HORNER APG XL7 User manual

User Manual forXL7 OCS
MAN0974-11-EN_XL7_UserManual
HE-XW1E0 / HEXT391C100
HE-XW1E2 / HEXT391C112
HE-XW1E3 / HEXT391C113
HE-XW1E4 / HEXT391C114
HE-XW1E5 / HEXT391C115
HE-XW1E6 / HEXT391C116

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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.
Cscape, SmartStack, SmartStix, SmartRail, SmartMod, and CsCAN are trademarks of Horner
APG.
Ethernet™is a trademark of Xerox Corporation.
microSD™and CompactFlash are registered trademarks of SanDisk Corporation.
For user manual updates, please visit our website:
North America:
Tel: (+) [phone]
Fax: (+) [phone]
Website: https://hornerautomation.com
Email: [e-mail]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Website: http://www.hornerautomation.eu
Email: [e-mail]

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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
media 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 XL7OCS 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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VISUAL MAP OF CHAPTERS
FIRST STEP of ANY TASK: DATASHEET
Each XL7 OCS unit is sent with a datasheet in the box. The datasheets are the first
documents to refer to for model-specific information related to XL7 OCS models for
specific installation information. To obtain updates to datasheets, manuals and user
documentation, visit a Horner website.
North America https://hornerautomation.com Europe http://www.hornerautomation.eu
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety /
Compliance
Mechanical
Installation
System Settings
Modbus
Communications
Introduction
Electrical Installation
Registers
Back-up Battery
Cscape Configuration
Maintenance
General I/O
Troubleshooting
High-Speed I/O
Serial
Communications
CAN Communications
Ethernet
Communications
Downloadable
Communications
User Interface
Audio Object
Video Object
Removable Media
Clone Unit
Fail-Safe System

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TABLE OF CONTENTS
PREFACE .....................................................................................................................................................2
ABOUT PROGRAMMING EXAMPLES.......................................................................................................3
VISUAL MAP OF CHAPTERS ....................................................................................................................4
TABLE OF CONTENTS...............................................................................................................................5
CHAPTER 1: SAFETY / COMPLIANCE .................................................................................................10
1.1 Safety Warnings and Guidelines..............................................................................................10
1.2 Grounding....................................................................................................................................... 11
1.3 Compliance .................................................................................................................................... 11
CHAPTER 2: INTRODUCTION................................................................................................................ 12
2.1Visual Overview of XL7 OCS..................................................................................................... 12
2.2 Connectivity to the XL7 OCS....................................................................................................14
2.3 Features of XL7 OCS .................................................................................................................. 15
2.4 Accessories...................................................................................................................................16
2.5 Useful Documents and References......................................................................................... 16
2.6 Opening Cscape Help File..........................................................................................................16
CHAPTER 3: MECHANICAL INSTALLATION...................................................................................... 17
3.1 Overview........................................................................................................................................ 17
3.2 Mounting Requirements ............................................................................................................ 17
3.3 Mounting Orientation .................................................................................................................18
3.4 Panel Cut-Out..............................................................................................................................20
3.5 Factors Affecting Panel Layout Design and Clearances ................................................... 21
CHAPTER 4: ELECTRICAL INSTALLATION ...................................................................................... 23
4.1 Grounding Definition ................................................................................................................. 23
4.2 Ground Specifications ............................................................................................................... 23
4.3 How to Test for Good Ground .................................................................................................24
4.4 Primary Power Port...................................................................................................................25
CHAPTER 5: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................26
5.1 System Menu - Overview..........................................................................................................26
5.2 System Menu –Navigation and Editing................................................................................. 27
5.3 Set Networks ...............................................................................................................................29
5.4 View Status..................................................................................................................................30
5.5 View Diags..................................................................................................................................... 31
5.6 View Battery Status................................................................................................................... 32
5.7 View I/O Slots.............................................................................................................................. 33
5.8 View Protocols ............................................................................................................................34
5.9 Set Fkeys Mode...........................................................................................................................35
5.9 Set Serial Ports...........................................................................................................................36
5.10 Set Time/Date ......................................................................................................................... 37
5.11 Set Beeper....................................................................................................................................39
5.12 Set Screen ................................................................................................................................40
5.13 Removable Media ........................................................................................................................41
5.14 Fail –Safe System ..................................................................................................................42

