HORNER HEXT251C216 User manual

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User Manual for XL4 OCS
MAN0964-12-EN_XL4_UserManual
HE-XC1E0
HE-XC1E2
HE-XC1E3
HE-XC1E4
HE-XC1E5
HE-XC1E6
HE-XC1E0-500
HE-XC1E2-500
HE-XC1E3-500
HE-XC1E4-500
HE-XC1E5-500
HE-XC1E6-500
HE-XC1E0-108
HE-XC1E2-108
HE-XC1E3-108
HE-XC1E4-108
HE-XC1E5-108
HE-XC1E6-108
European: HEXT251C112, HEXT251C113, HEXT251C114, HEXT251C115, HEXT251C116, HEXT251C216

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PREFACE
This manual explains how to use the XL4 OCS.
Copyright (C) 2012 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, 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]
Web: http://www.hornerautomation.com
Email: [e-mail]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Web: http://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 XL4 (HE-XC/HEXT251)
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 XL4 OCS module. THIS WARRANTY SHALL NOT APPLY TO THIS XL4 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
XL4 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 XL4 OCS module to appropriately design the end system, to appropriately
integrate the XL4 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
The datasheet is the first document you need to refer to for model-specific information
related to XL4 OCS models.
Visit our website to obtain updates to datasheets, manuals, and user documentation.
North America https://hornerautomation.com Europe http://www.hornerautomation.eu
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety / Compliance
Safety / Compliance
Safety / Compliance
Safety / Compliance
Introduction
Introduction
Introduction
Introduction
Mechanical
Installation
Serial
Communications
Back-Up Battery
Electrical Installation
CAN
Communications
Fail- Safe System
Ethernet
Communications
Clone Unit
Downloadable
Communication
Protocols
Maintenance
System Settings
Modbus
Communications
Removable Media
Troubleshooting
General I/O
High-Speed I/O
User Interface
Registers
Cscape
Configuration
Video Object

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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 1: SAFETY/ COMPLIANCE....................................................................................................... 9
1.1 Safety Warnings and Guidelines............................................................................................... 9
1.2 Grounding......................................................................................................................................10
1.3 CE Compliance .............................................................................................................................10
CHAPTER 2: INTRODUCTION................................................................................................................... 11
2.1 Visual Overview of XL4 OCS ..................................................................................................... 11
2.2 Connectivity to the XL4 OCS.................................................................................................... 13
2.3 Features of XL4 OCS..................................................................................................................14
2.4 Accessories................................................................................................................................... 15
2.5 Useful Documents and References......................................................................................... 15
2.6Opening Cscape Help File.......................................................................................................... 15
CHAPTER 3: MECHANICAL INSTALLATION......................................................................................16
3.1 Overview........................................................................................................................................ 16
3.2 Mounting Requirements ............................................................................................................16
3.3 Mounting Orientation ................................................................................................................. 17
3.4 Panel Cut-Out...............................................................................................................................18
3.5 XL4 Dimensions...........................................................................................................................18
3.6 Factors Affecting Panel Layout Design and Clearances ...................................................19
CHAPTER 4: ELECTRICAL INSTALLATION ....................................................................................... 21
4.1Grounding Definition .................................................................................................................. 21
4.2 Ground Specifications ................................................................................................................ 21
4.3 How to Test for Good Ground ................................................................................................. 22
4.4 Primary Power Port................................................................................................................... 23
CHAPTER 5: SERIAL COMMUNICATIONS.........................................................................................24
5.1 Overview.......................................................................................................................................24
5.2 Port Descriptions........................................................................................................................24
5.3 Serial Port ....................................................................................................................................24
5.4 Dip Switches ................................................................................................................................25
5.5 RS-485 Termination..................................................................................................................25
5.6 RS-485 Biasing ...........................................................................................................................26
5.7 Cscape Programming via Serial Port ....................................................................................26
5.8 Ladder-Controlled Serial Communication............................................................................ 26
5.9 Configuration via Mini-B USB ..................................................................................................26
CHAPTER 6: CAN COMMUNICATIONS............................................................................................... 27
6.1 Overview....................................................................................................................................... 27

