Page 1 User Manual for XL4 & XL4 Prime OCS MAN0964-14-EN_XL4/XL4P_UM XL4 Prime North America Europe North America Europe HE-XC1E0 HEXT251C100 HE-XPC1E0 HEXP251C100 HE-XC1E2 HEXT251C112 HE-XPC1E2 HEXP251C112 HE-XC1E3 HEXT251C113 HE-XPC1E3 HEXP251C113 HE-XC1E4 HEXT251C114 HE-XPC1E4 HEXP251C114 HE-XC1E5 HEXT251C115 HE-XPC1E5 HEXP251C115 HE-XC1E6 HEXT251C116 HE-XPC1E6...
Page 2: Preface
PREFACE This manual explains how to use the XL4/XL4 P OCS. Copyright (C) 2012 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written permission of Horner APG, Inc.
Page 3: Limited Warranty And Limitation Of Liability
HE-APG MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE-APG. THE TERM "ORIGINAL PURCHASER", AS USED IN THIS WARRANTY, SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM THE XL4/XL4 PRIME OCS module IS ORIGINALLY INSTALLED. THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES.
Page 4: Visual Map Of Key Chapters
FIRST STEP of ANY TASK: DATASHEET The datasheet is the first document you need to refer to for model-specific information related to XL4/XL4 Prime OCS models. Visit our website to obtain updates to datasheets, manuals, and user documentation. North America https://hornerautomation.com...
Page 5: Table Of Contents
Safety Warnings and Guidelines ....................10 Grounding ............................11 CE Compliance ..........................11 CHAPTER 2: INTRODUCTION ........................ 12 Visual Overview of XL4/XL4 P OCS ..................12 Connectivity to the XL4/XL4 P OCS ..................14 22.3 Features of XL4/XL4 P OCS ....................15 Useful Documents and References ..................
Page 6 CHAPTER 6: REGISTERS ........................49 Register Definitions ........................49 Useful %S and %SR Registers ....................50 Resource Limits .......................... 59 Register Map for XL4/XL4 Prime OCS I/O ................60 CHAPTER 7: CSCAPE CONFIGURATION ................... 62 Overview ............................62 Cscape Status Bar ........................62 Establishing Communications ....................
Page 7 MAN0964-14-EN_XL4_XL4P_UM 10.9 Configuration via Mini-B USB ....................112 CHAPTER 11: CAN COMMUNICATIONS ....................113 11.1 Overview ............................113 11.2 Port Description .......................... 113 11.3 CAN1 Port Wiring ........................114 11.4 Cscape Programming via CAN ....................114 11.5 Ladder-Controlled CAN Communication ................114 11.6 Using CAN for I/O Expansion (Network I/O) ................
Page 8 20.7 Battery Status in System Registers .................. 177 20.8 Replacing Rechargeable Backup Battery ................ 178 CHAPTER 21: XL4 PRIME BACK UP BATTERY .................. 180 CHAPTER 22: MAINTENANCE ......................182 22.1 Firmware Updates ........................182 22.2 How to Check for Current Firmware Revision ..............182 22.3...
Page 9 MAN0964-14-EN_XL4_XL4P_UM CHANGE LOG ............................190 INDEX ................................ 191 N o v e m b e r 1 0 , 2 0 2 1 P a g e 9 | 194...
Page 10: Chapter 1: Safety/ Compliance
MAN0964-14-EN_XL4_XL4P_UM 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 11: Grounding
MAN0964-14-EN_XL4_XL4P_UM 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.
Page 12: Chapter 2: Introduction
CHAPTER 2: INTRODUCTION Visual Overview of XL4/XL4 P OCS Figure 2.1 - Visual Overview of XL4/XL4 P OCS N o v e m b e r 1 0 , 2 0 2 1 P a g e 12 | 194...
Page 13 MAN1147 MAN1323 Model 6 MAN1148 MAN1324 User Manual -This manual provides general information that is common to XL4/XL4 P OCS models and can be downloaded from our web. Visit our website to obtain user documentation and updates. North America https://hornerautomation.com Europe http://www.hornerautomation.eu...
Page 14: Connectivity To The Xl4/Xl4 P Ocs
Solenoids Cscape Figure 2.2 – Visual Overview of Types of Devices that can be connected to XL4/XL4 P OCS N o v e m b e r 1 0 , 2 0 2 1 P a g e 14 | 194...
Page 15: Features Of Xl4/Xl4 P Ocs
MAN0964-14-EN_XL4_XL4P_UM 22.3 Features of XL4/XL4 P OCS The XL4/XL4 P OCS are all-in-one industrial control devices. They combine control, user interface, I/O and networking into a single, integrated package. Unique features of the XL4/XL4 P OCS include: • Bright, 65,536 color graphical touch-sensing LCD display or a bright white touch-sensing LED backlit display capable of up to 16,777,216 colors.
Page 16: Chapter 3: Mechanical Installation
XL4/XL4 Prime OCS. 1. Remove all connectors from the XL4/XL4 Prime OCS unit. 2. Make sure the gasket is installed on the XL4/XL4 Prime OCS and is free from dust and debris. Check that the corners of the gasket are secure.
Page 17: Mounting Orientation
XL4/XL4 Prime OCS Mounting Clip Slot for Clip Clip Rail Figure 3.2 – XL4/XL4 Prime OCS with Mounting Clips 3.3.2 XL4/XL4 Prime OCS Mounting Orientation 001XLE056 NOTE—For panel or DIN rail mounting: CAUTION—For DIN Rail mounting: The orientation shown above provides...
Page 18: Dimensions
MAN0964-14-EN_XL4_XL4P_UM Dimensions Figure 3.5 – XL4/XL4 P OCS Dimensions N o v e m b e r 1 0 , 2 0 2 1 P a g e 18 | 194...
Page 19: Installation Procedure
2. Carefully cut the host panel per the diagram, creating a 92mm x 92mm +/-0.1mm opening into which the XL4/XL4 Prime may be installed. If the opening is too large, water may leak into the enclosure, potentially damaging the unit. If the opening is too small, the OCS may not fit through the hole without damage.
Page 20: Factors Affecting Panel Layout Design And Clearances
MAN0964-14-EN_XL4_XL4P_UM 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 3.7.1 Clearance / Adequate Space Install devices to allow sufficient clearance to open and close the panel door.
