This manual explains how to use the XLe/XLt OCS Modules.
Copyright (C) 2008 Horner APG, LLC., 59 South State Avenue, Indianapolis, Indiana 46201. All rights
reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language or computer language, in any form by any means, electronic,
mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written
permission of Horner APG, Inc.
All software described in this document or media is also copyrighted material subject to the terms and
conditions of the Horner Software License Agreement.
Information in this document is subject to change without notice and does not represent a commitment on
the part of Horner APG.
Cscape, SmartStack, SmartStix and CsCAN are trademarks of Horner APG.
Ethernet is a trademark of Xerox Corporation.
Micro SD and CompactFlash are registered trademarks of SanDisk Corporation.
For user manual updates, contact Technical Support:
Horner APG, LLC. ("HE-APG") warrants to the original purchaser that the XLe/XLt OCS
HE-APG is free from defects in material and workmanship under normal use and service. The obligatio n of HE-APG
under this warranty shall be limited to the repair or exchange of a ny 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 disc losed t o the satisfaction of HE-APG
after examination by HE-APG of the allegedly defective part or parts. THIS WARRANTY IS EXPRESS LY 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 HEAPG NEITHER ASSUMES, NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY OTHER
LIABILITY IN CONNECTION WITH THE SALE OF THIS XLe/XLt OCS module. THIS WARRANTY SHALL NOT
APPLY TO THIS XLe/XLt OCS
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 XLe/XLt OCS
module
THE CONTINENTAL UNITED STATES.
In no event, whether as a result of breach of contract, warranty, tort (including negligence) or otherwise, shal l HE-
APG or its suppliers be liable of any special, consequential, incidental or penal damages inclu ding, but not limited to,
loss of profit or revenues, loss of use of the products or any associated equipment, damage to associated equipm ent,
cost of capital, cost of substitute products, facilities, services or replacement power, down time costs, or claims of
original purchaser's customers for such damages.
To obtain warranty service, return the product to your distributor with a description of the problem, proof of
purchase, post paid, insured and in a suitable package.
IS ORIGINALLY INSTALLED. THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF
module OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT,
module manufactured by
ABOUT PROGRAMMING EXAMPLES
Any example programs and program segments in t his manual or provided on accompanying diskettes are included
solely for illustrative purposes. Due to the many variables and requirements associated with any particular
installation, Horner APG cannot assume responsibility or liability for actual use based on the examples and diagr ams.
It is the sole responsibility of the system designer utilizing the XLe/ XLt OCS
system, to appropriately integrate the XLe/XLt OCS module and to make safety provisions for the end equ ipment as
is usual and customary in industrial applications as defined in any codes or standards which apply.
module to appropriately design the end
Note: The programming examples shown in this manual are for illustrative
purposes only. Proper machine operation is the sole responsibility of the
system integrator.
August 12, 2009 Page 3 of 100 ECN # 979
MAN0878-04-EN Table Of Contents
Table of Contents
VISUAL MAP OF MAJOR TASKS AND THE KEY CHAPTERS TO ASSIST YOU...................................
18.5 Technical Support Contacts......................................................................................................96
INDEX .........................................................................................................................................................97
TABLE OF FIGURES.................................................................................................................................99
August 12, 2009 Page 6 of 100 ECN # 979
MAN0878-04-EN VISUAL MAP
VISUAL MAP OF MAJOR TASKS AND THE KEY CHAPTERS TO ASSIST YOU
The following map is provided to show you the major types of tasks needed to be performed and the key
chapters in this manual you need to refer to for information and help.
Directions: Major tasks are listed at the top of the map with the key chapters listed beneath that you
need to consult in order to perform the tasks.
FIRST STEP of ANY TASK: DATASHEET
Each XLe/XLt unit is sent with a datasheet in the box. The datasheet is the first
to refer to for model-specific information related to XLe/XLt models such as pin-outs, jumper
settings, and other key installation information. The web version of this manual has all of the
XLe/XLt datasheets attached to it. Visit our website (see page
When found on the product, the following symbols specify:
WARNING – EXPLOSION HAZARD – Substitution of components may impair suitability for
Class I, Division 2
WARNING – EXPLOSION HAZARD – Do not disconnect equipment unless power has been
switched off or the area is known to be non-hazardous.
WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth)
ground before making any other connections.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly
recommended to fuse the voltage measurement inputs. Be sure to locate fuses as close to the
source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk of
fire and shock hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated failure
indicates a defective condition that will not
WARNING: Only qualified electrical personnel familiar with the construction and operation of
this equipment and the hazards involved should install, adjust, operate, or service this
equipment. Read and understand this manual and other applicable manuals in their entirety
before proceeding. Failure to observe this precaution could result in severe bodily injury or
loss of life.
• All applicable codes and standards need to be followed in the installation of this product.
• For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG or
Adhere to the following safety precautions whenever any type of connection is made to the module.
• Connect the green safety (earth) ground first before making any other connections.
• When connecting to electric circuits or pulse-initiating equipment, open their related breakers. Do
• Make connections to the module first; then connect to the circuit to be monitored.
• Route power wires in a safe manner in accordance with good practice and local code s.
• Wear proper personal protective equipment including safety glasses and insulated gloves when
• Ensure hands, shoes, and floors are dry before making any connection to a power line.
• Make sure the unit is turned OFF before making connection to terminals. Make sure all circuits
• Before each use, inspect all cables for breaks or cracks in the insulation. Replace immediately if
Warning: Consult user documentation.
clear by replacing the fuse.
larger.
make connections to live power lines.
not
making connections to power circuits.
are de-energized before making connections.
defective.
Warning: Electrical Shock Hazard.
August 12, 2009 Page 9 of 100 ECN # 979
CH. 1 MAN0878-04-EN
1.2 Grounding
Grounding is covered in various chapters within this manual.
For grounding specifications and testing for a good ground, refer to page
For panel grounding, refer to
18.
21.
1.3 CE Compliance
To check for compliance and updates, visit our website at:
2.1 Visual Overview of XLe/XLt and Topics Covered in this Manual
User Interface
See page 61.
Serial Comm
See page 23.
Figure 2-1 – Visual Overview of XLE/XLT and Topics of Interest Covered in the User Manual
2.1.1 Where to Find Information about the XLe/XLt
a. Datasheets - The datasheets are the first documents you need to refer to for key information
related to specific XLe/XLt models. (A datasheet is provided in the box with your unit.)
The datasheets for all XLe/XLt models are attached to the back of this manual on our website, and they
are also available individually on the web.
Datasheets contain pin-outs, jumper settings and other model specific information.
b. User Manual -This manual provides general information that is common to XLe/XLt models and can
be downloaded from our web. Visit our website (see page
Four main types of information are covered in the manual.
Safety and Installation guidelines / instructions (Mechanical and Electrical)
Descriptions of hardware features (Serial ports, Removable Media, Communication Options, etc.)
Configuration and Use of the XLe/XLt
Maintenance and Support
Removable
Media
See page 29.
Mechanical
Installation
See page 15.
General I/O
See page 33.
High Speed I/O
See page 39.
CAN Comm
See
page 25.
Electrical
Installation
See page 21.
96) to obtain user documentation and updates.
August 12, 2009 Page 11 of 100 ECN # 979
CH.2 MAN0878-04-EN
2.2 Connectivity to the XLe/XLt
The XLe/XLt has tremendous capabilities for connecting to a variety of devices. The diagram below
shows some examples of devices that can be used with the XLe/XLt.
Other OCS Devices
Smart Stix I/O
RCS116 I/O Base
2.3 Features of XLe/XLt
The XLe/XLt is an all-in-one industrial control device. It combines control, user interface, I/O and
networking into a single, integrated package. Unique features of the XLe/XLt include:
OPC Server
Sensors
Indicators
Alarms
Encoders
Pumps
Relays
Solenoids
Figure 2-2 – Visual Overview of Types of Devices that can be connected to XLe/XLt
• Bright, graphical LCD display (in XLe) (with touch sensing in XLt)
• Display of complex graphical objects including trends, gauges, meters and ani mations
• Advanced control capabilities including floating point, multiple auto-tuning PID loops and string
handling capabilities
• Removable media for up to two gigabyte of storage of programs, data logging or screen captures
• CsCAN networking port (optional) for communication with remote I/O, other controllers or PCs
• 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 XLe/XLt model used)
• Cscape programming software that allows all aspects of the XLe/XLt to be programmed and
configured from one integrated application
• Optional communication add-on modules that allow additional capabilities such as Ethernet or
modems
•Fail – Safe System which allows an application to continue running in the event of “Soft” failures
like (Battery power loss or Battery Backed register RAM / Application Flash corruption)
• Clone Unit allows 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. It can then be used to clone
a different OCS (exact same model)
CAN
XLe/XLt
I/O
Serial
Other OCS Devices
Drives
PLCs
Bar Code Readers
Printers
SCADA
OPC Servers
Serial I/O
August 12, 2009 Page 12 of 100 ECN # 979
MAN0878-04-EN CH. 2
2.4 Required and Suggested Accessories
The following list contains a sampling of required and suggested XLe/XLt accessories. Visit our website
(see page
96) to view updates on new products and accessories.