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6.2 Port Description.......................................................................................................................... 27
6.3 CAN1 Port Wiring ........................................................................................................................28
6.4 Cscape Programming via CAN ................................................................................................28
6.5 Ladder-Controlled CAN Communication ..............................................................................28
6.6 Using CAN for I/O Expansion (Network I/O)........................................................................28
CHAPTER 7: ETHERNET COMMUNICATION.....................................................................................29
7.1 Ethernet Module Protocols and Features ............................................................................29
7.2 Ethernet System Requirements .............................................................................................29
7.3 Ethernet Module Specifications..............................................................................................29
7.4 Ethernet Module Configuration ..............................................................................................30
7.5 Ethernet Configuration –IP Parameters .............................................................................. 33
7.6 Ethernet Module Protocol Configuration ............................................................................. 33
CHAPTER 8: DOWNLOADABLE COMMUNICATION PROTOCOLS...............................................34
8.1 Overview.......................................................................................................................................34
8.2 Protocol Config...........................................................................................................................36
8.3 Network Configuration.............................................................................................................. 37
8.4 Device List and Devices Configuration .................................................................................39
8.5 Scan List .......................................................................................................................................40
8.6 Data Mapping Configuration (Scan List Entry) ....................................................................41
CHAPTER 9: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................43
9.1 System Menu - Overview..........................................................................................................43
9.2 System Menu –Navigation and Editing.................................................................................45
9.3 System Menu –Details ..............................................................................................................46
9.4 Touch Screen Calibration.........................................................................................................66
CHAPTER 10: REMOVEABLE MEDIA .................................................................................................. 67
10.1 Overview....................................................................................................................................... 67
10.2 microSD Cards.........................................................................................................................67
10.3 microSD File System..............................................................................................................68
10.4 Using the Removable Media Manager...............................................................................68
10.5 Using Removable Media to Log Data.................................................................................69
10.6 Using Removable Media to Load and Save Applications..............................................69
10.7 Using Removable Media to View and Capture Screens ................................................69
10.8 Configuration of the Removable Media Object ...............................................................70
10.9 Removable Media (RM) Function Blocks in Cscape........................................................70
10.10 Removable Media (RM) Features—Program Features .................................................... 71
10.11 Removable Media (RM) Features—Graphic/Screen Editor ............................................ 71
10.12 Removable Media (RM) Features—Additional Configuration ........................................ 71
10.13 Filenames used with the Removable Media (RM) Function Blocks ............................ 72
10.14 System Registers used with RM.......................................................................................... 73
CHAPTER 11: GENERAL I/O...................................................................................................................74
11.1 Overview.......................................................................................................................................74
11.2 Removing the XL4 OCS I/O Cover ......................................................................................... 74
11.3 Model and I/O Overview ........................................................................................................... 75
11.4 Solid-State Digital Outputs ......................................................................................................76
11.5 Relay Outputs.............................................................................................................................. 77
11.6 Digital Inputs................................................................................................................................78
11.7 Analog Inputs ..............................................................................................................................79
11.8 Universal Analog Inputs............................................................................................................80
11.9 Analog Outputs............................................................................................................................81

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CHAPTER 12: HIGH SPEED I/O (HSC / PWM) ...................................................................................82
12.1 Overview.......................................................................................................................................82
12.2 Glossary ........................................................................................................................................83
12.3 High Speed Counter (HSC) Functions ...................................................................................84
12.4 HSC Functions Register Map ...............................................................................................93
12.5 High Speed Output Functions..............................................................................................96
12.6 High Speed Output Functions Register Map.................................................................. 100
12.7 PWM Examples...........................................................................................................................102
12.8 STP Examples .........................................................................................................................103
12.9 HSC I/O Filtering................................................................................................................... 104
CHAPTER 13: USER INTERFACE.........................................................................................................107
13.1 Overview......................................................................................................................................107
13.2 Screen Specifications...............................................................................................................107
13.3 Displaying and Entering Data................................................................................................ 108
13.4 Alpha-Numeric Keypad ....................................................................................................... 109
13.5 Screen Navigation.......................................................................................................................111
13.6 Ladder Based Screen Navigation ........................................................................................111
13.7 Beeper Acknowledgement .......................................................................................................112
13.8 Touch (Slip) Sensitivity .........................................................................................................112
13.9 Alarms .......................................................................................................................................113
13.10 Removable Media ...................................................................................................................115
13.11 Screen Saver............................................................................................................................117
13.12 Screen Brightness ..................................................................................................................117
13.13 Touch Screen Pressure.........................................................................................................118
CHAPTER 14: REGISTERS ....................................................................................................................120
14.1 Register Definitions ..................................................................................................................120
14.2 Useful %S and %SR Registers............................................................................................121
14.3 Resource Limits .....................................................................................................................129
14.4 Register Map for XL4 OCS I/O ...........................................................................................130
CHAPTER 15: CSCAPE CONFIGURATION.........................................................................................132
15.1 Overview......................................................................................................................................132
15.2 Cscape Status Bar .................................................................................................................132
15.3 Establishing Communications ................................................................................................133
15.4 Configuration...........................................................................................................................141
15.5 Digital / HSC Input Configuration......................................................................................142
15.6 Digital / PWM Output Configuration .................................................................................143
15.7 Analog Input Configuration ................................................................................................... 144
15.8 Analog Output Configuration ............................................................................................ 146
15.9 Scaling Analog Inputs...........................................................................................................147
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
16.6 Video Object Performance................................................................................................. 154
16.7 Web Cameras............................................................................................................................. 154
CHAPTER 17: BACK-UP BATTERY .....................................................................................................155
17.1 Overview......................................................................................................................................155