Page 21 ____Are noise suppression devices or isolation transformers required? Is there adequate distance between the base of the XL4/XL4 Prime OCS and noisy devices such as relays or motor starters? Ensure that power and signal wires are not routed in the same conduit.
Page 22: Chapter 4: Electrical Installation
ELECTRICAL INSTALLATION NOTE: The datasheet is the first document to refer to for model-specific information related to XL4/XL4 Prime OCS models such as pin-outs, jumper settings, and other key installation information. Visit our website to obtain datasheets, user documentation, and updates.
Page 23: How To Test For Good Ground
MAN0964-14-EN_XL4_XL4P_UM 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 a three-point ground test. Figure 4.1 shows a two-point ground connection test.
Page 24: Primary Power Port
MAN0964-14-EN_XL4_XL4P_UM Primary Power Port NOTE: The Primary Power Range is 10VDC to 30VDC. DC Input / Frame • Solid/Stranded Wire: 12-24 awg (2.5-0.2mm). • Strip length: 0.28” (7mm). • Torque, Terminal Hold-Down Screws: 4.5 – 7 in-lbs (0.50 – 0.78 N-m). •...
Page 25: Chapter 5: System Settings And Adjustments
SYSTEM SETTINGS AND ADJUSTMENTS System Menu - Overview The XL4/XL4 Prime has a built-in System Menu, which lets the user view System Settings and makes adjustments. To start the System Menu, press the SYSTEM key (or set %SR3 to 1), which will display the Main Menu.
Page 26 MAC ID2: Dflt Pgm Port MJ1-232 00:E0:C4:04:C0:35 MJ1 RS485 Bias IP2: 192.168.254.127 ( Use ↑↓ to adjust ) NetM2: 255.255.255.0 GatW2 0.0.0.0 XL4/XL4 System Menu Map Prime Figure 5.2 Model: XC1E6 Time: 14:58:03 Mode: Date: 08-Sep-2015 Set Networks Scan Rate(mS):...
Page 27: System Menu - Navigation And Editing
 and  Keys Enter Key As mentioned above, the System Menu is started by pressing the System key on the XL4/XL4 Prime. Next press ESC to exit the System Menu, or use  and  to select an item and press Enter to display the item’s Sub-Menu.
Page 28: System Menu - Details
MAN0964-14-EN_XL4_XL4P_UM 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 29: View Status
View Status The View Status Sub-Menu displays up to 19 System Settings. Only the Mode System Setting is editable. Model: XL1yz = Model number of this XL4/XL4 Prime OCS unit = indicates the installed I/O module = no I/O module Mode:...
Page 30: View Diags
The View Diags Sub-Menu displays up to 11 System Diagnostics, none of which are editable. The first two System Diagnostics are critical. If any of them indicate a Fault condition, the XL4/XL4 Prime OCS will not enter or remain in Run mode, and the problem must be investigated and corrected.
Page 31: View Battery Status
MAN0964-14-EN_XL4_XL4P_UM 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 32: View I/O Slots
The View I/O Slots Sub-Menu displays three System Settings, all of which are not editable. Internal to the XL4/XL4 Prime OCS, there is a CPU board, and up to two installed modules. Model XE100 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 33: View Protocols
MJ2 (Port 2) serial ports support downloadable protocols. To assign a downloadable protocol to an XL4/XL4 Prime OCS serial port, select the Protocol Config item in Cscape’s Program menu and then setup a protocol for Port 1 or Port 2 (or both).
Page 34: Set Fkeys Mode
MAN0964-14-EN_XL4_XL4P_UM Set Fkeys Mode The Set Fkeys Sub-Menu displays two System Settings, both of which are editable. 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 35: Set Serial Ports
MAN0964-14-EN_XL4_XL4P_UM 5.10 Set Serial Ports The Set Serial Ports Sub-Menu displays three System Settings, all of which are editable, 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 36: Set Time/Date
MAN0964-14-EN_XL4_XL4P_UM 5.11 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 5.1 – 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...
Page 37 MAN0964-14-EN_XL4_XL4P_UM 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 38: Set Beeper
MAN0964-14-EN_XL4_XL4P_UM 5.12 Set Beeper The Set Beeper Sub-Menu displays one System Setting, which is editable. (default) = Enables beeper Beeper Enable (does NOT affect ladder access) No = Disables beeper N o v e m b e r 1 0 , 2 0 2 1 P a g e 38 | 194...
Page 39: Set Screen
MAN0964-14-EN_XL4_XL4P_UM 5.13 Set Screen The Set Screen Sub-Menu displays four System Settings, all of which are editable. 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 40: Removable Media
MAN0964-14-EN_XL4_XL4P_UM 5.14 Removable Media The Removable Media Sub-Menu displays the Removable Media Manager. After selecting Removable Media from the Main Menu, one of four Sub-Menu screens will appear: Media Directory = No microSD card has been installed in the Memory slot No Card Media Directory = microSD card is installed, but it is still initializing...
Page 41 MAN0964-14-EN_XL4_XL4P_UM If a directory name is highlighted, pressing Enter will switch to that directory showing its files and sub-directories. In a sub-directory, highlighting .. (dot dot) and pressing Enter will move up one directory. 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"...
Page 42: Enable Autorun
MAN0964-14-EN_XL4_XL4P_UM 5.15 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.
Page 43: Enable Autoload
MAN0964-14-EN_XL4_XL4P_UM 5.16 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. N o v e m b e r 1 0 , 2 0 2 1 P a g e 43 | 194...
Page 44: Clone Unit
MAN0964-14-EN_XL4_XL4P_UM 5.17 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 45 MAN0964-14-EN_XL4_XL4P_UM Selecting Make Clone brings up the screen below for the user: 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 N o v e m b e r 1 0 , 2 0 2 1 P a g e 45 | 194...
Page 46: Load Clone
MAN0964-14-EN_XL4_XL4P_UM 5.18 Load Clone Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone” (one of the virtual buttons beneath the screen). NOTE: For security enabled files, Load Clone asks for password validation before loading the application. N o v e m b e r 1 0 , 2 0 2 1 P a g e 46 | 194...