Note: The XLe/XLt is not shipped with a programming cable in the box. To obtain a programming
cable, order HE500CBL300.
Table 2.1 – XLe/XLt Accessories
Part Number Description
HE-XEC
HE-XMC
HE-MC1 Removable Media card - compatible with XLe/XLt. Card capacity is 256 MB or larger.
10/100 Ethernet option kit - field installable. Kit includes all parts necessary for internal installation within
the XLe/XLt case, including a deeper plastic back cover adapted for Ethernet operation.
14.4 k Telephone modem option kit - field installable. Kit includes all parts necessary for internal installation
within the XLe/XLt case, including a deeper plastic back cover adapted for modem operation.
Media Card Reader for HE-MC1. Portable device allows HE-MC1 to be plugged into the USB port of
personal computers as a portable hard drive.
Power supply 100-240VAC or 140-340VDC Switching supply that outputs 1.5 A / 3 A
(HE-X24-AS/AL) at 24 VDC. Mounts on Standard DIN rail. Designed for X Family products.
Power supply 100-240 VAC or 140-340 VDC Switching supply that outputs 1.5 A / 3 A
(HE-X24-AS/AL) at 24VDC. Mounts on Standard DIN rail. Designed for X Family products.
USB programming kit. Includes USB to RS-232 adapter, and 6-foot RS-232 cable with D-sub connections.
Requires HE500CBL300 to program the XLe/XLt.
August 12, 2009 Page 13 of 100 ECN # 979
CH.2 MAN0878-04-EN
2.5 Useful Documents and References
The following information serves as a general listing of Horner controller products and other references of
interest with their corresponding manual numbers. Visit our website (see page
96) to obtain user
documentation and updates.
Note: This list is not intended for users to determine which products are appropriate for their application; controller
products differ in the features that they support. If assistance is required, refer to Technical Suppor
Controllers Manual Number
XLe Series (e.g., HE-XExxx) MAN0878
XLt Series (e.g., HE-XTxxx) MAN0878
QX Series (e.g., HE-QXxxx) MAN0798
NX Series (e.g., HE-NXxxx) MAN0781
LX Series (e.g., LX-xxx; also covers RCS116) MAN0755
Color Touch OCS (e.g., OCSxxx) MAN0465
OCS (Operator Control Station) (e.g., OCS1xx / 2xx; Graphic OCS250)
Remote Control Station (e.g., RCS2x0)
MiniOCS (e.g., HE500OCSxxx, HE500RCSxxx) MAN0305
Other Useful References Manual Number
CAN Networks MAN0799
Cscape Programming and Reference MAN0313
Wiring Accessories and Spare Parts Manual MAN0347
t (page 96).
MAN0227
August 12, 2009 Page 14 of 100 ECN # 979
MAN0878-04-EN CH.3
CHAPTER 3: MECHANICAL INSTALLATION
Note: Each XLe/XLt unit is sent with a datasheet in the box. The datasheet is the first document you
need to refer to for model-specific information related to XLe/XLt models such as pin-outs, jumper
settings, and other key installation information. The web version of this manual has all of the XLe/XLt
datasheets attached to it. Visit our website (see page
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
XLe/XLt products can be mounted through a panel or on DIN rail.
3.2.1 Mounting Procedures (Installed in a Panel Door)
001XLE055
Figure 3-1 – Panel Mounting of the XLe/XLt and Close-up View of Back
Once the panel design has been completed using the criteria and suggestions in the following sections,
use the following steps to panel mount the XLe/XLt.
1. Remove all connectors from the XLe/XLt unit.
2. Press the DIN rail clip up to make passing the unit through the cutout easier.
3. Make sure the gasket is installed on the XLe/XLt and is free from dust and debris. Check that the
corners of the gasket are secure.
4. Pass the unit through the panel.
5. Insert the each of the four (4) mounting clips into the slots in the XLe/XLt case. One clip should be
installed on each corner. Lightly tignten each screw so the clip is held in place.
