Page 1 User Manual for XLE / XLEe XLT / XLTe MAN0878-20.0_XLET_UM...
Page 2 Datasheets The datasheet is the first document to refer to for model-specific information related to XLE/XLT models for installation information. The web version of this manual has all of the XLE/XLT datasheets attached to it. Find the documents via the Documentation Search page on the Horner website. Datasheet Manual Numbers Model 0 MAN1112 Model 2 MAN1113 Model 3 MAN1114 Model 4 MAN1115 Model 5 MAN1116 Model 6 MAN1117 Visual Map Quick Start Installation Programming Troubleshooting "Safety and Compliance" " Mechanical Installation" "System Settings and Adjust- "Fail-Safe System" on on page 9 on page 15 ments" on page 24 page 149 "Introduction to the "Electrical Installation" on ...
Page 3 LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner APG, LLC. ("HE-APG") warrants to the original purchaser that the XLE/XLT OCS module manufactured by HE- APG is free from defects in material and workmanship under normal use and service. The obligation of HE-APG under this warranty shall be limited to the repair or exchange of any part or parts which may prove defective under normal use and service within two (2) years from the date of manufacture or eighteen (18) months from the date of installation by the original purchaser whichever occurs first, such defect to be disclosed to the satisfaction of HE-APG after examination by HE-APG of the allegedly defective part or parts. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE-APG NEITHER ASSUMES, NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS XLE/XLT OCS MODULE. THIS WARRANTY SHALL NOT APPLY TO THIS XLE/XLT OCS module OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. HE-APG MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE-APG. THE TERM "ORIGINAL PURCHASER", AS USED IN THIS WARRANTY, SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM THE XLE/XLT OCS MODULE IS ORIGINALLY INSTALLED. THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES. In no event, whether as a result of breach of contract, warranty, tort (including negligence) or otherwise, shall HE-APG or its suppliers be liable of any special, consequential, incidental or penal damages including, but not limited to, loss of profit or revenues, loss of use of the products or any associated equipment, damage to associated equipment, cost of capital, cost of substitute products, facilities, services or replacement power, down time costs, or claims of original purchaser's customers for such damages. To obtain warranty service, return the product to your distributor with a description of the problem, proof of purchase, post paid, insured and in a suitable package. ABOUT PROGRAMMING EXAMPLES Any example programs and program segments in this manual or provided on accompanying diskettes are included solely ...
Page 4 Preface This manual explains how to use the XLE/XLT OCS Modules. Copyright (C) 2008 H orner APG, LLC., 59 South State Avenue, Indianapolis, Indiana 46201. A ll rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any lan- guage or computer language, in any form by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written permission of Horner APG, Inc. All software described in this document or media is also copyrighted material subject to the terms and conditions of the Horner Software License Agreement. Information in this document is subject to change without notice and does not represent a commitment on the part of Horner APG. Cscape, SmartStack, SmartStix, SmartRail, and CsCAN are trademarks of Horner APG. Ethernet is a trademark of Xerox ® Corporation ® ® microSD and CompactFlash are registered trademarks of SanDisk Corporation ® Published with Madcap Flare . North America Tel: (+) (317) 916-4274 Fax: (+) (317) 639-4279 Website: https://hornerautomation.com Email: t echsppt@heapg.com ...
Page 5: Table Of Contents
Table of Cont ent s Safety and Compliance Introduction to the XLE/XLT Visual Overview Where to find more information for the XLE/XLT Connectivity to the XLE/XLT Features of the XLE/XLT Mechanical Installation Mounting Procedures Mounting Orientation Panel Cutout Installation Factors Affecting Panel Layout Design and Clearances Electrical Installation Ground Specifications How to Test for Good Ground Primary Power Port System Settings and Adjustments System Menu Set Network and Contrast View Status, Diags, I/O Slots and Protocols Set Keys, Serial Ports, Ethernet, Time/Date and Beeper Removable Media Fail-Safe System Clone Unit Touch Screen Calibration for XLT/XLTe System Register Tables Register Definitions...
Page 6 Totalize Pulse Period Measurement Quadrature HSC Register Map for XLE & XLT Pulse Width Modulation (PWM) Functions HSC Output Stepper Function Serial Communications Port Descriptions Serial Port Wiring Dip Switches RS-485 Termination RS-485 Biasing Cscape Programming via Serial Port Ladder-Controlled Serial Communication CAN Communications CAN Connector CAN Termination Cscape Programming via CAN Ethernet Communication Ethernet Module Protocols and Features Ethernet System Requirements Ethernet Module Configuration Ethernet Configuration - IP Parameters Ethernet Module Protocol Configuration Protocol Configuration Overview Protocol Device Driver Selection Network Configuration Device List and Device Configuration Scan List User Interface Screen Navigation Using Editable Screen Objects Ladder Based Screen Navigation...
Page 7 Settings Backup / Restore Data Flow Chart for Automatic Restore AutoLoad AutoRun Modbus Communications Modbus Slave Modbus Master Modbus Addressing Tables for XLE/XLT Units Backup Battery Precautions & Safety Steps for Battery Replacement Firmware Update Firmware Update Details Obtain Firmware Update Firmware Steps Firmware Update via microSD card Manual Firmware Update via %SR’s Auto firmware update via %SR’s Troubleshooting Connecting to the XLE/XLT Local Controller and Local I/O CsCAN Network Removable Media Troubleshooting Technical Support Contacts Change Log...
Page 8 Safety and Compliance Page 8...
Page 9: Safety And Compliance
Safety and Compliance Safety and Compliance Safety Warnings When found on the product, the following symbols specify: Warning: Consult user documentation. Warning: Electrical Shock Hazard. WARNING: EXPLOSION HAZARD – Substitution of components may impair suitability for Class I, Division 2. WARNING: EXPLOSION HAZARD – Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous. WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth) ground before making any other connections. WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly recommended to fuse the voltage measurement inputs. Be sure to locate fuses as close to the source as possible. WARNING: Replace fuse with the same type and rating to provide protection against risk of fire and shock hazards. WARNING: In the event of repeated failure, do not replace the fuse again as a repeated failure indicates a defective condition that will not clear by replacing the fuse. WARNING: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. NOTE: All applicable codes and standards need to be followed in the installation of this product. NOTE: For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG or larger. NOTE: See the "Electrical Installation" on page 21 for more details. Safety Precautions Adhere to the following safety precautions whenever any type of connection is made to the module: ...
Page 10 Introduction to the XLE and XLT Page 10...
Page 11: Introduction To The Xle/Xlt
Introduction to the XLE/XLT Introduction to the XLE/XLT Visual Overview Where to find more information for the XLE/XLT Connectivity to the XLE/XLT Features of the XLE/XLT Visual Overview Page 11 of 174...
Page 12: Where To Find More Information For The Xle/Xlt
Introduction to the XLE/XLT Where to find more information for the XLE/XLT Datasheets - The datasheets are the first documents to refer to for key information related to specific XLE/XLT mod- els. (A basic datasheet is provided in the box with the unit.) Find the documents via the Documentation Search page on the Horner website. Datasheet Manual Numbers Model 0 MAN1112 Model 2 MAN1113 Model 3 MAN1114 Model 4 MAN1115 Model 5 MAN1116 Model 6 MAN1117 Connectivity to the XLE/XLT Connectivity to the XLE/XLT...
Page 13: Features Of The Xle/Xlt
Introduction to the XLE/XLT Features of the XLE/XLT The XLE/XLT is an all-in-one industrial control device. It combines control, user interface, I/O and networking into a single, integrated package. Unique features of the XLE/XLT include: Bright, graphical LCD display (in XLE) (with touch sensing in XLT) Display of complex graphical objects including trends, gauges, meters and animations Advanced control capabilities including floating point, multiple auto-tuning PID loops and string handling cap- abilities Removable media for up to two terabytes of storage of programs, data logging or screen captures CsCAN networking port (optional) for communication with remote I/O, other controllers or PCs. Ethernet version (XLEe/XLTe) with native Ethernet for communication with other controllers, drives, PCs, etc. Configurable serial protocols for communication to drives, PLCs, or other serial peripherals. USB 2.0 full speed port for programming and monitoring. Full featured, built-in I/O including high resolution analog, thermocouple, RTD, high-speed counters, PWM outputs, and relays (depending upon the XLE/XLT model used). Cscape programming software that allows all aspects of the XLE/XLT, XLEe/XLTe to be programmed and configured from one integrated application. Optional communication add-on modules that allow additional capabilities such as Ethernet (pre-Rev TA only) or modems. Fail – Safe System which allows an application to continue running in the event of “Soft” failures such as (Bat- tery power loss or Battery Backed register RAM / Application Flash corruption) ...
Page 14 Mechanical Installation Page 14...
Page 15: Mechanical Installation
Mechanical Installation Mechanical Installation Mounting Procedures Mounting Orientation Panel Cutout Installation Factors Affecting Panel Layout Design and Clearances NOTE: The datasheet is the first document to refer to for model-specific information related to XLE/XLT m odels such as pin-outs, jumper settings, and other key installation information. See the Documentation Search for data- sheets. Mounting Procedures The mechanical installation greatly affects the operation, safety, and appearance of the system. Information is provided to mechanically install the unit such as cut-out sizes, mounting procedures, and other recommendations for the proper mechanical installation of the unit. XLE/XLT products can be mounted through a panel or on DIN rail. Once the panel design has been completed using the criteria and suggestions in the following sections, use the fol- lowing steps to panel mount the XLE/XLT. 1. Remove all connectors from the XLE/XLT unit. 2. Press the DIN rail clip up to make passing the unit through the cutout easier. 3. Make sure the gasket is installe`d on the XLE/XLT and is free from dust and debris. Check that the corners of the gasket are secure.
Page 16: Mounting Orientation
Mechanical Installation Mounting Procedures (Installed on DIN Rail) The XLE/XLT is designed to clip onto standard 35mm DIN rail. If your installation requires liquid or dust protection, make sure the XLE/XLT is placed in an appropriate sealed panel when mounting on DIN rail. Use the following steps to mount the XLE/XLT on DIN rail. 1. Move the DIN rail clip to the lower position. 2. Clip the “Top Clips” on the top of the DIN rail. 3. Press the unit into place and press the DIN rail clip up. A small flat-head screwdriver can be used in the slot of the DIN rail clip if clearance is an issue. NOTE: The DIN rail connection does not provide an earth ground. Refer to the "Electrical Installation" on page 21 for proper grounding information. Mounting Orientation NOTE: For panel or DIN rail mounting – The orientation shown above provides optimum legibility of the screen and ease of use of the keypad. CAUTION: For DIN rail mounting – To prevent the unit from slipping off the DIN rail, do NOT install the unit on its ...
Page 17: Panel Cutout
Mechanical Installation Panel Cutout For installations requiring NEMA4X liquid and dust protection the panel cutout should be cut with a tolerance of +/- 1 mm. The XLE/XLT is designed to fit 1 /4 DIN panel openings. There are a number of punches and enclosures designed to accommodate opening of this size. NOTE: When the communication add-on modules are installed such communication and I/O, the depth of the product increases from 2.264” (57.5mm) to 2.68” (68mm). NOTE: The keypad overlay appearance may differ. Page 17 of 174...
Page 18: Installation
Installation The XLE/XLT utilizes a clip installation method to ensure a robust and watertight seal to the enclosure. Please follow the steps below for the proper installation and operation of the unit. This equipment is suitable for Class I, Division 2, Groups A, B, C and D or non-hazardous locations only. Digital outputs shall be supplied from the same source as the operator control station. Jumpers on connector JP1 shall not be removed or replaced while the circuit is live unless the area is known to be free of ignitable concentrations of flammable gases or vapors. 1. Carefully locate an appropriate place to mount the XLE/XLT. Be sure to leave enough room at the top of the unit for insertion and removal of the microSD™ card. 2. Carefully cut the host panel per the diagram, creating a 92mm x 92mm +/-0.1mm opening into which the XLE/XLT may be installed. If the opening is too large, water may leak into the enclosure, potentially dam- aging the unit. If the opening is too small, the OCS may not fit through the hole without damage. 3. Remove any burrs and or sharp edges and ensure the panel is not warped in the cutting process. 4. Remove all Removable Terminals from the XLE/XLT. Insert the XLE/XLT through the panel cutout (from the front). The gasket must be between the host panel and the XLE/XLT. 5. Install and tighten the four mounting clips (provided in the box) until the gasket forms a tight seal (NOTE: Max torque 0.8 to 1.13 Nm, 7-10 in-lbs). 6. Reinstall the XLE/XLT I/O Removable Terminal Blocks. Connect communications cables to the serial port, USB ports, Ethernet. Factors Affecting Panel Layout Design and Clearances WARNING: ...
Page 19 Panel Door: Tie a low impedance ground strap between the panel box and the panel door to ensure that they have the same ground reference. Temperature / Ventilation Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient tem- perature range. Consider the impact on the design of the panel layout if operating at the extreme ends of the ambi- ent temperature range. For example, if it is determined that a cooling device is required, allow adequate space and clearances for the device in the panel box or on the panel door. Noise Consider the impact on the panel layout design and clearance requirements if noise suppression devices are needed. Be sure to maintain an adequate distance between the XLE/XLT and noisy devices such as relays, motor starters, etc. Shock and Vibration The XLE/XLT has been designed to operate in typical industrial environments that may inflict some shock and vibra- tion on the unit. For applications that may inflict excessive shock and vibration please use proper dampening tech- niques or relocate the XLE/XLT to a location that minimizes shock and/or vibration. Panel Layout Design and Clearance Checklist The following list provides highlights of panel layout design factors: Meets the electrical code and applicable standards for proper grounding, etc.? ...
Page 20 Electrical Installation Page 20...
Page 21: Electrical Installation
Electrical Installation Electrical Installation Ground Specifications How to Test for Good Ground Primary Power Port NOTE: The datasheet is the first document to refer to for model-specific information. Refer to the Documentation Search on the Horner website. Ground Specifications Ideally, a ground resistance measurement from equipment to earth ground is 0Ω. In reality it typically is higher. The US National Electrical Code (NEC) states the resistance to ground shall not exceed 25Ω. Horner Automation recom- mends less than 15Ω resistance from the equipment to ground. Resistance greater than 25Ω can cause undesir- able or harmful interference to the device. Grounding Definition - T he term Ground is defined as a conductive connection between a circuit or piece of equip- ment and the earth. Grounds are fundamentally used to protect an application from harmful interference causing either physical damage such as by lightning or voltage transients or from circuit disruption often caused by radio fre- quency interference (RFI). How to Test for Good Ground In order to test ground resistance, a Ground Resistance Tester must be used. A typical Ground Resistance Meter ...
Page 22: Primary Power Port
Electrical Installation Primary Power Port NOTE: The Primary Power Range is 10VDC to 30VDC. Primary Power Port Pins Signal Description Ground Frame Ground Input Power Supply Ground Input Power Supply Voltage 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) DC- is internally connected to I/O V-, but is isolated from CAN V-. A Class 2 power supply must be used. Power Up 1. OPTION: Attach ferrite core with a minimum of two turns of the DC+ and DC- signals from the DC supply that is powering the controllers. ...
Page 23 System Settings and Adjustments Page 23...
Page 24: System Settings And Adjustments
Fail-Safe System Clone Unit Touch Screen Calibration for XLT/XLTe System Menu The XLE/XLT controller has a built-in System Menu, which lets the user view System Settings and make adjust- ments. To start the System Menu, press the ↑ and ↓ keys at the same time (or set %SR3 to 1), which will display the Main Menu. Then use the ↑ and ↓ keys to select a Main Menu item and press Enter to display the item’s Sub-Menu. XLE Only: The XLE display shows up to six (6) lines of text at a time. For System Menu screens that contain more than 6 lines of text, use the ↑ and ↓ keys to scroll the display. XLT Only: The XLT display shows up to 12 lines of text at a time. For System Menu screens that contain more than 12 lines of text, scroll the display. R UN/OK LED lights indicate the following: RUN/OK LED Lights OFF i ndicates OCS is in IDLE/STOP mode. Flashing i ndicates DO / IO mode or RUN with no ladder ...
Page 25 System Settings and Adjustments System Menu – Navigation and Editing As mentioned above, the System Menu is started by pressing the ↑ a nd ↓ k eys at the same time for the XLE, or the System key on the XLT. Then, either press ESC to exit the System Menu, or use the ↑ a nd ↓ k eys to select an item and press Enter to display the item’s Sub-Menu. A Sub-Menu generally shows a list of System Settings and their values. After opening a Sub-Menu, if any of its Sys- tem Settings are editable, the first System Setting that can be edited is highlighted. If desired, the ↑ and ↓ k eys can be used to select a different System Setting to be edited. At this point, either press ESC to exit the Sub-Menu (returning to the Main Menu) or press Enter to edit the high- lighted System Setting. If Enter is pressed, the System Setting’s value will be highlighted, indicating that it is ready to be modified. When modifying a System Setting’s value, use either the arrow keys (← → ↑ ↓ ) or the numeric keys, or the appro- priate touch screen icons to select a new value. The arrow keys are used to edit System Settings that have just a few possible values. Each time the arrow key is pressed, a new possible value is displayed. When the desired value appears, press the Enter key to save it; oth- erwise press the ESC key to cancel the edit. ...
Page 26 System Settings and Adjustments XLE/XLEe System Menu Page 26 of 174...
Page 27 System Settings and Adjustments XLT/XLTe System Menu Page 27 of 174...
Page 28: Set Network And Contrast
Set Network and Contrast Set Network ID - The Network ID Sub-Menu only appears for XLE/XLT models that have CAN ports (XE1xx). This Sub-Menu displays two System Settings of which only Network ID is editable. Set Network ID Yes = NET1 connected to a CAN network and functioning properly Network Ok? No = Not ready to communicate on CAN network Network ID 1 to 253 = This node’s CsCAN Network ID; must be unique on network Set Network Baud Rate - The Network Baud Sub-Menu only appears for XLE/XLT models that have CAN ports (XE1xx). This Sub-Menu displays just one System Setting and it is editable. Set Network Baud Rate 125kB = 125kBd CAN network 250kB = 250kBd CAN network Network Baud? 500kB = 500kBd CAN network 1 MB = 1MBd CAN network Set Contrast - The Set Contrast Sub-Menu displays just one System Setting and it is editable.
Page 29: View Status, Diags, I/O Slots And Protocols
System Settings and Adjustments View Status, Diags, I/O Slots and Protocols View Status The View Status Sub-Menu displays up to 17 System Settings. The Lcl Net Use % and All Net Use % System Set- tings only appear for XLE/XLT models that have CAN ports (XE1xx). Only the Mode System Setting is editable. View Status XExyyz = 5 or 6 character Model number of this XLE/XLT unit x = 1 for models that have a CAN port 0 = no CAN port y y = the installed I/O module Model: 00 = no I/O module z = the installed COM module N = no COM module ...
Page 30 System Settings and Adjustments View Diags The View Diags Sub-Menu displays up to 14 System Diagnostics, all of which are not editable. The Net Errors, Net- work State, Network ID and Dup Net ID System Diagnostics only appear for XLE/XLT models that have CAN ports (XE1xx). The first five System Diagnostics are critical. If any of them indicate a Fault condition, the XLE/XLT will not enter or remain in Run mode, and the problem must be investigated and corrected. System Diagnostics - Critical Ok = System RAM power-up self-test passed System RAM: Fault = System RAM power-up self-test failed Ok = System BIOS power-up self-test passed System BIOS: Fault = System BIOS power-up self-test failed Ok = Firmware power-up self-test passed Firmware: Fault = Firmware power-up self-test failed Ok = All executed ladder instructions are legal for loaded firmware Logic Error: Fault = A ladder instruction not supported by firmware was found ...
Page 31 System Settings and Adjustments View I/O Slots The View I/O Slots Sub-Menu displays two System Settings, both of which are not editable. Internal to the XLE/XLT, there is a CPU board, and up to two installed modules. Models XE000 and XE100 have no installed I/O or COM modules. All other models have an I/O module in Slot 1 and can have a user-installed COM module in Slot 2. Depending on which I/O module is installed and which I/O module has been configured by Cscape, one of the fol- lowing six System Settings should appear for Slot 1: I/O Slot 1 - System Settings Slot 1: I/O: Empty = No I/O module installed or configured Slot 1: *Unsupported = Unsupported I/O module installed Slot 1: -I/O Missing = No I/O module installed but an I/O module is configured Slot 1: +I/O: XExyy = yy I/O module installed but no I/O module configured...
Page 32 System Settings and Adjustments View Protocols The View Protocols Sub-Menu displays two System Settings, both of which are not editable. Both the MJ1 (Port 1) and MJ2 (Port 2) serial ports support downloadable protocols. To assign a downloadable pro- tocol to an XLE/XLT serial port, select the Protocol Config item in Cscape’s Program menu and then setup a pro- tocol for Port 1 or Port 2 (or both). Refer to " Serial Communications" on page 102 for more details. In the View Protocols Sub-Menu, the currently downloaded protocol, if any, and its version number are displayed for both Port 1 and Port 2. Port 1 - Protocol Protocol Name = (None Loaded) or name of the protocol assigned to MJ1 Protocol Version = Blank or version of the protocol assigned to MJ1 Port 2 - Protocol Protocol Name = (None Loaded) or name of the protocol assigned to MJ2 Protocol Version = Blank or version of the protocol assigned to MJ2 ...
Page 33: Set Keys, Serial Ports, Ethernet, Time/Date And Beeper
System Settings and Adjustments Set Keys, Serial Ports, Ethernet, Time/Date and Beeper Set Keys The Set Fkeys Sub-Menu displays two System Settings, both of which are editable. Fkeys: Momentary = %K1-10 bits go On & Off as F1-F10 are pressed & released Toggle = %K1-10 bits toggle each time F1-F10 are pressed SYS_Fn enable = Reset and all clear system functions enabled = Reset and all clear system functions disabled 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 either an Ethernet (XEC) or a Modem (XMC) COM module is installed. Also, the Set Ethernet (Enet) item only appears if an Ethernet COM module is installed. Dflt Pgm Port MJ1-232 = MJ1 RS232 port is the default programming port Enet = Ethernet COM module is the default programming port...
Page 34 Set Time/Date The Set Time/Date Sub-Menu displays three System Settings. Time and Date are editable, and Day is auto- matically calculated from the Date setting. NOTE: Time and Date are split into three editable fields each. Use ← or → to select a field and then use ↓ or ↑ to edit the field. Set Time/Date Time: 10:21:36 = Current time (hours:minutes:seconds in 24-hour format) Date: 22-Jun-2022 = Current date (day-month-year) Day: Thursday = Current day of week calculated from the Date setting Set Beeper (XLT or XLTe only) NOTE: Does not apply to XLE or XLEe. The Set Beeper Sub-Menu displays one System Setting, which is editable Beeper Enable Yes (default) = Enables beeper = Disables beeper (does NOT affect ladder access) Page 34 of 174...
Page 35: Removable Media
System Settings and Adjustments Removable Media See also: "Removable Media" on page 133 Format a microSD Card 1. Select Removable Media in the System Menu of the controller. 2. Place card in the “Memory” slot. 3. Final Step: a. For XLE, press the bottom right soft key to get the submenu that includes “format”, select format. b. For XLT, press the bottom left and right keys to get the sub menu that includes “format”, select format. XLE/XLEe Removable Media Sub-Menu The Removable Media Sub-Menu displays the Removable Media. Refer to"Removable Media" on page 133 for more details. After selecting Removable Media from the Main Menu, one of four Sub-Menu screens will appear: Page 35 of 174...
Page 36 System Settings and Adjustments If the Removable Media Manager displays files or directories, as in the last example above, there are several options available: a. If → is pressed, the number of total and free bytes is displayed. Then, pressing ← returns to the normal file and directory display. b. If a soft key (on either side of the display) is pressed, a pop-up window appears on the right side of the dis- play, showing the function key options as follows: RM Function Keys F1 Delete = Delete the highlighted file or directory F2 DelAll = Delete all files and directories F3 Format = Format the microSD card F4 SavPgm = Save XLE/XLT application to DEFAULT.PGM Esc Cancel = Cancel current operation (back up one screen) Pressing the soft key again or pressing ESC returns to the normal file and directory display. c. If a directory name is highlighted, pressing Enter will switch to that directory showing its files and sub-dir- ectories. In a sub-directory, highlighting .. (dot dot) and pressing Enter will move up one directory. Page 36 of 174...
Page 37 System Settings and Adjustments XLT/XLTe Removable Media Sub-Menu The Removable Media Sub-Menu displays the Removable Media Manager. Refer to "Removable Media" on page 133 for more details. A fter selecting Removable Media from the Main Menu, one of four Sub-Menu screens will appear: Page 37 of 174...
Page 38 System Settings and Adjustments If the Removable Media Manager displays files or directories, there are several options available: Delete = Delete the highlighted file or directory DelAll = Delete all files and directories Format = Format the microSD card SavPgm = Save XLT application to DEFAULT.PGM = Enter Key = Shows number of total and free bytes in remov- able memory = Up Arrow = Down Arrow = Cancel current operation (back up one screen) Pressing Esc returns to the normal file and directory display. 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. Page 38 of 174...
Page 39: Fail-Safe System
System Settings and Adjustments Fail-Safe System See also: "Fail-Safe System" on page 149 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, Elec- tromagnetic Interference, event. Selecting “Fail-Safe System” menu will open the following menu screen: XLT: XLE: Selecting Backup/Restore Data displays the following screen: XLT: XLE: Fail-Safe Functions Backup = Copies Battery Backed RAM contents on to the onboard flash memory of the OCS. Restore = Copies the backed-up data from onboard flash to the battery backed RAM. Clear Backup = The backup data will be erased from the onboard flash. Exit = Goes back to previous menu.
Page 40 System Settings and Adjustments AutoRun Selecting AutoRun displays the following screen. XLT: XLE: AutoRun = OCS will be in IDLE mode after AutoLoad or Automatic Restore. = OCS will be automatically placed into RUN mode after AutoLoad or Automatic Restore. AutoLoad Selecting AutoLoad displays the following screen. XLT: XLE: AutoLoad = Does not load AUTOLOAD.PGM automatically when application p rogram is absent or cor- rupted. ...
Page 41: Clone Unit
System Settings and Adjustments Clone Unit See also: "Clone Unit" on page 143 ‘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 "Clone Unit" on page 143 for more details. It can then be used to clone a different OCS (exact same model). This feature can be used for: Replacing an OCS by another unit of the same model. Duplicating or “clone” units without a PC. Selecting Clone Unit displays the following screen: XLT: XLE: NOTE: a. In the above Figure, F3 and F4 (XLE menu) are inactive in Clone Unit. b. DSK – when selected shows number of total and free bytes in Removable Media. Page 41 of 174...
Page 42 System Settings and Adjustments Make Clone Selecting Make Clonedisplays the following screen. XLT: XLE: Make Clone AUTOLOAD.PGM Application file CLONE.DAT File having all unit settings and register values from Battery Backed RAM Load Clone Selecting Load Clonedisplays the following screen. XLT: XLE: NOTE: For security enabled files, Load Clone asks for password validation before loading the application. Page 42 of 174...
Page 43: Touch Screen Calibration For Xlt/Xlte
System Settings and Adjustments Touch Screen Calibration for XLT/XLTe NOTE: This does not apply for the XLE/XLEe 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 the figure below should appear. Thereafter, use a plastic tip stylus and follow the dialog instructions. For best results in screen calibration, use a stylus with a plastic tip. When the crosshair appears, touch the center of the crossbar as exactly as possible and release. A small “+” should appear and will move closer to the center of the crosshair. Once it has done so and disappeared again, repeat the process until “+” appears in the center of the cross hair. Then move on to the next step. Page 43 of 174...
Page 44 System Registers Page 44...
Page 45: System Register Tables
System Register Tables System Register Tables Register Definitions %S Registers %SR Registers For I/O Register Maps for individual controllers, refer to the Horner website Document Search page. There are two types of System Registers that may be u sed during programming. %S registers indicate the status of several system o perations. %SR egisters indicate the state of many system operations a nd can be used to control them in several cases. Some of the system registers h ave predefined I/O names, though they may still be changed if desired. Register Definitions When programming the an 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. For example, 16 single-bit registers can be used to store a word, or two 16-bit registers can be used to store a 32-bit value. ...
Page 46: %S Registers
System Register Tables %S Registers %S registers indicate s ystem status as follows: %S Registers Name Predefined Notes Name First Scan FST_SCN On for 1 scan only each time the program is first run Network OK NET_OK If on, the Network is OK 10ms pulse T_10MS Cycling pulse that is high for 5ms and low for 5ms 100ms pulse T_100MS Cycling pulse that is high for 50ms and low for 50ms 1 second pulse T_1SEC Cycling pulse that is high for 500ms and low for 500ms I/O OK IO_OK If on, the I/O system is OK Always On ALW_ON This bit is always on Always OFF ALW_OFF This bit is always off Pause Scan PAUSING_SCN On for at least 1 scan prior to Pause 'n Load...
Page 47: %Sr Registers
System Register Tables %SR Registers %SR registers are special word-length registers that d isplay and/or control system operations in the controller. Not all controllers s upport all defined system registers. XLE & XLT %SR Registers SR # Name and Description Default Min - Max Program Display (Read/Write) Name I/O Name Values (Read/Write) %SR1 User S creen Number (0=none) USER_SCR 0 to 1023...
Page 48 System Register Tables XLE & XLT %SR Registers 3= Online Change %SR6 Average Scan Rate ms ( / 10) Read Only Read Only %SR7 Minimum Scan Rate ms ( / 10) Read Only Read Only %SR8 Maximum Scan Rate ms ( / 10) Read Only Read Only %SR9 Current T ouch Pressure TCH_PRESSURE 0 to 3000 Read Only Read Only %SR10 Threshold T ouch Pressure TCH_ 0 to 3000...
Page 49 System Register Tables XLE & XLT %SR Registers %SR40 FPGA Image Rev Number ( / 10) Read Only Read Only %SR41 Vertical Pixel Count Read Only Read Only %SR42 Horizontal Pixel Count Read Only Read Only %SR43 Keypad Type Read Only Read Only %SR44 Real-Time-Clock Second RTC_SEC 0 to 59 Read Only Read Only %SR45 Real-Time-Clock Minute RTC_MIN 0 to 59...
Page 50 System Register Tables XLE & XLT %SR Registers Soft Key 7 = 40 Soft Key 8 = 41 Release = 255 (Keys pressed since power- up but not currently) %SR57 LCD Backlight Dimmer Register 0 to 255 Read Only Read Only 0-100 = 0% to 100% On 100-255 = 100% On %SR57.16 Temporarily disable Screen Saver Read/Write Read/Write %SR58 User LEDs USER_LEDS Read/Write Read/Write %SR59 Read Only Read Only Engine Build Number (Only last three numbers displayed) ...
Page 51 System Register Tables XLE & XLT %SR Registers %SR152.2 Reserved %SR152.3 MJ1 Termination Enable Read/Write Read/Write XLE, XLEe, XLT & XLTe %SR152.4 Reserved Read/Write Read/Write %SR153 - Reserved %SR164 FailSafe / clone ...
Page 52 System Register Tables XLE & XLT %SR Registers %SR174 Removable Media Protect Read/Write Read/Write %SR174.1 Request Media Card be Removed Read/Write Read/Write %SR174.2 Indicates safe to remove Media Card Read/Write Read/Write %SR175 Removable Media - Status Read Only Read Only %SR176-177 Removable Media Free Space (32-Bit Read Only Read Only DINT) %SR178-179 Removable Media Total Space (32-Bit ...
Page 53 System Register Tables XLE & XLT %SR Registers NOTE: Refer to MAN1142 for more details on Rechargeable Batteries 0=Waiting 1=Normal Charging 2=Hot Charge 3=Hot Charge 4= Battery Hot 5= Cold Charge 6=Battery Cold 7=No Battery 8= Not Charging (after 8 hours of char- ging) 9= CPU Hot, not charging 10 Battery voltage <2V, not charging 11= First 2 minutes Init Wait (Not Char- ging) %SR197 Charging Current Max mA Read Only Read Only %SR198 Battery Voltage is mV Read Only Read Only %SR199 Reserved ...
Page 54 Cscape Configuration Page 54...
Page 55: Cscape Configuration
Cscape Configuration Cscape Configuration XLE & XLT Background Cscape Status Bar Establishing Communications Cscape Configuration XLE & XLT Background XLE/XLT hardware is programmed with a Windows based PC application called Cscape. This application can be used to program, configure, monitor and debug all aspects of the XLE/XLT unit. Please see the on-line help provided with Cscape for additional details. Updating Programs from First Generation to Second Generation XLE/XLT Generation 1 products did not feature integrated Ethernet, so if the part number contains an E like HE-XT1E0 or HE-XE1E6 it is a second generation unit. Devices without integrated Ethernet can be checked using the hardware revision after the part number. Hardware revision “T” and later are Generation 2 products. For example, XE- XE103TB is hardware revision “T.” Cscape programs created for the first generation XLE and XLT can be loaded into Generation 2 products without any changes. If you created PGM files to be loaded into XLE or XLT devices via the microSD card, then these can be used. If your configuration contains no downloadable protocols, then you can use the PGM without any changes. If your PGM contains downloadable protocols, then you can either recreate the PGM with Cscape 9.8 or later, or ...
Page 56: Cscape Status Bar
Cscape Configuration Cscape Status Bar When the XLE/XLT 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 XLE/XLT and the Cscape program. Components of the Cscape Status Bar are explained below. Page 56 of 174...
Page 57: Establishing Communications
Cscape Configuration Establishing Communications The XLE/XLT can communicate with Cscape using USB to serial adapters, Ethernet, USB, or CAN (CsCAN). Communicating via USB Port - To communicate with the XLE or XLT via USB you will need the Automated Driver Installer located on the Horner Automation web site. T he drivers may be loaded from the HE-XEC Ethernet Utility / HTTP Web Server Demo / Communications Drivers section of the support files page on our website, found here: ttps://hornerautomation.com/support-files . Next, connect a PC’s (Personal Computer running a Windows Microsoft operating system) USB port via USB cable to the USB mini B port on the XLE/XLT OCS. The PC will detect a new device has been plugged into the USB port. Open Cscape and the first screen to open will be the Connection Wizard > USB > Next>> > Finish.
Page 58 Cscape Configuration If Controller USB COM Port is not present in the dropdown list, the Windows operating system has not yet recog- nized the OCS as an installed device. Be sure the installation process is complete and that the correct drivers are installed. The Connection Wizard must be completely closed and reopened to refresh the USB dropdown list. An alternate way to select the COM setting is to go to Cscape > Tools > Application Settings > Communication > Configure and choose connection method in Add Target. Page 58 of 174...
Page 59 Cscape Configuration Page 59 of 174...
Page 60 Select this option to communicate to t he device through the internal modem of the computer. Cscape will a utomatically detect the internal modem attached with PC and list in the Installed Modem attached drop down. User can select modem and telephone number for target c ontroller. NOTE: Cscape will do necessary i nitialization for the selected internal modem. Select this option to communicate o ver USB. Now Horner devices and Horner USB to serial converters are r ecognized and can be specifically selected. Connected Device NOTE: This configuration is required if the c ontroller to which Cscape is communicating is connected to a CsCAN network. Connected Device By default, this option is selected a nd networking feature of Cscape is disabled. On s electing this option, Networking feature of Cscape is enabled. CsCAN ID for t he target ...
Page 61: Communicating Via Mj1 Serial Port
Communicating via MJ1 Serial Port If a serial programming connection is to be used and the PC has a 9-pin serial COM port, which is increasingly rare, there is nothing to install assuming the port already works. All that is needed is a programming cable to go from the COM port to the OCS programming port. If a serial programming connection is to be used and the PC does not have a COM port, a USB-to-Serial adapter may be used. Horner offers the HE500USB600 USB-to-RS232 Serial Adapter, which comes as part of the E-CPK programming kit. Drivers for it are normally found automatically by the Windows operating system as long as an internet connection is established. Otherwise, the drivers may be loaded from the Horner FTP site at https://hornerautomation.com/support-files/ . Connect the PC’s serial port or the USB-to-Serial adaptor to the port labeled MJ1 on the XLE/XLT. The instructions are similar to using a USB port, as shown above. In the Connection Wizard, select the “Serial” option. If communications are successful, the target indicator should show the mode of the controller Target: yy(R) as shown above in "Cscape Status Bar" on page 56 If the controller is not communicating, you may need to set the target ID of the controller in Cscape or on the unit. The Target ID allows directing communications to a particular unit when multiple units are connected via a CsCAN network. 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 XLE/XLT OCS, press the UP and DOWN keys on the XLE/XLT simultaneously to enter the System Menu. The first item in the menu is Set Network ID. Pressing Enter allows you to vie or modify the ID of the unit. To change the Target ID of Cscape use the Controller > Set Target Network ID dialog.
Page 62: Communicating Via On Board Ethernet Port
Cscape Configuration 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 & go to 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. Once running or power cycled the configuration will come from the Cscape configuration stored in the unit. In Module configuration dialog, go to IP Address field enter unused IP Address and configure unused registers in Register field & then click OK. Screen shot for the same as follows: Download the configuration in to Controller. Connect LAN cable to the Controller in default LAN Port. From Cscape go to Tools > Editor Options > Communication Port > Configure. Select Ethernet and enter IP address which is configured in the file. Select mode as XL Series mode from drop down list. The controller should get connected to Cscape. If communications are successful, the target indicator should show the mode of the controller Target: yy(R) as shown in the as shown above in "Cscape Status Bar" on page 56. Page 62 of 174...
Page 63: Cscape Configuration
Cscape Configuration Cscape Configuration For more details refer to the Cscape Help File. An overview of configuration: 1. Start the configuration by selecting the Controller > Hardware Configure menu item. 2. If the controller 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 controller is NOT connected: a. Select Series > XL Series b. Select Device Type > XLE/XLEe or XLT/XLTe c. Select Model # > (See part number building below) Page 63 of 174...
Page 64 General I/O Configuration Page 64...
Page 65: General I/O Configuration
General I/O Configuration General I/O Configuration Built-in Digital and Analog I/O Overview Removing the Horner OCS Back Cover Digital / HSC Input Configuration Digital / PWM Output Configuration Analog Inputs Analog Outputs Built-in Digital and Analog I/O Overview The Horner OCS is a compact unit that contains high density and very versatile I/O. Using the I/O properly requires ...
Page 66: Removing The Horner Ocs Back Cover
General I/O Configuration Removing the Horner OCS Back Cover WARNING: Power, including I/O power must be removed from the unit prior to removing the back cover. Failure to do so could result in electrocution and/or damage to equipment. Some I/O configurations require jumper settings to be changed inside the Horner OCS unit. Examples of these set- tings are setting positive or negative logic on digital inputs or setting current or voltage on analog inputs.
Page 67: Digital / Hsc Input Configuration
General I/O Configuration Digital / HSC Input Configuration Horner controllers vary greatly on series and model numbers. Refer to the datasheets on the Document Search table on the Horner website. The inputs are designed to support both positive and negative input modes. For many models, the mode is set by a jumper setting and a configuration parameter in Cscape. The Model 6 does not require jumpers, and only requires a configuration parameter in Cscape. All the inputs on the unit must be configured to the same mode. In positive logic mode a positive voltage applied to the input will turn the input. The internal design of this mode is basically a resistor from the input to I/O ground. This mode is sometimes called sourcing. In negative logic mode, connecting the input to the I/O ground or zero volts will turn the input on. The internal design of this mode is basically a resistor from the input to the positive I/O voltage (usually 12 or 24V). This mode is some- times called sinking. Some of the digital inputs may support high-speed input functional such as counting or frequency measurement. Page 67 of 174...
Page 68 General I/O Configuration Digital Input Configuration Home > Hardware Configuration [select Device Type/Model#] > Local I/O Tab > I/O / Config Button > Mod- ule Setup > Digital In/HSC Select Hardware Configuration from the Home menu and ensure that the correct Device Type and Model# are selec- ted. Then select the Local I/O tab. After selecting Local I/O, select the Config button next to the I/O connector. The Module Configuration screen will appear, select the Module Setup tab. See below. ...
Page 69 General I/O Configuration The Module Setup allows a user to configure four types of I/O. NOTE: Not all controllers offer all four types. Refer to the controller's datasheet on the using Horner's Documentation Search page. Page 69 of 174...
Page 70 General I/O Configuration Select Digital In/HSC to open the Digital / HSC Input configuration dialog for a specific controller. The Active mode group box allows the user to select if inputs are active high (Positive logic) or active low (Negative logic). It is important that this setting matches the jumper settings on the hardware. The High-Speed Counters group box contains all the windows that are used to configure the four available high- speed counters on the Horner OCS. To configure a counter, the user needs to set the type, mode, and counts per rev. The type drop down includes the following options: Disabled Frequency Totalize Pulse Quadrature Marker (Only available in counter #3 if counter #1 is set to quadrature.) The mode drop-down items are set according to the type selection. The Counts Per Rev. window is enabled/dis- abled according to the type selection as well. Page 70 of 174...
Page 71: Digital / Pwm Output Configuration
General I/O Configuration Digital / PWM Output Configuration Solid State Digital Outputs Solid-state digital outputs are generally used to activate lamps, low voltage solenoids, relays, and other low voltage and low current devices. NOTE: The digital outputs used on some controllers are sourcing outputs. This means the output applies a positive voltage to the output pin when turned ON. When turned off, the output applies approximately zero volts with respect to the I/O ground. Use the Documentation Page t o view the datasheet for a specific controller for specifics on a mod- ule's I/O. The digital outputs used in the OCS have electronic short circuit protection and current limiting. While these elec- tronic protections work in most applications, some application may require external fusing on these outputs. The digital outputs in the 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. When the controller is stopped, the operation of each output is configurable. The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state. By default, digital outputs turn off. NOTE: The digital outputs feature an output fault bit. %I32 will turn on if any of the outputs experience a short circuit, over-current or the output driver overheats. Page 71 of 174...
Page 72: Relay Outputs
Fusing – External fusing is generally required to protect the relays, devices and wiring from shorts or over- loads. WARNING: T o protect the module and associated wiring from load faults, use external (5A) fuse(s) as shown. Fuses of lower current or fusing for the entire system need to be in place to assure the maximum current rating of the unit is not exceeded. WARNING: Connecting high voltage to any I/O pin can cause high voltage to appear at other I/O pins. Below is an example of Relay Fusing: Protection for Inductive Loads - Inductive loads can cause reverse currents when they shut off that can shorten the life of relay contacts. Some protective measures need to be determined by an engineer. Below you will find recommendations that will work for many applications. If you have additional questions on protection from inductive load, consult an application engineer or Horner Technical Support. Details on devices that may protect outputs can be found in the Spark Quencher Datasheet, MAN0962, which is located on the website. Output State on Controller Stop - When the controller is stopped, the operation of each output is configurable. The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state. By default, relay outputs turn off. Page 72 of 174...
Page 73: Digital Output Configuration
General I/O Configuration Digital Output Configuration Home > Hardware Configuration [select Device Type/Model#] > Local I/O Tab > I/O / Config Button > Mod- ule Setup > Digital Out/PWM Select Hardware Configuration from the Home menu and ensure that the correct Device Type and Model# are selec- ted. Then select the Local I/O tab. After selecting Local I/O, select the Config button next to the I/O connector. The Module Configuration screen will appear, select the Module Setup tab. See below. Page 73 of 174...
Page 74 General I/O Configuration The Module Setup allows a user to configure four types of I/O. NOTE: Not all controllers offer all four types. Refer to the controller's datasheet the using Horner's Documentation Search page. Select Digital Out/PWM to open the Digital / PWM Output Configuration dialogue. Page 74 of 174...
Page 75 General I/O Configuration The Q1 and Q2 group boxes allow the user to specify the operation of the multifunction outputs. PWM State On Controller Stop - Contains items that allow the user to specify how the PWM outputs behave when the controller is stopped. These items can either hold their value or default to some value when the controller is stopped. NOTE: The PWM outputs are set to the OFF state at power-up and during program download and remain in that state until the unit is placed in RUN. Output State On Controller Stop - Contains items to allow the user to specify how the remaining digital outputs behave when the controller is stopped. These items can either hold their value or default to some value when the controller is stopped. NOTE: The number of Output States on Controller Stop vary by product. Stop State - When a controller stops running ladder logic, the state of most output I/O modules can be configured. By default digital outputs turn OFF and analog outputs go to a zero output level. Outputs can be configures to hold the last state the outputs was in when the controller stopped, or it can be configured to go to a predefined state. NOTE: When a controller is in DO I/O mode the outputs are still controlled by the values in the controller's registers. NOTE: The number of Output State on Controller Stop varies by controller. See the datasheet on the Docu- mentation Page for more details. Page 75 of 174...
Page 76: Analog Inputs
General I/O Configuration Analog Inputs The analog inputs on the OCS allow voltage or current measurement from a variety of devices. The voltage or cur- rent mode is set though jumpers on the unit and settings in Cscape. Each channel can be separately configured for voltage or current mode. The analog inputs have a digital filter that can be used to filter electrical noise that may be unavoidable in some installations. The downside to digital filtering is the inputs will respond more slowly to sudden changes in the actual input. Home > Hardware Configuration [select Device Type/Model#] > Local I/O Tab > I/O / Config Button > Mod- ule Setup > Analog In Select Hardware Configuration from the Home menu and ensure that the correct Device Type and Model# are selec- ted. Then select the Local I/O tab. ...
Page 77 General I/O Configuration The Module Configuration screen will appear, select the Module Setup tab. See below. The Module Setup allows a user to configure four types of I/O. NOTE: Not all controllers offer all four types. Refer to the controller's datasheet on the Horner website's Documentation Page f or more information regarding specific models. Page 77 of 174...
Page 78 General I/O Configuration Select Analog In to open the Analog Input Configuration dialogue: The Channel x drop down windows allow the user to specify the mode for each analog input to operate. The Chan- nel x drop down windows are enabled/disabled according to which model is being configured. All of the models have the following modes available: 0..10V 0..20mA 4..20mA On the XL series, the Model 5 and Model 6 modules have more channel options. Page 78 of 174...
Page 79 General I/O Configuration Universal Analog Inputs Model 5 The universal analog inputs provide a high resolution, very flexible interface for a variety of analog inputs. T hese inputs include voltage, current, theremocouple, RTD, and millivolt. Each channel can be configured separately using jumpers and configuration settings in Cscape. Like the standard analog inputs, these inputs have a digital filter that can be used to filter electrical noise that may be unavoidable in some installations. The downside to digital filtering is the inputs will respond more slowly to sud- den changes in the actual input. Analog In for Model 5 Channels 1 & 2 0..10V 0..20mA 4..20mA 100mV PT100 D IN RTD, 1/20°C Type J Thermocouple, 1/20°C Type K Thermocouple, 1/20°C Type ...
Page 80 General I/O Configuration Model 5 Universal Analog Input Configuration 1. Select Analog In to access the Analog Input Configuration menu. 2. Select any of the Analog input types from the drop-downs by clicking the down arrow beneath each cor- responding Channel, as seen below: 3. Ensure the proper wiring is used for each of the pins on the Universal Analog Inputs as seen in the image and table below: Page 80 of 174...
Page 81 General I/O Configuration Table for Model 5 Universal Wiring J3 Connector for Universal Wiring TC (1+) or RTD (1+) or 100mV (1+) TC (1-) or RTD (1-) or 100mV (1-) TC (2+) or RTD (2+) or 100mV (2+) TC (2-) or RTD (2-) or 100mV (2-) 10V or 20mA OUT (1) 10V or 20mA OUT (2) Common 0-20mA IN (1) 0-10V IN (1) Common 0-20mA IN (2) 0-10V IN (2) Common Page 81 of 174...
Page 82 General I/O Configuration Universal Analog Inputs Model 6 The Universal Analog Inputs on the Model 6 IO board are unique from other Horner XL-series input/output cards in that they are configurable through the module configuration instead of having to change jumper settings in order to setup the input type. Analog In for Model 6 Channels 1-6 0..10V 0..20mA 4..20mA Disable 0-60mV PT100 D IN RTD, 1/10°C PT1000 D IN RTD, 1/10°C Type J Thermocouple, 1/10°C Type K Thermocouple, 1/10°C Type N Thermocouple, 1/10°C Type ...
Page 83 General I/O Configuration 3. Ensure the proper wiring is used for each of the 3 pins A , B, and C on the Universal Analog Inputs as seen in the reference image below: Page 83 of 174...
Page 84 General I/O Configuration Scaling Analog Inputs & Examples To access the Advanced Math Scaling function, select Home > View > Project Toolbox. This will open a side bar, and then select Advanced Math > Scale. Example 1 The Cscape Scale function, found in the Advanced Math functions, allows for very easy conversion of the raw input value into a meaningful reading. For example, a pressure transducer may be specified as a 4-20mA signal to signify a 0-2000 psi pressure reading. W ith the analog channel set to the 4..20mA range, the raw analog input value, which is in INT format ranges from 0 to 4mA to 32000 for 20mA. Use the Scale function to obtain an Integer pressure read- ing using the 0-32000 raw input range and the sensor’s 0-2000psi output range. Example 2: If readings with fractions are required, the raw Integer input value must first be translated in REAL, or Floating Point Format, see note below. . The Cscape INT-to-REAL Conversion function may be used to convert the raw input value from INT to REAL format in an intermediate memory location. The SCALE function, specified as REAL type, may be used to scale the converted raw value into a reading that supports digits beyond the decimal place, i.e. 475.25psi. Page 84 of 174...
Page 85: Analog Outputs
General I/O Configuration Analog Outputs NOTE: Refer to the datasheet for details on jumper settings. The analog outputs on Horner OCS devices provide high resolution voltage or current outputs. The voltage or cur- rent selection is controlled with jumpers and configuration settings in Cscape. NOTE: Each channel can be separately configured for voltage or current mode. When the controller is stopped, the operation of each output is configurable. The outputs can hold the state they were in before the controller stopped or they can go to a predetermined value. By default, analog outputs are set to a value of zero (0). The following figure illustrates the Analog Output Configuration dialog. To open the I/O configuration dialogs, select Controller > Hardware Configuration > Local I/O > Config > Module Setup. 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 con- troller is stopped. The Output Mode group box allows the user to select the operating modes for each of the analog outputs. The modes include the following: 0..10V ...
Page 86 High Speed I/O (HSC & PWM) Page 86...
Page 87: High Speed I/O
High Speed I/O High Speed I/O High Speed Counter (HSC) Functions Frequency Totalize Pulse Period Measurement Quadrature HSC Register Map for XLE & XLT Pulse Width Modulation (PWM) Functions HSC Output Overview XLE & XLT In addition to the compliment of simple analog and digital I/O, several of the XLE/XLT I/O modules support High Speed Counting (HSC) I/O functions and may also support Pulse Width Modulation (PWM) Output functions. ...
Page 88: Totalize
High Speed I/O Totalize In totalize mode, the accumulator is simply incremented each time the input transitions in a specific direction. Total- ize mode is configurable to specify the edge (rising or falling) on which the accumulator is incremented. Three different options are available to reset the current count: Configured reset value - When configuring the Totalize function, a value may be specified under the Counts per Rev column. When the totalizer accumulator reaches this value - 1, the accumulator will reset to zero on the next count. Specifying zero for this value allows the totalizer to count through the full 32-bit range before resetting. Ladder control - Setting registers %Q17-20 reset HSC1-4 (respectively) with no additional configuration. When these registers are asserted, the associated totalizer accumulator is reset and held at zero (level sens- itive). Direct digital input control (HSC1 and HSC2 only) - HSC3 (%I11) and HSC4 (%I12) may be configured as hardware digital reset signals for HSC1 and HSC2 (respectively). To enable these inputs as reset signals, specify the type as Totalize Reset (NOTE: The corresponding Totalize HSC must be previously configured before this option is available). The direct digital reset controls are edge sensitive with the edge polarity con- figurable. Maximum direct digital reset latency is 100μs. ...
Page 89: Pulse
High Speed I/O Pulse In pulse mode, the high-speed input can measure the width or period of a pulse stream in one of four modes and provides a continuous indication of the last sampled value. Width High 1μs Counts – In this sub-mode the accumulator v alue will contain the number of 1μs counts the pulse is high. Width Low 1μs Counts - In this sub-mode the accumulator value will contain the number of 1μs counts the pulse is low. 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. Period Rising Edges 1μs Counts – In this sub-mode the period of the input signal is reported in one (1) μs units. The period measurement will start on the rising edge of the input. Period Falling Edges 1μs Counts – In this sub-mode the period of the input signal is reported in one (1) μs units. The period measurement will start on the falling edge of the input. Page 89 of 174...
Page 90: Quadrature
High Speed I/O Quadrature Two HSC inputs are consumed for each of the two possible Quadrature counters. For example, selecting quad- rature mode for HSC 1 will use HSC inputs 1 and 2, which correspond to A and B quadrature signals. Therefore, HSC 1 and 3 may be configured for quadrature input. Alternately, HSC 3 may be configured to reset HSC1 (quad- rature) count on a marker input 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. Quadrature inputs are typ- ically used for reporting the value of an encoder. Two modes are available for quadrature that select whether the accumulator counts up or down when the phase of input 1 leads input 2. Check your encoder’s documentation to determine the output form it uses or try both modes to determine if the encoder counts up when expected. Using the above waveforms and a HSC input configuration of “Quadrature” - “1 leads 2, count up,” the accumulator will count up when 1 is rising and 2 is low, 1 is high and 2 is rising, 1 is falling and 2 is high, and when 1 is low and 2 is falling. This results in 4 counts per revolution. So in order to determine the number of cycles, the accumulator would have to be divided by 4. Three different options are available to reset (or set) the current count: Configured Counts per Rev Value - When configuring the quadrature function, a value may be specified under the Counts per Rev column. When rotation produces an increasing count, the quadrature accumulator resets to zero on reaching the Counts per Rev count. Alternately, when rotation produces a decreasing count, the quadrature accumulator is set to Counts per Rev – 1 on the count following zero. Specifying zero for this value allows the totalizer to count through the full 32-bit range before resetting. For example, if your encoder outputs 1024 counts per revolution, the value of 1024 can be entered into the configuration for Counts per rev. This will result in a counter that produces counts in the range of 0 to 1023. Ladder Control - Setting registers %Q17 or Q19 resets quadrature (HSC) 1 or quadrature (HSC) 3 (respect- ively) with no additional configuration. Setting registers %Q18 or Q20 sets quadrature (HSC) 1 or quadrature (HSC) 3 (respectively) to Counts per Rev – 1. Direct Digital Input Control (HSC3) [Marker] - When HSC input 1 and 2 are used for quadrature inputs, an ...
Page 91 High Speed I/O Asynchronous modes ignore the quadrature inputs and reset the quadrature accumulator to zero on the con- figured edge (rising, falling or both). These are the most common settings used. When configuring, asynchronous mode selections are prefixed with the word Async. Synchronous modes synchronize the reset (or set) to the selected quadrature input and the selected marker polarity. Figure 11.1 below indicates which mode to select based on the markers timing diagram. Consult the doc- umentation provided with your encoder to determine the marker pulse timing. NOTE: The Marker input is sampled within 50μs of the associated quadrature edge. It is left to the user to determine if this meets the time constraints of the measured drive. NOTE: If the Marker input pulse consecutively spans more than one of the specified edges, quadrature-decoding operation is unpredictable. *While not displayed in this figure, modes for low level (inverse logic) are also supported for each state. The accumulator is reset to zero on the specified edge if rotation is clockwise (as shown in figure above). However, if rotation is reversed, the accumulator is alternately set to Counts per rev – 1 on that same physical edge. When dir- ection is reversed, that same physical edge is seen (by the internal decoder) as having the opposite edge polarity as shown below. Page 91 of 174...
Page 92: Hsc Register Map For Xle & Xlt
Falling High Low, Reset on 2 falling Clockwise Rising CPR - 1 “ Counter Falling HSC Register Map for XLE & XLT HSC Register Map Register Frequency Totalize Pulse Quad %AI5-6 HSC1 (function) A ccumulator Quad 1 Acc %AI7-8 HSC2 (function) A ccumulator %AI9-10 HSC3 (function) ...
Page 93: Pulse Width Modulation (Pwm) Functions
Pulse Width Modulation (PWM) Functions On units that support the PWM, two dedicated outputs are available that can be configured for one of four modes of operation. Those modes are Normal, PWM, HSC (count = PV) and Stepper. Normal - When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives that respective output. Pulse Width Modulation (PWM) Functions - When either Q1 or Q2 is configured for PWM, the PWM function drives that respective output. Both PWM channels may be individually enabled; however, when both PWM outputs are enabled, both share the same output frequency (with the low going pulses synchronized). Otherwise, each PWM’s pulse width can be independently adjusted. The PWMs require three parameters (%AQs) to be set for operation. These parameters may be set at run-time. The register set and prescale calculation differ depending upon the XLE/XLT hardware being used, hardware revs A-R use the following resisters and scaling: Prescale Count (Revision A-R) for Gen 1 - The prescale (%AQ5-6) count sets the resolution of the internal counter used for generating the PWM output. The (prescale count + 1) is a divisor applied to a 16MHz clock that drives the internal PWM counter. For the highest resolution PWM output, this value should be set as low as possible (0 provides a 1/16 micro second resolution). Both the Period and Duty cycle (pulse width) are based on counts of the internal PWM counter. The frequency of the PWM output is calculated using the following formula: ...
Page 94 High Speed I/O PWM Functions Register Map PWM Functions Register Map Register Stepper %AQ1 Start Frequency HSC1 PWM1 Duty Cycle ( 32-bit) Preset Value %AQ2 Run Frequency %AQ3 HSC2 Accel Count PWM2 Duty Cycle ( 32-bit) Preset Value (32-bit) %AQ4 %AQ5 PWM Prescale Run Count (32-bit) (32-bit) %AQ6 %AQ7 PWM Period Decel Count ...
Page 95 High Speed I/O Period Count This value (%AQ7-8) sets the period of the output signal by specifying the number of internal PWM counter counts before the cycle is reset (larger count results in a smaller frequency). The duration of each count is determined by the pre-scaler value. This parameter affects the Period of both PWM outputs. See the previous formula to see how the pre-scale and period counts create an output frequency. For example, set- ting the PWM for 1μs resolution (pre-scale=15), and a period count of 20,000 would result in a 50Hz output. Duty Cycle Count This value (PWM1: %AQ1-2, PWM2: %AQ3-4) sets the width of the output signal by specifying the number of internal PWM counter counts that the output is maintained high. The duration of each count is determined by the pre-scaler value. Each PWM channel has its own duty cycle count parameter. Setting the period count to 1000 and the duty cycle count to 500 results in a duty cycle of 50 percent. Changing just the duty cycle count to a value of 250 results in a duty cycle of 25%. At controller power-up or during a download, the PWM output is maintained at zero until both the Period (count) and the Duty cycle (count) are loaded with non-zero values. When the controller is placed in stop mode, the state of the PWM outputs is dependent on the PWM State on Controller Stop configuration. This configuration allows for either hold-last-state or specific prescale, period and duty cycle counts. Specifying zero for either the period or duty causes the PWM output to remain low during stop mode. NOTE: The nominal output driver turn-on-time delay (to reach 50% output) is 25μs on Models 3-5. Therefore, this limitation should be considered when determining both the minimum pulse width and the duty cycle accuracy of the application. Page 95 of 174...
Page 96 AQ3 – PWM2 Duty C ycle AQ4 – Reserved AQ5 – P re-Scale(DWord) AQ5 – PWM1 P re-Scale AQ6 – PWM2 P re-Scale AQ7 – Period(DWord) AQ7 – PWM1 Period AQ8 – PWM2 Period 1. When an old XLE/XLT file is auto configured to a new XLE/XLEe or XLT/XLTe file, then the old formula and registers are taken and firmware will do the required adjustments for the PWM to function normally. 2. When a new XLE/XLT file is created, then the new formula will be applied and the configuration must be as per the new register set. PWM Wave Output Form PWM Output Waveform Table Rise Time 150ns Max Fall Time 150ns Max...
Page 97: Hsc Output
High Speed I/O HSC Output When using I/O models equipped with solid-state o utputs, the first two outputs may be used in conjunction with the first two High-Speed Counter inputs when those inputs are set to ‘Totalize’. When the HSC accumulator matches or exceeds the preset value, these configuration options allow the output to turn ON, turn OFF, toggle, or pulse for a configurable amount of time. The HSC Outputs function by comparing an HSC Input accumulator to its configured Preset value. With the Output Pulse option, a Pulse Time value is configured to determine the ON time. The location of these values may be found in the HSC function register map. Output ON: Starts with LOW. When the HSC accumulator becomes greater than or equal to the Preset value, the output will turn ON. Otherwise, it is turned OFF. Output OFF: Starts with HIGH. When the HSC accumulator becomes greater than or equal to the Preset value, the output will turn OFF. Otherwise, it is turned ON. Output Toggle: When the HSC accumulator becomes equal to the Preset value, the output will toggle, either from OFF to ON, or from ON to OFF. Output Pulse: When the HSC accumulator becomes equal to the Preset value, the output will turn ON and remain ON until the configured pulse time expires, then turn OFF. If another match occurs during the count- down to turn the output off, the pulse countdown restarts and the output remains ON until the countdown is complete. NOTE: T he output pulse time resolution is 50μ. NOTE: The state of outputs %Q1 and %Q2 are not reflected in their respective registers when selected for oper- ation other than ‘Normal’.
Page 98 High Speed I/O The Accumulator When the counter accumulator matches the match value stored in %AQ registers, the HSC output will be enabled. The firmware will then wait based on the configurable microsecond pulse width. After the elapsed time, the output will be turned off. If another match happens while the countdown to turn off the output, then the pulse countdown will restart but the output will not change state until the countdown happens. When HSC1 accumulator value is equal to AQ1-2 UDINT value, then the Output Q1 becomes high for AQ27-28 UDINT value microseconds. NOTE: Resolution for the pulse width will be limited to 50 microseconds on the XLE/XLT hardware. NOTE: a. Match value is stored in register AQ3-4 UDINT for HSC2. b. AQ29-30 UDINT is Pulse width value for HSC2 Example 1: Turn HSC1 Output ON if HSC accumulator 1 exceeds a count of 100,000. Assuming HSC #1 is already configured to ‘Totalize’: Select ‘HSC1 Output’ and the ‘Output ON’ option Load UDIINT value of 100,000 into %AQ1-2 HSC1 Preset value Download the program and input pulses to HSC #1 Observe UDINT %AI5-6 HSC1 Accumulator value for the accumulated count. When %AI5-6 HSC1 Accumulator reaches and exceeds the Preset value, the output Q1 will turn ON. The output Q1 will remain on until HSC1 is cleared with the %Q17 bit.
Page 99: Stepper Function
Step Function - A signal that has a zero (0) value before a certain instant of time and a constant nonzero value immediate after that instant. The Stepper requires five parameters (%AQ) to be set for operation. These parameters may be set at run-time but are ‘latched’ when the stepper is commanded to start: Stepper Parameters This value (%AQ1) sets the frequency for the first cycle during the acceleration phase and the fre- quency of the last cycle during the deceleration phase. When an acceleration or deceleration Start Fre- count is specified, the Start Frequency must be greater than zero (0) and must not exceed the run quency frequency or an error is generated. (cycles per second) NOTE: For XLE/XLEe and XLT/XLTe controllers, the Start Frequency should be a minimum of 20Hz or more. Run Fre- This value (%AQ2) sets the frequency for the last cycle during the acceleration phase, the con- quency sistent frequency during the run phase, and the frequency of the first cycle during the deceleration (cycles per mode. The Run Frequency must be greater than zero (0) and must not exceed 5000 cycles/sec. second) or an error is generated. This value (%AQ3-4) sets the number of cycles to occur within the acceleration phase. The fre- quency of the cycles within this mode will vary linearly between the specified Start and Run fre- Acceleration quency. The Accel count must not equal 1 or an error is generated. Setting this value to zero (0) Count disables this phase. ...
Page 100 High Speed I/O The stepper provides two Boolean r egisters to provide stepper status: Boolean Registers A high indication on this register i ndicates the stepper s equence can be started ( i.e. not currently Ready/Done busy) and also when the move is completed. A high indication on this register i ndicates that one of the analog parameters specified above is Error invalid or the s tepper a ction was aborted before t he operation was complete. This register is cleared on the next start c ommand if the error was corrected. The stepper requires one discrete register to control the stepper action. Setting this register starts the stepper cycle. This register must remain set to complete the entire cycle. Clearing this register before the cycle is complete aborts the step sequence and sets the error bit. NOTE: Setting the PLC mode to stop while the stepper is in operation causes the stepper output to immediately drop to zero and the current stepper count to be lost. NOTE: The stepper output level may cause damage or be incompatible with some motor drive inputs. Consult drive documentation to determine if output level and type is compatible. ...
Page 101 Serial Communications Page 101...
Page 102: Serial Communications
Serial Communications Serial Communications Port Descriptions Serial Port Wiring Dip Switches RS-485 Termination RS-485 Biasing Cscape Programming via Serial Port Ladder-Controlled Serial Communication All XLE/XLT models provide two serial ports, which are implemented with 8-pin modular RJ45 connectors and are labeled MJ1 and MJ2. The MJ1 serial port is normally used for XLE/XLT programming by connecting it to the COM port of a PC running Cscape. In addition, both MJ1 and MJ2 can be used for application-specific communication, using a variety of standard data exchange protocols. Port Descriptions The MJ1 serial port contains both a half-duplex RS-485 interface and an RS-232 interface with RTS/CTS hand- shaking. NOTE: MJ1 shares its serial port with the optional COM module, so when an optional Modem COM or other module is installed and active, the MJ1 connector is inactive. The MJ2 serial port contains both a full-duplex RS-485 interface and an RS-232 interface with no handshaking. ...
Page 103: Serial Port Wiring
Serial Communications Serial Port Wiring MJ1 Wiring RS-232 with full handshaking or RS-485 half-duplex RS-485 termination via switches; biasing via software MJ1 Pins SIGNAL DIRECTION 8 TXD 7 RXD 6 0V GROUND 5 +5V @ 60mA 4 RTS 3 CTS 2 RX-/TX- IN/OUT 1 RX+/TX+ IN/OUT MJ2 Wiring ...
Page 104: Dip Switches
Serial Communications Dip Switches DIP Switches NAME FUNCTION DEFAULT MJ1 RS-485 Termination ON = Terminated MJ2 RS-485 Termination ON = Terminated Bootload Always Off The DIP switches are used to provide a built-in termination to both the MJ1 port and MJ2 port if needed. The ter- mination for these ports should only be used if this device is located at either end of the multidrop/daisy- chained RS-485 network. Page 104 of 174...
Page 105: Rs-485 Termination
RS-485 Biasing RS-485 biasing passively asserts a line-idle state when no device is actively transmitting, which is useful for multi- drop RS-485 networking. Both serial ports allow internal 390 Ω RS-485 bias resistors to be switched in, pulling pin 1 up to 3.3V and pin 2 down to ground. The Set Serial Ports item in the System Menu chapter can be used to enable RS-485 biasing. Also, an application graphics screen that writes to %SR164 can do the same thing. Setting %SR164.1 enables MJ1 bias- ing and setting %SR164.2 enables MJ2 biasing. If biasing is used, it should be enabled in only one of the devices attached to the RS-485 network. Cscape Programming via Serial Port If a PC COM port is connected to the XLE/XLT MJ1 serial port, Cscape can access the XLE/XLT for programming and monitoring. Ladder-Controlled Serial Communication Using Serial Communication function blocks, both MJ1 and MJ2 support Generic, Modbus Master and Modbus Slave Protocols. In addition, external modems can be connected and accessed using Init, Dial, and Answer Modem function blocks. It is possible to load the program and monitor data via the USB 2.0 slave port on XLE/XLT Rev T and later. To load via USB, configure the communications port in Cscape as follows, the unit must be connected via the USB mini- USB port to the PC or laptop: 1. Select Tools from the Toolbar 2. Select Applications Settings > Communications.
Page 106 Communications Page 106...
Page 107: Can Communications
CAN Communications CAN Communications CAN Connector CAN Termination Cscape Programming via CAN Some XLE/XLT models p rovide a CAN networking port, which is implemented with a 5-pin connector, labeled CAN1. The CAN1 port allows the XLE/XLT OCS to exchange global data with other OCS/RCS controllers and to access remote Network I/O devices (SmartStix, SmartBlocks and SmartRail Modules). The CAN1 port also supports pass- through communications for programming multiple OCS controllers over the CsCAN network. The p ort also allows the XLE/XLT to exchange global data with other OCS controllers and to access remote Network I/O devices. The XLE/XLT CAN 1 port implements the ISO 11898-2 physical layer and the CAN 2.0A data link layer standards. Also, since the CAN 1 port is powered by an internal isolated power supply, external CAN power is not required. CAN Connector Use the CAN Connector when using CsCAN network. Solid/Stranded Wire: 12-24 awg (2.5-0.2mm). Strip Length: 0.28” (7mm). Locking spring-clamp, two-terminators per conductor. ...
Page 108: Can Termination
CAN Communications CAN Termination Termination: 121Ω, 1%, 1/4watt or greater wattage is recommended. 120 ohm, 5%, 1/4 Watt or greater wattage may be used in most cases. Two termination resistors total should be used between CN_H and CN_L, one at each physical end of the network. Cscape Programming via CAN The CAN 1 port supports CsCAN Programming Protocol. If a PC has a CAN interface installed (via USB), and the PC CAN port is connected to the XLE/XLT CAN 1 port, Cscape can access the XLE/XLT for programming and mon- itoring. In addition, the XLE/XLT supports single-point-programming of all XLE/XLT and other OCS devices that are con- nected to a CAN network. If the PC COM port is connected to the XLE/XLT programming port the XLE/XLT can act as a pass-through gateway allowing Cscape to access all XLE/XLT and OCS devices that are attached to the CAN network. Refer to " Serial Communications" on page 102 f or more details. Ladder-Controlled CAN Communication - Using Put and Get Network Words function blocks, the CAN 1 port can exchange digital and analog global data with other XLE/XLT or OCS/RCS devices (nodes) attached to the CAN network. In addition, Put and Get Network Heartbeat function blocks allow nodes on the CAN network to regularly announce their presence and to detect the presence (or absence) of other nodes on the network. Using CAN for I/O Expansion (Network I/O) Connecting Network I/O devices (SmartStix Modules) to the XLE/XLT CAN 1 port, allows the XLE/XLT I/O to be eco-...
Page 109 Ethernet Communication Page 109...
Page 110: Ethernet Communication
Protocol / Feature Protocol / Feature Description ICMP (Ping) Internet Control M essage Protocol EGD Ethernet Global D ata SRTP Slave (90-30 S ervice Request) Service Request T ransfer Protocol CsCAN TCP Server Horner APG CsCAN o ver Ethernet (for Cscape to OCS programming) Modbus Slave Modbus over E thernet Ethernet / IP ODVA CIP over E thernet FTP (File Server) File Transfer P rotocol ASCII Over TCP/IP ASCII Data over E thernet ...
Page 111: Ethernet Module Configuration
Ethernet Communication Ethernet Module Configuration NOTE: The following configuration is required for all applications regardless of the protocols used. Additional con- figuration 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 Hard- ware Configuration dialog. Page 111 of 174...
Page 112 Ethernet Communication Click the Config button to the right of LAN1, revealing the Ethernet Module Configuration dialog: IP Address: Enter the static IP Address for the Ethernet Module being configured. NOTE: IP Addresses are entered as four numbers, each ranging from 0 to 255. These four numbers are called octets and they are always separated by decimal points. Net Mask: Enter the Net Mask (sometimes called Subnet Mask) being used by all nodes on the local net- work. Typical local networks use Class C IP Addresses, in which case the low octet (rightmost number) is used to uniquely identify each node on the local network. In this case, the default Net Mask value of 255.255.255.0 should be used. Gateway: Enter the IP Address of a Gateway Server on the local network that allows for communication out- side of the local network. To prevent the Ethernet Module from communicating outside the local network, set the Default Gateway IP Address to 0.0.0.0 (the default setting). Status Register: Enter an OCS Register reference (such as %R100) to indicate which 16-bit OCS register will have the Ethernet Status word written to it. Table 12.3 shows how this register value is formatted and explains the meaning of each bit in the Status Word. Page 112 of 174...
Page 113 Ethernet Communication Ethernet Status Word Register Format High Byte Low Byte Bit 16 Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Link TCP Connections Status Values Status Bit Status Indication Minimum Maximum Reserved Always 0 Link Duplex (Auto-Negotiated) 0 = ...
Page 114: Ethernet Configuration - Ip Parameters
Ethernet Communication Ethernet Configuration - IP Parameters For primary operation, the IP address, Net Mask, and Gateway should be set in the LAN Config of the Cscape Hard- ware 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. The following points on IP parameter configuration should be considered. IP Parameters in Non-Volatile RAM: The IP parameters of the Cscape LAN Config are written to non-volatile RAM on power down. I P parameter settings made in the System Menu are not written to non-volatile RAM. Any IP parameters settings made in the system menu will be lost after cycling power to the unit. It will revert back to the last downloaded Cscape LAN Config that was loaded into non-volatile RAM at power down. “Cscape LAN Config”/ “Get Settings from” Configuration: When ‘Get settings from’ is set to Configuration, the IP parameters specified under ‘Default Settings’ is used after downloading to the controller. The IP para- meters are represented in System Menu / Set Networks and can be edited. However, any edits made from System Menu / Set Networks is not retained through a power cycle. After power cycle, the unit reverts to the last downloaded Cscape LAN Config that was loaded into non-volatile RAM at power down. “Cscape LAN Config” / “Get Settings from” Register: When ‘Get settings from’ is set to Register, the IP para- meters are retrieved from the OCS registers assigned in LAN Config. Configured registers must be pop- ulated with the desired IP parameters. The IP parameters are represented in System Menu > Set Networks. The IP parameters cannot be edited from System Menu > Set Networks while the unit is in run mode. The IP parameters always fol- low the values in the registers unless the OCS unit is placed in idle mode. Then the IP parameters can be edited in System Menu > Set Networks. When the OCS is placed back into run mode, it reverts to the registers for IP parameters. Ethernet Module Protocol Configuration The Protocol Support area contains a list of all the protocols supported by the platform being configured. To activate ...
Page 115 Downloadable Protocols Page 115...
Page 116: Protocol Configuration
Protocol Configuration Protocol Configuration Overview Protocol Device Driver Selection Network Configuration Device List and Device Configuration Scan List 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. Remote devices that communicate serially must do so under certain rules of data transfer known as a protocol. Many device manufactures have created their own protocol for communications with their device. F or a OCS to com- municate with a specific device, it must be loaded with the corresponding serial communications protocol device driver that supports that protocol. A limited number of protocol device drivers are packaged with the Cscape distribution; however, as more are developed, they will be made available as add-on packages. A device driver is typically distributed as a Windows module, which contains the configuration menus, help files and the target executable driver code. W hen updating device drivers, an install routine loads the device driver to the Cscape directory structure and makes that driver avail- able to Cscape applications. Once installed, the protocol device driver can be included as part of a Cscape application by selecting it from a list of installed protocol device drivers and attaching it to the desired serial port (Home >...
Page 117: Protocol Device Driver Selection
Protocol Configuration These basic types are also subdivided into read or write operations. For polled operations, a Read operation only reads from a remote device. L ikewise a Read/Write operation continuously reads from the remote device unless the target OCS register value changes from one ladder scan to another. In this case, the new OCS value is written to the target device. For triggered operations, only a read or write action is available. When downloaded to the OCS , the Scan List is scanned sequentially to generate data transactions with the remote device. T his transaction scanning can be on a continual basis (automatic) or controlled from ladder logic (manual) once a complex connection is created via a program. The specific transaction-scanning mode is selected from the Network Config menu. Protocol Device Driver Selection From the Cscape Home > Protocols m enu, select the port drop-down box to select a protocol device driver. A ll pro- tocol device drivers currently loaded in Cscape are displayed in the drop down selection along with their version numbers. A selected protocol can be removed by selecting None from the drop-down selection. S ome OCS models can be limited in the number of ports or number of protocol device drivers that can be selected. O nce a protocol is selected, the Network, Devices and Data (Scan List) must be configured through corresponding dialogues access- ible through the respective buttons (Network, Devices and Scan List).
Page 118: Network Configuration
Protocol Configuration Network Configuration Network Configuration provides the required parameters to configure the network. Each protocol is different and may not require the entire Network Config field. Please refer to the table below for the options in the Network Config field. Page 118 of 174...
Page 119 Protocol Configuration Network Protocols Baud Rate, Data Bits, These field define the bit level transfer over the serial port. Stop Bits, Parity None – No h andshake lines are used Multidrop F ull – Rx remains active while Tx is occurring. Handshake Multidrop H alf – Rx is shut off while Tx is occurring. Radio M odem – Wait for CTS acknowledgment before transmitting (legacy r adio modem support). Protocol If a driver supports multiple protocols, it is selected here, ( i.e. Modbus supports RTU or ANSI). Mode Specifies if port operates in RS232 or RS485 mode. Retries Specifies number of times a transaction is retried on a failed r esponse. Timeout Specifies the amount of time for a device to wait for a valid r esponse. Update Interval – ...
Page 120: Device List And Device Configuration
Protocol Configuration Device List and Device Configuration Device List This configuration list is reached from the Device button on the Protocol Config screen and provides a list of the con- figured devices on the Network. D evices must be created and exist in this list before corresponding Scan List entries can be created for this device. T ypically, the number of entries is limited to 128 devices. Add - Opens the Device Config dialog to add a new device to the list. Delete - Remove selected device from list (all corresponding Scan List entries are also removed). Config - Invoke the Device Config dialog for the currently selected device. T his can also be accomplished by double-clicking a device entry. Mapping - Invoke the Scan List limiting the entries displayed for the selected device. Page 120 of 174...
Page 121 Protocol Configuration Device Configuration This configuration is reached from the device list when adding or modifying an existing device. W hile each protocol is somewhat different and can contain protocol specific field, all protocols typically support at least: Device Name - Specifies a tag name for this device. T his tag name is used in the Data Mapping con- figuration to identify this device. T his allows device addresses to be modified without the need to update all associated Data Mapping entries. Device ID - Specifies the target device communications ID or station address. Swap Words on 32-bit Data - I f a Scan List e ntry is configured to transfer 32-bits and this option is checked, the high and low 16-bit values are swapped when transferred between the target and OCS. Disable Device - From Cscape 9.90 SP3 and firmware 15.40 onwards, disable device feature has been added in protocol device configuration. This option is used to disable a particular slave configured in the net- work. Single bit register has to be configured to use this function. Setting the bit high disables the slave and OCS will not send any serial ( TCP for ethernet protocols) packets only to this slave until the bit is high. Set- ting the bit low enables the communication with the slave again.
Page 122: Scan List
Protocol Configuration Scan List This configuration list is reached from the Scan List b utton on the Protocol Config screen or the Mapping button on the Device List screen and provides a Scan List of the Data Mapping entries. T o transfer data between the OCS and remote target, a Scan List must be created that defines each transaction. E ach mapping entry (transaction) con- tains the source and destination registers, the number of consecutive registers transferred, the direction of the trans- fer and what triggers the transfer. Typically, the number of entries is limited to 512. NOTE: The order of the Scan List is the order in which the transactions occur. S ort functions are provided to change the order of the list. ...
Page 123 Protocol Configuration Menu Edit > Copy All - Copies Scan List to clipboard in a tab delimited format suitable for pasting into an applic- ation like Microsoft Excel. Edit > Paste - Loads Scan List from clipboard. P asted items are added to the scan list even if they are duplic- ates. View > Toggle All Name View - Expands Scan List such that each point and corresponding local name is displayed. Sort Scan List b y different criteria. T he firmware will scan the devices based on the order they are displayed or sorted. T here are four ways to sort the scan list: a. By Local Address – Sorts the list by local register address in increasing order. b. By Target Address – Sorts the list by target register address in increasing order. c. ...
Page 124 Protocol Configuration Data Mapping Configuration (Scan List Entry) Target Device Name - Selects the target device (by tag name) to use for this transaction. O nly those device entries previously created from the Device Config menu are available. Device Register - Specifies the target device’s register to use for this transaction. T his designation is target- specific. T he configuration menu displays an error if a specified address is unacceptable. G enerally, the data type of the local (OCS ) register must match the data type of the device register. ...
Page 125 Protocol Configuration types, only the local register(s) that change in value are written. M ore specifically, only one write trans- action occurs per scan per mapping entry for the register or consecutive sub-group of local registers that changed in value. D epending on the protocol, the number of points written with that write trans- action are limited either to one or the number of consecutive points that changed value. d. