HORNER XL4 User manual

User Manual for XL4 &
XL4 Prime OCS
MAN0964-14-EN_XL4/XL4P_UM
XL4
XL4 Prime
North America
Europe
North America
Europe
HE-XC1E0
HEXT251C100
HE-XPC1E0
HEXP251C100
HE-XC1E2
HEXT251C112
HE-XPC1E2
HEXP251C112
HE-XC1E3
HEXT251C113
HE-XPC1E3
HEXP251C113
HE-XC1E4
HEXT251C114
HE-XPC1E4
HEXP251C114
HE-XC1E5
HEXT251C115
HE-XPC1E5
HEXP251C115
HE-XC1E6
HEXT251C116
HE-XPC1E6
HEXP251C116

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PREFACE
This manual explains how to use the XL4/XL4 P 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/XL4 PRIME US
(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/XL4 PRIME OCS module. THIS
WARRANTY SHALL NOT APPLY TO THIS XL4/XL4 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 XL4/XL4 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 EXAMPLESP
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/XL4 P OCS module to appropriately design the end system, to
appropriately integrate the XL4/XL4 P 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/XL4 Prime 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 EXAMPLESP ....................................................................................................3
VISUAL MAP OF KEY CHAPTERS............................................................................................................4
TABLE OF CONTENTS...............................................................................................................................5
CHAPTER 1: SAFETY/ COMPLIANCE......................................................................................................10
1.1 Safety Warnings and Guidelines..............................................................................................10
1.2 Grounding....................................................................................................................................... 11
1.3 CE Compliance .............................................................................................................................. 11
CHAPTER 2: INTRODUCTION................................................................................................................ 12
2.1 Visual Overview of XL4/XL4 P OCS ....................................................................................... 12
2.2 Connectivity to the XL4/XL4 P OCS.......................................................................................14
22.3 Features of XL4/XL4 P OCS ................................................................................................. 15
2.4 Useful Documents and References......................................................................................... 15
CHAPTER 3: MECHANICAL INSTALLATION...................................................................................... 16
3.1 Overview........................................................................................................................................ 16
3.2 Mounting Requirements ............................................................................................................16
3.3 Mounting Orientation ................................................................................................................. 17
3.4 Dimensions....................................................................................................................................18
3.6 Installation Procedure................................................................................................................ 19
3.7 Factors Affecting Panel Layout Design and Clearances ..................................................20
CHAPTER 4: ELECTRICAL INSTALLATION ...................................................................................... 22
4.1 Grounding Definition ................................................................................................................. 22
4.2 Ground Specifications ............................................................................................................... 22
4.3 How to Test for Good Ground ................................................................................................. 23
4.4 Primary Power Port...................................................................................................................24
CHAPTER 5: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................25
5.1 System Menu - Overview..........................................................................................................25
5.2 System Menu –Navigation and Editing................................................................................. 27
5.3 System Menu –Details ..............................................................................................................28
5.4 View Status..................................................................................................................................29
5.5 View Diags....................................................................................................................................30
5.6 View Battery Status.................................................................................................................... 31
5.7 View I/O Slots.............................................................................................................................. 32
5.8 View Protocols ............................................................................................................................ 33
5.9 Set Fkeys Mode...........................................................................................................................34
5.10 Set Serial Ports .......................................................................................................................35
5.11 Set Time/Date .............................................................................................................................36
5.12 Set Beeper................................................................................................................................38
5.13 Set Screen....................................................................................................................................39
5.14 Removable Media ...................................................................................................................40
5.15 Enable AutoRun ......................................................................................................................42