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17.2 Storing Register Contents.......................................................................................................155
17.3 Battery Life.................................................................................................................................155
17.4 Lithium Battery Safety.........................................................................................................155
17.5 Battery Charging Cycle............................................................................................................156
17.6 Battery Charging Status..........................................................................................................156
17.7 Battery Charging State............................................................................................................156
17.8 Battery Status in System Registers..................................................................................156
CHAPTER 18: FAIL –SAFE SYSTEM ..................................................................................................157
18.1 Overview......................................................................................................................................157
18.2 Settings................................................................................................................................... 158
18.3 Backup / Restore Data ........................................................................................................ 158
18.4 AutoLoad .................................................................................................................................163
18.5 AutoRun...................................................................................................................................165
CHAPTER 19: CLONE UNIT ................................................................................................................. 166
19.1 Overview..................................................................................................................................... 166
19.2 Make Clone............................................................................................................................. 166
19.3 Load Clone ..............................................................................................................................170
CHAPTER 20: MAINTENANCE............................................................................................................172
20.1 Firmware Updates .................................................................................................................172
20.2 Replacing Backup Battery ...................................................................................................173
CHAPTER 21: MODBUS COMMUNICATIONS....................................................................................175
21.1 Modbus Overview......................................................................................................................175
21.2 Modbus Slave Overview...........................................................................................................175
21.3 Modbus Master Overview........................................................................................................176
21.4 Modbus Addressing Table ...................................................................................................177
CHAPTER 22: TROUBLESHOOTING / TECHNICAL SUPPORT ....................................................178
22.1 Connecting to the XL4 OCS....................................................................................................178
22.2 Local Controller and Local I/O .......................................................................................... 180
22.3 CsCAN Network..................................................................................................................... 180
22.4 Basic Troubleshooting..........................................................................................................182
22.5 Technical Support Contacts................................................................................................182
INDEX OF CONTENTS............................................................................................................................ 183
INDEX OF FIGURES AND TABLES ....................................................................................................... 187

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CHAPTER 1: SAFETY/ COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
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.
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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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 floor 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 CE Compliance
To check for compliance and updates, visit our website:
North America https://hornerautomation.com
Europe http://www.hornerautomation.eu

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CHAPTER 2: INTRODUCTION
2.1 Visual Overview of XL4 OCS
Figure 2.1 - Visual Overview of XL4 OCS

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2.1.1 Where to Find Information about the XL4 OCS
a. Datasheets - The datasheets are the first documents you need to refer to
for key information related to specific XL4 OCS models.
The datasheets for all XL4 OCS models are available on our website and
contain pin-outs, jumper settings and other model specific information.
Table 2.1 –Datasheet Manual Numbers
Model 0
MAN1143
Model 2
MAN1144
Model 3
MAN1145
Model 4
MAN1146
Model 5
MAN1147
Model 6
MAN1148
User Manual -This manual provides general information that is common to XL4 OCS models
and can be downloaded from our web. Visit our website to obtain user documentation and
updates.
North America https://hornerautomation.com
Europe http://www.hornerautomation.eu
2.1.2 Four main types of information are covered in the manual.
a. Safety and Installation guidelines / instructions
(Mechanical and Electrical)
b. Descriptions of hardware features
(Serial ports, Removable Media, Communication Options, etc.)
c. Configuration and Use of the XL4 OCS
d. Maintenance and Support
2.1.3 Manual Index
Major topics of interest may be found in the Index towards the end of this manual.
2.1.4 Table of Figures
Location of important drawing, illustrations, etc. may be found in the Table of Figures.

