HORNER XL7 OCS User Manual
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HORNER XL7 OCS User Manual

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MAN0974-09-EN_XL7_UserManual
HE-XW1E0 / HEXT391C100
HE-XW1E2 / HEXT391C112
HE-XW1E3 / HEXT391C113
HE-XW1E4 / HEXT391C114
HE-XW1E5 / HEXT391C115
HE-XW1E6 / HEXT391C116
XL7 OCS

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  • Page 1 XL7 OCS User Manual for MAN0974-09-EN_XL7_UserManual HE-XW1E0 / HEXT391C100 HE-XW1E2 / HEXT391C112 HE-XW1E3 / HEXT391C113 HE-XW1E4 / HEXT391C114 HE-XW1E5 / HEXT391C115 HE-XW1E6 / HEXT391C116...

  • Page 2: Preface

    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.

  • Page 3: About Programming Examples

    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.

  • Page 4: Visual Map Of Chapters

    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.

  • Page 5: Table Of Contents

    Safety Warnings and Guidelines ....................9 Grounding ............................10 Compliance ........................... 10 CHAPTER 2: INTRODUCTION ......................... 11 Visual Overview of XL7 OCS ...................... 11 Connectivity to the XL7 OCS ....................13 Features of XL7 OCS ........................14 Accessories ........................... 15 Useful Documents and References ..................
  • Page 6 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 ..........................
  • Page 7 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...
  • Page 8 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...

  • Page 9: Chapter 1: Safety / Compliance

    MAN0974-09-EN_XL7_UserManual CHAPTER 1: SAFETY / COMPLIANCE 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.

  • Page 10: Grounding

    Before each use, inspect all cables for breaks or cracks in the insulation. Replace immediately if defective. Grounding Grounding is covered in various chapters within this manual. Compliance To check for compliance and updates, visit the Horner website. North America https://hornerautomation.com Europe http://www.horner-apg.com...

  • Page 11: Chapter 2: Introduction

    MAN0974-09-EN_XL7_UserManual CHAPTER 2: INTRODUCTION Visual Overview of XL7 OCS Figure 2.1 – Overview of the XL7 March 4 , 2019 Page 11 | 185...
  • Page 12 Datasheet - The datasheet is the first document to refer to for key information related to specific XL7 OCS models. The datasheets for all XL7 OCS models are available on the Horner websites and contain pin-outs, jumper settings and other model specific information.

  • Page 13: Connectivity To The Xl7 Ocs

    Serial I/O Indicators Alarms Cscape Encoders OPC Server Pumps Modbus TCP Devices Relays Solenoids Flash Drive Cscape Figure 2.2 – Visual Overview of Types of Devices that can be connected to XL7 OCS March 4 , 2019 Page 13 | 185...

  • Page 14: Features Of Xl7 Ocs

    The XL7 OCS are all-in-one industrial control devices. They combine control, user interface, I/O and networking into a single, integrated package. Unique features of the XL7 OCS include: Bright, 65,536 color graphical touch sensing LCD display in all models of XL7.

  • Page 15: Accessories

    MAN0974-09-EN_XL7_UserManual Accessories Please visit the Horner Control Accessories website for communication, programming, and I/O accessories. North America http://hornerautomation.com/product-category/home/control-accessories/ Europe http://horner-apg.com/en/products.aspx 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.horner-apg.com...

  • Page 16: Chapter 3: Mechanical Installation

    CHAPTER 3: MECHANICAL INSTALLATION NOTE: The datasheet is the first document to refer to for model-specific information related to XL7 OCS models such as pin-outs, jumper settings, and other key installation information. Visit the Horner websites to obtain datasheets, user documentation, and updates.

  • Page 17: Mounting Orientation

    3. Pass the unit through the panel. 4. Insert each of the four (4) mounting clips into the slots in the XL7 OCS case. One clip should be installed on each corner. Lightly tighten each screw so the clip is held in place.
  • Page 18 3.3.2 XL7 OCS Mounting Orientation Figure 3.3 – Orientation of XL7 OCS NOTE: There are no orientation restrictions on the XL7 OCS. However, the above orientation provides for optimum readability of the screen and ease of use of the keypad.

  • Page 19: Panel Cut-Out

    MAN0974-09-EN_XL7_UserManual Panel Cut-Out For installations requiring NEMA 4X liquid and dust protection the panel cutout should be cut with a tolerance of +/- 0.005” (0.1mm). Figure 3.5 – XL7 OCS Dimensions March 4 , 2019 Page 19 | 185...

  • Page 20: Factors Affecting Panel Layout Design And Clearances

    MAN0974-09-EN_XL7_UserManual Factors Affecting Panel Layout Design and Clearances WARNING: It is important to follow the requirements of the panel manufacturer and to follow all applicable electrical codes and standards. The designer of a panel layout needs to assess the requirements of a particular system and to consider the following design factors 3.5.1 Clearance / Adequate Space Install devices to allow sufficient clearance to open and close the panel door.
  • Page 21 MAN0962. 3.5.6 Shock and Vibration The XL7 OCS has been designed to operate in typical industrial environments that may inflict some shock and vibration on the unit. For applications that may inflict excessive shock and vibration please use proper dampening techniques or relocate the XL7 OCS to a location that minimizes shock and/or vibration.

  • Page 22: Chapter 4: Electrical Installation

    CHAPTER 4: ELECTRICAL INSTALLATION NOTE: The datasheets are the first documents to refer to for model-specific information related to XL7 OCS models such as pin-outs, jumper settings, and other key installation information. Visit the Horner websites to obtain datasheets, user documentation, and updates.

  • Page 23: How To Test For Good Ground

    MAN0974-09-EN_XL7_UserManual How to Test for Good Ground In order to test ground resistance, a Ground Resistance Tester must be used. A typical Ground Resistance Meter Kit contains a meter, two or three wire leads, and two ground rods. Instructions are supplied for either a two-point or three-point ground test. GROUND RESISTANCE METER GROUND DISCONNECTED...

  • Page 24: Primary Power Port

    MAN0974-09-EN_XL7_UserManual Primary Power Port Table 4.1 – Primary Power Port Pins Signal Description Frame Ground Input power supply ground +24V Input power supply positive voltage 10-30VDC supply Figure 4.1 – Power Connector (Primary Power Port) DC INPUT / FRAME Solid/Standard Wire: 12-24 awg (2.5-0.2mm). Strip Length: 0.28”...

  • Page 25: Chapter 5: Serial Communications

    CHAPTER 5: SERIAL COMMUNICATIONS Overview All XL7 OCS models provide two independent serial ports, on the first 8-pin modular RJ45 connector, which is labeled MJ1/MJ2. The MJ1 serial port is RS232 while the MJ2 port is RS485. By default, MJ1 can be connected to the COM port of a PC running Cscape, for OCS programming.

  • Page 26: Rs485 Termination

    MAN0974-09-EN_XL7_UserManual Figure 5.2 – Dip Switches RS485 Termination Proper RS485 termination minimizes signal reflections and improves reliability. Both the MJ2 and MJ3 serial ports allow an internal termination resistor to be placed across Pins 1 and 2 by DIP Switch Setting. Only the two devices physically located at the endpoints of the RS485 network should be terminated.

  • Page 27: Cscape Programming Via Serial Port

    The XL7 OCS MJ1 and MJ3 serial ports support CsCAN Programming Protocol. If a PC COM port is connected to the XL7 OCS MJ1 or MJ3 serial port, Cscape can access the XL7 OCS for programming and monitoring. Programming can also be done via the CAN port, USB A port, or Ethernet.

  • Page 28: Chapter 6: Can Communications

    – one only). Port Description The XL7 OCS CAN ports implement the ISO 11898-2 physical layer and the CAN 2.0 A data link layer standards. Also, since the CAN ports are powered by an internal isolated power supply, external CAN power is not required.