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5.15 Enable AutoRun ......................................................................................................................43
5.16 Enable AutoLoad ....................................................................................................................44
5.17 Clone Unit.....................................................................................................................................45
5.18 Load Clone ...............................................................................................................................46
5.19 WebMI License Details........................................................................................................... 47
5.20 Touch screen calibration ......................................................................................................48
CHAPTER 6: REGISTERS.......................................................................................................................49
6.1 Register Definitions ...................................................................................................................49
6.2 Useful %S and %SR registers.................................................................................................49
6.3 Register Map for XL7 OCS I/O ................................................................................................ 57
6.4 Resource Limits..........................................................................................................................59
CHAPTER 7: CSCAPE CONFIGURATION ...........................................................................................60
7.1 Overview.......................................................................................................................................60
7.2 Cscape Status Bar......................................................................................................................60
7.3 Establishing Communications ..................................................................................................61
7.4 Configuration ..............................................................................................................................69
7.5 Digital / HSC Input Configuration............................................................................................ 71
7.6 Digital / PWM Output Configuration...................................................................................... 72
7.7 Analog Input Configuration ..................................................................................................... 73
7.8 Analog Output Configuration..................................................................................................74
CHAPTER 8: GENERAL I/O................................................................................................................... 75
8.1 Overview....................................................................................................................................... 75
8.2 Removing the XL7 OCS I/O Cover.......................................................................................... 75
8.3 Model and I/O Overview ........................................................................................................... 77
8.4 Solid-State Digital Outputs ......................................................................................................78
8.5 Relay Outputs.............................................................................................................................. 79
8.6 Digital Inputs.................................................................................................................................81
8.7 Analog Inputs ..............................................................................................................................82
8.8 Universal Analog Inputs............................................................................................................83
8.9 Analog Outputs...........................................................................................................................84
CHAPTER 9: HIGH SPEED I/O (HSC / PWM).....................................................................................85
9.1 Overview.......................................................................................................................................85
9.2 Glossary ........................................................................................................................................86
9.3 High Speed Counter (HSC) Functions ...................................................................................87
9.4 HSC Functions Register Map ...................................................................................................96
9.5 High Speed Output Functions .................................................................................................99
9.6 High Speed Output Functions Register Map.......................................................................103
9.7 PWM Examples.......................................................................................................................... 104
9.8 STP Examples............................................................................................................................ 105
9.9 HSC I/O Filtering....................................................................................................................... 106
CHAPTER 10: SERIAL COMMUNICATIONS ..................................................................................... 109
10.1 Overview..................................................................................................................................... 109
10.2 Port Descriptions.................................................................................................................. 109
10.3 Wiring and Dip Switches ..................................................................................................... 109
10.4 RS485 Termination................................................................................................................110
10.5 RS485 Biasing.........................................................................................................................110
10.6 Cscape Programming via Serial Port.................................................................................. 111
10.7 Ladder-Controlled Serial Communication.........................................................................111
10.8 Configuration via Mini-B USB ...............................................................................................111

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CHAPTER 11: CAN COMMUNICATIONS ..............................................................................................112
11.1 Overview.......................................................................................................................................112
11.2 Port Description..........................................................................................................................112
11.3 CAN Port Wiring..........................................................................................................................113
11.4 Cscape Programming via CAN ................................................................................................113
11.5 Ladder-Controlled CAN Communication ..............................................................................113
11.6 Using CAN for I/O Expansion (Network I/O)........................................................................113
CHAPTER 12: ETHERNET COMMUNICATION....................................................................................114
12.1 Ethernet Module Protocols and Features ............................................................................114
12.2 Ethernet System Requirements .............................................................................................114
12.3 Ethernet Module Specifications..............................................................................................114
12.4 Ethernet Module Configuration ..........................................................................................115
12.5 Ethernet Configuration –IP Parameters ..........................................................................118
12.6 Ethernet Module Protocol Configuration .........................................................................118
CHAPTER 13: DOWNLOADABLE COMMUNICATION PROTOCOLS..............................................119
13.1 Overview.......................................................................................................................................119
13.2 Protocol Config..........................................................................................................................122
13.3 Network Configuration.............................................................................................................123
13.4 Device List and Device Configuration ..............................................................................125
13.5 Scan List ......................................................................................................................................126
13.6 Data Mapping Configuration (Scan List Entry) ..............................................................127
CHAPTER 14: USER INTERFACE.........................................................................................................129
14.1 Overview......................................................................................................................................129
14.2 Screen Specifications ...........................................................................................................129
14.3 Displaying and Entering Data .............................................................................................130
14.4 Alpha-numeric Keypad..........................................................................................................131
14.5 Screen Navigation .................................................................................................................133
14.6 Ladder Based Screen Navigation ......................................................................................134
14.7 Beeper Acknowledgement ..................................................................................................134
14.8 Touch (Slip) Sensitivity ........................................................................................................135
14.9 Alarms ......................................................................................................................................136
14.10 Removable Media ..................................................................................................................138
14.11 Screen Saver.......................................................................................................................... 140
14.12 Screen Brightness ................................................................................................................ 140
14.13 Touch Screen Pressure.........................................................................................................141
CHAPTER 15: AUDIO PLAYBACK CONFIGURATION......................................................................143
15.1 Audio Overview..........................................................................................................................143
15.2 Audio Configuration in Cscape...........................................................................................143
15.3 Audio Config Details ................................................................................................................ 144
15.4 Audio Files.............................................................................................................................. 145
CHAPTER 16: VIDEO OBJECT ............................................................................................................ 146
16.1 Video Object Overview............................................................................................................ 146
16.2 Opening Video Object in Cscape........................................................................................147
16.3 Video Properties: Video Type............................................................................................ 149
16.4 Video Properties: Control................................................................................................... 150
16.5 Configuring Display Properties ...........................................................................................151
16.6 Video Object Performance...................................................................................................151
16.7 Web Cameras...............................................................................................................................151
CHAPTER 17: REMOVABLE MEDIA ....................................................................................................152