6. Tighten the screws on the clips such that the gasket is compressed against the panel.
96) to obtain datasheets, user documentation, and
Slot
for Clip
DIN
Rail
August 12, 2009 Page 15 of 100 ECN # 979
CH. 3 MAN0878-04-EN
r
d
3.2.2 Mounting Procedures (Installed on DIN Rail)
Top
Clip
Note: Mount the XLe/XLt with
the DIN Rail in the horizontal
position to avoid slippage.
DIN
Rail Clip
Figure 3-2 – DIN Rail Mounting of the XLe/XLt
The XLe/XLt is designed to clip onto standard 35 millimeter DIN rail. If your installation requires liquid or
dust protection, make sure the XLe/XLt is placed in an appropriate sealed panel when mounting on DIN
rail. Use the following steps to mount the XLe/XLt on DIN rail.
1. Move the DIN rail clip to the lower position.
2. Clip the “Top Clip s” on the top of the DIN rail.
3. Press the unit into place and press the DIN rail clip up. A small flat-head screw driver can be
used in the slot of the DIN rail clip if clearance is an issue.
Note: The DIN rail connection does not
provide an earth ground. Refer to CHAPTER 4 for proper
grounding information.
3.3 Mounting Orientation
001XLE056
NOTE:For panel or DIN rail mounting:
The orientation shown above provides fo
optimum readability of the screen an
ease of use of the keypad.
CAUTION: For DIN Rail mounting:
To prevent the unit from slipping off the DIN Rail, do
install the unit on its sides as shown. Be sure the
not
DIN Rail is in the horizontal position. .
Figure 3-3 – Orientation of XLe/XLt OCS
August 12, 2009 Page 16 of 100 ECN # 979
MAN0878-04-EN CH.3
3.4 Panel Cut-Out
For installations requiring NEMA4X liquid and dust protection the panel cutout should be cut with a
tolerance of ± 0.005” (0.1 mm). The XLe/XLt is designed to fit ¼ DIN panel openings. There are a
number of punches and enclosures designed to accommodate ope ning of this size.
3.622 [92mm]
3.622 [92mm]
001XLE002
Figure 3-4 – XLe/XLt Panel Cut-out
3.5 Dimensions
XLt XLe
Note – Your keypad overlay
appearance may differ.
Standard US/EU overlays
pictured here for example
.
Figure 3-5 – XLe/XLt Dimensions
Note: When the communication add-on modules are installed such as Ethernet or Modem the depth of
the product increases from 2.264 (57.5 mm) to 2.68 (68 mm).
August 12, 2009 Page 17 of 100 ECN # 979
CH. 3 MAN0878-04-EN
3.6 Factors Affecting Panel Layout Design and Clearances
Warning: It is important to follow the requirements of the panel manufacturer and to follow
all applicable electrical codes and standards.
The designer of a panel layout needs to assess the requirements of a particular system and to consider
the following design factors. A convenient checklist is provided on page
19.
3.6.1 Clearance / Adequate Space
Install devices to allow sufficient clearance to open and close the panel door.
Table 3.1 – Minimum Clearance Requirements for Panel Box and Door
Minimum Distance between base of device and
sides of cabinet
Minimum Distance between base of device and
wiring ducts
If more than one device installed in panel box (or on
door):
Minimum Distance between bases of each device
4 inches between bases of each device
2 inches (50.80mm)
1.5 inches (38.10mm)
(101.60mm)
When door is closed:
Minimum distance between device and closed door
2 inches (50.80mm)
(Be sure to allow enough depth for XLe/XLt.)
3.6.2 Grounding
Warning: Be sure to meet the ground requirements of the panel manufacturer and also meet
applicable electrical codes and standards.
Panel box
: The panel box needs to be properly connected to earth ground to provide a good
common ground reference.
Panel door
: Tie a low impedance ground strap between the panel box and the panel door to
ensure that they have the same ground reference.
3.6.3 Temperature / Ventilation
Ensure that the panel layout design allows for adequate ventilation and maintains the specified
ambient temperature range. Consider the impact on the design of the panel layout if operating at
the extreme ends of the ambient temperature range. For example, if it is determined that a
cooling device is required, allow adequate space and clearances for the device in the panel box
or on the panel door.
August 12, 2009 Page 18 of 100 ECN # 979
MAN0878-04-EN CH.3
3.6.4 Orientation
When panel-mounted, there are no orientation restrictions on the XLe/XLt. However, the
orientation shown in
the keypad. When DIN Rail mounted, observe the orientation shown in
Figure 3-3 provides for optimum readability of the screen and ease of use of
Figure 3-2.
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 XLe/XLt and noisy
devices such as relays, motor starters, etc.
