HORNER HE-XPW1E0 User manual

User Manual for
XL7/XL7 PRIME OCS
MAN0974-13-EN_XL7_XL7P_UM
XL7
XL7 PRIME
North America
Europe
North America
Europe
HE-XW1E0
HEXT391C100
HE-XPW1E0
HEXP391C100
HE-XW1E2
HEXT391C112
HE-XPW1E2
HEXP391C112
HE-XW1E3
HEXT391C113
HE-XPW1E3
HEXP391C113
HE-XW1E4
HEXT391C114
HE-XPW1E4
HEXP391C114
HE-XW1E5
HEXT391C115
HE-XPW1E5
HEXP391C115
HE-XW1E6
HEXT391C116
HE-XPW1E6
HEXP391C116

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PREFACE
This manual explains how to use the XL7/XL7 PRIME 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: technical.sup[email protected]

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LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the XL7/XL7 PRIME (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/XL7 PRIME OCS module. THIS WARRANTY SHALL NOT APPLY TO THIS XL7/XL7
PRIME 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/XL7 PRIME 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/XL7 PRIME
OCS module to appropriately design the end system, to appropriately integrate the XL7/XL7 PRIMEOCS
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/XL7 PRIME 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/XL7 PRIME 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
2.1 Visual Overview of XL7/XL7 PRIME OCS ...................................................................................12
2.2 Connectivity to the XL7/XL7 PRIME OCS...................................................................................14
2.3 Features of XL7/XL7 PRIME OCS...............................................................................................15
2.4 Accessories................................................................................................................................16
2.5 Useful Documents and References...........................................................................................16
CHAPTER 3: MECHANICAL INSTALLATION.........................................................................................17
3.1 Overview...................................................................................................................................17
3.2 Mounting Requirements...........................................................................................................17
3.3 Mounting Orientation...............................................................................................................18
3.4 XL7/XL7 PRIME Back Cover Dimensions ...................................................................................20
3.5 XL7/XL7 PRIME Dimensions......................................................................................................21
3.6 Installation Procedure...............................................................................................................22
3.7 Factors Affecting Panel Layout Design and Clearances............................................................23
CHAPTER 4: ELECTRICAL INSTALLATION ...........................................................................................25
4.1 Grounding Definition ................................................................................................................25
4.2 Ground Specifications...............................................................................................................25
4.3 How to Test for Good Ground ..................................................................................................26
4.4 Primary Power Port...................................................................................................................27
CHAPTER 5: SYSTEM SETTINGS AND ADJUSTMENTS ........................................................................28
5.1 System Menu - Overview..........................................................................................................28
5.2 System Menu –Navigation and Editing....................................................................................29
5.3 Set Networks.............................................................................................................................31
5.4 View Status ...............................................................................................................................32
5.5 View Diags.................................................................................................................................33
5.6 View Battery Status...................................................................................................................34
5.7 View I/O Slots............................................................................................................................35
5.8 View Protocols..........................................................................................................................36
5.9 Set Fkeys Mode.........................................................................................................................37
5.9 Set Serial Ports..........................................................................................................................38
5.10 Set Time/Date .......................................................................................................................39
5.11 Set Beeper.................................................................................................................................41
5.12 Set Screen..............................................................................................................................42
5.13 Removable Media.....................................................................................................................43
5.14 Fail –Safe System..................................................................................................................44

