HORNER XL7 OCS User manual

User Manual forXL7 OCS
MAN0974-09-EN_XL7_UserManual
HE-XW1E0 / HEXT391C100
HE-XW1E2 / HEXT391C112
HE-XW1E3 / HEXT391C113
HE-XW1E4 / HEXT391C114
HE-XW1E5 / HEXT391C115
HE-XW1E6 / HEXT391C116

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PREFACE
This manual explains how to use the XL7 OCS.
Copyright© 2013 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All
rights reserved. No part of this publication may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any 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, SmartMod, 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]
Website: https://hornerautomation.com
Email: [e-mail]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Website: http://www.horner-apg.com
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 XL7 (HE-
XW/HEXT391) OCS module manufactured by HE-APG is free from defects in material and
workmanship under normal use and service. The obligation of HE-APG under this warranty shall
be limited to the repair or exchange of any part or parts which may prove defective under
normal use and service within two (2) years from the date of manufacture or eighteen (18)
months from the date of installation by the original purchaser whichever occurs first, such
defect to be disclosed to the satisfaction of HE-APG after examination by HE-APG of the
allegedly defective part or parts. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE-APG
NEITHER ASSUMES, NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY
OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS XL7 OCS module. THIS WARRANTY
SHALL NOT APPLY TO THIS XL7 OCS module OR ANY PART THEREOF WHICH HAS BEEN
SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. HE-APG MAKES NO
WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE-
APG. THE TERM "ORIGINAL PURCHASER", AS USED IN THIS WARRANTY, SHALL BE DEEMED
TO MEAN THAT PERSON FOR WHOM THE XL7 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 XL7 OCS module to appropriately design the end system, to appropriately
integrate the XL7OCS 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 CHAPTERS
FIRST STEP of ANY TASK: DATASHEET
Each XL7 OCS unit is sent with a datasheet in the box. The datasheets are the first
documents to refer to for model-specific information related to XL7 OCS models for
specific installation information. To obtain updates to datasheets, manuals and user
documentation, visit a Horner website.
North America https://hornerautomation.com Europe http://www.horner-apg.com
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety /
Compliance
Mechanical
Installation
Serial
Communications
Maintenance
Introduction
Electrical Installation
CAN Communications
Modbus
Communications
Ethernet
Communications
Troubleshooting
Downloadable
Communication
Protocols
System Settings
Removable Media
General I/O
High-Speed I/O
User Interface
Registers
Cscape Configuration
Audio Configuration
Video Configuration
Back-up Battery
Fail-Safe System
Clone Unit

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TABLE OF CONTENTS
PREFACE .....................................................................................................................................................2
ABOUT PROGRAMMING EXAMPLES.......................................................................................................3
VISUAL MAP OF CHAPTERS....................................................................................................................4
TABLE OF CONTENTS...............................................................................................................................5
CHAPTER 1: SAFETY / COMPLIANCE .................................................................................................. 9
1.1 Safety Warnings and Guidelines............................................................................................... 9
1.2 Grounding......................................................................................................................................10
1.3 Compliance ...................................................................................................................................10
CHAPTER 2: INTRODUCTION................................................................................................................. 11
2.1 Visual Overview of XL7 OCS...................................................................................................... 11
2.2 Connectivity to the XL7 OCS.................................................................................................... 13
2.3 Features of XL7 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............................................................................................................................... 19
3.5 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: SERIAL COMMUNICATIONS.........................................................................................25
5.1 Overview....................................................................................................................................... 25
5.2 Port Descriptions........................................................................................................................25
5.3 Wiring and Dip Switches ...........................................................................................................25
5.4 RS485 Termination ...................................................................................................................26
5.5 RS485 Biasing.............................................................................................................................26
5.6 Cscape Programming via Serial Port .................................................................................... 27
5.7 Ladder-Controlled Serial Communication............................................................................ 27
5.8 Configuration via Mini-B USB .................................................................................................. 27
CHAPTER 6: CAN COMMUNICATIONS...............................................................................................28
6.1 Overview.......................................................................................................................................28
6.2 Port Description..........................................................................................................................28
6.3 CAN Port Wiring..........................................................................................................................29
6.4 Cscape Programming via CAN ................................................................................................ 29
6.5 Ladder-Controlled CAN Communication ..............................................................................29
6.6 Using CAN for I/O Expansion (Network I/O)........................................................................29
CHAPTER 7: ETHERNET COMMUNICATION.....................................................................................30
7.1 Ethernet Module Protocols and Features ............................................................................30