Page 47: Webmi License Details
MAN0964-14-EN_XL4_XL4P_UM 15.19 WebMI License Details License details page displays the information about the WebMI license. Please refer to MAN1036 for the WebMI Manual. 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 %SR209.9 to SR209.16...
Page 48: Touch Screen Calibration
MAN0964-14-EN_XL4_XL4P_UM 5.20 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 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 5.3 should appear.
Page 49: Chapter 6: Registers
REGISTERS Register Definitions When programming the XL4/XL4 Prime 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 50: Useful %S And %Sr Registers
MAN0964-14-EN_XL4_XL4P_UM %QG Global Digital Output Specially defined single-bit outputs that go to the network. %R General Purpose Register Retentive 16-bit registers. %S System Bit Single-bit bit coils predefined for system use. %SR System Register 16-bit registers predefined for system use. %T Temporary Bit Non-retentive single-bit registers.
Page 51 MAN0964-14-EN_XL4_XL4P_UM NOTE: Note every OCS supports every %SR. Table 6.2 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values User Screen Number %SR1 USER_SCR 0 to 1023 Read/Write Read/Write *Excludes RCC Units Alarm Screen Number (0=none) %SR2 ALRM_SCR...
Page 52 MAN0964-14-EN_XL4_XL4P_UM Table 6.2 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values %SR6 Average Scan Rate ms ( / 10) Read Only Read Only %SR7 Minimum Scan Rate ms ( / 10) Read Only Read Only %SR8...
Page 53 MAN0964-14-EN_XL4_XL4P_UM Table 6.2 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values %SR37 Model Number Read Only Read Only %SR38 Engine Version ( /100) Read Only Read Only %SR39 BIOS Rev Number ( / 100) Read Only Read Only %SR40...
Page 54 MAN0964-14-EN_XL4_XL4P_UM Table 6.2 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values 7= 23 8 = 24 9 = 25 System = 26 Escape = 27 Left = 28 Right = 29 Up = 30 Down = 31 Shift = 32...
Page 55 MAN0964-14-EN_XL4_XL4P_UM Table 6.2 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values *XLEe, XLTe, X2, X4, & X7 only %SR113-130 Reserved %SR131-135 OCS Model: ASCII, 10 characters Read Only Read Only %SR136 Communication Download Timeout Read Only...
Page 56 MAN0964-14-EN_XL4_XL4P_UM Table 6.2 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values Make Clone Fail (This bit goes high %SR164.11 MK_CLN_FL Read / Write Read / Write when Make/Create Clone fails) %SR164.12 Load Clone Fail (This big goes high LD_CLN_FL...
Page 57 MAN0964-14-EN_XL4_XL4P_UM Table 6.2 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values TRUE to switch programs, FALSE when %SR193.2 Read Only Read Only complete TRUE if executing program is %SR193.3 Read Only Read Only temporary test TRUE during last scan of switched-from...
Page 58 MAN0964-14-EN_XL4_XL4P_UM Table 6.2 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values %SR210 Time Zone: set in minutes + / - UTC. Read/Write Read/Write (Ex: EST is -4 hours = -240 minutes) %SR211 Daylight Saving: YES = 1 Daylight Saving: NO = 0...
Page 59: Resource Limits
MAN0964-14-EN_XL4_XL4P_UM Resource Limits Table 6.3 – Resource Limits Resource Value 16000 16000 49999 1023 2048 2048 64 (per ID) 64 (per ID) %AIG 32 (per ID) %AQG 32 (per ID) CsCAN, Ping, EGD, SRTP, Modbus TCP Master (Downloadable protocol) & Slave, Ethernet IP, Ethernet FTP, or HTTP @ 10MBd or 100MBd CsCAN...
Page 60: Register Map For Xl4/Xl4 Prime Ocs I/O
MAN0964-14-EN_XL4_XL4P_UM Register Map for XL4/XL4 Prime OCS I/O Table 6.4 – I/O Register Map Description Registers no I/O 102 I/O 103 I/O 104 I/O 105 I/O 106 I/O %I1-%I12 Unused Digital Inputs %I13-%I16 Unused Reserved Digital Inputs Reserved %I17-%I24 Unused...
Page 61 MAN0964-14-EN_XL4_XL4P_UM Table 14.6 – HSC Functions Register Map Register Frequency Totalize Pulse Quad %AI5-6 HSC1 (function) Accumulator Quad 1 Acc %AI7-8 HSC2 (function) Accumulator %AI9-10 HSC3 (function) Accumulator Quad 2 Acc %AI11-12 HSC4 (function) Accumulator %AQ1-2 HSC1 Preset %AQ3-4 HSC2 Preset %Q17 Clear HSC1 Clear Quad 1...
Page 62: Chapter 7: Cscape Configuration
Cscape Status Bar When the XL4/XL4 Prime 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 XL4/XL4 Prime OCS and the Cscape program.
Page 63: Establishing Communications
MAN0964-14-EN_XL4_XL4P_UM Establishing Communications The XL4/XL4 Prime OCS can communicate with Cscape using USB to USB, USB to serial adapters, serial port communications via MJ1 Port, Ethernet (with an Ethernet adapter board), onboard Ethernet Port, CAN (CsCAN), or modems. If a direct USB connection is to be used, connect the Mini-USB port on the OCS (only on select models) to an open USB port on the PC.
Page 64 The PC will detect a new device has been plugged into the USB port. Now that the XL4/XL4 Prime is plugged in, go to Cscape → Controller → Connection Wizard. If you are just opening Cscape, Connection Wizard usually opens by default.
Page 65 MAN0964-14-EN_XL4_XL4P_UM 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 7.2 –...
Page 66 MAN0964-14-EN_XL4_XL4P_UM 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 7.3 – Cscape: Alternative Connection Method Screenshot Figure 7.4 – 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 67 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 68 ID and do not require the ID to be configured. To check or change the ID on the XL4/XL4 Prime OCS, press the System Menu key. The first item in the menu is Set Networks. Pressing Enter allows you to view or modify the ID of the unit.
Page 69 ID and do not require the ID to be configured. To check or change the ID on the XL4/XL4 Prime OCS, press the System Menu Key. The first item in the menu is Set Networks. Pressing Enter allows you to view or modify the ID of the unit.
