for more information on control-based screen navigation.
13.6 Beeper Acknowledgement
The XL7 contains an internal beeper that provides an audible acknowledgment when an operator
touches a graphic object that accepts touch input. When the graphic object is enabled, a short 5ms tone
is emitted. When the graphic object is disabled, a longer 100ms tone is emitted to enounce that
graphical object is not currently accepting the touch input.
If beep acknowledgement is not desired, the beeper function can be disabled from the system menu.
13.7 Touch (Slip) Sensitivity
Touch slip sensitivity is preset to meet most applications; however, adjustment is available to reduce the
sensitivity for touch release. That is, once a graphical object (button) is touched and held by a finger,
the default touch slip sensitivity allows for a slight slip of the finger on the graphical object before the
XL7 assumes touch has been released (equates to approximately a quarter inch of movement with a
stylus).
In some applications (such as jog buttons) where the operator is pushing a button for a period of time,
the amount of slip while holding a button pressed may exceed the default sensitivity. To increase the
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Highest
(Red)
Unacknowledged Alarms Exist
—
(Yellow)
Acknowledged Alarms Exist
Lowest
(Green)
No Alarms Exist
amount of tolerable slip and prevent false releases of the button, the XL7 allows adjustment of the
allowable slide up to 5x the default value.
To enable the touch (slip) sensitivity, first an OCS data register must be allocated through the Graphics
editor Configuration menu for Display Settings. Once a Touch Sensitivity register is assigned, that
register may be modified [range = 1(Low) to 5 (High)] to the desired slide amount. If a value outside the
valid range is entered in the touch sensitivity register, it is ignored and the last valid value is used.
13.8 Alarms
Alarm presentation to the operator is highly configurable and beyond the scope of this document to
describe fully. For more information refer to the graphics editor help file. This section presents a typical
configuration thereby providing an introductory description on what the operator should expect.
The alarm object is generally used to enunciate alarms to the operator. While the display characteristics
of this object is configurable, it is generally displayed as a button that changes colors to indicate the
highest state of the alarm(s) in the alarm group it is monitoring. The following indicates the priority of
the alarm states and the default colors associated with these states.
Figure 13.5 – Alarm Object
To view, acknowledge and/or clear alarms, the operator must access the alarm viewer. This is
accomplished by touching an (enabled) alarm object. When accessed, the alarm viewer is displayed as
pop-up alarm viewer dialog similar to that shown in Figure 13.6.
Figure 13.6 – Alarm Viewer
The currently selected entry is indicated by a yellow highlight which can be moved up or down by
touching the arrow buttons or by directly touching an entry. If more entries exist than can fit on the
page, a scroll bar is displayed on the right side that also indicates the current relative position.
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Highest
(Red)
Device Error
—
(Yellow)
Device Full (threshold adjustable)
Lowest
(Green)
Device OK
The current state of the displayed alarm is indicated by its color and optionally by an abbreviated
indicator after the date/time stamp (ALM, ACK, RTN). The operator can acknowledge an alarm by
selecting it from the list and touching the ACK button. The operator can also clear an alarm if that
function is enabled in the alarm object. If not enabled, the Clear buttons are grayed and do not respond
to touch. Once view operations are complete, simply touch the Esc button to remove the pop-up alarm
viewer.
Note that OCS registers %SR181 and %SR182 are available for ladder use, which indicate presence of
unacknowledged or acknowledged alarm (respectively). The screen designer may implement these
registers to switch screens or activate the beeper to attract the operator’s attention.
13.9 Removable Media
The removable media object is generally used to inform the operator on the current state of the
removable media device and allow access to its file structure. The removable media object is displayed
as a button that changes colors to indicate the current state of the removable media device. The
following indicates the device states and the default colors associated with these states.
Figure 13.7 – Removable Media Object
To view and perform file operations, the operator must access the removable viewer. This is
accomplished by either touching an (enabled) removable media object or through the system menu.
When accessed, the removable media viewer is displayed as pop-up removable media dialog similar to
that shown in Figure 13.8.
Note that the removable media object can be configured to open the removable media viewer at a
certain directory complete with restrictions on transversing back up the file path. This may be used to
restrict operator access to non-critical files.
Figure 13.8 – Removable media viewer
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..
change display to parent directory
<DIR>
change display to child directory
bmp, jpeg
display bitmap (if compatible format)
pgm
load application (if compatible model and version)
The currently selected entry is indicated by a yellow highlight which can be moved up or down by
touching the arrow buttons or by directly touching an entry. If more entries exist than can fit on the
page, a scroll bar is displayed on the right side that also indicates the current relative position.
File operations are accomplished by pressing the appropriate button at the bottom of the removable
media viewer. The configuration of the removable media object that invokes the removable media
viewer defines what buttons are enabled and available to the user. A button is grayed and does not
respond to touch if configured as disabled.
The (Enter) button (if enabled) performs certain operations based on the selected file’s type:
Alternately, the (enter) button can be configured to simply load the ASCII representation of the file path
(including the file name) to a group of OCS registers. That pathname can then be used by ladder for
opening and manipulating that file.
