HORNER XL7 User manual

User Manual for
XL7 & XL7 Prime
MAN0974-14-EN_XL7_XL7P_UM

Visual Map

Thedatasheetisthefirstdocumenttorefertoformodel-specificinformationrelatedtoEXL6/XL6Primemodelsforinstall-
ationinformation.Thewebversionofthismanualhasallofthedatasheetslinked.

FindthedocumentsviatheDocumentationSearchpageontheHornerwebsite.
Datasheet Manual Numbers
XL7Model0
XL7PrimeModel0
MAN1161
MAN1340
XL7Model2
XL7PrimeModel2
MAN1162
MAN1341
XL7Model3
XL7PrimeModel3
MAN1163
MAN1342
XL7Model4
XL7PrimeModel4
MAN1164
MAN1343
XL7Model5
XL7PrimeModel5
MAN1165
MAN1344
XL7Model6
XL7PrimeModel6
MAN1166
MAN1345
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Visual Map
Quick Start Installation Programming Troubleshooting
"SafetyandCompliance"
onpage10
"MechanicalInstallation"
onpage16
"SystemSettingsandAdjust-
ments"onpage27 "Fail-SafeSystem"onpage170
"IntrototheXL7&XL7
Prime"onpage12
"ElectricalInstallation"on
page24
"RemovableMedia"on
page160 "CloneUnit"onpage166

"SerialCommunications"
onpage114
"GeneralI/OConfiguration"
onpage72
"FirmwareUpdates"on
page191
"CANCommunications"
onpage118
"HighSpeedI/O(HSC/
PWM)"onpage92
"ModbusCommunications"on
page178
"ProtocolConfiguration"
onpage127 "UserInterface"onpage138 "XL7RechargeableBack-up Battery"onpage182
"EthernetCom-
munications"onpage121
"SystemRegisterTables"on
page51
"PrimeOCSPrimeBattery"on
page188

"CscapeConfiguration"on
page61 "Troubleshooting"onpage194
"VideoObject"onpage153

"AudioPlaybackCon-
figuration"onpage149

LIMITED WARRANTY AND LIMITATION OF LIABILITY
HornerAPG,LLC,("HE-APG")warrantstotheoriginalpurchaserthattheXL7/XL7Prime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respons-
ibilityofthesystemdesignerutilizingtheXL7/XL7PrimeOCSmoduletoappropriatelydesigntheendsystem,toappro-
priatelyintegratetheXL7/XL7Prime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.


PREFACE

ThismanualexplainshowtousetheXL7/XL7PrimeOCS.

Copyright(C)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lan-
guage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,andCsCANaretrademarksofHornerAPG.EthernetisatrademarkofXerox
Corporation®.

microSD®andCompactFlashareregisteredtrademarksofSanDiskCorporation®.

PublishedwithMadcapFlare®.



North America
Tel:(+)(317)916-4274
Fax:(+)(317)639-4279
Web:http://www.hornerautomation.com
Email:[email protected]


Europe
Tel:(+)353-21-4321-266
Fax:(+)353-21-4321-826
Web:http://hornerautomation.eu
Email:[email protected]


Table of Contents
Safety and Compliance 10
Intro to the XL7 & XL7 Prime 12
VisualOverviewofXL7/XL7Prime 12
WheretofindmoreinformationfortheXL7&XL7Prime 13
ConnectivitytotheXL7&XL7Prime 13
FeaturesofXL7/XL7PrimeOCS 14
Mechanical Installation 16
MountingRequirements 16
MountingOrientation 17
XL7/XL7PrimeBackCoverDimensions 18
XL7/XL7PrimeDimensions 19
InstallationProcedure 20
FactorsAffectingPanelLayoutDesignandClearances 21
Electrical Installation 24
GroundSpecifications 24
HowtoTestforGoodGround 24
PrimaryPowerPort 25
System Settings and Adjustments 27
OCSLEDIndicatorLights 27
SystemMenu–NavigationandEditing 28
SystemMenuMap 29
SetNetworks 30
ViewStatus&Diags 31
ViewBatteryStatus,I/OSlots&Protocols 33
SetFkeysMode,SerialPorts,Ethernet,Time/Date,Beeper&Screen 36
RemovableMedia 42
Fail–SafeSystem 43
CloneUnit 46
WebMILicenseDetails 48
TouchScreenCalibration 49
System Register Tables 51
RegisterDefinitions 51
%SRegisters 52
%SRRegisters 53
Cscape Configuration 61
CscapeStatusBar 61
EstablishingCommunications 62
CommunicatingviaMJ1SerialPort 67
CommunicatingviaOnBoardEthernetPort 68
CscapeConfiguration 70
General I/O Configuration 72
Built-inDigitalandAnalogI/OOverview 72
RemovingtheHornerOCSBackCover 73
Digital/HSCInputConfiguration 74
Digital/PWMOutputConfiguration 78
SolidStateDigitalOutputs 78
RelayOutputs 79
DigitalOutputConfiguration 80
AnalogInputConfiguration 83