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5.16 Enable AutoLoad ....................................................................................................................43
5.17 Clone Unit.....................................................................................................................................44
5.18 Load Clone ...............................................................................................................................46
15.19 WebMI License Details...........................................................................................................47
5.20 Touch Screen Calibration .....................................................................................................48
CHAPTER 6: REGISTERS.......................................................................................................................49
6.1 Register Definitions ...................................................................................................................49
6.2 Useful %S and %SR Registers................................................................................................50
6.3 Resource Limits..........................................................................................................................59
6.4 Register Map for XL4/XL4 Prime OCS I/O...........................................................................60
CHAPTER 7: CSCAPE CONFIGURATION ...........................................................................................62
7.1 Overview.......................................................................................................................................62
7.2 Cscape Status Bar......................................................................................................................62
7.3 Establishing Communications .................................................................................................63
7.4 Configuration ............................................................................................................................... 71
7.5 Digital / HSC Input Configuration........................................................................................... 72
7.6 Digital / PWM Output Configuration...................................................................................... 73
7.7 Analog Input Configuration .....................................................................................................74
7.8 Analog Output Configuration.................................................................................................. 76
7.9 Scaling Analog Inputs................................................................................................................ 77
CHAPTER 8: GENERAL I/O...................................................................................................................78
8.1 Overview.......................................................................................................................................78
8.2 Removing the XL4/XL4 Prime OCS I/O Cover....................................................................78
8.3 Model and I/O Overview ........................................................................................................... 79
8.4 Solid-State Digital Outputs ......................................................................................................80
8.5 Relay Outputs...............................................................................................................................81
8.6 Digital Inputs................................................................................................................................82
8.7 Analog Inputs ..............................................................................................................................83
8.8 Universal Analog Inputs............................................................................................................84
8.9 Analog Outputs...........................................................................................................................85
CHAPTER 9: HIGH SPEED I/O (HSC / PWM).....................................................................................86
9.1 Overview.......................................................................................................................................86
9.2 Glossary ........................................................................................................................................87
9.3 High Speed Counter (HSC) Functions ...................................................................................88
9.4 HSC Functions Register Map ...................................................................................................97
9.5 High Speed Output Functions ............................................................................................... 100
9.6 High Speed Output Functions Register Map...................................................................... 104
9.7 PWM Examples.......................................................................................................................... 105
9.8 STP Examples............................................................................................................................ 106
9.9 HSC I/O Filtering........................................................................................................................107
CHAPTER 10: SERIAL COMMUNICATIONS .......................................................................................110
10.1 Overview.......................................................................................................................................110
10.2 Port Descriptions....................................................................................................................110
10.3 Serial Port.................................................................................................................................110
10.4 Dip Switches..............................................................................................................................111
10.5 RS-485 Termination ...............................................................................................................111
10.6 RS-485 Biasing........................................................................................................................112
10.7 Cscape Programming via Serial Port.................................................................................112
10.8 Ladder-Controlled Serial Communication........................................................................112