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7.2 Ethernet System Requirements .............................................................................................30
7.3 Ethernet Module Specifications..............................................................................................30
7.4 Ethernet Module Configuration ............................................................................................... 31
7.5 Ethernet Configuration –IP Parameters ..............................................................................34
7.6 Ethernet Module Protocol Configuration .............................................................................34
CHAPTER 8: DOWNLOADABLE COMMUNICATION PROTOCOLS...............................................35
8.1 Overview....................................................................................................................................... 35
8.2 Protocol Config........................................................................................................................... 37
8.3 Network Configuration..............................................................................................................38
8.4 Device List and Device Configuration ...................................................................................40
8.5 Scan List ........................................................................................................................................41
8.6 Data Mapping Configuration (Scan List Entry) ...................................................................42
CHAPTER 9: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................44
9.1 System Menu - Overview..........................................................................................................44
9.2 System Menu –Navigation and Editing.................................................................................45
9.3 System Menu –Details ..............................................................................................................47
9.4 Touch screen calibration..........................................................................................................66
CHAPTER 10: REMOVABLE MEDIA.....................................................................................................67
10.1 Overview....................................................................................................................................... 67
10.2 microSD Cards......................................................................................................................... 67
10.3 microSD File System.............................................................................................................. 67
10.4 Using the Removable Media Manager...............................................................................68
10.5 Using Removable Media to Log Data.................................................................................68
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 a Removable Media ................................................................................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 XL7 OCS I/O Cover..........................................................................................74
11.3 Model and I/O Overview ...........................................................................................................76
11.4 Solid-State Digital Outputs ...................................................................................................... 77
11.5 Relay Outputs..............................................................................................................................78
11.6 Digital Inputs................................................................................................................................80
11.7 Analog Inputs ...............................................................................................................................81
11.8 Universal Analog Inputs............................................................................................................82
11.9 Analog Outputs...........................................................................................................................83
CHAPTER 12: HIGH SPEED I/O (HSC / PWM) ...................................................................................84
12.1 Overview.......................................................................................................................................84
12.2 Glossary ........................................................................................................................................85
12.3 High Speed Counter (HSC) Functions ...................................................................................86
12.4 HSC Functions Register Map ...............................................................................................94
12.5 High Speed Output Functions.............................................................................................. 97
12.6 High Speed Output Functions Register Map....................................................................101

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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 .......................................................................................112
13.7 Beeper Acknowledgement .......................................................................................................112
13.8 Touch (Slip) Sensitivity .........................................................................................................113
13.9 Alarms .......................................................................................................................................114
13.10 Removable Media ...................................................................................................................116
13.11 Screen Saver............................................................................................................................118
13.12 Screen Brightness ..................................................................................................................118
13.13 Touch Screen Pressure.........................................................................................................119
CHAPTER 14: REGISTERS .....................................................................................................................121
14.1 Register Definitions ...................................................................................................................121
14.2 Useful %S and %SR registers.............................................................................................121
14.3 Register Map for XL7 OCS I/O............................................................................................125
14.4 Resource Limits .....................................................................................................................127
CHAPTER 15: CSCAPE CONFIGURATION.........................................................................................128
15.1 Overview......................................................................................................................................128
15.2 Cscape Status Bar .................................................................................................................128
15.3 Establishing Communications ................................................................................................129
15.4 Configuration..........................................................................................................................137
15.5 Digital / HSC Input Configuration......................................................................................139
15.6 Digital / PWM Output Configuration ................................................................................ 140
15.7 Analog Input Configuration .....................................................................................................141
15.8 Analog Output Configuration .............................................................................................142
CHAPTER 16: AUDIO PLAYBACK CONFIGURATION......................................................................143
16.1 Audio Configuration in Cscape ..............................................................................................143
16.2 Audio Config Details ............................................................................................................ 144
16.3 Audio Files.............................................................................................................................. 144
CHAPTER 17: VIDEO OBJECT............................................................................................................. 146
17.1 Video Object Overview............................................................................................................ 146
17.2 Opening Video Object in Cscape............................................................................................147
17.3 Video Properties: Video Type................................................................................................ 149
17.4 Video Properties: Control................................................................................................... 150
17.5 Configuring Display Properties...............................................................................................151
17.6 Video Object Performance.......................................................................................................151
17.7 Web Cameras...............................................................................................................................151
CHAPTER 18: BACK-UP BATTERY.....................................................................................................152
18.1 Overview......................................................................................................................................152
18.2 Storing Register Contents...................................................................................................152
18.3 Battery Life .............................................................................................................................152
18.4 Lithium Battery Safety.........................................................................................................152
18.5 Battery Charging Cycle ........................................................................................................153

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18.6 Battery Charging Status ......................................................................................................153
18.7 Battery Charging State ........................................................................................................153
18.8 Battery Status in System Registers..................................................................................153
CHAPTER 19: FAIL –SAFE SYSTEM ................................................................................................. 154
19.1 Overview..................................................................................................................................... 154
19.2 Settings....................................................................................................................................155
19.3 Backup / Restore Data .........................................................................................................155
19.4 AutoLoad .................................................................................................................................159
19.5 AutoRun....................................................................................................................................161
CHAPTER 20: CLONE UNIT.................................................................................................................162
20.1 Overview..................................................................................................................................162
20.2 Clone.........................................................................................................................................162
20.3 Load Clone ............................................................................................................................. 166
CHAPTER 21: MAINTENANCE ............................................................................................................ 168
21.1 Firmware Updates.................................................................................................................... 168
21.2 Backup Battery ......................................................................................................................... 169
CHAPTER 22: MODBUS COMMUNICATIONS....................................................................................171
22.1 Modbus Overview....................................................................................................................... 171
22.2 Modbus Slave Overview........................................................................................................171
22.3 Modbus Master Overview ....................................................................................................172
22.4 Modbus Addressing Table ...................................................................................................173
CHAPTER 23: TROUBLESHOOTING & TECHNICAL SUPPORT....................................................174
23.1 Connecting to the XL7 OCS ....................................................................................................174
23.2 Local Controller and Local I/O ...........................................................................................176
23.3 CsCAN Network......................................................................................................................177
23.4 Removable Media - Basic Troubleshooting.....................................................................178
23.5 Technical Support Contacts................................................................................................178
MAIN INDEX...........................................................................................................................................179
INDEX OF FIGURES & TABLES ........................................................................................................183

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CHAPTER 1: SAFETY / COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
Warning: Consult user documentation.
Warning: Electrical Shock Hazard.
WARNING –EXPLOSION HAZARD –Do not disconnect equipment unless power has been
switched off or the area is known to be non-hazardous
WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth)
ground before making any other connections.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly
recommended to fuse the voltage measurement inputs. Be sure to locate fuses as close to
the source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk of
fire and shock hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated
failure indicates a defective condition that will not clear by replacing the fuse.
WARNING –EXPLOSION HAZARD: Substitution of components may impair suitability for
Class I, Division 2
WARNING: The USB parts are for operational maintenance only. Do not leave permanently
connected unless area is known to be non-hazardous
WARNING –EXPLOSION HAZARD - BATTERIES MUST ONLY BE CHANGED IN AN AREA
KNOWN TO BE NON-HAZARDOUS
WARNING: Battery May Explode If Mistreated. Do not recharge, disassemble or dispose of in
fire.
WARNING: Only qualified electrical personnel familiar with the construction and operation of
this equipment and the hazards involved should install, adjust, operate, or service this
equipment. Read and understand this manual and other applicable manuals in their entirety
before proceeding. Failure to observe this precaution could result in severe bodily injury or
loss of life.

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