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2.2 Connectivity to the XL4 OCS
The XL4 OCS has excellent capabilities for connecting to a variety of devices. The diagram
below shows some examples of devices that can be used with the XL4 OCS.
Figure 2.2 –Visual Overview of Types of Devices that can be connected to XL4 OCS
CAN
Serial
I/O
XL4 OCS
Other OCS Devices
Drives
PLCs
Bar Code Readers
Printers
SCADA
OPC Servers
Serial I/O
Sensors
Indicators
Alarms
Encoders
Pumps
Relays
Solenoids
Other OCS Devices
Smart Stix I/O
RCX116 I/O Base
OPC
Ethernet
Cscape
OPC Server
Modbus TCP Devices
USB
Flash Drive
Cscape

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2.3 Features of XL4 OCS
The XL4 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 XL4 OCS include:
•Bright, 65,536 color graphical touch-sensing LCD display or a bright white touch-sensing
LED backlit display capable of up to 16,777,216 colors.
•Transflective screen models ending in -500 have heaters and are equivalent to the
environmental specifications of the standard XL4e-22 models.
•Transflective screen models ending in -108 do not have heaters and have equivalent
environmental specifications to the standard XL4 models (without dashes).
•Display of complex graphical objects including trends, gauges, meters and animations.
•High-performance graphic processing.
•Advanced control capabilities including floating point, multiple auto-tuning PID loops
and string handling capabilities.
•Removable media for 32 gigabytes of storage of programs, data logging or screen
captures.
•CsCAN networking port for communication with remote I/O, other controllers or PCs.
•USB port for communication with PCs and programming of controller.
•Configurable serial protocols for communication to drives, PLCs, or other serial
peripherals.
•Full featured, built-in I/O including high resolution analog, thermocouple, RTD, high-
speed counters, PWM outputs and relays (depending upon the XL4 OCS model used).
•Advanced high-speed I/O capabilities.
•Cscape programming software that allows all aspects of the XL4 OCS to be programmed
and configured from one integrated application.
•Optional communication add-on modules.
•On board Ethernet port (10/100Mbps) for Cscape programming and application defined
communication, with Auto MDI/MDI-X.

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2.4 Accessories
Please visit the Horner Control Accessories website for communication, programming and I/O
accessories.
North America http://hornerautomation.com/product-category/home/control-accessories/
Europe http://horner-apg.com/en/products.aspx
2.5 Useful Documents and References
Visit our website to obtain user documentation, supplemental documents, certificates, and
other documentation.
North America https://hornerautomation.com
Europe http://www.hornerautomation.eu
2.6 Opening Cscape Help File
After opening the Cscape Help file, either use the Contest, Index or Search tabs to located
information. The Cscape Help file has more information than the scope of this user manual.
Select “Index” tab.

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CHAPTER 3: MECHANICAL INSTALLATION
NOTE: The datasheet is the first document to refer to for model-specific information related
to XL4 OCS models such as pin-outs, jumper settings, and other key installation information.
Visit our website to obtain datasheets, user documentation, and updates.
North America https://hornerautomation.com
Europe http://www.hornerautomation.eu
3.1 Overview
The mechanical installation greatly affects the operation, safety and appearance of the
system. Information is provided to mechanically install the unit such as cut-out sizes,
mounting procedures, and other recommendations for the proper mechanical installation of
the unit.
3.2 Mounting Requirements
3.2.1 Mounting Procedures (Installed in a Panel Door)
Figure 3.1 –Panel Mounting of an XL4 Series OCS
Once the panel design has been completed using the criteria and suggestions in the following
sections, use the following steps to panel mount the XL4 OCS.
1. Remove all connectors from the XL4 OCS unit.
2. Make sure the gasket is installed on the XL4 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 the each of the four (4) mounting clips into the slots in the XL4 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 4-8 in-lbs (0.45 –0.90 N-m).
001XLE055