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17.1 Overview......................................................................................................................................152
17.2 microSD Cards ...........................................................................................................................152
17.3 microSD File System.................................................................................................................152
17.4 Using the Removable Media Manager..............................................................................153
17.5 Using Removable Media to Log Data....................................................................................153
17.6 Using Removable Media to Load and Save Applications................................................ 154
17.7 Using Removable Media to View and Capture Screens .................................................. 154
17.8 Configuration of a Removable Media ...............................................................................155
17.9 Removable Media (RM) Function Blocks in Cscape ..........................................................155
17.10 Removable Media (RM) Features—Program Features ..................................................156
17.11 Removable Media (RM) Features—Graphic/Screen Editor ..........................................156
17.12 Removable Media (RM) Features—Additional Configuration ......................................156
17.13 Filenames used with the Removable Media (RM) Function Blocks ...........................157
17.14 System Registers used with RM........................................................................................ 158
CHAPTER 18: CLONE UNIT ..................................................................................................................159
18.1 Overview......................................................................................................................................159
18.2 Clone.........................................................................................................................................159
18.3 Load Clone ..............................................................................................................................163
CHAPTER 19: FAIL –SAFE SYSTEM ..................................................................................................165
19.1 Overview......................................................................................................................................165
19.2 Settings................................................................................................................................... 166
19.3 Backup / Restore Data ........................................................................................................ 166
19.4 AutoLoad .................................................................................................................................170
19.5 AutoRun...................................................................................................................................172
CHAPTER 20: MODBUS COMMUNICATIONS ..................................................................................173
20.1 Modbus Overview ..................................................................................................................173
20.2 Modbus Slave Overview.......................................................................................................173
20.3 Modbus Master Overview ....................................................................................................174
20.4 Modbus Addressing Table ...................................................................................................175
CHAPTER 21: BACK-UP BATTERY .....................................................................................................176
21.1 Overview......................................................................................................................................176
21.2 Storing Register Contents.......................................................................................................176
21.3 Battery Life.................................................................................................................................176
21.4 Lithium Battery Safety.........................................................................................................176
21.5 Battery Charging Cycle ........................................................................................................177
21.6 Battery Charging Status ......................................................................................................177
21.7 Battery Charging State............................................................................................................177
21.8 Battery Status in System Registers..................................................................................177
CHAPTER 22: MAINTENANCE ............................................................................................................178
22.1 Firmware Update Overview ....................................................................................................178
22.2 How to Check for Current Firmware Revision................................................................178
22.3 Details.......................................................................................................................................179
22.4 Firmware Update for the XL7............................................................................................ 180
22.5 Backup Battery........................................................................................................................181
CHAPTER 23: TROUBLESHOOTING & TECHNICAL SUPPORT....................................................183
23.1 Connecting to the XL7 OCS ....................................................................................................183
23.2 Local Controller and Local I/O .......................................................................................... 185
23.3 CsCAN Network..................................................................................................................... 186
23.4 Removable Media - Basic Troubleshooting.....................................................................187

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23.5 Technical Support Contacts................................................................................................187
CHANGE LOG ........................................................................................................................................ 188
MAIN INDEX.......................................................................................................................................... 189
INDEX OF FIGURES & TABLES ........................................................................................................193

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CHAPTER 1: SAFETY / COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
Warning: Consult user documentation.
Warning: Electrical Shock Hazard.
WARNING –EXPLOSION HAZARD –Do not disconnect equipment unless power has been
switched off or the area is known to be non-hazardous
WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth)
ground before making any other connections.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly
recommended to fuse the voltage measurement inputs. Be sure to locate fuses as close to
the source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk of
fire and shock hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated
failure indicates a defective condition that will not clear by replacing the fuse.
WARNING –EXPLOSION HAZARD: Substitution of components may impair suitability for
Class I, Division 2
WARNING: The USB parts are for operational maintenance only. Do not leave permanently
connected unless area is known to be non-hazardous
WARNING –EXPLOSION HAZARD - BATTERIES MUST ONLY BE CHANGED IN AN AREA
KNOWN TO BE NON-HAZARDOUS
WARNING: Battery May Explode If Mistreated. Do not recharge, disassemble or dispose of in
fire.
WARNING: Only qualified electrical personnel familiar with the construction and operation of
this equipment and the hazards involved should install, adjust, operate, or service this
equipment. Read and understand this manual and other applicable manuals in their entirety
before proceeding. Failure to observe this precaution could result in severe bodily injury or
loss of life.