HORNER XL+ OCS User manual

User Manual for XL+ OCS
MAN1106-07-EN_XL+_UserManual
XL+ Part Numbers
North America
Europe
Model 0
HE-XP7E0
HEXT751C100
Model 2
HE-XP7E2
HEXT751C112
Model 3
HE-XP7E3
HEXT751C113
Model 4
HE-XP7E4
HEXT751C114
Model 5
HE-XP7E5
HEXT751C115
Model 6
HE-XP7E6
HEXT751C116

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PREFACE
This manual explains how to use the XL+ OCS.
Copyright© 2017 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All
rights reserved. No part of this publication may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any language or computer language, in any
form by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise,
without the prior agreement and written permission of Horner APG, Inc.
All software described in this document or media is also copyrighted material subject to the
terms and conditions of the Horner Software License Agreement.
Information in this document is subject to change without notice and does not represent a
commitment on the part of Horner APG.
Ethernet™is a trademark of Xerox Corporation.
microSD™and CompactFlash are registered trademarks of SanDisk Corporation.
For user manual updates, contact Technical Support:
North America:
Tel: (+) [phone]
Fax: (+) [phone]
Web: http://www.hornerautomation.com
Email: techspp[email protected]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Web: 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 XL+ (HE-XP) 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 XL+ OCS module. THIS WARRANTY SHALL NOT APPLY TO THIS XL+ 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
XL+ OCS module IS ORIGINALLY INSTALLED. THIS WARRANTY SHALL APPLY ONLY WITHIN
THE BOUNDARIES OF THE CONTINENTAL UNITED STATES.
In no event, whether as a result of breach of contract, warranty, tort (including negligence) or
otherwise, shall HE-APG or its suppliers be liable of any special, consequential, incidental or
penal damages including, but not limited to, loss of profit or revenues, loss of use of the
products or any associated equipment, damage to associated equipment, cost of capital, cost
of substitute products, facilities, services or replacement power, down time costs, or claims of
original purchaser's customers for such damages.
To obtain warranty service, return the product to your distributor with a description of the
problem, proof of purchase, postpaid, insured, and in a suitable package.
ABOUT PROGRAMMING EXAMPLES
Any example programs and program segments in this manual or provided on accompanying
diskettes are included solely for illustrative purposes. Due to the many variables and
requirements associated with any particular installation, Horner APG cannot assume
responsibility or liability for actual use based on the examples and diagrams. It is the sole
responsibility of the system designer utilizing the XL+ OCS module to appropriately design the
end system, to appropriately integrate the XL+ OCS module and to make safety provisions for
the end equipment as is usual and customary in industrial applications as defined in any codes
or standards which apply.
NOTE: The programming examples shown in this manual are for illustrative purposes only.
Proper machine operation is the sole responsibility of the system integrator.

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VISUAL MAP OF KEY CHAPTERS
FIRST STEP of ANY TASK: DATASHEET
Each XL+ 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 XL+ 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
Maintenance
Cscape Configuration
Troubleshooting
General I/O
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
LIMITED WARRANTY AND LIMITATION OF LIABILITY........................................................................3
ABOUT PROGRAMMING EXAMPLES.......................................................................................................3
VISUAL MAP OF KEY CHAPTERS............................................................................................................4
TABLE OF CONTENTS...............................................................................................................................5
CHAPTER ONE: SAFETY AND COMPLIANCE..................................................................................... 9
1.1 Safety Warnings and Guidelines............................................................................................... 9
1.2 Grounding......................................................................................................................................10
1.3 Compliance ...................................................................................................................................10
CHAPTER 2: INTRODUCTION................................................................................................................. 11
2.1 Visual Overview of XL+ OCS...................................................................................................... 11
2.2 Connectivity to the XL+ OCS.................................................................................................... 13
2.3 Features of XL+ OCS ..................................................................................................................14
2.4 Accessories................................................................................................................................... 15
2.5 Useful Documents and References......................................................................................... 15
2.6 Opening Cscape Help File.......................................................................................................... 15
CHAPTER 3: MECHANICAL INSTALLATION......................................................................................16
3.1 Overview........................................................................................................................................ 16
3.2 Mounting Requirements ............................................................................................................ 16
3.3 Mounting Orientation ................................................................................................................. 19
3.4Panel Cut-Out..............................................................................................................................20
3.5 XL+ Dimensions ........................................................................................................................... 21
3.6 Factors Affecting Panel Layout Design and Clearances .................................................. 22
CHAPTER 4: ELECTRICAL INSTALLATION ......................................................................................24
4.1 Grounding Definition .................................................................................................................24
4.2 Ground Specifications ...............................................................................................................24
4.3 How to Test for Good Ground .................................................................................................25
4.4 Primary Power Port...................................................................................................................26
CHAPTER 5: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................ 27
5.1 System Menu - Overview.......................................................................................................... 27
5.2 System Menu –Navigation and Editing.................................................................................29
5.3 Set Network ID ............................................................................................................................. 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
5.10 Set Serial Ports .......................................................................................................................38
5.11 Set Time/Date .............................................................................................................................39
5.12 Set Beeper.................................................................................................................................41
5.13 Set Screen....................................................................................................................................42
5.14 Removable Media ...................................................................................................................43

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5.15 Fail –Safe System ..................................................................................................................44
5.16 Enable AutoRun ......................................................................................................................45
5.17 Enable AutoLoad ........................................................................................................................46
5.18 Clone Unit.................................................................................................................................47
5.19 Load Clone ...............................................................................................................................48
5.20 WebMI License Details...........................................................................................................49
5.21 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 XL+ OCS I/O ................................................................................................60
6.4 Resource Limits........................................................................................................................... 61
CHAPTER 7: CSCAPE CONFIGURATION ...........................................................................................62
7.1 Overview.......................................................................................................................................62
7.2 Cscape Status Bar...................................................................................................................... 62
7.3 Establishing Communications .................................................................................................63
7.4 Configuration ............................................................................................................................... 71
7.5 Digital / HSC Input Configuration........................................................................................... 73
7.6 Digital / PWM Output Configuration......................................................................................74
7.7 Analog Input Configuration ..................................................................................................... 75
7.8 Analog Output Configuration..................................................................................................78
CHAPTER 8: GENERAL I/O................................................................................................................... 79
8.1 Overview....................................................................................................................................... 79
8.2 Removing the XL+ OCS I/O Cover..........................................................................................79
8.3 Model and I/O Overview ............................................................................................................81
8.4 Solid-State Digital Outputs ......................................................................................................82
8.5 Relay Outputs..............................................................................................................................83
8.6 Digital Inputs................................................................................................................................84
8.7 Analog Inputs ..............................................................................................................................85
8.8 Universal Analog Inputs Model 5............................................................................................86
8.9 Universal Analog Inputs............................................................................................................86
8.10 Analog Outputs .......................................................................................................................87
CHAPTER 9: HIGH SPEED I/O (HSC / PWM).....................................................................................87
9.1 Overview.......................................................................................................................................88
9.2 Glossary ........................................................................................................................................88
9.3 High Speed Counter (HSC) Functions ...................................................................................89
9.4 HSC Functions Register Map ...................................................................................................95
9.5 High Speed Output Functions .................................................................................................98
9.6 High Speed Output Functions Register Map.......................................................................102
9.7 PWM Examples...........................................................................................................................103
9.8 STP Examples............................................................................................................................ 104
CHAPTER 10: SERIAL COMMUNICATIONS ..................................................................................... 105
10.1 Overview..................................................................................................................................... 105
10.2 Port Descriptions.................................................................................................................. 105
10.3 Wiring ...................................................................................................................................... 106
10.4 RS485 Termination and Biasing........................................................................................107
10.5 Cscape Programming via Serial Port................................................................................107
10.6 Ladder-Controlled Serial Communication.......................................................................107
CHAPTER 11: CAN COMMUNICATIONS ............................................................................................ 108

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11.1 Overview..................................................................................................................................... 108
11.2 Port Description........................................................................................................................ 108
11.3 CAN Port Wiring........................................................................................................................ 109
11.4 Cscape Programming via CAN .............................................................................................. 109
11.5 Ladder-Controlled CAN Communication ............................................................................ 109
11.6 Using CAN for I/O Expansion (Network I/O)...................................................................... 109
CHAPTER 12: ETHERNET COMMUNICATION....................................................................................110
12.1 Ethernet Module Protocols and Features ............................................................................110
12.2 Ethernet System Requirements .............................................................................................110
12.3 Ethernet Module Specifications..............................................................................................110
12.4 Ethernet Module Configuration ...........................................................................................111
12.5 Ethernet Configuration –IP Parameters ..........................................................................115
12.6 Ethernet Module Protocol Configuration .........................................................................115
CHAPTER 13: DOWNLOADABLE COMMUNICATION PROTOCOLS..............................................116
13.1 Overview.......................................................................................................................................116
13.2 Protocol Config...........................................................................................................................118
13.3 Network Configuration..............................................................................................................119
13.4 Device List and Device Configuration ...............................................................................121
13.5 Scan List ......................................................................................................................................122
13.6 Data Mapping Configuration (Scan List Entry) ..............................................................123
CHAPTER 14: USER INTERFACE.........................................................................................................125
14.1 Overview......................................................................................................................................125
14.2 Screen Specifications ...........................................................................................................125
14.2 Displaying and Entering Data .............................................................................................125
14.3 Alpha-Numeric Keypad ........................................................................................................127
14.4 Screen Navigation .................................................................................................................129
14.5 Ladder-Based Screen Navigation ......................................................................................130
14.6 Beeper Acknowledgement ...................................................................................................131
14.7 Touch (Slip) Sensitivity .........................................................................................................131
14.8 Alarms ......................................................................................................................................132
14.9 Removable Media ..................................................................................................................134
14.10 Screen Saver...........................................................................................................................137
14.11 Screen Brightness .................................................................................................................137
14.12 Touch Screen Pressure........................................................................................................138
CHAPTER 15: AUDIO PLAYBACK CONFIGURATION..................................................................... 140
15.1 Audio Configuration in Cscape ............................................................................................. 140
15.2 Audio Config Details ..............................................................................................................141
15.3 Audio Files....................................................................................................................................141
CHAPTER 16: VIDEO OBJECT .............................................................................................................143
16.1 Video Object Overview.............................................................................................................143
16.2 Opening Video Object in Cscape....................................................................................... 144
16.3 Video Properties: Video Type............................................................................................ 146
16.4 Video Properties: Control....................................................................................................147
16.5 Configuring Display Properties ......................................................................................... 148
16.6 Video Object Performance................................................................................................. 148
16.7 Web Cameras............................................................................................................................. 148
CHAPTER 17: REMOVABLE MEDIA ................................................................................................... 149
17.1 Overview..................................................................................................................................... 149
17.2 microSD Cards .......................................................................................................................... 149

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17.3 microSD File System................................................................................................................ 149
17.4 Using the Removable Media Manager............................................................................. 150
17.5 Using Removable Media to Log Data................................................................................... 150
17.6 Using Removable Media to Load and Save Applications..................................................151
17.7 Using Removable Media to View and Capture Screens ....................................................151
17.8 Configuration of a Removable Media ...............................................................................152
17.9 Removable Media (RM) Function Blocks in Cscape ..........................................................152
17.10 Removable Media (RM) Features—Program Features ..................................................153
17.11 Removable Media (RM) Features—Graphic/Screen Editor ..........................................153
17.12 Removable Media (RM) Features—Additional Configuration ......................................153
17.13 Filenames used with the Removable Media (RM) Function Blocks .......................... 154
17.14 System Registers used with RM.........................................................................................155
Chapter 18: CLONE UNIT ....................................................................................................................156
18.1 Overview......................................................................................................................................156
18.2 Clone.........................................................................................................................................156
18.3 Load Clone ............................................................................................................................. 160
Chapter 19: FAIL –SAFE SYSTEM ....................................................................................................162
19.1 Overview......................................................................................................................................162
19.2 Settings....................................................................................................................................163
19.3 Backup / Restore Data ........................................................................................................ 164
19.4 AutoLoad ................................................................................................................................ 168
19.5 AutoRun...................................................................................................................................170
Chapter 20: MODBUS COMMUNICATIONS....................................................................................... 171
20.1 Modbus Overview ...................................................................................................................171
20.2 Modbus Slave Overview........................................................................................................171
20.3 Modbus Master Overview ....................................................................................................172
20.4 Opening Cscape Help File ....................................................................................................173
20.5 Modbus Addressing Table ...................................................................................................174
CHAPTER 21: MAINTENANCE .............................................................................................................175
21.1 Firmware Update Overview ....................................................................................................175
21.2 How to Check for Current Firmware Revision ...................................................................175
21.3 Details ..........................................................................................................................................176
21.4 Firmware Update for XL+....................................................................................................177
21.5 Backup Battery.......................................................................................................................178
CHAPTER 22: TROUBLESHOOTING / TECHNICAL SUPPORT ................................................... 180
22.1 Connecting to the XL+ OCS................................................................................................... 180
22.2 Local Controller and Local I/O ...........................................................................................182
22.3 CsCAN Network......................................................................................................................183
22.4 Removable Media - Basic Troubleshooting.................................................................... 184
22.5 Technical Support Contacts............................................................................................... 184
CHANGE LOG............................................................................................................................................ 185
MAIN INDEX .............................................................................................................................................. 186
INDEX OF FIGURES AND TABLES........................................................................................................ 190

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CHAPTER ONE: SAFETY AND 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.

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a. All applicable codes and standards need to be followed in the installation of this product.
b. For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG,
or larger.
Adhere to the following safety precautions whenever any type of connection is made to the
module.
a. Connect the green safety (earth) ground first before making any other connections.
b. When connecting to electric circuits or pulse-initiating equipment, open their related
breakers. Do not make connections to live power lines.
c. Make connections to the module first; then connect to the circuit to be monitored.
d. Route power wires in a safe manner in accordance with good practice and local codes.
e. Wear proper personal protective equipment including safety glasses and insulated
gloves when making connections to power circuits.
f. Ensure hands, shoes, and floors are dry before making any connection to a power line.
g. Make sure the unit is turned OFF before making connection to terminals. Make sure all
circuits are de-energized before making connections.
h. Before each use, inspect all cables for breaks or cracks in the insulation. Replace
immediately if defective.
1.2 Grounding
Grounding is covered in various chapters within this manual.
1.3 Compliance
To check for compliance and updates, visit the Horner website.
North America https://hornerautomation.com
Europe http://www.hornerautomation.eu