3.6.6 Shock and Vibration
The XLe/XLt 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 XLe/XLt to a location that minimizes
shock and/or vibration.
3.6.7 Panel Layout Design and Clearance Checklist
The following list provides highlights of panel layout design factors.
____Meets the electrical code and applicable standards for prope r grounding, etc.?
____Meets the panel manufacturer’s requirements for grounding, etc.?
____Is the panel box properly connected to earth ground? Is the panel door properly grounded? Has the
appropriate procedure been followed to properly ground the devices
in the panel box and on the
panel door?
____Are minimum clearance requirements met? (See Table 3.1.) 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 XLe/XLt?
____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 XLe/XLt 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?
August 12, 2009 Page 19 of 100 ECN # 979
CH. 3 MAN0878-04-EN
NOTES
August 12, 2009 Page 20 of 100 ECN # 979
MAN0878-04-EN CH. 4
CHAPTER 4: ELECTRICAL INSTALLATION
Note: Each XLe/XLt unit is sent with a datasheet in the box. The datasheet is the first document you
need to refer to for model-specific information related to XLe/XLt models such as pin-outs, jumper
settings, and other key installation information. The web version of this manual has all of the XLe/XLt
datasheets attached to it. Visit our website (see page
updates.
4.1 Grounding Definition
Ground: The term Ground is defined as a conductive connection between a circuit or piece of
equipment and the earth. Grounds are fundamentally used to protect an application from harmful
interference causing either physical damage such as by lightning or voltage transients or from circuit
disruption often caused by radio frequency interference (RFI).
4.2 Ground Specifications
Ideally, a ground resistance measurement from equipment to earth ground is 0 ohms. In reality it typically
is higher. The U.S. National Electrical Code (NEC) states the resistance to ground shall not
ohms. Horner APG recommends less than 15 ohms resistance from our equipment to ground.
Resistance greater than 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.
connection test.
GROUND RESISTANCE METER
GROUND
DISCONNECTED
FROM SERVICE
GROUND ROD
Figure 4-1 – Two-Point Ground Connection Test
96) to obtain datasheets, user documentation, and
exceed 25
Figure 4-1 shows a two-point ground
METAL WATER PIPE OR
OTHER GOOD GROUN D
August 12, 2009 Page 21 of 100 ECN # 979
CH. 4 MAN0878-04-EN
(
)
4.4 Primary Power Port
Table 4.1 – Primary Power Port Pins
Pin Signal Description
1 Frame Ground
2 0V Input power supply ground
3 +24V Input power supply positive voltage
+
-
10-30 VDC
supply
+
-
Figure 4-2 – Power Connector (Primary Power Port)
+
-
Power Connector
Power Up:
Connect to Earth Ground.
Apply 10 – 30 VDC.
Screen lights up.
Torque rating 4.5 - 7 Lb-In
0.50 – 0.78 N-m
PIN 1
PIN 2
PIN 3
001NX002
Figure 4-3 – As Viewed Looking at the XLe/XLt
August 12, 2009 Page 22 of 100 ECN # 979
MAN0878-04-EN CH. 5
8
CHAPTER 5: SERIAL COMMUNICATIONS
5.1 Overview
All XLe/XLt models provide two serial ports, which are implemented with 8-pin modular RJ45 connectors,
and are labeled MJ1 and MJ2. The MJ1 serial port is normally used for XLe/XLt programming by
connecting it to the COM port of a PC running Cscape. In addition, both MJ1 and MJ2 can be used for
application-specific communication, using a variety of standard data exchange protocols.
5.2 Port Descriptions
The MJ1 serial port contains both a half-duplex RS-485 interface and an RS-232 interface with RTS/CTS
handshaking. Note: MJ1 shares its serial port with the optional COM module, so when an optional Ethernet or Modem COM module is installed and active, the MJ1 connector is inactive.
The MJ2 serial port contains both a full-duplex RS-485 interface and an RS-232 interface with no
handshaking. Both the MJ1 and MJ2 RS-485 interfaces provide switchable termination and bias resistors
internally.
5.3 Wiring
Figure 5-1 along with Table 5.1 and Table 5.2 show how the MJ1 and MJ2 serial
port pins are assigned.
Note: MJ1 and MJ2 look the
same but have different pin
assignments and functions.
4 RTS1 RS-232 Request to Send In
5 +5* +5 Vdc 60mA max Out
6 0V Ground
−
7 TD1 RS-232 Transmit Data In
8 RD1 RS-232 Receive Data Out
• * +5 on XLe Rev E and later
• * +5 on all revisions XLt
MJ2 Pinouts in Full and Half Duplex Modes
1
Table 5.2 – – MJ2 Serial Port Pin Assignments
Pin Signal Signal Description Direction
1 RX+ RS-485 Receive Positive In
2
RX−
3 TX+ RS-485 Transmit Positive Out
4
TX−
5 +5* +5 Vdc 60mA max Out
6 0V Ground
RS-485 Receive Negative In
RS-485 Transmit Negative Out
−
8
1
7 TD1 RS-232 Transmit Data In
8 RD1 RS-232 Receive Data Out
1
Signals are labeled for connection to a DTE device
August 12, 2009 Page 23 of 100 ECN # 979
Pin MJ1 Pins MJ2 Pins
Signal Direction Signal Direction
TXD OUT TXD OUT
8
RXD IN RXD IN
7
0 V Ground 0 V Ground
6
+5 60mA OUT +5 60mA OUT
5*
RTS OUT TX- OUT
4
CTS IN TX+ OUT
3
RX- / TX- IN / OUT RX- IN
2
RX+ / TX+ IN / OUT RX+ IN
1
Pin MJ2 Pins
Signal Direction
TXD OUT
8
RXD IN
7
0 V Ground
6
+5 60mA OUT
5*
TX- OUT
4
TX+ OUT
3
TX-/RX- IN/OUT
2
TX+/RX+ IN/OUT
1
* +5Vdc 60mA Max
MJ2 Half Duplex Mode
Pin MJ2 Pins
Signal Direction
TXD OUT
8
RXD IN
7
0 V Ground
6
+5 60mA OUT
5*
TX- OUT
4
TX+ OUT
3
RX- IN
2
RX+ IN
1
* +5Vdc 60mA Max
MJ2 Full Duplex Mode
CH. 5 MAN0878-04-EN
5.4 RS-485 Termination
Proper RS-485 termination minimizes reflections and improves reliability.
Both serial ports allow an internal 121-Ohm RS-485 termination resistor to be placed across pins 1 and 2.
This can be done by installing a jumper. Please refer to the XLe/XLt data sheet for jumper locations.
In any case, only
the two devices physically located at the endpoints of the RS-485 network should be
terminated.
5.5 RS-485 Biasing
RS-485 biasing passively asserts a line-idle state when no device is actively transmitting, whic h is useful
for multi-drop RS-485 networking.
Both serial ports allow internal 390-Ohm RS-485 bias resistors to be switched in, pulling pin 1 up to 3.3V
and pulling pin 2 down to ground. The Set Serial Ports item in the System Menu (see page
51) can be
used to enable RS-485 biasing. Also, an application graphics screen that writes to %SR164 can do the
same thing. Setting %SR164.1 enables MJ1 biasing and setting %SR164.2 enables MJ2 biasing.
If biasing is used, it should be enabled in only
one of the devices attached to the RS-485 network.
5.6 Cscape Programming via Serial Port
The XLe/XLt MJ1 serial port supports CsCAN Programming Protocol, but MJ2 does not. If a PC COM
port is connected to the XLe/XLt MJ1 serial port, Cscape can access the XLe/XLt for programming and
monitoring.
5.7 Ladder-Controlled Serial Communication
Using Serial Communication function blocks, both MJ1 and MJ2 support Generic, Modbus Master and
Modbus Slave Protocols. In addition, external modems can be connected and accessed using Init, Dial
and Answer Modem function blocks.
5.8 Downloadable Serial Communication Protocols
Both MJ1 and MJ2 also support downloadable protocols, such as Allen Bradley DF1, CsCAN Master, GE
Fanuc SNP and Modbus Master.
August 12, 2009 Page 24 of 100 ECN # 979
MAN0878-04-EN CH. 6
CHAPTER 6: CAN COMMUNICATIONS
Note: For additional CAN information, refer to the CAN Networks manual (
(See page
96 for our website address.)
6.1 Overview
Some XLe/XLt models (XE1xx) provide a CAN networking port, which is implemented with a 5-pin
connector, labeled NET1.
Like the MJ1 serial port, the NET1 port can be used for XLe/XLt programming by connecting it to the CAN
port of a PC running Cscape. The NET1 port also allows the XLe/XLt to exchange global data with other
OCS/RCS controllers and to access remote Network I/O devices (SmartStix Modules).
6.2 Port Description
The XLe/XLt NET1 port implements the ISO 11898-2 physical layer and the CAN 2.0A data link layer
standards. Also, since the NET1 port is powered by an internal isolated power supply, external CAN
power is not required.
