Horner APG XL7 User Manual
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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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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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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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.
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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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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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