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5.15 Enable AutoRun.....................................................................................................................45
5.16 Enable AutoLoad ...................................................................................................................46
5.17 Clone Unit .................................................................................................................................47
5.18 Load Clone.............................................................................................................................48
5.19 WebMI License Details..........................................................................................................49
5.20 Touch screen calibration.......................................................................................................50
CHAPTER 6: REGISTERS .....................................................................................................................51
6.1 Register Definitions...................................................................................................................51
6.2 Useful %S and %SR registers.....................................................................................................51
6.3 Register Map for XL7/XL7 PRIME OCS I/O ................................................................................60
6.4 Resource Limits.........................................................................................................................62
CHAPTER 7: CSCAPE CONFIGURATION..............................................................................................63
7.1 Overview...................................................................................................................................63
7.2 Cscape Status Bar......................................................................................................................63
7.3 Establishing Communications...................................................................................................64
7.4 Configuration............................................................................................................................72
7.5 Digital / HSC Input Configuration..............................................................................................74
7.6 Digital / PWM Output Configuration........................................................................................75
7.7 Analog Input Configuration.......................................................................................................76
7.8 Analog Output Configuration....................................................................................................77
CHAPTER 8: GENERAL I/O .................................................................................................................78
8.1 Overview...................................................................................................................................78
8.2 Removing the XL7/XL7 PRIME OCS I/O Cover...........................................................................78
8.3 Model and I/O Overview ..........................................................................................................80
8.4 Solid-State Digital Outputs........................................................................................................81
8.5 Relay Outputs ...........................................................................................................................82
8.6 Digital Inputs.............................................................................................................................84
8.7 Analog Inputs............................................................................................................................85
8.8 Universal Analog Inputs............................................................................................................86
8.9 Analog Outputs.........................................................................................................................87
CHAPTER 9: HIGH SPEED I/O (HSC / PWM).......................................................................................88
9.1 Overview...................................................................................................................................88
9.2 Glossary.....................................................................................................................................89
9.3 High Speed Counter (HSC) Functions........................................................................................90
9.4 HSC Functions Register Map.....................................................................................................99
9.5 High Speed Output Functions.................................................................................................102
9.6 High Speed Output Functions Register Map...........................................................................106
9.7 PWM Examples.......................................................................................................................107
9.8 STP Examples ..........................................................................................................................108
9.9 HSC I/O Filtering......................................................................................................................109
CHAPTER 10: SERIAL COMMUNICATIONS .......................................................................................112
10.1 Overview.................................................................................................................................112
10.2 Port Descriptions.................................................................................................................112
10.3 Wiring and Dip Switches .....................................................................................................112
10.4 RS485 Termination..............................................................................................................113
10.5 RS485 Biasing ......................................................................................................................113
10.6 Cscape Programming via Serial Port ...................................................................................114
10.7 Ladder-Controlled Serial Communication...........................................................................114

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10.8 Configuration via Mini-B USB..............................................................................................114
CHAPTER 11: CAN COMMUNICATIONS.............................................................................................115
11.1 Overview.................................................................................................................................115
11.2 Port Description......................................................................................................................115
11.3 CAN Port Wiring......................................................................................................................116
11.4 Cscape Programming via CAN.................................................................................................116
11.5 Ladder-Controlled CAN Communication ................................................................................116
11.6 Using CAN for I/O Expansion (Network I/O)...........................................................................116
CHAPTER 12: ETHERNET COMMUNICATION ...................................................................................117
12.1 Ethernet Overview..................................................................................................................117
12.2 Ethernet Module Protocols and Features ..............................................................................117
12.3 Ethernet System Requirements..............................................................................................117
12.4 Ethernet Module Specifications..........................................................................................118
12.5 Ethernet Module Configuration..........................................................................................119
12.6 Ethernet Configuration –IP Parameters.............................................................................122
12.7 Ethernet Module Protocol Configuration...............................................................................122
CHAPTER 13: DOWNLOADABLE COMMUNICATION PROTOCOLS ...................................................123
13.1 Overview.................................................................................................................................123
13.2 Protocol Config .......................................................................................................................125
13.3 Network Configuration ...........................................................................................................126
13.4 Device List and Device Configuration..................................................................................128
13.5 Scan List ..................................................................................................................................129
13.6 Data Mapping Configuration (Scan List Entry)....................................................................130
CHAPTER 14: USER INTERFACE ........................................................................................................132
14.1 Overview.................................................................................................................................132
14.2 Screen Specifications...........................................................................................................132
14.3 Displaying and Entering Data ..............................................................................................133
14.4 Alpha-numeric Keypad........................................................................................................134
14.5 Screen Navigation ...............................................................................................................136
14.6 Ladder Based Screen Navigation.........................................................................................137
14.7 Beeper Acknowledgement..................................................................................................137
14.8 Touch (Slip) Sensitivity ........................................................................................................138
14.9 Alarms .................................................................................................................................139
14.10 Removable Media ...............................................................................................................141
14.11 Screen Saver........................................................................................................................143
14.12 Screen Brightness................................................................................................................143
14.13 Touch Screen Pressure........................................................................................................144
CHAPTER 15: AUDIO PLAYBACK CONFIGURATION..........................................................................146
15.1 Audio Overview.......................................................................................................................146
15.2 Audio Configuration in Cscape............................................................................................146
15.3 Audio Config Details................................................................................................................147
15.4 Audio Files...........................................................................................................................148
CHAPTER 16: VIDEO OBJECT ............................................................................................................149
16.1 Video Object Overview...........................................................................................................149
16.2 Opening Video Object in Cscape.........................................................................................150
16.3 Video Properties: Video Type..............................................................................................152
16.4 Video Properties: Control....................................................................................................153
16.5 Configuring Display Properties............................................................................................154