6.3 Wiring
Figure 6-1 and Table 6.1 show how the NET1 port pins are assigned.
CAN Connector
Use the CAN Connector
when using CsCAN network.
Torque rating 4.5 – 7 Lb-In
(0.50 – 0.78 N-m)
Figure 6-1 – NET1 Port Connector
Table 6.1 – NET1 Port Pin Assignments
Pin Signal Signal Description Direction
1 V- CAN Ground
2 CN_L CAN Data Low In/Out
3 SHLD Shield Ground
4 CN_H CAN Data High In/Out
5 NC No Connect
MAN0799) on our website.
Note: The V+ connection is
not required on the XLe/XLt.
The XLe/XLt network port is
self-powered. Supporting
devices can require this
connection, and this pin can
be used to land the extra wire
required for those devices.
−
−
−
August 12, 2009 Page 25 of 100 ECN # 979
CH. 6 MAN0878-04-EN
6.4 Cscape Programming via CAN
The NET1 port supports CsCAN Programming Protocol. If a PC has a CAN interface installed (via PCI
card or USB), and the PC CAN port is connected to the XLe/XLt NET1 port, Cscape can access the
XLe/XLt for programming and monitoring.
In addition, the XLe/XLt supports single-point-programming of all XLe/XLt and other OCS/RCS devices
that are connected to a CAN network. If the PC COM port is connected to the XLe/XLt MJ1 serial port
CHAPTER 5), the XLe/XLt can act as a pass-through gateway allowing Cscape to access all
(see
XLe/XLt and OCS/RCS devices that are attached to the CAN network.
6.5 Ladder-Controlled CAN Communication
Using Put and Get Network Words function blocks, the NET1 port can exchange digital and analog global
data with other XLe/XLt or OCS/RCS devices (nodes) attached to the CAN network.
In addition, Put and Get Network Heartbeat function blocks allow nodes on the CAN network to regularly
announce their presence and to detect the presence (or absence) of other nodes on the network.
6.6 Using CAN for I/O Expansion (Network I/O)
Connecting Network I/O devices (SmartStix Modules) to the XLe/XLt NET1 port, allows the XLe/XLt I/O to
be economically expanded and distributed. A variety of SmartStix Modules is available for this purpose.
August 12, 2009 Page 26 of 100 ECN # 979
MAN0878-04-EN CH. 7
CHAPTER 7: COMMUNICATION OPTIONS
7.1 Overview
To supplement the built-in MJ1 and MJ2 serial ports (see
are available. This is accomplished by installing a COM module internal to the XLe/XLt controller.
Currently, there are two COM modules available for this purpose: Ethernet (XEC) and Modem (XMC).
7.1.1 MJ1 sharesits serial port with the optional COM module, so when an Ethernet or Modem
COM module is installed and active, the MJ1 connector is inactive.
Internal to the XLe/XLt, there is a CPU board, and up to two installed modules. Models XE000/XT000
and XE100/XT100 have no installed I/O or COM modules. All other models have an I/O module in Slot 1
and can have a user-installed COM module in Slot 2.
This chapter briefly describes both the Ethernet and Modem COM module options. For detailed
information regarding these modules, please refer to the individual documents provided with the modules.
7.2 Ethernet COM Module (XEC) Option
An Ethernet COM module can be installed to allow Cscape programming of an XLe/XLt over a Local Area
Network or over the Internet. In addition, the Horner OPC Server can be installed on a PC to allow other
standard PC applications (such as database and spreadsheets programs) access to XLe/XLt register
data.
The Ethernet COM module supports both 10 BaseT (10 MHz) and 100 BaseTx (100 MHz) as well as both
half and full duplex communication. Both the connection speed and the duplex are auto-negotiated.
Although the physical connection between the Ethernet COM Module and the Local Area Network is done
using a standard Ethernet cable (CAT5 or better with RJ45 modular plug), a Serial Port Tunnel protocol
is employed that makes the Ethernet COM Module appear as a serial port to Cscape or OPC Server
software running on the PC.
On the XLe/XLt end of the Serial Port Tunnel, the Ethernet COM module should be properly configured
using the XLe/XLt System Menu (see
CHAPTER 11). This configuration consists of making Ethernet the
Default Programming Port and setting its target IP Address, Net Mask and optionally the Gateway IP
Address. The Gateway IP Address is required if the XLe/XLt will be accessed from outside the Local
Area Network (e.g. the Internet).