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10.9 Configuration via Mini-B USB ..............................................................................................112
CHAPTER 11: CAN COMMUNICATIONS ..............................................................................................113
11.1 Overview.......................................................................................................................................113
11.2 Port Description..........................................................................................................................113
11.3 CAN1 Port Wiring ........................................................................................................................114
11.4 Cscape Programming via CAN ................................................................................................114
11.5 Ladder-Controlled CAN Communication ..............................................................................114
11.6 Using CAN for I/O Expansion (Network I/O)........................................................................114
CHAPTER 12: ETHERNET COMMUNICATION....................................................................................115
12.1 Ethernet Overview .....................................................................................................................115
12.2 Ethernet Module Protocols and Features ............................................................................115
12.3 Ethernet System Requirements .............................................................................................115
12.4 Ethernet Module Specifications..........................................................................................116
12.5 Ethernet Module Configuration ..........................................................................................117
12.6 Ethernet Configuration –IP Parameters .........................................................................120
12.7 Ethernet Module Protocol Configuration ............................................................................120
CHAPTER 13: DOWNLOADABLE COMMUNICATION PROTOCOLS..............................................121
13.1 Overview.......................................................................................................................................121
13.2 Protocol Config..........................................................................................................................123
13.3 Network Configuration.............................................................................................................124
13.4 Device List and Devices Configuration ............................................................................126
13.5 Scan List ......................................................................................................................................127
13.6 Data Mapping Configuration (Scan List Entry) ..............................................................128
CHAPTER 14: USER INTERFACE.........................................................................................................130
14.1 Overview......................................................................................................................................130
14.2 Screen Specifications ...........................................................................................................130
14.3 Displaying and Entering Data ..............................................................................................131
14.4 Alpha-Numeric Keypad ........................................................................................................132
14.5 Screen Navigation .................................................................................................................134
14.6 Ladder Based Screen Navigation ......................................................................................134
14.7 Beeper Acknowledgement ..................................................................................................135
14.8 Touch (Slip) Sensitivity ........................................................................................................135
14.9 Alarms ......................................................................................................................................136
14.10 Removable Media ..................................................................................................................138
14.11 Screen Saver.......................................................................................................................... 140
14.12 Screen Brightness ................................................................................................................ 140
14.13 Touch Screen Pressure.........................................................................................................141
CHAPTER 15: VIDEO OBJECT .............................................................................................................143
15.1 Video Object Overview.............................................................................................................143
15.2 Opening Video Object in Cscape....................................................................................... 144
15.3 Video Properties: Video Type................................................................................................ 146
15.4 Video Properties: Control....................................................................................................147
15.5 Configuring Display Properties ......................................................................................... 148
15.6 Video Object Performance................................................................................................. 148
15.7 Web Cameras............................................................................................................................. 148
CHAPTER 16: REMOVEABLE MEDIA ................................................................................................ 149
16.1 Overview..................................................................................................................................... 149
16.2 microSD Cards....................................................................................................................... 149
16.3 microSD File System............................................................................................................ 150

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16.4 Using the Removable Media Manager............................................................................. 150
16.5 Using Removable Media to Log Data.................................................................................151
16.6 Using Removable Media to Load and Save Applications..............................................151
16.7 Using Removable Media to View and Capture Screens....................................................151
16.8 Configuration of the Removable Media Object..............................................................152
16.9 Removable Media (RM) Function Blocks in Cscape.......................................................152
16.10 Removable Media (RM) Features—Program Features ..................................................153
16.11 Removable Media (RM) Features—Graphic/Screen Editor ..........................................153
16.12 Removable Media (RM) Features—Additional Configuration ......................................153
16.13 Filenames used with the Removable Media (RM) Function Blocks .......................... 154
16.14 System Registers used with RM.........................................................................................155
CHAPTER 17: CLONE UNIT ..................................................................................................................156
17.1 Overview......................................................................................................................................156
17.2 Make Clone..................................................................................................................................156
17.3 Load Clone ................................................................................................................................. 160
CHAPTER 18: FAIL –SAFE SYSTEM ..................................................................................................162
18.1 Overview......................................................................................................................................162
18.2 Settings....................................................................................................................................163
18.3 Backup / Restore Data .........................................................................................................163
18.4 AutoLoad ................................................................................................................................ 168
18.5 AutoRun...................................................................................................................................170
CHAPTER 19: MODBUS COMMUNICATIONS.....................................................................................171
19.1 Modbus Overview.......................................................................................................................171
19.2 Modbus Slave Overview........................................................................................................171
19.3 Modbus Master Overview ....................................................................................................172
19.4 Modbus Addressing Table ...................................................................................................173
CHAPTER 20: XL4 RECHARGEABLE BACK-UP BATTERY ..........................................................174
20.1 Overview..................................................................................................................................174
20.2 Storing Register Contents...................................................................................................174
20.3 Battery Life .............................................................................................................................174
20.4 Lithium Battery Safety.........................................................................................................174
20.5 OCS Battery Charging Cycle...............................................................................................175
20.6 Battery Charging Status ......................................................................................................176
20.7 Battery Status in System Registers..................................................................................177
20.8 Replacing Rechargeable Backup Battery ........................................................................178
CHAPTER 21: XL4 PRIME BACK UP BATTERY.................................................................................. 180
CHAPTER 22: MAINTENANCE ............................................................................................................182
22.1 Firmware Updates.....................................................................................................................182
22.2 How to Check for Current Firmware Revision................................................................182
22.3Firmware Update Details .....................................................................................................183
22.4 Firmware Update Steps ...................................................................................................... 184
CHAPTER 23: TROUBLESHOOTING / TECHNICAL SUPPORT ................................................... 185
23.1 Connecting to the XL4/XL4 Prime OCS ............................................................................. 185
23.2 Local Controller and Local I/O ...........................................................................................187
23.3 CsCAN Network..................................................................................................................... 188
23.4 USB Interfaces....................................................................................................................... 189
23.5 Basic Troubleshooting......................................................................................................... 189
23.6 Technical Support Contacts............................................................................................... 189

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CHANGE LOG..........................................................................................................................................190
INDEX ........................................................................................................................................................ 191

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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/XL4 P OCS
Figure 2.1 - Visual Overview of XL4/XL4 P OCS

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2.1.1 Where to Find Information about the XL4/XL4 POCS
a. Datasheets - The datasheets are the first documents you need to refer to
for key information related to specific XL4/XL4 Prime OCS models.
The datasheets for all XL4/XL4 Prime 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 #
XL4
XL4 P
Model 0
MAN1143
MAN1319
Model 2
MAN1144
MAN1320
Model 3
MAN1145
MAN1321
Model 4
MAN1146
MAN1322
Model 5
MAN1147
MAN1323
Model 6
MAN1148
MAN1324
User Manual -This manual provides general information that is common to XL4/XL4 P 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/XL4 P 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.

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2.2 Connectivity to the XL4/XL4 P OCS
The XL4/XL4 P 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/XL4 P OCS.
Figure 2.2 –Visual Overview of Types of Devices that can be connected to XL4/XL4 P OCS
CAN
Serial
I/O
XL4/XL4 Prime
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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22.3 Features of XL4/XL4 P OCS
The XL4/XL4 P 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/XL4
P 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 XL4 -22 models.
•Transflective screen models ending in -108 do not have heaters and have equivalent
environmental specifications to the standard XL4/XL4 P 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/XL4 Prime OCS
model used).
•Advanced high-speed I/O capabilities.
•Cscape programming software that allows all aspects of the XL4/XL4 Prime 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.
2.4 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

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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/XL4 Prime 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/XL4 Prime 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/XL4 Prime OCS.
1. Remove all connectors from the XL4/XL4 Prime OCS unit.
2. Make sure the gasket is installed on the XL4/XL4 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 the each of the four (4) mounting clips into the slots in the XL4/XL4
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 4-8 in-lbs (0.45 –0.90 N-m).
001XLE055

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3.3 Mounting Orientation
3.3.1 XL4/XL4 Prime OCS Mounting Clip
Figure 3.2 –XL4/XL4 Prime OCS with Mounting Clips
3.3.2 XL4/XL4 Prime OCS Mounting Orientation
Figure 3.3 –Orientation of XL4/XL4 Prime 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 Dimensions
Figure 3.5 –XL4/XL4 P OCS Dimensions

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3.6 Installation Procedure
•The XL4/XL4 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.
•This equipment is suitable for Class I, Division 2, Groups A, B, C and D or non-
hazardous locations only.
•Digital outputs shall be supplied from the same source as the operator control station.
•Jumpers 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.
1. Carefully locate an appropriate place to mount the XL4/XL4 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 92mm x 92mm +/-0.1mm
opening into which the XL4/XL4 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 XL4/XL4 Prime. Insert the XL4/XL4 Prime
through the panel cutout (from the front). The gasket must be between the host panel
and the XL4/XL4 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, 7 to 10 in-lbs.
6. Reinstall the XL4/XL4 Prime I/O Removable Terminal Blocks. Connect communications
cables to the serial port, USB ports, Ethernet port, and CAN port as required.

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3.7 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 .
3.7.1 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)
3.7.2 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.
3.7.3 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.