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16.6 Video Object Performance..................................................................................................154
16.7 Web Cameras..........................................................................................................................154
CHAPTER 17: REMOVABLE MEDIA ...................................................................................................155
17.1 Overview.................................................................................................................................155
17.2 microSD Cards.........................................................................................................................155
17.3 microSD File System................................................................................................................155
17.4 Using the Removable Media Manager................................................................................156
17.5 Using Removable Media to Log Data......................................................................................156
17.6 Using Removable Media to Load and Save Applications........................................................157
17.7 Using Removable Media to View and Capture Screens..........................................................157
17.8 Configuration of a Removable Media .................................................................................158
17.9 Removable Media (RM) Function Blocks in Cscape................................................................158
17.10 Removable Media (RM) Features—Program Features.......................................................159
17.11 Removable Media (RM) Features—Graphic/Screen Editor................................................159
17.12 Removable Media (RM) Features—Additional Configuration............................................159
17.13 Filenames used with the Removable Media (RM) Function Blocks....................................160
17.14 System Registers used with RM ..........................................................................................161
CHAPTER 18: CLONE UNIT ...............................................................................................................162
18.1 Overview.................................................................................................................................162
18.2 Clone ...................................................................................................................................162
18.3 Load Clone...........................................................................................................................166
CHAPTER 19: FAIL –SAFE SYSTEM ...................................................................................................168
19.1 Overview.................................................................................................................................168
19.2 Settings................................................................................................................................169
19.3 Backup / Restore Data.........................................................................................................169
19.4 AutoLoad.............................................................................................................................173
19.5 AutoRun...............................................................................................................................175
CHAPTER 20: MODBUS COMMUNICATIONS ..................................................................................176
20.1 Modbus Overview...............................................................................................................176
20.2 Modbus Slave Overview......................................................................................................176
20.3 Modbus Master Overview...................................................................................................177
20.4 Modbus Addressing Table...................................................................................................178
CHAPTER 21: RECHARGEABLE BACK-UP BATTERY ...........................................................................179
21.1 Overview.................................................................................................................................179
21.2 Storing Register Contents .......................................................................................................179
21.3 Battery Life..............................................................................................................................179
21.4 Lithium Battery Safety.........................................................................................................179
21.5 OCS Battery Charging Cycle.................................................................................................180
21.6 Battery Charging Status.......................................................................................................181
21.7 Battery Status in System Registers .........................................................................................182
21.8 Backup Battery....................................................................................................................183
CHAPTER 22: XL7 PRIME BACK UP BATTERY .........................................................................................185
CHAPTER 23: MAINTENANCE..........................................................................................................187
23.1 Firmware Update Overview....................................................................................................187
23.2 How to Check for Current Firmware Revision.....................................................................187
23.3 Details..................................................................................................................................188
23.4 Firmware Update for the XL7/XL7 PRIME...........................................................................189
CHAPTER 24: TROUBLESHOOTING & TECHNICAL SUPPORT...........................................................190

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24.1 Connecting to the XL7/XL7 PRIME OCS...............................................................................190
24.2 Local Controller and Local I/O.............................................................................................192
24.3 CsCAN Network...................................................................................................................193
24.4 Removable Media - Basic Troubleshooting.........................................................................194
24.5 USB Interfaces.....................................................................................................................194
24.6 Technical Support Contacts.................................................................................................194
CHANGE LOG .....................................................................................................................................195
INDEX.................................................................................................................................................196

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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.