HORNER HEXT251C216 User manual

MAN0964-12-EN_XL4_UserManual
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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