AnalogOutputs 90
High Speed I/O (HSC / PWM) 92
Overview 92
HighSpeedI/OGlossary 93
HighSpeedCounter(HSC)Functions 94
Frequency 94
Totalize 94
PulseWidthMeasurement 96
PeriodMeasurement 97
Quadrature 98
HSCFunctions 99
StatusBits 100
HSCFunctionsRegisterMaps 101
HighSpeedOutputFunctions 105
StepperFunction 107
HighSpeedOutputFunctionsRegisterMap 108
HSCI/OFiltering 111
Serial Communications 114
PortDescriptions 114
Wiring 114
DipSwitches 115
RS485Termination 115
RS485Biasing 115
CscapeProgrammingviaSerialPort 116
Ladder-ControlledSerialCommunication 116
ConfigurationviaMini-BUSB 116
CAN Communications 118
PortDescription 118
CAN1PortWiring 118
CscapeProgrammingviaCAN 119
Ladder-ControlledCANCommunication 119
UsingCANforI/OExpansion(NetworkI/O) 119
Ethernet Communications 121
EthernetModuleProtocolsandFeatures 121
EthernetModuleSpecifications 121
EthernetModuleConfiguration 122
EthernetConfiguration–IPParameters 125
EthernetModuleProtocolConfiguration 125
Protocol Configuration 127
Overview 127
ProtocolDeviceDriverSelection 128
NetworkConfiguration 129
DeviceListandDeviceConfiguration 131
ScanList 133
User Interface 138
ScreenSpecifications 138
DisplayingandEnteringData 139
Alpha-NumericKeypad 140
ScreenNavigation 141
Ladder-BasedScreenNavigation 142
BeeperAcknowledgment 142
Touch(Slip)Sensitivity 143
Alarms 143

RemovableMedia 145
ScreenSaver 146
ScreenBrightness 146
TouchScreenPressure 147
Audio Playback Configuration 149
AudioOverview 149
AudioConfigurationinCscape 150
AudioConfigurationDetails 150
AudioFiles 151
Video Object 153
VideoObjectOverview 153
OpeningVideoObjectinCscape 154
VideoPropertiesConfiguration 156
VideoObjectPerformance 158
WebCameras 158
Removable Media 160
microSDCards 160
UsingtheRemovableMediaManager 161
LogData 161
ViewandCaptureScreens 162
RemovableMediaObject 162
FunctionBlocksinCscape 163
Filenames 164
SystemRegistersusedwithRM 164
Clone Unit 166
MakeClone 166
LoadClone 168
Fail-Safe System 170
FortheXLSeries 170
FortheXLPrimeSeries 170
Fail-SafeSystem 170
Settings 171
Backup/RestoreData 171
AutoLoad 174
AutoRun 176
Modbus Communications 178
ModbusSlaveOverview 178
ModbusMasterOverview 179
ModbusAddressingTable 180
XL7 Rechargeable Back-up Battery 182
StoringRegisterContents 182
BatteryLife 182
LithiumBatterySafety 182
OCSBatteryChargingCycle 183
BatteryChargingStatus 184
BatteryStatusinSystemRegisters 185
Safety&theRechargeableBackupBattery 185
StepstoReplacetheRechargeableBattery 186
Prime OCS Prime Battery 188
PrimeOCSBattery&Safety 188
ReplacingthePrimeOCSBattery 189
Firmware Updates 191
CheckforCurrentFirmwareRevision 191