Page 70 MAN0964-14-EN_XL4_XL4P_UM 7.3.2 Communicating via On Board Ethernet Port From Cscape go to Controller → Hardware Configuration 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 71: Configuration
Base model, I/O, and any communication options. (3) If the XL4/XL4 Prime 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 72: Digital / Hsc Input Configuration
The High-Speed Counters group box contains all of the windows that are used for configuring the four (4) available high-speed counters on the XL4/XL4 Prime OCS. In configuring a counter, the user needs to set the type, mode, and counts per rev.
Page 73: Digital / Pwm Output Configuration
MAN0964-14-EN_XL4_XL4P_UM Digital / PWM Output Configuration The following figure illustrates the Digital / PWM Output Configuration dialog. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 7.7 – Digital / PWM Output Configuration Dialog The Q1 and Q2 group boxes allow the user to specify the operation of the multi-function outputs.
Page 74: Analog Input Configuration
MAN0964-14-EN_XL4_XL4P_UM Analog Input Configuration The following figure illustrates the Analog Input Configuration dialog of a Model 2. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 7.8 – Analog Input Configuration Dialog The Channel x drop down windows allow the user to specify the mode for each analog input to operate.
Page 75 MAN0964-14-EN_XL4_XL4P_UM On Model 5 and Model 6 I/O, other options on channels are outlined below: Table 7.2 – Analog In for Models 5 & 6 Model 5 Model 6 Channels 1 & 2 Channels 1-6 0..10V 0..10V 0..20mA 0..20mA 4..20mA 4..20mA 100mV Disable...
Page 76: Analog Output Configuration
MAN0964-14-EN_XL4_XL4P_UM Analog Output Configuration The following figure illustrates the Analog Output Configuration dialog. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 7.9 – Analog Output Configuration Dialog (Model 6) 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.
Page 77: Scaling Analog Inputs
MAN0964-14-EN_XL4_XL4P_UM Scaling Analog Inputs To access the Advanced Math Scaling function, select Tools → Project Toolbox. This will open a side bar, and then select Advanced Math → Scale. Figure 7.10 –Scaling Analog Inputs N o v e m b e r 1 0 , 2 0 2 1 P a g e 77 | 194...
Page 78: Chapter 8: General I/O
Each XL4/XL4 Prime OCS I/O jumper is set to a factory default. Refer to the data sheet for your XL4/XL4 Prime OCS model to find the default setting to determine if a jumper change is necessary for your application.
Page 79: Model And I/O Overview
Model 4 Model 5 Model 6 Table 8.1 shows the different types of I/O included with the various XL4/XL4 Prime OCS models. Specific specifications, jumper settings, and wiring diagrams can be found on the XL4/XL4 Prime Datasheets. N o v e m b e r 1 0 , 2 0 2 1...
Page 80: 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 XL4/XL4 Prime 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 81: Relay Outputs
Relay outputs are designed to switch loads that typically have high voltage, current requirements, or require isolation that relays provide. NOTE: The design of the XL4/XL4 Prime OCS does not require external coil power for the relays to function. The relays will activate anytime the XL4/XL4 Prime OCS is powered.
Page 82: Digital Inputs
Cscape settings pages. Digital Inputs NOTE: Refer to the datasheet for XL4/XL4 Prime OCS model you are using for details on jumper settings. NOTE: The digital inputs on the XL4/XL4 Prime OCS are designed for low voltage DC inputs.
Page 83: Analog Inputs
MAN0964-14-EN_XL4_XL4P_UM Analog Inputs NOTE: See the Datasheet for the XL4/XL4 Prime OCS model you are using 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 84: Universal Analog Inputs
MAN0964-14-EN_XL4_XL4P_UM 8.8 Universal Analog Inputs NOTE: See the Datasheet for the XL4/XL4 Prime OCS model you are using 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 85: Analog Outputs
Figure 8.9 – Loop Power Requirements Analog Outputs NOTE: Refer to the datasheet for XL4/XL4 Prime OCS model you are using for details on jumper settings. The HE-XC1E6 does not require jumpers and only requires a configuration parameter in Cscape.
Page 86: Chapter 9: High Speed I/O (Hsc / Pwm)
HIGH SPEED I/O (HSC / PWM) Overview In addition to the compliment of simple analog and digital I/O, several of the XL4/XL4 PLUS 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 87: Glossary
MAN0964-14-EN_XL4_XL4P_UM Glossary Table 9.1 – 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 88: High Speed Counter (Hsc) Functions
MAN0964-14-EN_XL4_XL4P_UM High Speed Counter (HSC) Functions The XL4/XL4 PLUS 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 89 MAN0964-14-EN_XL4_XL4P_UM 9.3.2 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 90 MAN0964-14-EN_XL4_XL4P_UM 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 91 MAN0964-14-EN_XL4_XL4P_UM 9.3.3 Pulse Width Measurement CHAPTER 2 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 92 MAN0964-14-EN_XL4_XL4P_UM 9.3.4 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 93 MAN0964-14-EN_XL4_XL4P_UM 9.3.5 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 94 MAN0964-14-EN_XL4_XL4P_UM 9.3.6 Register Match CHAPTER 3 Totalizer & Quadrature counter modes support a register match function. When the accumulator value matches either the Match 1 or Match 2 value configured in the corresponding %AQ registers, a high-speed output can Turn On, Turn Off, or Toggle. An internal %I register mirrors the output state whether the high-speed output is configured or not.
Page 95 9.3.7 HSC Functions CHAPTER 4 The high-speed input on the XL4/XL4 PLUS contains many optional tasks. All of which can be disabled, or set to an internal pre-assigned register (Assigned %Q) or to one of the external high speed inputs (External Input #1, 2, 3, or 4), or they can be set as an “overflow interrupt”...
Page 96 MAN0964-14-EN_XL4_XL4P_UM 9.3.8 Status Bits CHAPTER 5 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 9.4.
Page 97: Hsc Functions Register Map
MAN0964-14-EN_XL4_XL4P_UM 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 9.3 –...
Page 98 MAN0964-14-EN_XL4_XL4P_UM NOTE: Four Count Mode requires FPGA update. Table 9.4 – 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 99 MAN0964-14-EN_XL4_XL4P_UM %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 100: High Speed Output Functions
MAN0964-14-EN_XL4_XL4P_UM 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. 9.5.1 Normal When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives that respective output.
Page 101 MAN0964-14-EN_XL4_XL4P_UM 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 102 9.5.5 Stepper Function The XL4/XL4 PLUS supports two stepper functions, one on each high-speed output when in two counter mode. In four counter mode, the XL4/XL4 PLUS supports one stepper function The Stepper requires five parameters (%AQs) to be set for operation. These parameters may be set at run-time but are ‘latched’...
Page 103 MAN0964-14-EN_XL4_XL4P_UM 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 104: High Speed Output Functions Register Map
MAN0964-14-EN_XL4_XL4P_UM 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 105: Pwm Examples
MAN0964-14-EN_XL4_XL4P_UM 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 106: Stp Examples
%I1619 for channel 1 and 2 respectfully). The Ready/Done bit will turn OFF during the move, and then back ON once the move is completed. NOTE: The pulse generation hardware on the XL4/XL4 PLUS can generate any frequency that can be evenly divided into 10MHz (10,000,000Hz) under the maximum recommended frequencies for each model.
Page 107: Hsc I/O Filtering
MAN0964-14-EN_XL4_XL4P_UM 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 108 MAN0964-14-EN_XL4_XL4P_UM 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 109 MAN0964-14-EN_XL4_XL4P_UM Figure 3: Input signal before filtering Figure 4: Input signal after filtering This delay will be 4μs. N o v e m b e r 1 0 , 2 0 2 1 P a g e 109 | 194...
Page 110: Chapter 10: Serial Communications
10.1 Overview All XL4/XL4 Prime OCS models provide two serial ports, which are implemented with single 8- pin modular RJ45 connectors, are labeled MJ1 and MJ2. The MJ1 serial port is RS-232 while the MJ2 port is RS-485. MJ1 defaults to OCS programming by connecting it to the COM port of a PC running Cscape.
Page 111: Dip Switches
MAN0964-14-EN_XL4_XL4P_UM 10.4 Dip Switches Figure 10.2 – Dip Switches 10.5 RS-485 Termination Proper RS-485 termination minimizes reflections and improves reliability. The 485 serial port allows an internal RS-485 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 RS-485 network should be terminated.
Page 112: Biasing
It is possible to download or upload and use the data monitoring functions once connected. NOTE: It is advisable to use an isolated USB cable between the PC or laptop and the XL4/XL4 Prime when third party devices are connected to the XL4/XL4 Prime to avoid damage to the PC or laptop and/or the XL4/XL4 Prime.
Page 113: Chapter 11: Can Communications
11.1 Overview All XL4/XL4 Prime OCS models provide a CAN networking port, which is implemented with a 5- pin connector. The connector is labeled CAN1. Figure 11.1 – CAN1 Connector The CAN1 port allows the XL4/XL4 Prime OCS to exchange global data with other OCS/RCS controllers and to access remote Network I/O devices (SmartStix, Smart Blocks, and Smart Rail Modules).
Page 114: Can1 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 XL4/XL4 Prime OCS CAN1 port, Cscape can access the XL4/XL4 Prime OCS for programming and monitoring.
Page 115: Chapter 12: Ethernet Communication
Ethernet Global Data SRTP Slave (90-30 Service Service Request Transfer Protocol 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 116: Ethernet Module Specifications
MAN0964-14-EN_XL4_XL4P_UM 12.4 Ethernet Module Specifications Speeds 10 BaseT Ethernet (10Mbps) 100 BaseTx Fast Ethernet (100Mbps) Modes Half or Full Duplex Auto-Negotiation Both 10/100Mbps and Half/Full Duplex Connector Type Shielded RJ-45 Cable Type CAT5 (or better) UTP (Recommended) Port Auto MDI/MDI-X (Auto Crossover) Table 12.2 –...
Page 117: Ethernet Module Configuration
MAN0964-14-EN_XL4_XL4P_UM 12.5 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 menu and its Hardware Configuration sub-menu to open the Hardware Configuration dialog (Figure 12.1).
Page 118 MAN0964-14-EN_XL4_XL4P_UM Click the Config button to the right of the LAN1 for LAN 1 or LAN2 for LAN 2, revealing the Ethernet Module Configuration dialog as shown in figure as shown in Figure 12.2. Figure 12.2 – Ethernet Module Configuration Configure the Ethernet Module parameters as follows: IP Address: Enter the static IP Address for the Ethernet Module being configured.
Page 119 MAN0964-14-EN_XL4_XL4P_UM Table 12.3 - Ethernet Status Word Register Format High Byte Low Byte Bit 1 Link TCP Connections Status Values Status Bit(s) Status Indication Minimum Maximum Reserved Always 0 Link Duplex (Auto-Negotiated) 0 = Half Duplex 1 = Full Duplex Link Speed (Auto-Negotiated) 0 = 10MHz 1 = 100MHz...
Page 120: Ethernet Configuration - Ip Parameters
Configure Selected Protocol button. This will open a new dialog with configuration options for the selected protocol. For detailed information on individual protocol configuration, refer to latest version of ETN 300 Manual SUP0740 on the Horner website. North America https://hornerautomation.com Europe http://www.hornerautomation.eu...
Page 121: Chapter 13: Downloadable Communication Protocols
MAN0964-14-EN_XL4_XL4P_UM CHAPTER 13: DOWNLOADABLE COMMUNICATION PROTOCOLS 13.1 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 122 (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://horner-apg.com/en/products/software/ocs-protocols.aspx...
Page 123: Protocol Config
MAN0964-14-EN_XL4_XL4P_UM 13.2 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 124: Network Configuration
MAN0964-14-EN_XL4_XL4P_UM 13.3 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. See Table 13.1 below for Network Config details.
Page 125 MAN0964-14-EN_XL4_XL4P_UM Table 13.1 – 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 126: Device List And Devices Configuration
MAN0964-14-EN_XL4_XL4P_UM 13.4 Device List and Devices 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 127: Scan List
MAN0964-14-EN_XL4_XL4P_UM 13.5 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 128: Data Mapping Configuration (Scan List Entry)
MAN0964-14-EN_XL4_XL4P_UM 13.6 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 129 MAN0964-14-EN_XL4_XL4P_UM 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 130: Chapter 14: User Interface
14.1 Overview This chapter presents the user interface (or operator view) of the XL4/XL4 Prime and some of the model specific characteristics of the XL4/XL4 Prime as compared to the rest of the OCS line. This chapter does NOT cover building screens or using the CSCAPE graphics editor. For instructions on creating screens and using the graphics editor, refer to the Graphics Editor Help File in CSCAPE.
Page 131: Displaying And Entering Data
Figure 14.1 – 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 XL4/XL4 Prime, these graphical objects (through ladder manipulation of attribute bits) can change color, flash, or change visibility to attract operator attention.
Page 132: Alpha-Numeric Keypad
MAN0964-14-EN_XL4_XL4P_UM 14.4 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 below in Figure 14.2. Once invoked, the operator may touch the appropriate keys to enter a specific value.
Page 133 MAN0964-14-EN_XL4_XL4P_UM Since the alpha-numeric keypad services several different graphical objects, certain keys on the alpha-numeric keypad may be disabled (grayed) when the keypad is invoked for certain objects. The following describes the alpha-numeric keypad variation based on object. Numeric Object When editing a numeric value, the [+/-] or the [.] key are disabled (grayed) if the object is NOT configured for floating-point value or a signed value.
Page 134: Screen Navigation
MAN0964-14-EN_XL4_XL4P_UM 14.5 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 14.3).
Page 135: Beeper Acknowledgement
MAN0964-14-EN_XL4_XL4P_UM 14.7 Beeper Acknowledgement The XL4/XL4 Prime contains an internal beeper that provides an audible acknowledgment when an operator touches a graphic object that accepts touch input. When the graphic object is enabled, a short 5ms tone is emitted. When the graphic object is disabled, a longer 100ms tone is emitted to enounce that graphical object is not currently accepting the touch input.
Page 136: Alarms
MAN0964-14-EN_XL4_XL4P_UM 14.9 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 in CSCAPE. This section presents a typical configuration thereby providing an introductory description on what the operator should expect.
Page 137 MAN0964-14-EN_XL4_XL4P_UM Alarm Viewer Figure 14.6 – 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 138: Removable Media
MAN0964-14-EN_XL4_XL4P_UM 14.10 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 139 MAN0964-14-EN_XL4_XL4P_UM 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 140: Screen Saver
MAN0964-14-EN_XL4_XL4P_UM 14.11 Screen Saver The XL4/XL4 Prime screen backlight life is typically five (5) years when in continuous use. If the application does not require interaction with the XL4/XL4 Prime 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 141: 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 142 MAN0964-14-EN_XL4_XL4P_UM 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 143: Chapter 15: Video Object
MAN0964-14-EN_XL4_XL4P_UM CHAPTER 15: VIDEO OBJECT 15.1 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 144: Opening Video Object In Cscape
MAN0964-14-EN_XL4_XL4P_UM 15.2 Opening Video Object in Cscape NOTE: Video Object requires Firmware 14.03 or newer to use with the XL4/XL4 Prime devices. In Cscape, select the XL4/XL4 Prime and model number by selecting Controller → Hardware Configuration from the toolbar.
Page 145 MAN0964-14-EN_XL4_XL4P_UM Then double click on the icon in the middle to open the Video Properties dialog. N o v e m b e r 1 0 , 2 0 2 1 P a g e 145 | 194...
Page 146: Video Properties: Video Type
MAN0964-14-EN_XL4_XL4P_UM 15.3 Video Properties: Video Type Figure 15.1 – 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 147: Video Properties: Control
MAN0964-14-EN_XL4_XL4P_UM 15.4 Video Properties: Control Figure 15.2 – 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 148: Configuring Display Properties
Cscape, few frames will be missed when video is played. 15.7 Web Cameras If multiple web cameras are directly connected to the XL4/XL4 Prime, then only one web cam will be considered. If user needs to connect multiple web cams, USB hub needs to be used. A maximum of four channels (web cameras) are supported.
Page 149: Chapter 16: Removeable Media
To install a microSD card: Align its 8-pin gold edge connector down, facing the front of the XL4/XL4 Prime OCS unit as shown in Figure 16.2; then carefully push it all the way into the Memory Card slot. Ensure that it clicks into place.
Page 150: Microsd File System
PC, with a microSD-compatible card reader, can read files that have been written by the XL4/XL4 Prime OCS and can write files that can be read by the XL4/XL4 Prime OCS. However, the XL4/XL4 Prime OCS does not support long filenames, but instead implements the 8.3 filename format.
Page 151: Using Removable Media To Log Data
Using Read and Write Removable Media function blocks, an application ladder program can read and write XL4/XL4 Prime 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. In addition, an application ladder program can use Rename and Delete Removable Media function blocks to rename and delete files.
Page 152: Configuration Of The Removable Media Object
MAN0964-14-EN_XL4_XL4P_UM 16.8 Configuration of the Removable Media Object 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 153: Removable Media (Rm) Features-Program Features
MAN0964-14-EN_XL4_XL4P_UM 16.10 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 154: Filenames Used With The Removable Media (Rm) Function Blocks
MAN0964-14-EN_XL4_XL4P_UM 16.13 Filenames used with the Removable Media (RM) Function Blocks The RM function blocks support the flash with a 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 155: System Registers Used With Rm
MAN0964-14-EN_XL4_XL4P_UM 16.14 System Registers used with RM %SR174 – Removable Media Protect. Write a one (1) to %SR174 to prohibit read/write access to the 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 156: Chapter 17: Clone Unit
MAN0964-14-EN_XL4_XL4P_UM CHAPTER 17: CLONE UNIT 17.1 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 157 MAN0964-14-EN_XL4_XL4P_UM 2. Selecting “Make Clone” will open the following menu screen: Figure 17.2 – Make Clone Menu before Cloning NOTE: 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 158 MAN0964-14-EN_XL4_XL4P_UM 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 17.4 – Clone Unit Files NOTE: Make/Create clone operation automatically includes the security in AUTOLOAD.PGM file for security enabled files.
Page 159 MAN0964-14-EN_XL4_XL4P_UM 4. Once the cloning is successful, OCS gives a message as below: Figure 17.5 – 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 160: Load Clone
MAN0964-14-EN_XL4_XL4P_UM 17.3 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 161 MAN0964-14-EN_XL4_XL4P_UM 3. User needs to confirm Load Clone as shown below: Figure 17.8 – Load Clone Confirm Screen 4. 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 162: Chapter 18: Fail - Safe System
MAN0964-14-EN_XL4_XL4P_UM CHAPTER 18: FAIL – SAFE SYSTEM 18.1 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 •...
Page 163: Settings
MAN0964-14-EN_XL4_XL4P_UM 18.2 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. Set the ‘Enable AutoLoad’ option in the device to YES. 4.
Page 164 MAN0964-14-EN_XL4_XL4P_UM Backup OCS Data: When initiated, this will allow the user to manually copy battery-backed RAM contents on to the onboard flash memory of the OCS. This will have the effect of backing up all the registers and controller settings (Network ID, etc.) that would otherwise be lost due to a battery failure. %SR164.4 is set to 1 when backup operation is performed.
Page 165 MAN0964-14-EN_XL4_XL4P_UM Restore OCS Data: When initiated, this will allow the user to manually copy the backed-up data from the onboard flash to the battery-backed RAM. A restore operation will be automatically initiated if 1) a backup has been previously created and 2) on power-up the battery-backed RAM registers fail their check.
Page 166 MAN0964-14-EN_XL4_XL4P_UM Clear Backup Data: When initiated, the backup data will be erased from the onboard flash and no backup will exist. %SR164.4 and %SR164.3 is reset to 0 when backed up data is erased. Figure 18.5 – Clear Backup Data Exit: Goes back to the previous screen.
Page 167 MAN0964-14-EN_XL4_XL4P_UM 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 168: Autoload
MAN0964-14-EN_XL4_XL4P_UM 18.4 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 169 MAN0964-14-EN_XL4_XL4P_UM 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 170: Autorun
MAN0964-14-EN_XL4_XL4P_UM 18.5 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 171: Chapter 19: Modbus Communications
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 XL4/XL4 Prime can act as either a Master or a Slave. Modbus protocol (serial) allows for one master and multiple slaves. The master always initiates the conversation by sending a request to a particular slave.
Page 172: Modbus Master Overview
For complete Modbus Master instructions, please refer to the Help file in Cscape. When acting as a Modbus master, there are two primary mechanisms used by the XL4/XL4 Prime to allow the user to specify the data to be read/written from/to the slaves.
Page 173: Modbus Addressing Table
Register 1 for each type). Since only four register types can be represented in this manner, XL4/XL4 Prime Modbus Function Blocks pack several XL4/XL4 Prime register types into each Modbus register type. Starting addresses of each XL4/XL4 Prime register type are shown in the Traditional Modbus Reference column of the Table 19.1.
Page 174: Chapter 20: Xl4 Rechargeable Back-Up Battery
NOTE: For more details on the back-up battery, refer to the Battery Manual [MAN1142]. 20.1 Overview The XL4 has an advanced battery system that uses a rechargeable lithium-ion battery. The battery powers the real time clock when power is removed, and it is needed for register data retention.
Page 175: Ocs Battery Charging Cycle
MAN0964-14-EN_XL4_XL4P_UM 20.5 OCS Battery Charging Cycle There are various charging states that are executed based on battery temperature, level of battery charge, and self-test results. The battery temperature can be determined by checking the CPU temperature in the controller System Menu: View Battery Status or by monitoring System Register %SR195.
Page 176: Battery Charging Status
MAN0964-14-EN_XL4_XL4P_UM 20.6 Battery Charging Status Viewed in the System Menu under “View Battery Status” or read as a numeric value in %SR196. The battery temperature, Tb, is equal to the CPU temperature minus 30°C: Tb = CPU° - 30°C. Table 20.1 – Charging State Table State - Name Description...
Page 177: Battery Status In System Registers
MAN0964-14-EN_XL4_XL4P_UM 20.7 Battery Status in System Registers NOTE: Registers NOT supported by the XL Prime controllers. Table 20.2 – Battery Status %SR55.13 ON if battery is missing or if voltage is below 2.5V %SR195 CPU temperature in °C %SR196 Charge State; Refer to Table 20.1 %SR197 Charging Current mA %SR198...
Page 178: Replacing Rechargeable Backup Battery
MAN0964-14-EN_XL4_XL4P_UM 20.8 Replacing Rechargeable Backup Battery The XL4 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 179 MAN0964-14-EN_XL4_XL4P_UM Below are the steps to replace the lithium-ion battery, part no. BAT00019, available from Horner APG. Make sure the user program and any data stored in retentive memory is backed up. 2. Disconnect all power from the XL4 OCS unit including I/O power. Unplug I/O connections.
Page 180: Chapter 21: Xl4 Prime Back Up Battery
NOTE: For XL series controller battery information (not the Prime series) please refer to the chapter above. The XL4 Prime has an improved memory architecture that does not require a battery for program or register retention. The onboard lithium coin-cell battery runs the real time clock and is user replaceable with an expected lifetime of seven (7) to ten (10) years.
Page 181 MAN0964-14-EN_XL4_XL4P_UM The XL4 Prime OCS uses a lithium coin-type battery with part no. HE-BAT013, with harness and connector available from Horner APG. Below are the steps to replace the battery: Make sure the user program and any data stored in retentive memory is backed up.
Page 182: Chapter 22: Maintenance
MAN0964-14-EN_XL4_XL4P_UM CHAPTER 22: MAINTENANCE 22.1 Firmware Updates The XL4/XL4 Prime OCS products contain field updatable firmware to allow new features to be added to the product. Firmware updates should only be performed when a new feature or correction is required.
Page 183: Firmware Update Details
2) Save Firmware files to microSD card or USB, these are the removable media devices. 3) Update the firmware through the controller’s Firmware Update function NOTE: Files from the Horner website come as a .ZIP file which need to be unzipped and placed in the root of the drive for them to function properly.
Page 184: Firmware Update Steps
MAN0964-14-EN_XL4_XL4P_UM 22.4 Firmware Update Steps a. Unzip all files from downloaded .zip file (Step One, p.1) onto removable media. b. Plug the removable media into a powered-up OCS controller. c. Press and hold the SYSTEM key until the Boot Installer Screen appears. d.
Page 185: Chapter 23: Troubleshooting / Technical Support
MAN0964-14-EN_XL4_XL4P_UM CHAPTER 23: TROUBLESHOOTING / TECHNICAL SUPPORT Chapter 22 provides commonly requested troubleshooting information and checklists for the following topics. • Connecting to the XL4/XL4 Prime OCS controller • Local controller and local I/O • CsCAN Network • Removable media...
Page 186 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 187: Local Controller And Local I/O
MAN0964-14-EN_XL4_XL4P_UM 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 •...
Page 188: Cscan Network
Use the proper Belden wire type or equivalent for the network as specified in MAN0799. 2. The XL4/XL4 Prime OCS does not provide 24VDC to the network. An external voltage source must be used for other devices such as SmartStix I/O.
Page 189: Usb Interfaces
Description Action The media card should be formatted with XL4/XL4 Prime OCS does not read media card. the XL4/XL4 Prime OCS. Make sure the project file is saved as a .pgm file and not a .csp file. In addition, the XL4/XL4 Prime OCS will not download project file must be .pgm.
Page 190 #6442 – Battery Charging Cycle Battery Status in SR 11-5-2021 #6984 – Added XL4 Prime Throughout Added Backup Battery for XL4 Prime CHAPTER 21: XL4 Prime BACK UP BATTERY #6429 – Revised Register Map 6.4 Register Map for XL4/XL4 PRIME OCS I/O...
Page 191 CAN1 Port Connector, 114 Device List and Device Configuration, 126 CE, 11 Device Manager, 186 Clear Backup Data, 166 Devices to Connect to XL4/XL4 Prime, 14 Clone Unit, 44, 156 Digital Inputs, 82 CLONE.DAT, 158 Dimensions, 18 COM, 30, 32, 35, 110, 112, 114, 185, 186...
Page 192 New-value mode, 132 Overview, 78 Numeric Object, 133 GENERAL I/O, 78 Opening Video Object in Cscape, 144 Glossary, High Speed I/O, 87 Orientation of XL4/XL4 Prime OCS, 17 Ground Specification, 22 Overview Grounding Battery, 174 Locations of Information, 11 Panel Box...
Page 193 Load / Save Applications, 151 Navigate / Edit, 27 Log Data, 151 System Menu (XL4/XL4 Prime) Overview, 149 Screenshot, 25 Save Applications XL4/XL4 Prime, 151 SYSTEM SETTINGS AND ADJUSTMENTS, View / Capture, 151 REMOVABLE MEDIA, 149 Sytem Menu Removable Media Manager, 150...
Page 194 View I/O Slots, 32 Troubleshooting Checklist (Ethernet port View Protocols, 33 Programming) [For XL4/XL4 Prime only], View Status, 29 Visual Overview of XL4/XL4 Prime and Troubleshooting Checklist (serial port – Topics, 12 MJ1) Programming, 186 Where to Find Information, 13...

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HORNER XL4 User Manual

Chapter 1: Safety/ Compliance

Chapter 2: Introduction

Chapter 3: Mechanical Installation

Chapter 4: Electrical Installation

Chapter 5: System Settings and Adjustments

Chapter 6: Registers

Chapter 7: Cscape Configuration

Chapter 8: General I/O

Chapter 9: High Speed I/O (Hsc / Pwm)

Chapter 10: Serial Communications

Chapter 11: Can Communications

Chapter 12: Ethernet Communication

Chapter 13: Downloadable Communication Protocols

Chapter 14: User Interface

Chapter 15: Video Object

Chapter 16: Removeable Media

Chapter 17: Clone Unit

Chapter 18: Fail - Safe System

Chapter 19: Modbus Communications

Chapter 20: Xl4 Rechargeable Back-Up Battery

Chapter 21: Xl4 Prime Back up Battery

Chapter 22: Maintenance

Chapter 23: Troubleshooting / Technical Support

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