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3.3 Mounting Orientation
3.3.1 XL4 OCS Mounting Clip
Figure 3.2 –XL4 OCS with Mounting Clips
3.3.2 XL4 OCS Mounting Orientation
Figure 3.3 –Orientation of XL4 OCS
Slot
for Clip
DIN
Rail Clip
CAUTION—For DIN Rail mounting:
To prevent the unit from slipping off the DIN Rail, do
not install the unit on its sides as shown. Be sure the
DIN Rail is in the horizontal position.
NOTE—For panel or DIN rail mounting:
The orientation shown above provides
for optimum readability of the screen
and ease of use of the keypad.
001XLE056

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3.4 Panel Cut-Out
For installations requiring NEMA4X liquid and dust protection the panel cutout should be cut
with a tolerance of +/- 0.005” (0.1mm).
Figure 3.4 –Panel Cutout Tolerances
3.5 XL4 Dimensions
Figure 3.5 –XL4 OCS Dimensions
3.622 [92mm]
3.622 [92mm]
001XLE002

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3.6 Factors Affecting Panel Layout Design and Clearances
The designer of a panel layout needs to assess the requirements of a particular system and to
consider the following design factors .
3.6.1 Clearance / Adequate Space
Install devices to allow sufficient clearance to open and close the panel door.
Table 3.1 –Minimum Clearance Requirements for Panel Box and Door
Minimum Distance between base of device and
sides of cabinet
2” (50.80mm)
Minimum Distance between base of device and
wiring ducts
1.5” (38.10mm)
If more than one device installed in panel box
(or on door):
Minimum Distance between bases of each
device
4” (101.60mm) between bases of each
device
When door is closed:
Minimum distance between device and closed
door
(Be sure to allow enough depth for the OCS.)
2” (50.80mm)
3.6.2 Grounding
Panel Box: The panel box needs to be properly connected to earth ground to provide a good
common ground reference.
Panel Door: Tie a low impedance ground strap between the panel box and the panel door to
ensure that they have the same ground reference.
3.6.3 Temperature / Ventilation
Ensure that the panel layout design allows for adequate ventilation and maintains the
specified ambient temperature range. Consider the impact on the design of the panel layout if
operating at the extreme ends of the ambient temperature range. For example, if it is
determined that a cooling device is required, allow adequate space and clearances for the
device in the panel box or on the panel door.
WARNING: It is important to follow the requirements of the panel manufacturer and to
follow all applicable electrical codes and standards.
WARNING: Be sure to meet the ground requirements of the panel manufacturer and also
meet applicable electrical codes and standards.

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3.6.4 Orientation
When panel-mounted, there are no orientation restrictions on the XL4 OCS.
3.6.5 Noise
Consider the impact on the panel layout design and clearance requirements if noise
suppression devices are needed. Be sure to maintain an adequate distance between the XL4
OCS and noisy devices such as relays, motor starters, etc.
For details on output protection, especially when using contactors, solenoids, etc. see
MAN0962.
3.6.6 Shock and Vibration
The XL4 OCS has been designed to operate in typical industrial environments that may inflict
some shock and vibration on the unit. For applications that may inflict excessive shock and
vibration, please use proper dampening techniques or relocate the XL4 OCS to a location that
minimizes shock and/or vibration.
3.6.7 Panel Layout Design and Clearance Checklist
The following list provides highlights of panel layout design factors :
____Meets the electrical code and applicable standards for proper grounding, etc.?
____Meets the panel manufacturer’s requirements for grounding, etc.?
____Is the panel box properly connected to earth ground? Is the panel door properly grounded?
Has the appropriate procedure been followed to properly ground the devices in the panel
box and on the panel door?
____Are minimum clearance requirements met? Can the panel door be easily opened and
closed? Is there adequate space between device bases as well as the sides of the panel and
wiring ducts?
____Is the panel box deep enough to accommodate the XL4 OCS?
____Is there adequate ventilation? Is the ambient temperature range maintained? Are cooling
or heating devices required?
____Are noise suppression devices or isolation transformers required? Is there adequate
distance between the base of the XL4 OCS and noisy devices such as relays or motor
starters? Ensure that power and signal wires are not routed in the same conduit.
____Are there other requirements that impact the particular system, which need to be
considered?