FirmwareUpdateDetails 192
DownloadFirmware 192
FirmwareUpdateSteps 192
Troubleshooting 194
ConnectingtotheOCS 194
LocalControllerandLocalI/O 195
CsCANNetwork 196
USBInterfaces 196
BasicTroubleshooting 197
TechnicalSupportContacts 197
Change Log 198

Safety and
Compliance

Page 9

Safety and Compliance
Safety and Compliance

Safety Warnings
Whenfoundontheproduct,thefollowingsymbolsspecify:
Warning:Consultuserdocumentation. Warning:ElectricalShockHazard.

WARNING: EXPLOSION HAZARD–SubstitutionofcomponentsmayimpairsuitabilityforClassI,Division2.
WARNING: EXPLOSION HAZARD–Donotdisconnectequipmentunlesspowerhasbeenswitchedofforthe
areaisknowntobenon-hazardous.

WARNING:Toavoidtheriskofelectricshockorburns,alwaysconnectthesafety(orearth)groundbeforemaking
anyotherconnections.
WARNING:Toreducetheriskoffire,electricalshock,orphysicalinjuryitisstronglyrecommendedtofusethe
voltagemeasurementinputs.Besuretolocatefusesasclosetothesourceaspossible.
WARNING:Replacefusewiththesametypeandratingtoprovideprotectionagainstriskoffireandshockhazards.
WARNING:Intheeventofrepeatedfailure,donotreplacethefuseagainasarepeatedfailureindicatesadefective
conditionthatwillnotclearbyreplacingthefuse.
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.

NOTE:Allapplicablecodesandstandardsneedtobefollowedintheinstallationofthisproduct.
NOTE:ForI/Owiring(discrete),usethefollowingwiretypeorequivalent:Belden9918,18AWGorlarger.
NOTE:Seethe"ElectricalInstallation"onpage24formoredetails.

Safety Precautions

Adheretothefollowingsafetyprecautionswheneveranytypeofconnectionismadetothemodule:
lConnectthegreensafety(earth)groundfirstbeforemakinganyotherconnections.
lWhenconnectingtoelectriccircuitsorpulse-initiatingequipment,opentheirrelatedbreakers.Donotmake
connectionstolivepowerlines.
lMakeconnectionstothemodulefirst;thenconnecttothecircuittobemonitored.
lRoutepowerwiresinasafemannerinaccordancewithgoodpracticeandlocalcodes.
lWearproperpersonalprotectiveequipmentincludingsafetyglassesandinsulatedgloveswhenmakingcon-
nectionstopowercircuits.
lEnsurehands,shoes,andfloorsaredrybeforemakinganyconnectiontoapowerline.
lMakesuretheunitisturnedOFFbeforemakingconnectiontoterminals.Makesureallcircuitsarede-ener-
gizedbeforemakingconnections.
lBeforeeachuse,inspectallcablesforbreaksorcracksintheinsulation.Replaceimmediatelyifdefective.


CE Compliance

Tocheckforcomplianceandupdates,visitourwebsite.
NorthAmericahttps://hornerautomation.com/certifications
Europehttps://www.hornerautomation.eu/support/certifications-2/
Page 10 of 198

Introduction to
the XL7 & XL7 Prime
Page 11

Intro to the XL7 &XL7 Prime
Intro to the XL7 & XL7 Prime
Visual Overview of XL7/XL7 Prime 12
Where to find more information for the XL7 & XL7 Prime 13
Connectivity to the XL7 & XL7 Prime 13
Features of XL7/XL7 Prime OCS 14


Visual Overview of XL7/XL7 Prime
1. Touchscreen
2. FunctionKeys
3. Mj1:RS232/MJ2:1/2DuplexRS485
4. DipSwitches
5. MJ3:RS-232/485SerialPort
6. CAN1Port
7. PWR:10-30VDCIn
8. AudioIn&OutPorts
9. USB2.0"A":FlashDrive
10. LAN1&2Ports
11. CAN2Port
12. USBmini"B":Programming
13. microSD:DataStorage
NOTE:SeePrecaution#12onpage4aboutUSBandgrounding.
Page 12 of 198

Intro to the XL7 &XL7 Prime
Where to find more information for the XL7 & XL7 Prime
Datasheets-Thedatasheetsarethefirstdocumentstorefertoforkeyinformationrelatedtospecificmodels.(A
basicdatasheetisprovidedintheboxwiththeunit.)

FindthedocumentsviatheDocumentationSearchpageontheHornerwebsite.
Datasheet Manual Numbers
XL7Model0
XL7PrimeModel0
MAN1161
MAN1340
XL7Model2
XL7PrimeModel2
MAN1162
MAN1341
XL7Model3
XL7PrimeModel3
MAN1163
MAN1342
XL7Model4
XL7PrimeModel4
MAN1164
MAN1343
XL7Model5
XL7PrimeModel5
MAN1165
MAN1344
XL7Model6
XL7PrimeModel6
MAN1166
MAN1345

Connectivity to the XL7 & XL7 Prime
Connectivity
CAN I/O USB Serial Ethernet
OtherOCSDevices Sensors FlashDrive OtherOCSDevices Cscape
SmartStixI/O Indicators Cscape Drives OPCServer
SmartBlockI/O Alarms

PLCs ModbusTCPDevices
SmartRailI/O Encoders Printers

OPC Pumps SCADA

Relays OPCServer
Solenoids Portal
I/ODevices
SmartRailDevices


Page 13 of 198

Intro to the XL7 &XL7 Prime
Features of XL7/XL7 Prime OCS
TheXL7/XL7PRIMEOCSareall-in-oneindustrialcontroldevices.Theycombinecontrol,userinterface,I/Oand
networkingintoasingle,integratedpackage.UniquefeaturesoftheXL7/XL7PRIMEOCSinclude:

nBright,65,536colorgraphicaltouchsensingLCDdisplayinallmodelsofXL7/XL7PRIME.
nDisplayofcomplexgraphicalobjectsincludingtrends,gauges,metersandanimations.
nHighperformancegraphicprocessing.
nAdvancedcontrolcapabilitiesincludingfloatingpoint,multipleauto-tuningPIDloopsandstringhandlingcap-
abilities.
nRemovablemediafor32GBofstorageofprograms,dataloggingorscreencaptures.
nCsCANnetworkingportforcommunicationwithremoteI/O,othercontrollersorPCs.
nHighspeedUSBportforcommunicationwithPCsandprogrammingofcontroller.
nConfigurableserialprotocolsforcommunicationtodrives,PLCs,orotherserialperipherals.
nFullfeatured,built-inI/Oincludinghighresolutionanalog,thermocouple,RTD,highspeedcounters,PWM
outputsandrelays(dependingupontheXL7/XL7PRIMEOCSmodelused).
nAdvancedhighspeedI/Ocapabilities.
nCscapeprogrammingsoftwarethatallowsallaspectsoftheXL7/XL7PRIMEOCStobeprogrammedand
configuredfromoneintegratedapplication.
nOptionalcommunicationadd-onmodules.
nOnboardEthernetport(10/100Mbps)forCscapeprogrammingandapplicationdefinedcommunication,with
AutoMDI/MDI-X.

Page 14 of 198

Mechanical
Installation

Page 15

Mechanical Installation
Mechanical Installation
Mounting Requirements 16
Mounting Orientation 17
XL7/XL7 Prime Back Cover Dimensions 18
XL7/XL7 Prime Dimensions 19
Installation Procedure 20
Factors Affecting Panel Layout Design and Clearances 21


NOTE:Thedatasheetisthefirstdocumenttorefertoformodel-specificinformationrelatedtoXL7&XL7Prime
modelssuchaspin-outs,jumpersettings,andotherkeyinstallationinformation.SeetheDocumentationSearchfor
datasheets.


Themechanicalinstallationgreatlyaffectstheoperation,safetyandappearanceofthesystem.Informationis
providedtomechanicallyinstalltheunitsuchascut-outsizes,mountingprocedures,andotherrecommendations
forthepropermechanicalinstallationoftheunit.

Mounting Requirements
Oncethepaneldesignhasbeencompletedusingthecriteriaandsuggestionsinthefollowingsections,usethefol-
lowingstepstopanelmounttheXL7&XL7PrimeOCS.

1. RemoveallconnectorsfromtheXL7&XL7PrimeOCSunit.
2. MakesurethegasketisinstalledontheXL7/XL7PRIMEOCSandisfreefromdustanddebris.Checkthat
thecornersofthegasketaresecure.
3. Passtheunitthroughthepanel.
4. Inserteachofthefour(4)mountingclipsintotheslotsintheXL7/XL7PRIMEOCScase.Oneclipshouldbe
installedoneachcorner.Lightlytighteneachscrewsotheclipisheldinplace.
5. Tightenthescrewsontheclipssuchthatthegasketiscompressedagainstthepanel.Recommendedtorque
is7-10in-lbs(0.8-1.13Nm).

Page 16 of 198

Mechanical Installation
Mounting Orientation

XL7 & XL7 Prime OCS Mounting Clip


XL7 & XL7 Prime OCS Mounting Orientation

NOTE:TherearenoorientationrestrictionsontheXL7/XL7PRIMEOCS.However,theaboveorientationprovides
foroptimumreadabilityofthescreenandeaseofuseofthekeypad.

Page 17 of 198

Mechanical Installation
XL7/XL7 Prime Back Cover Dimensions
Standard Back Cover Dimensions


Extended I/O Back Cover Dimensions


Page 18 of 198

Mechanical Installation
XL7/XL7 Prime Dimensions


+1.6mm/-0mmcutouttolerance


Page 19 of 198

Mechanical Installation
Installation Procedure
nTheXL7/XL7PRIMEutilizesaclipinstallationmethodtoensurearobustandwatertightsealtotheenclos-
ure.Pleasefollowthestepsbelowfortheproperinstallationandoperationoftheunit.
nThisequipmentissuitableforClassI,Division2,GroupsA,B,CandDornon-hazardouslocationsonly.
nDigitaloutputsshallbesuppliedfromthesamesourceastheoperatorcontrolstation.
nJumpersonconnectorJP1shallnotberemovedorreplacedwhilethecircuitisliveunlesstheareaisknown
tobefreeofignitableconcentrationsofflammablegasesorvapors.

TheXL7/XL7PRIMEutilizesaclipinstallationmethodtoensurearobustandwatertightsealtotheenclosure.
Pleasefollowthestepsbelowfortheproperinstallationandoperationoftheunit.
1. CarefullylocateanappropriateplacetomounttheXL7/XL7PRIME.Besuretoleaveenoughroomatthetop
oftheunitforinsertionandremovalofthemicroSD™card.
2. Carefullycutthehostpanelperthediagram,creatinga131.2mmx189.7mmwitha+1.6mm/-0mmpanel
cutouttolerance,openingintowhichtheXL7Primemaybeinstalled.Iftheopeningistoolarge,watermay
leakintotheenclosure,potentiallydamagingtheunit.Iftheopeningistoosmall,theOCSmaynotfitthrough
theholewithoutdamage.
3. Removeanyburrsandorsharpedgesandensurethepanelisnotwarpedinthecuttingprocess.
4. RemoveallRemovableTerminalsfromtheXL7/XL7PRIME.InserttheXL7/XL7PRIMEthroughthepanel
cutout(fromthefront).ThegasketmustbebetweenthehostpanelandtheXL7/XL7PRIME.
5. Installandtightenthefourmountingclips(providedinthebox)untilthegasketformsatightsealNOTE:Max
torqueis0.8to1.13Nm,or7to10in-lbs.
6. ReinstalltheXL7/XL7PRIMEI/ORemovableTerminalBlocks.Connectcommunicationscablestotheserial
port,USBports,Ethernetport,andCANportasrequired.

Page 20 of 198