Once view operations are complete, simply touch the Esc button to remove the pop-up removable
media viewer.
If the removable media is used in an application, the removable media device requires changing by the
operator, and the application is attempting to write to the removable media when it is removed, the
screen designer should create objects that allow the operator to temporally halt access to the
removable media. This prevents corruption to the file system if the removable media is removed during
a file write sequence. The graphic objects should set OCS register %SR174.1 (when requesting the card
be removed) and provide an indicator based on OCS register %SR174.2 (which indicates that it is safe to
remove the removable media).
Figure 13.9 – Example application segment for safe removal of removable media
13.10 Screen Saver
The XL7 screen backlight life is typically 5 years when in continuous use. If the application does not
require interaction with the XL7 for long periods of time, the backlight life can be extended by using the
screen saver function. When enabled through the system menu, the backlight is shut off (screen goes
black) after a specified time of no touch activity on the screen. When the screen saver shuts off the
backlight, any operator touch on the screen or function keys reactivates the backlight.
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Note that when the screen saver is active (backlight shut off), any initial touch activity on the screen (or
function key) to reactivate the backlight is otherwise ignored by the XL7. Any additional touch activity is
also ignored by the XL7 for approximately one second thereafter.
It is possible for the application to temporarily disable the screen saver by generating a positive
transition to %SR57.16 (coil only) at a rate faster than the screen saver timeout value. This may be
desired while waiting for alarm acknowledgement.
13.11 Screen Brightness
The XL7 provides a feature that allows screen dimming for night operation. To enable this feature, the
application must access and control system register %SR57 (Display Backlight Brightness). Screen
brightness is continuously variable by driving %SR57 through the range of 100 (full bright) to 0 (full off).
It is left to the screen designer on how to present a Screen Brightness control to the user, if required.
NOTE: the backlight life may be shorted when screen is dimmed or screen brightness is varied on a
repetitive basis.
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INTENTIONALLY LEFT BLANK
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Table 14.1 - Types of Registers found in the XL7 OCS
16-bit input registers used to gather analog input data such as voltages,
temperatures, and speed settings coming from an attached device
16-bit output registers used to send analog information such a voltages, levels or
speed settings to an attached device
These are digital flags used to control the displaying of screens on a unit which has
the ability to display a screen. If the bit is SET, the screen is displayed
%I Digital Input
Single-bit input registers. Typically, an external switch is connected to the registers
Single-bit flags used to give the programmer direct access to any front panel keys
appearing on a unit
%M Retentive Bit
Retentive single-bit registers
Single-bit output registers. Typically, these bits are connected to an actuator,
indicator light or other physical outputs
%R General Purpose Register
Retentive 16-bit registers
%S System Bit
Single-bit bit coils predefined for system use
%SR System Register
16-bit registers predefined for system use
%T Temporary Bit
Non-retentive single-bit registers
Table 14.2 – Common %S Register Definitions
Register
Description
%S1
Indicate First Scan
%S2
Network is OK
%S3
10mS timebase
%S4
100mS timebase
%S5
1 second timebase
%S6
I/O is OK
%S7
Always ON
%S8
Always OFF
%S9
Pause 'n Load soon
%S10
Pause 'n load done
%S11
I/O being forced
%S12
Forcing is enabled
%S13
Network I/O is OK
%S16
Ethernet COM module is OK
Table 14.3 – %SR Registers
Register
Name
Description
Min Val
Max Val
%SR1
USER_SCR
Current User Screen Number
1
1023
%SR2
ALRM_SCR
Current Alarm Screen Number (0=none)
0
1023
%SR3
SYS_SCR
Current System Screen Number (0=none)
0
14
%SR4
SELF_TEST
Bit-Mapped Self-Test Result
0
65535
%SR5
CS_MODE
Control Station Mode (0=Idle, 1=Do I/O, 2=Run)
0
2
XL7 User Manual
CHAPTER 14: REGISTERS
14.1 Register Definitions
When programming the XL7 OCS, data is stored in memory that is segmented into different types. This
memory in the controller is referred to as registers. Different groups of registers are defined as either
bits or words (16 bits). Multiple registers can usually be used to handle larger storage requirements.
For example 16 single bit registers can be used to store a Word or two 16 bit registers can be used to
store a 32-bit value.