On the PC end of the Serial Port Tunnel, the PC should be connected to the Local Area Network (or to
the Internet) and a Com Port Redirector driver must be installed on the PC and properly configured.
The Com Port Redirector allows multiple “virtual” PC serial ports to be created and each one can be
assigned to a different target device IP Address, thus allowing access to Ethernet COM modules in
multiple XLe/XLt controllers.
After installing and configuring both the Ethernet COM module and the Com Port Redirector, Cscape or
OPC Server software should be set up to commun icate to one of the “virtual” serial ports, at which point
they should function as if a “real” PC serial port was connected to the XLe/XLt MJ1 serial port.
CHAPTER 5), additional communication options
August 12, 2009 Page 27 of 100 ECN # 979
CH. 7 MAN0878-04-EN
7.3 Modem COM Module (XMC) Option
A Modem COM module can be installed to allow Cscape programming of an XLe/XLt 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 XLe/XLt System Menu (see
CHAPTER 11). Doing
this puts the Modem COM module in auto-answer mode, so Cscape can call the XLe/XLt 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.
August 12, 2009 Page 28 of 100 ECN # 979
MAN0878-04-EN CH. 8
CHAPTER 8: REMOVABLE MEDIA
8.1 Overview
All XLe/XLt models provide a Removable Media slot, labeled Memory, which supports standard Micro SD
Flash memory cards. Micro SD cards can be used to save and load applications, to capture graphics
screens and to log data for later retrieval.
8.2 Micro SD Cards
When the Micro SD card format was introduced, it was originally called TransFlash. Cards labeled either
Micro SD or TransFlash, with up to 2.0 GB of Flash memory, are compatible with the XLe/XLt Memory
slot.
The XLe/XLt Memory slot is equipped with a “push-in, push-out” connector and a Micro SD card can be
safely inserted into the Memory slot whether the XLe/XLt power is On or Off.
To install a Micro SD card: Align its 8-pin gold edge connector down, facing the front of the
XLe/XLt unit as shown in
Ensure that it clicks into place.
To remove the Micro SD card: Push down on the top of the card gently to release the spring.
The card pops up for removal.
8.3 Micro SD File System
The XLe/XLt Micro SD Memory slot uses the PC-compatible FAT16 File System. This means that a PC,
with a Micro SD-compatible card reader, can read files that have been written by the XLe/XLt and can
write files that can be read by the XLe/XLt.
However, the XLe/XLt does not
This means that all file and directory names must
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
exceed 147 characters.
not
Figure 8-1; then carefully push it all the way into the Memory slot.
Figure 8-1 – Installing Removable Memory Card
support long filenames, but instead implements the 8.3 filename format.
consist of up to 8 characters, followed by an optional
August 12, 2009 Page 29 of 100 ECN # 979
CH. 8 MAN0878-04-EN
8.4 Using the Removable Media Manager
The Removable Media Manager is an interactive XLe/XLt screen that performs the following functions:
• Display number of total and free bytes
• Browse file and directory lists
• Delete files and directories
• Format a Micro SD card
• Load and save application programs
• View screen capture bitmaps
The Removable Media Manager can be accessed via the System Menu (see
CHAPTER 11) or by using
Cscape to place a Removable Media Manager object on an application graphics screen.
8.5 Using Removable Media to Log Data
Using Read and Write Removable Media function blocks, an application ladder program can read and
write XLe/XLt 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.
8.6 Using Removable Media to Load and Save Applications
A special file type, with a .PGM extension, is used to store XLe/XLt application programs on Micro SD.
To load an application from Micro SD to the XLe/XLt, use the Removable Media Manager to find and
highlight the desired .PGM file, and then press Enter.
To save an application from the XLe
to Micro SD, open the Removable Media Manager in the System
Menu and press the F4 function key. The application will be saved in a file called DEFAULT.PGM in the
Micro SD root directory.
To save an application from the XLt
to Micro SD, open the Removable Media Manager in System Menu
and press the Save Pgm
soft key displayed at the bottom of the XLt’s touch screen. The
application will be saved in a file called DEFAULT.PGM in the Micro SD root directory.
Note: Saving an application to Micro SD can only
available on a Removable Media Manager object that was placed on an
is not
be done from the System Menu and
application graphics screen by Cscape.
Cscape can also save an application directly to a Micro SD card, which is plugged into the PC’s Micro SD
compatible card reader by selecting the Export to Removable Media item on the File menu.
August 12, 2009 Page 30 of 100 ECN # 979
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