  • Page 29: Can Port Wiring

    The CAN1 port supports CsCAN Programming Protocol. If a PC has a CAN interface installed (via PCI card or USB), and the PC CAN port is connected to the XL7 OCS CAN1 port, Cscape can access the XL7 OCS for programming and monitoring.

  • Page 30: Chapter 7: Ethernet Communication

    Ethernet Global Data SRTP (Slave 90-30 Service Request Transfer Protocol Service Request) CsCAN TCP Server Horner APG CsCAN over Ethernet (for Cscape to OCS programming) Modbus Slave Modbus over Ethernet Ethernet / IP ODVA CIP over Ethernet FTP (File Server)

  • Page 31: Ethernet Module Configuration

    MAN0974-09-EN_XL7_UserManual Ethernet Module Configuration NOTE: The following configuration is required for all applications regardless of the protocols used. Additional configuration procedures must be performed for each protocol used. To configure the Ethernet Module, use Cscape Programming Software to perform the following steps On the main Cscape screen, select the Controller →...
  • Page 32 MAN0974-09-EN_XL7_UserManual Click the Config button to the right of LAN1 for LAN 1 or LAN2 for LAN2, revealing the Ethernet Module Configuration dialog as shown in Figure 7.2 Figure 7.2 – Ethernet Module Configuration Configure the Ethernet Module parameters as follows: IP Address: Enter the static IP Address for the Ethernet Module being configured.
  • Page 33 MAN0974-09-EN_XL7_UserManual Table 7.3 - Ethernet Status Word Register Format High Byte Low Byte Dup Spd Link TCP Connections Status Values Status Bit(s) Status Indication Minimum Maximum Reserved Always 0 0 = Half 1 = Full Link Duplex (Auto-Negotiated) Duplex Duplex Link Speed (Auto-Negotiated) 0 = 10MHz 1 = 100MHz...

  • Page 34: Ethernet Configuration - Ip Parameters

    MAN0974-09-EN_XL7_UserManual Ethernet Configuration – IP Parameters For primary operation, the IP address, Net Mask, and Gateway should be set in the LAN config of the Cscape Hardware Configuration. There are options to get IP parameters from the LAN Config or to get parameters from registers. It is possible to set the Ethernet IP parameters from the OCS System Menu, but only as a temporary measure.

  • Page 35: Chapter 8: Downloadable Communication Protocols

    MAN0974-09-EN_XL7_UserManual CHAPTER 8: DOWNLOADABLE COMMUNICATION PROTOCOLS Overview Through loadable protocol device drivers, certain models of the OCS family can provide the ability to exchange data with remote devices such as variable-frequency drives, PLCs, and remote I/O devices. This feature greatly expands the OCS ’s control capability with negligible effect on the OCS ’s ladder scan time.
  • Page 36 (automatic) or controlled from ladder logic (manual) once a complex connection is programmatically created (i.e., dialup modem). The specific transaction-scanning mode is selected from the Network Config menu. The following Horner Automation websites offer OCS Protocol Software Downloads. North America http://hornerautomation.com/support-files/ Europe http://www.horner-apg.com/en/products/software/ocs-protocols.aspx...

  • Page 37: Protocol Config

    MAN0974-09-EN_XL7_UserManual Protocol Config After opening Cscape, choose Program → Protocol Config, and select the port drop-down box to select a protocol device driver. All protocol device drivers currently loaded in Cscape are displayed in the dropdown selection. Some OCS models can be limited in the number of ports or number of protocol device drivers that can be selected.

  • Page 38: Network Configuration

    MAN0974-09-EN_XL7_UserManual Network Configuration Network Configuration provides the required parameters to configure the network. Each protocol is different and may not require all the Network Config field. Please refer to the table below for the options in the Network Config field. March 4 , 2019 Page 38 | 185...
  • Page 39 MAN0974-09-EN_XL7_UserManual Table 8.1 – Network Protocols Baud Rate, Data Bits, Stop These field define the bit level transfer over the serial port. Bits, Parity None – No handshake lines are used Handshake Multidrop Full – Rx remains active while Tx is occurring. Multidrop Half –...

  • Page 40: Device List And Device Configuration

    MAN0974-09-EN_XL7_UserManual Device List and Device Configuration Device List The Device List is reached from the Device button on the Protocol Config screen and provides a list of the configured devices on the Network. Devices must be created and exist in this list before corresponding Scan List entries can be created for this device.

  • Page 41: Scan List

    MAN0974-09-EN_XL7_UserManual Scan List This can be accessed from the Scan List button on the Protocol Config screen or the Mapping button on the Device List screen and provides a Scan List of the Data Mapping entries. To transfer data between the OCS and remote target, a Scan List must be created that defines each transaction.

  • Page 42: Data Mapping Configuration (Scan List Entry)

    MAN0974-09-EN_XL7_UserManual Data Mapping Configuration (Scan List Entry) Update Type This field specifies the direction and what triggers the transfer of data between the OCS and target device for a mapping entry. Polled Read On every transaction scan, a read-only target device register(s) transaction occurs. Polled Read/Write On every transaction scan, a read target device register transaction occurs unless a local register value has changed.
  • Page 43 MAN0974-09-EN_XL7_UserManual Polled Read/Write/Init On every transaction scan, a read target device register transaction occurs unless a local register value has changed. The write transaction only updates those local registers that have changed in value. If several non-consecutive local registers (contained in a single mapping entry) change value between transaction scans, it takes several consecutive scans to write each changed register.

  • Page 44: Chapter 9: System Settings And Adjustments

    MAN0974-09-EN_XL7_UserManual CHAPTER 9: SYSTEM SETTINGS AND ADJUSTMENTS Press the upper right corner to bring out the function keys and SYSTEM key in order to access the Main Menu. System Menu - Overview The XL7 has a built-in System Menu, which lets the user view System Settings and makes adjustments.

  • Page 45: System Menu - Navigation And Editing

    MAN0974-09-EN_XL7_UserManual System Menu – Navigation and Editing As mentioned above, the System Menu is started by pressing the System key on the XL7. Next press ESC to exit the System Menu or use  and  to select an item and press Enter display the item’s Sub-Menu.
  • Page 46 MAN0974-09-EN_XL7_UserManual Sub-Menus Sub-Menus Network Ok? Network ID Fkeys: Momentary XL7 System Termination SYS-Fn enable: MAC ID: 00:E0:C4:04:C7: Menu Map IP Address: 192.168.254.1 ( Use ↑↓ to adjust ) Network 255.255.255.0 Mask: Gateway 0.0.0.0 Dflt Pgm Port MJ1-232 NetM2: 255.255.255.0 MJ2 RS485 Bias GatW2 0.0.0.0 MJ3 RS485 Bias...

  • Page 47: System Menu - Details

    MAN0974-09-EN_XL7_UserManual System Menu – Details The following sections describe each of the Sub-Menus in detail. Set Networks This sub menu allows setting for the CAN and Ethernet network to be viewed or changed. Yes= CAN1 connected to a CAN network and functioning properly CAN Ok? No= Not ready to communicate on CAN network CAN ID...
  • Page 48 0.1 to 999.9= Average number of mS for each ladder scan OCS Net Use % 0.0 to 100.0 = CAN network bandwidth % used by this XL7 OCS node All Net Use % 0.0 to 100.0 = CAN network bandwidth % used by all nodes...
  • Page 49 The View Diags Sub-Menu displays up to 11 System Diagnostics, none of which are editable. The first two System Diagnostics are critical. If either of these indicate a Fault condition, the XL7 OCS will not enter or remain in Run mode, and the problem must be investigated and corrected.
  • Page 50 MAN0974-09-EN_XL7_UserManual View Battery Status The View Battery Status displays the following information. Waiting The charging system is waiting for voltages and temperatures to stabilize. Battery Charging The battery is charging. Battery Full Shows at the end of a charge cycle. Remains in this state until the battery is steadily discharging.
  • Page 51 The View I/O Slots Sub-Menu displays three System Settings, none of which may be edited. Internal to the XL7 OCS, there is a CPU board, and up to two installed modules. Model 0 has no installed I/O or COM modules. All other models have an I/O module and can have a user-installed COM module.
  • Page 52 As mentioned in 0, both the MJ1/MJ2 (Port 1) and MJ3 (Port 2) serial ports support downloadable protocols. To assign a downloadable protocol to an XL7 OCS serial port, select the Protocol Config item in Cscape’s Program menu and then set up a protocol for Port 1 or Port 2 (or both).
  • Page 53 MAN0974-09-EN_XL7_UserManual Set Fkeys Mode The Set Fkeys Sub-Menu displays two System Settings, both of which may be edited. Momentary= %K1-5 bits go On & Off as F1-F5 are pressed & released Fkeys Toggle= %K1-5 bits toggle each time F1-F4 are pressed Yes = Reset and all clear system functions enabled SYS_Fn enable No = Reset and all clear system functions disabled...
  • Page 54 MAN0974-09-EN_XL7_UserManual Set Serial Ports The Set Serial Ports Sub-Menu displays three System Settings, all of which may be edited, and one optional item. For the Dflt Pgm Port System setting, only MJ1-232 can be selected, unless a Modem (XMC) COM module is installed. MJ1-232= MJ1 RS232 port is the default programming port Dflt Pgm Port Modem= Modem COM module is the default programming port...
  • Page 55 MAN0974-09-EN_XL7_UserManual Set Time/Date The following instructions are to set and display the real-time clock in the controller. More details can be found in the Help File in Cscape. Table 9.1 Clock and Time Setting Terms Coordinated Universal Time Abbreviated to UTC, Coordinated Universal Time is the (UTC) primary time standard by which the world regulates clocks and time.
  • Page 56 MAN0974-09-EN_XL7_UserManual To Set Time Zone: The Time Zone setting is an hourly offset from UTC time. If using the Time Zone setting, set it first, then set the local time. UTC time will be automatically set based on the time zone and local time settings. If using NTP: NTP utilizes UTC time, therefore when using NTP, the appropriate hourly offset from UTC time must entered into the time zone setting.
  • Page 57 MAN0974-09-EN_XL7_UserManual Set Beeper The Set Beeper Sub-Menu displays one System Setting, which may be edited. (default) = Enables beeper Beeper Enable (does NOT affect ladder access) No = Disables beeper March 4 , 2019 Page 57 | 185...
  • Page 58 MAN0974-09-EN_XL7_UserManual Set Screen The Set Screen Sub-Menu displays four System Settings, all of which may be edited. Yes = Enable screen saver Saver enable (default) = Disable screen saver 5 - 1200 = Amount of time in minutes to expire with NO touch Timeout (min) activity before activating screen saver (black screen) (default)
  • Page 59 MAN0974-09-EN_XL7_UserManual Removable Media The Removable Media Sub-Menu displays the Removable Media Manager. Having selected Removable Media from the Main Menu, one of four Sub-Menu screens will appear: Media Directory No Card = No microSD card has been installed in the memory slot Media Directory Initializing = microSD card is installed, but it is still initializing...
  • Page 60 MAN0974-09-EN_XL7_UserManual Fail – Safe System The Fail-Safe System is a set of features that allow an application to continue running in the event of certain types of "soft" failures. These "soft" failures include: • Battery power loss • Battery-Backed Register RAM or Application Flash corruption due to, for example, an excessive EMI event.
  • Page 61 MAN0974-09-EN_XL7_UserManual Enable AutoRun “Enable AutoRun” displays the following options which can be selected: No = OCS will be in IDLE mode after AutoLoad or Automatic Restore. Enable AutoRun Yes = OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore. March 4 , 2019 Page 61 | 185...
  • Page 62 MAN0974-09-EN_XL7_UserManual Enable AutoLoad “Enable AutoLoad” displays the following options which can be selected: No = Does not load AUTOLOAD.PGM automatically when application program is absent or corrupted. Enable AutoLoad Yes = Loads AUTOLOAD.PGM file automatically from RM when application program is absent or corrupted. March 4 , 2019 Page 62 | 185...
  • Page 63 MAN0974-09-EN_XL7_UserManual Clone Unit ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” application program and unit settings stored in Battery backed RAM of an OCS into the RM. Refer to the Removable Media Chapter for details on using RM).
  • Page 64 MAN0974-09-EN_XL7_UserManual Load Clone Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”. NOTE: For security enabled files, Load clone asks for password validation before loading the application. March 4 , 2019 Page 64 | 185...
  • Page 65 MAN0974-09-EN_XL7_UserManual WebMI License Details License details page displays the information about the WebMI license. Refer to MAN1036 for the WebMI Manual for more details. The information can also be viewed from Cscape using the following %SR registers: %SR209.3 WebMI server status %SR209.4 WebMI user logged in status %SR209.8 to SR209.16...

  • Page 66: Touch Screen Calibration

    MAN0974-09-EN_XL7_UserManual Touch screen calibration The touch screen is calibrated at the factory and rarely needs modification. However, if actual touch locations do not appear to correspond with responding objects on the display, field adjustment is available. Ensure SYS_fn Enable is set to YES in the System Menu. To access the field adjustable touch screen calibration dialog, press and hold both the SYS and F1 key for longer than 2 seconds and a dialog similar to Figure 9.3 should appear.

  • Page 67: Chapter 10: Removable Media

    OCS Memory slot (larger sizes were not tested at time of publication). The Memory slot is equipped with a “push-in, push-out” connector and a microSD card can be safely inserted into the Memory slot whether the XL7 OCS power is On or Off. To install a microSD card: Align its 8-pin gold edge connector down, facing the front of the XL7 OCS unit;...

  • Page 68: Using The Removable Media Manager

    Using Read and Write Removable Media function blocks, an application ladder program can read and write XL7 OCS register data in the form of comma-delimited files, with a .CSV extension. These files are compatible with standard database and spreadsheet PC programs.

  • Page 69: Using Removable Media To Load And Save Applications

    MAN0974-09-EN_XL7_UserManual 10.6 Using Removable Media to Load and Save Applications A special file type, with a .PGM extension, is used to store XL7 OCS application programs on microSD. To load an application from microSD to the XL7 OCS, use the Removable Media Manager (open the Removable Media Manager in the System Menu) to find and highlight the desired .PGM file, and then press the Enter key.

  • Page 70: Configuration Of A Removable Media

    MAN0974-09-EN_XL7_UserManual 10.8 Configuration of a Removable Media The configuration of the Removable Media Object that loads the Removable Media Viewer defines what buttons are enabled and available to the user. (Enter) button performs certain operations based on the selected file’s type: - change display to parent directory <DIR>...

  • Page 71: Removable Media (Rm) Features-Program Features

    MAN0974-09-EN_XL7_UserManual 10.10 Removable Media (RM) Features—Program Features a. Datalog Configuration—This feature allows the controller to periodically log register values to Removable Media. The register data is stored in .csv (comma separated value) format, which is compatible with 3 party PC applications, such as Microsoft Excel. b.

  • Page 72: Filenames Used With The Removable Media (Rm) Function Blocks

    MAN0974-09-EN_XL7_UserManual 10.13 Filenames used with the Removable Media (RM) Function Blocks The RM function blocks support the flash with a DOS/Windows standard FAT-16 file system. All names must be limited to the “8.3” format where the filename contains eight characters a period then a three-character extension.

  • Page 73: System Registers Used With Rm

    MAN0974-09-EN_XL7_UserManual 10.14 System Registers used with RM Table 10.4 – System Registers used with RM %SR174 Removable Write a 1 to %SR174 to prohibit read/write access to the Media Protect removable media card. Write a zero (0) to allow access. %SR175 Status This shows the current status of the RM interface %SR176 Free Space...

  • Page 74: Chapter 11: General I/O

    To remove the I/O cover of the XL7 OCS, remove the four (4) Phillips screws from the I/O back. It may help to place the XL7 OCS unit face down on a clean work surface. Once the four screws are removed the I/O cover can be lifted straight off.
  • Page 75 MAN0974-09-EN_XL7_UserManual Figure 11.2 – XL7 I/O Cover Removed (sample I/O board) Once the back is removed the jumper selection can be changed. The jumper settings are documented on each data sheet using a diagram such as Figure 11.3 below and a description of the jumper settings.

  • Page 76: Model And I/O Overview

    MAN0974-09-EN_XL7_UserManual 11.3 Model and I/O Overview Table 11.1 – I/O and Model Overview mA/V mA/V mA/V XL7 Models DC In Relays HS In RTD/TC HE-XW1E0 / HEXT391C100 HE-XW1E2 / HEXT391C112 HE-XW1E3 / HEXT391C113 HE-XW1E4 / HEXT391C114 HE-XW1E5 / HEXT391C115 HE-EXV1E6/ HEXT505C116 March 4 , 2019...

  • Page 77: Solid-State Digital Outputs

    While these electronic protections work in most applications, some application may require external fusing on these outputs. The digital outputs in the XL7 OCS are typically controlled via %Q bits in the register mapping. Some of the outputs are designed for high-speed applications and can be used for PWM or frequency output applications.

  • Page 78: Relay Outputs

    Relay outputs are designed to switch loads that typically have high voltage or current requirements or require the isolation that relays provide. NOTE: The design of the XL7 OCS does not require external coil power for the relays to function. The relays will activate anytime the XL7 OCS is powered.
  • Page 79 Some protective measures need to be determined by an engineer. If you have questions on protection from inductive load, consult Horner Automation Technical Support. Details on devices that may protect outputs can be found in the Spark Quencher Datasheet, MAN0962.

  • Page 80: Digital Inputs

    MAN0974-09-EN_XL7_UserManual 11.6 Digital Inputs NOTE: Refer to the datasheet for XL7 OCS model being used for details on jumper settings. NOTE: The digital inputs on the XL7 OCS are designed for low voltage DC inputs The inputs are designed to support both positive and negative input modes. The mode is set by a jumper setting and a configuration parameter in Cscape.

  • Page 81: Analog Inputs

    11.7 Analog Inputs NOTE: See the data sheet for the XL7 OCS model being used for jumper settings and see the appropriate page in this manual (see Index) for details on how to use Cscape to configure the digital filtering.

  • Page 82: Universal Analog Inputs

    11.8 Universal Analog Inputs NOTE: See the data sheet for the XL7 OCS model being used for jumper settings and see the appropriate pages in this manual (see Index) for details on how to use Cscape to configure the digital filtering.

  • Page 83: Analog Outputs

    11.9 Analog Outputs NOTE: Refer to the datasheet for XL7 OCS model being used for details on jumper settings. The analog outputs on XL7 OCS devices provide high-resolution voltage or current outputs. The voltage or current selection is controlled with jumpers and configuration settings in Cscape.

  • Page 84: Chapter 12: High Speed I/O (Hsc / Pwm)

    12.1 Overview In addition to the compliment of simple analog and digital I/O, several of the XL7 OCS I/O modules support High Speed Counting (HSC) I/O functions and may also support Pulse Width Modulation (PWM) Output functions (non-relay modules). The HSC functions include internal timing, frequency, totalizing, pulse width/period, and quadrature measurement.

  • Page 85: Glossary

    MAN0974-09-EN_XL7_UserManual 12.2 Glossary Table 12.1 – Glossary of High Speed I/O Terms Register used to accumulate or store up a sum or count of many items or Accumulator events. A special function to zero out the value in a specific register. (Not used with Clear Frequency or Period Measurement.) Disable...

  • Page 86: High Speed Counter (Hsc) Functions

    MAN0974-09-EN_XL7_UserManual 12.3 High Speed Counter (HSC) Functions The XL7 supports two very high speed, configurable counters. There are four dedicated inputs that can be configured to a number of different options. Each of the two counters can run in one of five modes. Those modes are Totalizer, Frequency Counter, Pulse Width Measurement, Period Measurement and Quadrature measurement.
  • Page 87 MAN0974-09-EN_XL7_UserManual 12.3.2 Totalize In totalize mode, the accumulator is simply incremented or decremented each time the input transitions in a specific direction. The totalizer supports the following modes: Internal This mode ties the input to the counter to an internal 10MHz or 1MHz clock.
  • Page 88 MAN0974-09-EN_XL7_UserManual Rising Edge Signal Falling Edge Signal Three different options are available to reset the current count. They are: • Configured reset value Counts per When configuring the Totalize function, a value may be specified under the column. When the totalizer accumulator reaches this value - 1, the accumulator will reset to zero on the next count.
  • Page 89 MAN0974-09-EN_XL7_UserManual 12.3.3 Pulse Width Measurement In pulse width measurement mode, the high-speed input can measure the width of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode the Disable and Latch special functions are allowed. Refer to the HSC Glossary for a description of these functions.
  • Page 90 MAN0974-09-EN_XL7_UserManual 12.3.4 Period Measurement In period measurement mode, the high-speed input can measure the period of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode, the Disable and Latch special functions are allowed. Refer to the HSC Glossary for a description of these functions.
  • Page 91 MAN0974-09-EN_XL7_UserManual 12.3.5 Quadrature Quadrature mode uses two HSC inputs, any of the four HSC inputs can be assigned for this purpose. Quadrature mode works much like the totalizer except the accumulator will automatically increment or decrement based on the rotation phase of the two inputs. See the following example for more details.
  • Page 92 MAN0974-09-EN_XL7_UserManual 12.3.6 Register Match All counter modes support a register match function. When the accumulator value matches the Match 1 or Match 2 value setup in %AQ registers a high-speed output with either turn on, turn off or toggle based on settings in Cscape. 12.3.7 HSC Functions The high-speed input on the XL7 contains many optional tasks.
  • Page 93 MAN0974-09-EN_XL7_UserManual 12.3.8 Status Bits There are three status bits (%I registers for each high-speed counter). Overflow Flag: This status bit turns high when the Accumulator “overflows”, it moves from 4,294,967,295 (-1 if Signed) to 0, this bit can be reset with the “Output Reset Bit”. See Table 11.4.

  • Page 94: Hsc Functions Register Map

    MAN0974-09-EN_XL7_UserManual 12.4 HSC Functions Register Map The register assignments for the high-speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below. Table 12.4 –...
  • Page 95 MAN0974-09-EN_XL7_UserManual NOTE: Four Count Mode requires FPGA update. Table 12.5 – HSC Functions Register Map for 4 HSC Configuration Register Frequency Pulse Totalize %AI401-402 Accumulator - Counter 1 %AI403-404 Latch Value – Counter 1 %AI405-406 Accumulator – Counter 2 %AI407-408 Latch Value –...
  • Page 96 MAN0974-09-EN_XL7_UserManual %Q1651 Clear – Counter 4 %Q1652 Disable – Counter 4 %Q1653 Direction – C4 %Q1654 Output Reset – Counter 4 %Q1655 Preload Disable – Counter 4 %Q1656 Latch Disable – Counter 4 %Q1657-1664 Reserved %I1601 Overflow Flag – Counter 1 %I1602 Underflow Flag –...

  • Page 97: High Speed Output Functions

    MAN0974-09-EN_XL7_UserManual 12.5 High Speed Output Functions On units that support high-speed output functions, two dedicated outputs are available that can be configured for one of four modes of operation. Those modes are Normal, PWM, HSC Match and Stepper. 12.5.1 Normal When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives that respective output.
  • Page 98 MAN0974-09-EN_XL7_UserManual At controller power-up or during a download, the PWM output is maintained at zero until both the Frequency and the Duty cycle are loaded with non-zero values. When the controller is placed in PWM State on Controller Stop stop mode, the state of the PWM outputs is dependent on the configuration.
  • Page 99 MAN0974-09-EN_XL7_UserManual 12.5.4 High Speed Counter Match When either Q1 or Q2 is configured for HSC Output operation, their output state is based on a comparison between the counter accumulator and match registers. Refer to the Functions section for more details. 12.5.5 Stepper Function The XL7 supports two stepper functions, one on each high-speed output when in two counter mode.
  • Page 100 MAN0974-09-EN_XL7_UserManual The stepper provides two Boolean registers to provide stepper status: A high indication on this register indicates the stepper sequence can Ready/Done be started (i.e. not currently busy) and also when the move is completed. A high indication on this register indicates that one of the analog parameters specified above is invalid or the stepper action was Error aborted before the operation was complete.

  • Page 101: High Speed Output Functions Register Map

    MAN0974-09-EN_XL7_UserManual 12.6 High Speed Output Functions Register Map The register assignments for the high speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below.

  • Page 102: Pwm Examples

    MAN0974-09-EN_XL7_UserManual 12.7 PWM Examples Example 1 Duty Cycle Frequency To get a 50% Duty Cycle @ Set %AQ421-422 = 16,000 Set %AQ423-424 = 10,000 10kHz waveform on PWM1: Example 2 Duty Cycle Frequency Set %AQ421-422 = 16,000 To get a 50% Duty Cycle on Set %AQ423-424 = 1,000 PW1 and 90 % Duty Cycle on Set %AQ431-432 = 28,800...

  • Page 103: Stp Examples

    MAN0974-09-EN_XL7_UserManual 12.8 STP Examples Example 1 Start Accel Count Run Count Decel Count Frequency Frequency 10,000,000 Set %AQ423- Set %AQ425- Set %AQ427-8 steps Set %AQ421 Set %AQ422 4 = 1,000,000 6 = 8,000,000 = 1,0000,000 control = 2500 (Hz) = 5000 (Hz) (Steps) (Steps) (Steps)

  • Page 104: Hsc I/O Filtering

    MAN0974-09-EN_XL7_UserManual 12.9 HSC I/O Filtering This feature is used to enable digital Filter for HSC Inputs. Selecting Digital In/HSC configuration opens up the following dialog where in HSC I/O Filtering is available. Input signal is filtered based on the filter frequency and Number of samples selected. User has to select Filter Frequency and Number of samples based on the frequency of the Input signal.
  • Page 105 MAN0974-09-EN_XL7_UserManual The state (high or low) of the high-speed input is sampled with every rising input edge of the filter frequency. The rising edges of the filter frequency are totaled in a sample counter, and when that total equals the number of samples configured, the sample counter is reset. If the high-speed input state did not change by the time of the sample counter reset, that state, high or low, is passed on to the high-speed accumulator.
  • Page 106 MAN0974-09-EN_XL7_UserManual Figure 3: Input signal before filtering Figure 4: Input signal after filtering This delay will be 4μs. March 4 , 2019 Page 106 | 185...

  • Page 107: Chapter 13: User Interface

    MAN0974-09-EN_XL7_UserManual CHAPTER 13: USER INTERFACE 13.1 Overview This chapter presents the user interface (or operator view) of the XL7 and some of the model specific characteristics of the XL7 as compared to the rest of the OCS line. This chapter does NOT cover building screens or using the Cscape graphics editor.

  • Page 108: Displaying And Entering Data

    MAN0974-09-EN_XL7_UserManual 13.3 Displaying and Entering Data Figure 13.1 – Example Screen Multiple objects are provided for displaying data such as virtual panel lights, push buttons, numeric value displays, bar graphs, meters, graphs and animated bitmaps. On the XL7, these graphical objects (through ladder manipulation of attribute bits) can change color, flash or change visibility to attract operator attention.

  • Page 109: Alpha-Numeric Keypad

    MAN0974-09-EN_XL7_UserManual 13.4 Alpha-numeric Keypad To allow entry of a specific number or text, several of the input objects invoke a pop-up alpha- numeric keypad when the object is touched. An example of the alpha-numeric keypad invoked from a numeric input object is shown in Figure 13.2. Once invoked, the operator may touch the appropriate keys to enter a specific value.
  • Page 110 MAN0974-09-EN_XL7_UserManual Enter Once the desired value is entered, pressing the key moves that value into the object (and the corresponding OCS register) and the alpha-numeric keypad disappears. Alternately, Enter pressing the key any time before the key cancels the operation, leaves the objects current value unchanged, and the alpha-numeric keypad disappears.

  • Page 111: Screen Navigation

    MAN0974-09-EN_XL7_UserManual 13.5 Screen Navigation To allow the operator to change screens, a screen jump object is generally used. This object may be visually represented as a 3-D button (responding to touch) or remain invisible and logically tied to an OCS register. An optional system ICON may be configured for display along with the legend, which aids in identifying the object as one that causes a screen change (shown below in Figure 13.3) Screen jumps can also be triggered on other keys or based on control logic for more advanced...

  • Page 112: Ladder Based Screen Navigation

    MAN0974-09-EN_XL7_UserManual 13.6 Ladder Based Screen Navigation Ladder logic can use several techniques to control screen navigation. Coils can be tied to %D registers to make them screen coils. These coils have two modes, switch and alarm. If the ladder program energizes an alarm display coil, the screen associated with this coil is displayed and overrides the normal user screens.

  • Page 113: Touch (Slip) Sensitivity

    MAN0974-09-EN_XL7_UserManual 13.8 Touch (Slip) Sensitivity slip Touch sensitivity is preset to meet most applications; however, adjustment is available to reduce the sensitivity for touch release. That is, once a graphical object (button) is touched slip slip and held by a finger, the default touch sensitivity allows for a slight of the finger on the graphical object before the XL7 assumes touch has been released (equates to...

  • Page 114: Alarms

    MAN0974-09-EN_XL7_UserManual 13.9 Alarms Alarm presentation to the operator is highly configurable and beyond the scope of this document to describe fully. For more information refer to the graphics editor help file. This section presents a typical configuration thereby providing an introductory description on what the operator should expect.
  • Page 115 MAN0974-09-EN_XL7_UserManual Figure 13.6 – Alarm Viewer The currently selected entry is indicated by a yellow highlight which can be moved up or down by touching the arrow buttons or by directly touching an entry. If more entries exist than can fit on the page, a scroll bar is displayed on the right side that also indicates the current relative position.

  • Page 116: Removable Media

    MAN0974-09-EN_XL7_UserManual 13.10 Removable Media The removable media object is generally used to inform the operator on the current state of the removable media device and allow access to its file structure. The removable media object is displayed as a button that changes colors to indicate the current state of the removable media device.
  • Page 117 MAN0974-09-EN_XL7_UserManual File operations are accomplished by pressing the appropriate button at the bottom of the removable media viewer. The configuration of the removable media object that invokes the removable media viewer defines what buttons are enabled and available to the user. A button is grayed and does not respond to touch if configured as disabled.

  • Page 118: Screen Saver

    MAN0974-09-EN_XL7_UserManual 13.11 Screen Saver The XL7 screen backlight life is typically five (5) years when in continuous use. If the application does not require interaction with the XL7 for long periods of time, the backlight life can be extended by using the screen saver function. When enabled through the System Menu, the backlight is shut off (screen goes black) after a specified time of no touch activity on the screen.

  • Page 119: Touch Screen Pressure

    With a unique change to the touch monitoring firmware user can measure the pressure being exerted on the touch screen. This feature has been added in some Horner XL series controllers. This allows the OCS programmer to be notified of the touch pressure and it can configure the pressure required to accept a touch event.
  • Page 120 MAN0974-09-EN_XL7_UserManual There are two system registers that provide this touch feature: %SR9 (I/O Name - TCH_PRESSURE) Records the highest pressure level of the last touch on the screen that exceeds the threshold value set in %SR10. This is a range of 0 to 3000. Zero (0) indicates no pressure and 3000 is the maximum amount of pressure that can be measured.

  • Page 121: Chapter 14: Registers

    14.1 Register Definitions When programming the XL7 OCS, data is stored in memory that is segmented into different types. This memory in the controller is referred to as registers. Different groups of registers are defined as either bits or words (16 bits). Multiple registers can usually be used to handle larger storage requirements.
  • Page 122 MAN0974-09-EN_XL7_UserManual Table 14.3 – %SR Registers Register Name Description Min Val Max Val %SR1 USER_SCR Current User Screen Number 1023 %SR2 ALRM_SCR Current Alarm Screen Number (0=none) 1023 %SR3 SYS_SCR Current System Screen Number (0=none) %SR4 SELF_TEST Bit-Mapped Self-Test Result 65535 Control Station Mode (0=Idle, 1=Do I/O, %SR5...
  • Page 123 MAN0974-09-EN_XL7_UserManual Table 14.3 – %SR Registers Register Name Description Min Val Max Val %SR43 KEY_TYPE Keypad Type %SR44 RTC_SEC Real-Time-Clock Second %SR45 RTC_MIN Real-Time-Clock Minute %SR46 RTC_HOUR Real-Time-Clock Hour %SR47 RTC_DATE Real-Time-Clock Date %SR48 RTC_MON Real-Time-Clock Month %SR49 RTC_YEAR Real-Time-Clock Year 1996 2095 %SR50...
  • Page 124 MAN0974-09-EN_XL7_UserManual Table 14.3 – %SR Registers Register Name Description Min Val Max Val %SR178-179 Removable Media Indicates the total card capacity in K bytes. %SR180 Reserved Unacknowledged Alarm (high bit indicates %SR181 ALM_UNACK what group #) %SR182 ALM_ACT Active Alarm (high bit indicates what group #) %SR183 SYS_BEEP System Beep Enable (0=disabled;...

  • Page 125: Register Map For Xl7 Ocs I/O

    Expiration Date of WebMI License, license detail. For additional information on system bits and registers, refer to the on-line help found in Cscape. 14.3 Register Map for XL7 OCS I/O Table 14.4 – I/O Register Map Description Registers XL7 with...
  • Page 126 MAN0974-09-EN_XL7_UserManual Table 14.5 – PWM Function Registers Map Register Stepper %AQ1 PWM1 Duty Cycle (32- HSC1 Start Frequency %AQ2 bit) Preset Value Run Frequency %AQ3 PWM2 Duty Cycle (32- HSC2 Accel Count %AQ4 bit) Preset Value (32-bit) %AQ5 PWM Prescale Run Count (32-bit) (32-bit)

  • Page 127: Resource Limits

    MAN0974-09-EN_XL7_UserManual 14.4 Resource Limits Table 14.5– Resource Limits Resource Value Resource Value CsCAN, Ping, EGD, SRTP, Modbus TCP Master (Downloadable Ethernet protocol) & Slave, Ethernet IP, FTP, or HTTP @ 10MBd or 100MBd CsCAN 125kBd, 250kBd, 500kBd, or 1MBd 16000 Serial Ports 1 RS232, 1 RS485 Ports IDs Per...

  • Page 128: Chapter 15: Cscape Configuration

    Please see the on-line help provided with Cscape for additional details. 15.2 Cscape Status Bar When the XL7 OCS is connected to a PC using Cscape software a Status Bar appears at the bottom of the screen. The Cscape Status Bar can be used to determine if communications have been established between the XL7 OCS and the Cscape program.

  • Page 129: Establishing Communications

    MAN0974-09-EN_XL7_UserManual 15.3 Establishing Communications The XL7 OCS can communicate with Cscape using USB to USB, USB to serial adapters, serial port communications via MJ1 Port, Ethernet, CAN (CsCAN) or modems. To communicate with the XL7 via USB you will need the automated driver installer located on the Horner APG web site.
  • Page 130 MAN0974-09-EN_XL7_UserManual The PC will detect a new device has been plugged into the USB port. Now that the XL7 is plugged in, go to Cscape → Controller → Connection Wizard. If you are just opening Cscape, Connection Wizard usually opens by default. Select USB and click Next >>.
  • Page 131 MAN0974-09-EN_XL7_UserManual If the Connection Wizard does not pop up upon opening Cscape, then select Controller (in the Cscape tool bar) → Connection Wizard, choose your connection method. If you are connecting for the first time, we suggest connecting via USB. Figure 15.2 –...
  • Page 132 MAN0974-09-EN_XL7_UserManual An alternate way to select the COM setting is to go to Cscape → Tools → Application Settings → Communications → Configure and choose connection method in Add Target. Figure 15.3 – Cscape: Alternative Connection Method Screenshot Figure 15.4 – Add Target Screenshot in Cscape NOTE: The following fields, Target Name, Connection Medium, Connected Device, and Connection Settings, need to be filled for communication configuration if Cscape Connection Wizard was not used.
  • Page 133 NOTE: Cscape will do necessary initialization for the selected internal modem. Select this option to communicate over USB. Now Horner devices and Horner USB to serial converters are recognized and can be specifically selected.
  • Page 134 Units without CsCAN network ports respond to any network ID and do not require the ID to be configured. To check or change the ID on the XL7 OCS, press the System Menu key. The first item in the menu is Set Networks. Pressing Enter allows the ID of the unit to be viewed or modified.
  • Page 135 MAN0974-09-EN_XL7_UserManual 15.3.1 Communicating via MJ1 Serial Port Start by configuring Cscape to use the correct communications port. This can be done using the Tools → Options → Communication Port dialog in Cscape. Next, connect the PC’s serial port to the port labeled MJ1 on the XL7. If communications are successful, the target indicator should show the mode of the controller Target: yy(R) as shown in the status section above.
  • Page 136 MAN0974-09-EN_XL7_UserManual 15.3.2 Communicating via On Board Ethernet Port From Cscape go to Controller → Hardware Configure and do auto configuration for the connected controller, Click on Config of Ethernet and select Module Setup. The IP address, Net Mask, and Gateway of the controller may be temporarily set from the System Menu under the Set Networks menu item.

  • Page 137: Configuration

    2. If the XL7 OCS is connected to the PC press the Auto Config System button to automatically detect the Base model, I/O and any communication options. 3. If the XL7 OCS is not connected press the Config button to the right of the top of the unit. This allows the base CPU to be selected.
  • Page 138 MAN0974-09-EN_XL7_UserManual To access the I/O Setup Screen, select Config from the Hardware Configuration/ Local I/O dialog. Then select the Module Setup tab, see screenshot below. March 4 , 2019 Page 138 | 185...

  • Page 139: Digital / Hsc Input Configuration

    The High-Speed Counters group box contains all of the windows that are used for configuring the 4 available high-speed counters on the XL7 OCS. In configuring a counter, the user needs to set the type, mode, and counts per rev.

  • Page 140: Digital / Pwm Output Configuration

    MAN0974-09-EN_XL7_UserManual 15.6 Digital / PWM Output Configuration The following figure illustrates the Digital / PWM Output Configuration dialog. Figure 15.7 – Digital / PWM Output Configuration Dialog The Q1 and Q2 group boxes allow the user to specify the operation of the multi-function outputs. The PWM State On Controller Stop group box contains items that allow the user to specify how the PWM outputs behave when the controller is stopped.

  • Page 141: Analog Input Configuration

    MAN0974-09-EN_XL7_UserManual 15.7 Analog Input Configuration The following figure illustrates the Analog Input Configuration dialog. Figure 15.11 – Analog Input Configuration Dialog The Channel x drop down windows allow the user to specify the mode for each analog input to operate. The Channel x drop down windows are enabled/disabled according to which model is being configured.

  • Page 142: Analog Output Configuration

    MAN0974-09-EN_XL7_UserManual 15.8 Analog Output Configuration The following figure illustrates the Analog Output Configuration dialog. Figure 15.8 – Analog Output Configuration Dialog The Output value on Stop group box contains items that allow the user to specify how the analog output channels behave when the controller is stopped. The outputs can either hold their value or default to a value when the controller is stopped.

  • Page 143: Chapter 16: Audio Playback Configuration

    MAN0974-09-EN_XL7_UserManual CHAPTER 16: AUDIO PLAYBACK CONFIGURATION 16.1 Audio Configuration in Cscape 1. In Cscape, select the XL7 and model number by selecting Controller → Hardware Configuration from the toolbar. Click OK. 2. Next select Program from the toolbar and then Audio Config. The following dialog will open.

  • Page 144: Audio Config Details

    MAN0974-09-EN_XL7_UserManual 16.2 Audio Config Details • Triggers – This register is used to play a particular audio by enabling the corresponding big address. • Status – This register gives the status of the audio files, see table below. • Status Register – 16 Bits x 2 Table 16.1 - 1st and 2nd Status Registers Bit Number Description...
  • Page 145 MAN0974-09-EN_XL7_UserManual Add – Selecting this button display the following window, where an audio filename with full path needs to be configure. The Modify and Delete button are also available in the Audio Config dialog. IMPORTANT: 1. Audio files are not downloaded from Cscape; they must be present 2.

  • Page 146: Chapter 17: Video Object

    MAN0974-09-EN_XL7_UserManual CHAPTER 17: VIDEO OBJECT 17.1 Video Object Overview The Video Object feature allows two options for video type: Stream and Playback. The Video Object trigger is used to start, stop, and pause video, and the System Register provides the status of the video object, which supports various resolutions and frames per second.

  • Page 147: Opening Video Object In Cscape

    MAN0974-09-EN_XL7_UserManual 17.2 Opening Video Object in Cscape NOTE: Video Object requires Firmware 14.03 or newer to use with the XL7 devices. In Cscape, select the XL7 and model number by selecting Controller → Hardware Configuration from the toolbar. Open the Graphics Editor by selecting the “T” button from the toolbar. In Graphic Editor, select the video button from the toolbar.
  • Page 148 MAN0974-09-EN_XL7_UserManual Then double click on the icon in the middle to open the Video Properties dialog. March 4 , 2019 Page 148 | 185...

  • Page 149: Video Properties: Video Type

    MAN0974-09-EN_XL7_UserManual 17.3 Video Properties: Video Type Figure 17.1 – Configuring Video Type There are two options for video type: Stream and Playback Stream – This option can be selected to view live video from a web cam. Four channels are supported through the USB hub.

  • Page 150: Video Properties: Control

    MAN0974-09-EN_XL7_UserManual 17.4 Video Properties: Control Figure 17.2 – Configuring Control Trigger The Video Properties: The video control trigger is used to start, stop and pause video. Video trigger is done by bit level addressing. The trigger reserves eight (8) bits and uses the first two (2) bits.

  • Page 151: Configuring Display Properties

    MAN0974-09-EN_XL7_UserManual 17.5 Configuring Display Properties Figure 17.3 – Configuring Display Properties Resolution Options 320x240 (QVGA) Frames per Seconds 10, 15, 20, 24, 30 & MAX_FPS 17.6 Video Object Performance 1. When Video Object is active, navigating to System Menu or any popup window, causes Video Object to be inactive.

  • Page 152: Chapter 18: Back-Up Battery

    The OCS uses a small, single cell in a metal enclosure. The battery is UL recognized and comes from quality suppliers. The OCS has safety circuitry built into the charging IC and additional external protection including fusing. These circuits were closely evaluated by UL and Horner engineering for use in hazardous environments. March 4 , 2019...

  • Page 153: Battery Charging Cycle

    MAN0974-09-EN_XL7_UserManual 18.5 Battery Charging Cycle The battery is charged at unit power up. The first two minutes after boot there is a wait period before charging begins. 2. In all charge cycles, battery is charge fully to 4.2V (4200mV). 3. Charging mA should be 100 mA. 4.

  • Page 154: Chapter 19: Fail - Safe System

    MAN0974-09-EN_XL7_UserManual CHAPTER 19: FAIL – SAFE SYSTEM 19.1 Overview The Fail-Safe System is a set of features that allow an application to continue running in the event of certain types of "soft" failures. These "soft" failures include: Battery power loss Battery-Backed Register RAM or Application flash corruption due to, for example, an excessive EMI event.

  • Page 155: Settings

    MAN0974-09-EN_XL7_UserManual 19.2 Settings To use the fail – safe feature, the user needs to do the following: From Cscape, create AUTOLOAD.PGM for the application program using ‘Export to Removable Media’. 2. Place the Removable Media with AUTOLOAD.PGM in the device. 3.
  • Page 156 MAN0974-09-EN_XL7_UserManual Figure 19.3 – Backup Registers Restore OCS Data: When initiated, this will allow the user to manually copy the backed-up data from the onboard flash memory to the Battery-Backed RAM. A restore operation will be automatically initiated if a backup has been previously created and on power-up the Battery-Backed RAM registers fail their check.
  • Page 157 MAN0974-09-EN_XL7_UserManual Clear Backup Data: When initiated, the backup data will be erased from the onboard flash memory and no backup will exist. %SR164.4 and %SR164.3 is reset to 0 when backed up data is erased. Figure 19.5 – Clear Backup Data Exit: Goes back to the previous screen.
  • Page 158 MAN0974-09-EN_XL7_UserManual The OCS follows the following sequence in execution of Automatic Restore: OCS Power Cycle Battery Backed RAM Registers check failed Backup exists? Controller placed in Application IDLE mode Program erased Data copied from Onboard FLASH to OCS Battery backed Controller Resets AutoRun OCS put in IDLE...

  • Page 159: Autoload

    MAN0974-09-EN_XL7_UserManual 19.4 AutoLoad This System Menu option allows the user to specify whether the OCS automatically loads the application AUTOLOAD.PGM located in Removable Media. When the AutoLoad setting is enabled (set to YES), it can either be manually initiated or automatically initiated at power-up.
  • Page 160 MAN0974-09-EN_XL7_UserManual The OCS follows the following sequence in execution of AutoLoad: Power up OCS Application Program absent Application Program corrupted AutoLoad OCS put in IDLE mode Enabled? AutoLoad run sequence AUTOLOAD.PGM present in failed (with reasons for the RM of the device ? failure) AutoLoad initiated.

  • Page 161: Autorun

    MAN0974-09-EN_XL7_UserManual 19.5 AutoRun This System Menu option, when enabled (YES), allows the user to automatically place the OCS into RUN mode after the AutoLoad operation or automatic Restore Data operation. When the AutoRun setting is disabled (NO), the OCS remains in the IDLE mode after a Restore Data or AutoLoad operation.

  • Page 162: Chapter 20: Clone Unit

    MAN0974-09-EN_XL7_UserManual CHAPTER 20: CLONE UNIT 20.1 Overview ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” application program and unit settings stored in Battery backed RAM of an OCS into the RM. Refer to the Removable Media chapter for details in using RM).
  • Page 163 MAN0974-09-EN_XL7_UserManual 2. Selecting “Clone Unit” menu will open the following menu screen: Figure 20.2 – Clone Unit Menu before Cloning Free/Total – displays number of free and total bytes in Removable Media. 3. Make/Create Clone option enables user to duplicate / Clone application file, all unit settings and all register values from Battery Backed RAM.
  • Page 164 MAN0974-09-EN_XL7_UserManual After confirmation, the OCS will create two new files in the root directory of the Removable Media Drive as shown below: AUTOLOAD.PGM Application file CLONE.DAT File having all unit settings and register values from Battery Backed RAM Figure 20.4 – Clone Unit Files NOTE: Make/Create clone operation automatically includes the security in AUTOLOAD.PGM file for security enabled files.
  • Page 165 MAN0974-09-EN_XL7_UserManual 4. Once the cloning is successful, OCS gives a message as below: Figure 20.5 – Cloning Status Make/Create clone can also be triggered by setting %SR164.9 bit to “1” from Ladder program or graphics. Once the operation is completed, this bit is made zero by the firmware. When Make clone operation is triggered by this SR bit, it does not ask the user for confirmation for making clone.

  • Page 166: Load Clone

    MAN0974-09-EN_XL7_UserManual 20.3 Load Clone This option loads the application, all unit settings and register values from Removable media to the Battery backed RAM (Regardless of AutoLoad settings) and then resets the OCS for the settings to take effect. User needs to perform the following to Load Clone: Select “Clone Unit”...
  • Page 167 MAN0974-09-EN_XL7_UserManual 2. User needs to confirm Load Clone as shown below: Figure 20.8 – Load Clone Confirm Screen 3. After confirmation, all unit settings and register values will be loaded from Removable media to the Battery backed RAM (Regardless of AutoLoad settings) and then OCS resets for the settings to take effect.

  • Page 168: Chapter 21: Maintenance

    CHAPTER 21: MAINTENANCE 21.1 Firmware Updates The XL7 OCS products contain field updatable firmware to allow new features to be added to the product at a later time. Firmware updates should only be performed when a new feature or correction is required.

  • Page 169: Backup Battery

    MAN0974-09-EN_XL7_UserManual 21.2 Backup Battery The XL7 has an advanced battery system that uses a rechargeable lithium-ion battery. The battery powers the real time clock when power is removed. To store registers, the battery continues to power the OCS for less than a second after external power is removed. In this time the registers and other retentive data is saved to internal flash memory.
  • Page 170 Make sure the user program and any data stored in retentive memory is backed up. 2. Disconnect all power from the XL7 OCS unit including I/O power. 3. On the back of the XL7 OCS, unscrew the battery plate cover using a Phillips head screwdriver.

  • Page 171: Chapter 22: Modbus Communications

    MAN0974-09-EN_XL7_UserManual CHAPTER 22: MODBUS COMMUNICATIONS 22.1 Modbus Overview For complete Modbus instructions, please refer to the Help file in Cscape. Modbus (serial) is a popular, de-facto standard protocol that allows industrial devices from multiple manufacturers to easily share data in real-time. For Modbus serial communications, the XL7 can act as either a Master or a Slave.

  • Page 172: Modbus Master Overview

    Modbus addressing style for each slave on the network, minimal address conversion is required. Also, if the slave is another Horner product (i.e. another OCS), the “Native Addressing” option can be selected (i.e. %R1, %M17, etc.), and this skips the conversion to Modbus style altogether.

  • Page 173: Modbus Addressing Table

    MAN0974-09-EN_XL7_UserManual 22.4 Modbus Addressing Table To access XL7 registers, a Modbus Master must be configured with the appropriate register type and offset. This is usually accomplished with one of two methods: Method 1: The first method uses Traditional Modbus References, in which the high digit represents the register type and the lower digits represent the register offset (starting with Register 1 for each type).

  • Page 174: Chapter 23: Troubleshooting & Technical Support

    MAN0974-09-EN_XL7_UserManual CHAPTER 23: TROUBLESHOOTING & TECHNICAL SUPPORT 23.1 Connecting to the XL7 OCS Cscape connects to the local controller automatically when the serial connection is made. The status bar below shows an example of a successful connection. This status bar is located in the bottom right hand corner of the Cscape window.
  • Page 175 Run Mode from the System Menu on the controller will make MJ1 available to Cscape. 5. Successful communications with USB-to-serial adapters vary. If in doubt, Horner APG offers a USB to serial adapter. Part numbers HE-XCK and HE-CPK.

  • Page 176: Local Controller And Local I/O

    MAN0974-09-EN_XL7_UserManual 23.2 Local Controller and Local I/O The System Menu provides the following status indications that are useful for troubleshooting and system maintenance. - Self-test results, diagnostics. - RUN and OK status - Network status and usage - Average logic scan rate - Application memory usage - Loaded firmware versions - Loaded protocols...

  • Page 177: Cscan Network

    Use the proper Belden wire type or equivalent for the network as specified in MAN0799. 2. The XL7 OCS does not provide 24VDC to the network. An external voltage source must be used for other devices such as SmartStix I/O.

  • Page 178: Removable Media - Basic Troubleshooting

    Table 23.2 – Removable Media Troubleshooting Description Action XL7 OCS does not read media card. The media card should be formatted with the XL7 OCS. Make sure the project file is saved as a .pgm file and XL7 OCS will not download project not a .csp file.

  • Page 179: Main Index

    MAN0974-09-EN_XL7_UserManual MAIN INDEX %Q bits, 77 Count, 97, 99 Accessories, 15 Csape Program accumulator, 86, 87, 89, 91 Via Serial Port, 27 Add Target Screenshot in Cscape, 132 Cscape, 2, 14, 25, 27, 29, 51, 52, 68, 69, 74, 77, 79, Alarms, 114 80, 81, 82, 83, 84, 112, 125, 128, 134, 174, 175, Alpha-numeric keypad, 109...
  • Page 180 New-value mode, 109 General I/O Opening Cscape Help File, 15 Overview, 74 Opening Video Object in Cscape, 147 GENERAL I/O, 74 Orientation of XL7 OCS, 18 Glossary, High Speed I/O, 85 Output State on Controller Stop, 79 Ground Specification, 22 Overview Grounding...
  • Page 181 MAN0974-09-EN_XL7_UserManual Pulse Width Modulation, 84, 97 Set Time/Date, 55 PWM, 14, 77, 84, 97, 98, 101, 102, 140 Solid-State Digital Outputs, 77 Examples, 102 sourcing, 77 Frequency Formula, 99 Sourcing, 80 Registers, 101 stepper, 84, 99, 100 PWM Functions Register Map, Four Counter, 101 stop state, 77, 79 Quadrature, 86, 91, 139 Storing Register Contents, 152...
  • Page 182 XL7 Manual PREFACE, 2 Video Object XL7 OCS Dimensions, 19 Playback, 149 XL7 OCS Mounting Clip, 17 Stream, 149 XL7 OCS Mounting Orientation, 18 View Diags, 49 XL7 OCS with Mounting Clips, 17 March 4 , 2019 Page 182 | 185...

  • Page 183: Index Of Figures & Tables

    Figure 02.2 – Visual Overview of Types of Devices that can be connected to XL7, 13 Figure 03.1 – Panel Mounting of an XL7 Series OCS, 16 Figure 03.2 – XL7 OCS with Mounting Clips, 17 Figure 03.3 – Orientation of XL7 OCS, 18 Figure 03.5 –...
  • Page 184 MAN0974-09-EN_XL7_UserManual Figure 15.03 – Cscape Alternative Connection Method Screenshot, 132 Figure 15.04 – Add Target Screenshot in Cscape, 132 Figure 15.05 – LAN1 Configuration Dialog, 136 Figure 15.06 – Digital / HSC Input Configuration Dialog, 139 Figure 15.11 – Analog Input Configuration Dialog, 141 Figure 15.7 –...
  • Page 185 Table 12.10 – PWM Examples, 102 Table 12.11 – STP Examples, 103 Table 13.1 – Alpha-Numeric Keypad Variations, 110 Table 14.1 - Types of Registers found in the XL7 OCS, 121 Table 14.2 – Common %S Register Definitions, 121 Table 14.3 - %SR Registers, 122 Table 14.4 –...

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