%AI Analog Input
%AQ Analog Output
%D Display Bit
%K Key Bit
%Q Digital Output
14.2 Useful %S and %SR registers
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Table 14.3 – %SR Registers
Register
Name
Description
Min Val
Max Val
%SR6
SCAN_RATE
Average Scan Rate ( / 10)
-
1000
%SR7
MIN_RATE
Minimum Scan Rate ( / 10)
-
1000
%SR8
MAX_RATE
Maximum Scan Rate ( / 10)
-
1000
%SR9-10
EDIT_BUF
Data Field Edit Buffer
0
232-1
%SR11-12
LADDER_SIZE
Ladder Code Size
2
256K
%SR 13-16
Reserved
-
- - %SR17-18
IO_SIZE
I/O Configuration Table Size
16
127K
%SR19-20
NET_SIZE
Network Configuration Table Size
34
1K
%SR21-22
SD_SIZE
Security Data Table Size
- - %SR23
LADDER_CRC
Ladder Code CRC
0
65535
%SR 24-25
Reserved
-
-
-
%SR26
IO_CRC
I/O Configuration Table CRC
0
65535
%SR27
NET_CRC
Network Configuration Table CRC
0
65535
%SR28
SD_CRC
Security Data Table CRC
0
65535
%SR29
NET_ID
This Station’s Primary Network ID (CsCAN)
1
253
Network Baud Rate (CsCAN)
(0=125KB; 1=250KB; 2=500KB; 3=1MB)
Network Mode (0=network not required; 1=network
3=network required and optimized)
%SR32
LCD_CONT
LCD Display Contrast setting
0
255
%SR33
FKEY_MODE
Function Key Mode (0=Momentary; 1=Toggle)
0
1
RS232 Serial Protocol Mode
(Ladder- Controlled); 3=Modbus RTU; 4=Modbus ASCII)
%SR35-36
SERIAL_NUM
This Station’s 32-bit Serial Number
0
232-1
%SR37
MODEL_NUM
This Station’s Binary Model Number
0
65535
%SR38
ENG_REV
Firmware Rev Number ( / 100)
0000
9999
%SR39
CPLD_REV
BIOS Rev Number ( / 100)
000
255
%SR40
FPGA_REV
FPGA Image Rev Number ( / 10)
000
255
%SR41
LCD_COLS
Vertical Pixel Count
%SR42
LCD_ROWS
Horizontal Pixel Count
%SR43
KEY_TYPE
Keypad Type
%SR44
RTC_SEC
Real-Time-Clock Second
0
59
%SR45
RTC_MIN
Real-Time-Clock Minute
0
59
%SR46
RTC_HOUR
Real-Time-Clock Hour
0
23
%SR47
RTC_DATE
Real-Time-Clock Date
1
31
%SR48
RTC_MON
Real-Time-Clock Month
1
12
%SR49
RTC_YEAR
Real-Time-Clock Year
1996
2095
%SR50
RTC_DAY
Real-Time-Clock Day (1=Sunday)
1 7 %SR51
NET_CNT
Network Error Count
0
65535
%SR52
WDOG_CNT
Watchdog-Tripped Error Count
0
65535
%SR53-54
BAD_LADDER
Bad Ladder Code Error Index
0
65534
%SR55
F_SELF_TEST
Filtered Bit-Mapped Self-Test Result
0
65535
%SR56
LAST_KEY
Key Code of Last Key Press or Release
0
255
LCD Backlight Dimmer Register
0 = 0% On; 25=25% On; 100-255 = 100% On
%SR58
USER_LEDS
User LED Control / Status
0
65535
%SR59-60
Reserved
-
- - %SR61
NUM_IDS
This Station’s Number of Network IDs
1
253
%SR62
NUM_IDS
This Station’s Number of Network IDs
1
253
%SR63
SS_BASE
SmartStack I/O Base Selector
0
7
%SR30 NET_BAUD
%SR31 NET_MODE
%SR34 SERIAL_PROT
required; 2=network optimized;
(0=Firmware Update (RISM); 1=CsCAN; 2=Generic
0 3
0 3
0 4
%SR57 BAK_LITE
0 255
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Table 14.3 – %SR Registers
Register
Name
Description
Min Val
Max Val
%SR64
SS_STATUS
SmartStack I/O Base Status
0 2 %SR65-76
SS_INFO_1
SmartStack I/O Module #1 Information Structure
- - %SR77-88
SS_INFO_2
SmartStack I/O Module #2 Information Structure
-
-
%SR89-100
SS_INFO_3
SmartStack I/O Module #3 Information Structure
-
-
%SR101-112
SS_INFO_4
SmartStack I/O Module #4 Information Structure
-
-
%SR113-114
GOBJ_SIZE
Graphics Object Table Size
8
256K
%SR115-116
GSTR_SIZE
Graphics String Table Size
8
128K
%SR117-118
GBMP_SIZE
Graphics Bitmap Table Size
4
256K
%SR119-120
GTXT_SIZE
Graphics Text Table Size
8
128K
%SR121-122
GFNT_SIZE
Graphics Font Table Size
8
256K
%SR123-124
PROT_SIZE
Protocol Table Size
16
64K
%SR125
GOBJ_CRC
Graphics Object Table CRC
0
65535
%SR126
GSTR_CRC
Graphics String Table CRC
0
65535
%SR127
GBMP_CRC
Graphics Bitmap Table CRC
0
65535
%SR128
GTXT_CRC
Graphics Text Table CRC
0
65535
%SR129
GFNT_CRC
Graphics Font Table CRC
0
65535
%SR130
PROT_CRC
Protocol Table CRC
0
65535
%SR131-163
Reserved
-
-
-
Read bit indicating Auto Restore of Register Data has
been performed (Fail Safe)
%SR164.4
Read bit indicating Backup of Register Data has been
performed (Fail Safe)
%SR164.5
Enable AUTORUN (Fail Safe)
%SR164.6
Enable AUTOLOAD (Fail Safe)
%SR164.7
Backup trigger bit
%SR164.8
Clear Backup trigger bit
%SR164.9
MAKE_CLONE trigger bit
%SR164.10
LOAD_CLONE trigger bit
Status indicating Make Clone Fail (This bit goes high
when Make / Create clone fails)
Status indicating Load Clone Fail (This bit goes high
when Load clone fails)
%SR165-174
Reserved
%SR175
Removable Media
Current Removable Media interface status
0
6
Indicates free space on the Removable Media card in K
bytes.
%SR178-179
Removable Media
Indicates the total card capacity in K bytes.
0
231
%SR180
Reserved
-
-
-
Unacknowledged Alarm (high bit indicates what group
#)
%SR182
ALM_ACT
Active Alarm (high bit indicates what group #)
%SR183
SYS_BEEP
System Beep Enable (0=disabled; 1=enabled)
%SR184
USER_BEEP
Software configurable (0=OFF; 1=ON)
%SR185
SCR_SAVER
Screen Saver Enabled (0=disabled; 1=enabled)
%SR186
SCR_SA_TM
Screen Saver Time in minutes (delay)
%SR187
NET_USE
Average Net Usage of all units on the CAN network
%SR188
NET_MIN
Minimum Net Usage of all units on the CAN network
%SR189
NET_MAX
Maximum Net Usage of all units on the CAN network
%SR190
NT_TX_AVG
Average Net Usage of this unit
%SR191
NT_TX_MIN
Minimum Net Usage of this unit
%SR192
NT_TX_MAX
Maximum Net Usage of this unit
%SR164.3
%SR164.11
%SR164.12
%SR176-177 Removable Media
%SR181 ALM_UNACK
0 231
For additional information on system bits and registers, refer to the on-line help found in Cscape.
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Table 14.4 – Register Map for XL7 OCS I/O
Fixed
Address
XL7 Model
2 3 4
5
Digital Inputs
1-12
1-12
1-24
1-12
Reserved
13-32
13-31
25-31
13-31
ESCP Alarm
n/a
32
32
32
Digital Outputs
1-6
1-12
1-16
1-12
Reserved
7-24
13-24
17-24
13-24
Analog Inputs
1-4
1-2
1-2
1-2
Reserved
5-12
3-12
3-12
3-12
Reserved
n/a
1-8
1-8
1-8
Analog Outputs
n/a
n/a
n/a
9-10
Reserved areas maintain backward compatibility with other XL Series OCS models
Table 14.5– Resource Limits
Resource
Value
Resource
Value
CsCAN, Ping, EGD, SRTP, Modbus TCP
MBd
%SR
448
CsCAN
125 kBd, 250 kBd, 500 kBd, or 1 MBd
%T
16000
Serial Ports
1 RS232, 1 RS485 Ports
IDs Per CsCAN
Network
%R
49999
Keypad
5 keys (4 fn keys and a System Key)
%K 5 Display
800 x 480 7” TFT, 65K colors
%D
1023
Screen Memory
64 MB
%I
2048
User Screens
1023
Data Fields Per
User Screen
%AI
512
Ladder Code
1024 kB
%AQ
512
14.3 Register Map for XL7 OCS I/O
Digital/Analog I/O Function
%I1
%Q1
%AI1
%AQ1
14.4 Resource Limits
%S 16 Ethernet
%M 16000
%Q 2048
Master (Downloadable protocol) & Slave,
Ethernet IP, FTP, or HTTP @ 10 MBd or 100
64 w/o repeat (253 w/ 3 repeaters)
1023
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NOTES
Page 78 of 110
Ready
User:
HE-XExx1-CsCAN (Model=)
Equal
Local :1 Target :2(R) [no
forces]
MOD
Equal Indicator – indicates whether the current program in Cscape is equal to the program
stored in the Target Controller.
the same as the program stored in the Target
pe was
Communications Status - indicates the current status of the
“pass through” Connector.
•
•
Message Line -
The contents of
these messages
are context
sensitive. The
Message line can
be empty.
Current User -
indicates who is logged
(for security purposes).
Controller Model - Network (Model Confirmation)
•
•
work that the program
•
•
•
•
File Modified Indicator - indicates that
the file in the selected window has
aved.
XL7 User Manual
CHAPTER 15: CSCAPE CONFIGURATION
15.1 Overview
XL7 OCS hardware is programmed with a Windows based PC application called Cscape. This application
can be used to program, configure, monitor and debug all aspects of the XL7 OCS unit. Please see the
on-line help provided with Cscape for additional details.
15.2 Cscape Status Bar
When the XL7 OCS is connected to a PC using Cscape software a Status Bar appears at the bottom of the
screen. The Cscape Status Bar can be used to determine if communications have been established
between the XL7 OCS and the Cscape program. Components of the Cscape Status Bar are explained
below.
• If Equal, the program in Cscape is the same as the program stored in the Target Controller.
• If Not Equal, the program in Cscape is not
Controller.
• If Unknown, there may have been a change since the last time the program in Csca
compared to the Target Controller.
been modified but has not been s
Controller Model indicates the controller model for
which the program in Cscape is configured.
Network indicates the type of net
in Cscape expects to use (e.g., CsCAN).
(Model Confirmation) provides the following
indications:
(Model=) - the actual Target Controller matches the
configured Controller Model and Network.
(Model Not=) – the actual Target Controller does not
match the configured Controller Model and Network.
(Model ?) – there may have been a change since the
last time the Target Controller was compared to the
configured Controller Model and Network.
Local: xx – indicates the Network ID of the OCS to which
the Cscape program is physically connected through its
serial port. It can serve as a pass through device to other
nodes on the network.
Target: yy(R) – indicates the Network ID of the device with
which the Cscape program is exchanging data.
Note: The Local unit and Target unit can be the
same unit or they can be separate units.
The following are status indicators:
(R) – Running
(D) - Do I/o
(I) – Idle
(?) – Cscape is not communicating with the remote unit.
[no forces] – indicates no I/O has been forced.
Figure 15.1 - Cscape Status Bar
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15.3 Establishing Communications
The preferred method of communicating between Cscape and an XL7 OCS is via USB port. The XL7 OCS
can communicate with Cscape using USB to USB, USB to serial adapters, serial port communications via
MJ1 Port, Ethernet, CAN (CsCAN) or modems. For communications other than USB or the MJ1 port
please refer to the manual which ships with the communications adapter hardware being used for
programming.
To communicate with the XL7 via USB you will need the automated driver installer located on the
Horner APG web site.
For XL7 use Cscape Ver 9.30 SP6 or newer.
Next, connect a PC’s (Personal Computer running a Windows Microsoft operating system) USB port via
USB cable to the USB mini B port on the XL7 OCS.
Figure 15.2 – USB Programming Connector
The PC will detect a new device has been plugged into the USB port.
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Now that the XL7 is plugged in, go to Cscape, Tools, Application Settings, Communications and choose
the USB port (in this example Com 3).
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If communication is established, the target indicator will show the mode of the controller
Target: yy(R) as shown in the status section above in this chapter, section Cscape Status Bar.
If the controller is not communicating, ensure the target ID is set correctly. If not, set the target ID of the
controller in Cscape or on the unit. The Target ID allows directing communications to a particular unit
when multiple units are connected via a CsCAN network. Units without CsCAN network ports respond
to any network ID and do not require the ID to be configured.
To check or change the ID on the XL7 OCS, press the system menu key.
The first item in the menu is Set Networks. Pressing Enter allows the ID of the unit to be viewed or
modified.
To change the Target ID of Cscape use the Controller | Set Target Network ID dialog.
15.3.1 Communicating via MJ1 Serial Port
Start by configuring Cscape to use the correct communications port. This can be done using the Tools |
Options | Communication Port dialog in Cscape.
Next, connect the PC’s serial port to the port labeled MJ1 on the XL7.
If communications are successful, the target indicator should show the mode of the controller Target:
yy(R) as shown in the status section above.
If the controller is not communicating, it may be required to set the target ID of the controller in Cscape
or on the unit. The Target ID allows directing communications to a particular unit when multiple units
are connected via a CsCAN network. Units without CsCAN network ports respond to any network ID and
do not require the ID to be configured.
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To check or change the ID on the XL7, press the System Button to enter the system menu. The first item
in the menu is Set Network ID.
Pressing Enter allows the ID of the unit to be viewed or modified.
To change the Target ID of Cscape use the Controller | Set Target Network ID dialog.
15.3.2 Communicating via On Board Ethernet Port
From Cscape go to Controller -> I/O Configure and do auto configuration for the connected controller,
Click on Config of Ethernet & go to Module Setup.
The IP address, Net Mask and Gateway of the controller may be temporarily set from the system menu
under the Set Networks menu item. Once running or power cycled the configuration will come from the
Cscape configuration stored in the unit.
In Module configuration dialog go to IP Address field enter unused IP Address and configure unused
registers in Register field & then click OK. Screen shot for the same as follows:
Download the configuration in to Controller. Connect LAN cable to the Controller in default LAN Port.
From Cscape go to Tools -> Editor Options -> Communication Port -> configure. Select Ethernet and
enter IP address which is configured in the file. Select mode as XL Series mode from drop down list.
The controller should get connected to Cscape. If communications are successful, the target indicator
should show the mode of the controller Target: yy(R) as shown in the status section above.
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15.4 Configuration
An overview of configuration:
1. Start the configuration by selecting the Controller | I/O Configure menu item.
2. If the XL7 OCS is connected to the PC press the Auto Config System button to automatically
detect the Base model, I/O and any communication options.
3. If the XL7 OCS is not connected press the Config button to the right of the top of the unit. This
allows the base CPU to be selected.
4. Select either XL7 OCS Cscan from the type drop down box.
5. Once the type of XL7 OCS is selected, the model # drop down box will provide the XL7 OCS
model numbers from which to choose from.
6. Once the XL7 OCS CPU is selected, press OK to exit the dialog and configure the I/O that is
present in the first slot.
7. The I/O configure dialog (Specifically the Module Setup tab) provides 4 buttons to configure all
of the I/O. Go through each area of I/O and configure it.
8. Once done configuring the I/O OK out of configuration dialogs.
Configuring the XL7 OCS I/O has four main portions that are covered in this chapter. For additional
information on I/O, refer the chapters covering General I/O or High Speed I/O in this manual.
The four areas of I/O configuration are:
- Digital in / HSC
- Digital out / PWM
- Analog in
- Analog out
15.5 Digital Input / HSC Configuration
The following figure illustrates the Digital Input / HSC Configuration dialog.
Figure 15.3 – Digital Input / HSC Configuration Dialog
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The Active mode group box allows the user to select if inputs are active high (Positive logic) or active low
(Negative logic). It is important that this setting match what the jumper settings are on the hardware.
The High Speed Counters group box contains all of the windows that are used for configuring the 4
available high speed counters on the XL7 OCS. In configuring a counter, the user needs to set the type,
mode, and counts per rev.
The type drop down includes the following options:
- Disabled
- Frequency Measurement
- Period Measurement
- Totalize
- Pulse Width Measurement
- Quadrature
For detailed descriptions of
the High Speed Counter types
available within the drop down
menu, see Chapter 11, starting on
page 45 of this manual.
15.6 Digital Output / PWM Configuration
The following figure illustrates the Digital Output / PWM Configuration dialog.
Figure 15.4 – Digital Output / PWM Configuration Dialog
The Q1 and Q2 group boxes allow the user to specify the operation of the multi-function outputs.
The PWM State On Controller Stop group box contains items that allow the user to specify how the
PWM outputs behave when the controller is stopped. These items can either hold their value or default
to some value when the controller is stopped.
Note that the PWM outputs are set to the OFF state at power-up and during program download and
remain in that state until the unit is placed in RUN
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The Output State On Controller Stop group box contains items to allow the user to specify how the
remaining digital outputs behave when the controller is stopped. These items can either hold their value
or default to some value when the controller is stopped.
15.7 Analog Input Configuration
The following figure illustrates the Analog Input Configuration dialog.
Figure 15.5 – Analog Input Configuration Dialog
The Channel x drop down windows allow the user to specify the mode for each analog input to operate.
The Channel x drop down windows are enabled/disabled according to which model is being configured.
All of the models have the following modes available:
- 0..10V
- 0..20mA
- 4..20mA
On model 005, all channels (1-4) also have the following modes available:
- 100mV
- PT100 DIN RTD, 1/20°c
- Type J Thermocouple, 1/20°c
- Type K Thermocouple, 1/20°c
- Type N Thermocouple, 1/20°c
- Type T Thermocouple, 1/20°c
- Type E Thermocouple, 1/20°c
- Type R Thermocouple, 1/20°c
- Type S Thermocouple, 1/20°c
- Type B Thermocouple, 1/20°c
The Filter Constant provides filtering to all channels.
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15.8 Analog Output Configuration
The following figure illustrates the Analog Output Configuration dialog.
Figure 15.6 – Analog Output Configuration Dialog
The Output value on Stop group box contains items that allow the user to specify how the analog
output channels behave when the controller is stopped. The outputs can either hold their value or
default to a value when the controller is stopped.
The Output Mode group box allows the user to select the operating modes for each of the analog
outputs. The modes include the following:
- 0..10V
- 0..20mA
- 4..20mA
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Chapter 16: Fail – Safe System
16.1 Overview
The Fail-Safe System is a set of features that allow an application to continue running in the event of
certain types of "soft" failures. These "soft" failures include:
- Battery power loss
- Battery-Backed Register RAM or Application Flash corruption due to, for example, an excessive
EMI event.
The Fail-Safe System has the following capabilities:
- Manually backup the current Battery-Backed RAM Register Settings into Flash memory.
- Manually restore Register Settings from the values previously backed up in Flash to Battery-
Backed RAM.
- Detect corrupted Register Settings at power-up and then automatically restore them from Flash.
- Detect corrupted or empty application in Flash memory at power-up and then automatically
load the AUTOLOAD.PGM application file from Removable Media (Compact Flash or MicroSD).
- If an automatic Register Restore or Application Load occurs, the OCS can automatically be
placed in RUN mode
The fail-safe system can be accessed by going to the system menu of the controller. A new menu “FailSafe System” has been added at the end of the main system menu for this. Selecting “Fail-Safe System”
menu will open the following menu screen:
Figure 16.1 – Fail – Safe System Menu
16.2 Settings
To use the fail – safe feature, the user needs to do the following:
1. Backup the current Battery-Backed RAM Register contents in On-Board Flash memory using
System Menu options.
2. From Cscape, create AUTOLOAD.PGM for the application program using ‘Export to Removable
Media’.
3. Place the Removable Media with AUTOLOAD.PGM in the device.
4. Set the ‘Enable AutoLoad’ option in the device to YES.
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5. Set the ‘Enable AutoRun’ option to YES if the controller needs to be placed in RUN mode
automatically after automatic restore of data or AutoLoad operation.
16.3 Backup / Restore Data
Selecting this option brings up a screen having four operations:
- Backup OCS Data.
- Restore OCS Data.
- Clear Backup Data.
- Exit
Figure 16.2 – Backup / Restore Data
Backup OCS Data:
When initiated, this will allow the user to manually copy Battery-Backed RAM contents on to the
onboard FLASH memory of the OCS. This will have the effect of backing up all the registers and
controller settings (Network ID, etc.) that would otherwise be lost due to a battery failure.
%SR164.4 is set to 1 when backup operation is performed.
Figure 16.3 – Backup Registers
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Restore OCS Data:
When initiated, this will allow the user to manually copy the backed up data from the onboard FLASH to
the Battery-Backed RAM.
A restore operation will be automatically initiated if a backup has been previously created and on
power-up the Battery-Backed RAM registers fail their check.
The following process will be followed for restoring data:
- The controller will be placed in IDLE mode.
- Data will be copied from onboard FLASH to OCS Battery-Backed RAM
- The controller will reset.
- The controller will be put in RUN mode if the AutoRun setting is ‘Yes’ else it will remain in IDLE
mode.
Figure 16.4 – Restore OCS Data
%SR164.3 is set to 1 only when an automatic restore operation is performed - not on a manual one. This
bit is reset to 0 when a new backup is created.
Restoring of data can be manually performed by selecting RESTORE option from the Backup / Restore
Data menu. This will cause the controller to reset.
Clear Backup Data:
When initiated, the backup data will be erased from the onboard Flash and no backup will exist.
%SR164.4 and %SR164.3 is reset to 0 when backed up data is erased.
Exit: Goes back to the previous screen.
Figure 16.5 – Clear Backup Data
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OCS Power Cycle
Battery Backed RAM
Registers check failed
Backup
exists?
Controller placed in
IDLE mode
Data copied from Onboard FLASH to OCS Battery backed
RAM
Controller Resets
AutoRun
Enabled?
OCS put in RUN Mode
OCS put in IDLE
Mode
NO
YES
YES
NO
Application
Program erased
The OCS follows the following sequence in execution of Automatic Restore:
Figure 16.6 – Flow Chart for Automatic Restore
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16.4 AutoLoad
This system menu option allows the user to specify whether the OCS automatically loads the application
AUTOLOAD.PGM located in Removable Media.
When the AutoLoad setting is enabled (set to YES), it can either be manually initiated or automatically
initiated at power-up.
The automatic initiation will happen only in the following two cases:
• When there is no application program in the OCS and a valid AUTOLOAD.PGM is available in the
removable media of the device.
• When the program residing in onboard memory is corrupted and a valid AUTOLOAD.PGM is
available in the removable media of the device.
AutoLoad can be manually initiated when the SYS-F3 key is pressed (OCS can be in any of the following
mode – Idle / Run / DOIO). This also requires a valid AUTOLOAD.PGM to be present in the removable
media of the device.
When the AutoLoad setting is not enabled (set to NO), OCS will be in IDLE mode and the application is
not loaded.
If the AUTOLOAD.PGM is security enabled, the user will be prompted to enter the password before
loading the application. The application will be loaded from the Removable media only after getting the
correct password.
%SR164.6 can be set to enable AutoLoad feature.
Figure 16.7 – AutoLoad Menu
Page 93 of 110
The OCS follows the following sequence in execution of AutoLoad:
Power up OCS
Application Program absent
or
Application Program corrupted
AutoLoad
Enabled?
AUTOLOAD.PGM present in
the RM of the device ?
AutoLoad initiated.
OCS put in IDLE mode
AutoLoad run sequence
failed (with reasons for
failure)
NO
NO
YES
YES
AutoRun
Enabled?
OCS put in RUN Mode
OCS put in IDLE Mode
NO
YES
XL7 User Manual
Figure 16.8 – Flow Chart for AutoLoad
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16.5 AutoRun
This system menu option, when enabled (YES), allows the user to automatically place the OCS into RUN
mode after the AutoLoad operation or automatic Restore Data operation.
When the AutoRun setting is disabled (NO), the OCS remains in the IDLE mode after a Restore Data or
AutoLoad operation.
%SR164.5 can be set by putting the system into RUN mode automatically, once an AutoLoad has been
performed or an Automatic Restore has occurred.
If for any reason the AutoLoad-Run (Loading the AUTOLOAD.PGM automatically and OCS put in RUN mode)
sequence does not succeed, a pop-up message box saying "AUTO-LOAD-RUN SEQUENCE FAILED" will be
displayed. It will also show the reason for its failure. On acknowledging this message box the AutoLoad-Run
sequence will be terminated, controller will return to the first user-screen and will be placed in IDLE mode.
Figure 16.9 – AutoRun Menu
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CHAPTER 17: CLONE UNIT
17.1 Overview
‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones”
application program and unit settings stored in Battery backed RAM of an OCS into the RM (refer
Removable Media, Chapter 9, for details in using RM). It can then be used to clone a different OCS (exact
same model).
This feature can be used for:
- Replacing an OCS by another unit of the same model.
- Duplicating or “clone” units without a PC.
17.2 Clone
User needs to perform the following to Clone:
1. The ‘Clone Unit’ can be accessed by going to the ‘System Menu’ of the OCS. A new menu “Clone
Unit” has been added at the end of the main system menu as shown below:
Figure 17.1 – System Menu
2. Selecting “Clone Unit” menu will open the following menu screen:
Figure 17.2 – Clone Unit Menu before Cloning
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Free/Total – displays number of free and total bytes in Removable Media.
3. Make/Create Clone option enables user to duplicate / Clone application file, all unit settings and all
register values from Battery Backed RAM.
Selecting Make Clone brings up the screen below for the user:
Figure 17.3 – Clone Unit Confirm Screen
After confirmation, the OCS will create two new files in the root directory of the Removable Media Drive
as shown below:
AUTOLOAD.PGM Application file
CLONE.DAT File having all unit settings and register values from Battery Backed RAM
Figure 17.4 – Clone Unit Files
NOTE: Make/Create clone operation automatically includes the security in \AUTOLOAD.PGM file for
security enabled files.
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4. Once the cloning is successful, OCS gives a message as below:
Figure 17.5 – Cloning Status
Make/Create clone can also be triggered by setting %SR164.9 bit to “1” from Ladder program or
graphics. Once the operation is completed, this bit is made zero by the firmware. When Make clone
operation is triggered by this SR bit, it does not ask the user for confirmation for making clone. The
success / failure of the operation is also not notified on screen to the user.
In case of failure of “Make Clone” operation, %SR164.11 bit is set to “1” by the firmware and never
reset.
NOTE: Backup of registers in flash memory is not performed by Clone Feature. If user desires, Backup
should be done as explained in Chapter 16 (Fail Safe System).
17.3 Load Clone
This option loads the application, all unit settings and register values from Removable media to the
Battery backed RAM (Regardless of AutoLoad settings) and then resets the OCS for the settings to take
effect.
User needs to perform the following to Load Clone:
1. Select “Clone Unit” from main system menu of OCS as shown below:
Figure 17.6 – System Menu
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2. Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”.
Figure 17.7 – Clone Unit Menu after Cloning
3. User needs to confirm Load Clone as shown below:
Figure 17.8 – Load Clone Confirm Screen
4. After confirmation, all unit settings and register values will be loaded from Removable media to the
Battery backed RAM (Regardless of AutoLoad settings) and then OCS resets for the settings to take
effect.
NOTE: For security enabled files, Load clone asks for password validation before loading the application.
Load clone can also be triggered by setting %SR164.10 bit to “1” from Ladder program or graphics. Once
the operation is completed, this bit is made zero by the firmware. When Load clone operation is
triggered by this SR bit, it does not ask the user for confirmation for loading clone. The success / failure
of the operation is also not notified on screen to the user.
In case of failure of “Load Clone” operation, %SR164.12 bit is set to “1” by the firmware and never reset.
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CHAPTER 18: MAINTENANCE
18.1 Firmware Updates
The XL7 OCS products contain field updatable firmware to allow new features to be added to the
product at a later time. Firmware updates should only be performed when a new feature or correction
is required.
Warning: Firmware updates should only be performed when the equipment being controlled by
the XL7 OCS is in a safe, non-operational state. Communication or hardware failures during the
firmware update process can cause the controller to behave erratically resulting in injury or
equipment damage. Make sure the functions of the equipment work properly after a firmware
update before returning the device to an operational mode.
Steps for updating the firmware:
1. Loading new firmware will erase any program stored in the OCS for safety and compatibility
reasons. Please backup the application prior to performing a firmware update.
2. Copy the supplied files onto a FAT32 formatted MicroSD or USB based flash device.
3. Insert the flash device into the XL7 making sure no other memory or drives are connected to the
device.
4. Press and hold the system menu for at least 6 seconds and a firmware update menu will be
presented.
5. If you are just updating the firmware, press the “Update Firmware” button. If you are updating
the bootloader, firmware and FPGA, press the “Update Bootloader” button. On early versions
of firmware this can take several minutes. This will take about 15 seconds on newer firmware.
18.2 Backup Battery
The XL7 has an advanced battery system. It uses a rechargeable lithium battery. The battery powers
the real time clock when power is removed. To store registers, the battery continues to power the OCS
for less than a second after external power is removed. In this time the registers and other retentive
data is saved to internal flash memory. This battery will need about 8 hours of charging to last
approximately 2 years when powered off.
NOTE: For the registers to be retentive the battery only need to be charged and present at power down.
Under normal conditions the battery in the XL7 OCS should last approximately seven years. Higher
operating temperatures or variations in batteries may reduce this time.
18.2.1 Indications the battery needs replacing
The XL7 OCS indicates the battery is low, failed or missing in a variety of ways. At power-up, an error
message is displayed indicating the low or missing battery. The user program can monitor the battery
using %SR55.13. This bit will turn on if the battery is low or missing. The system menu also contains a
battery status message under the diagnostics sub-menu (see the chapter on System Settings and
Adjustments).
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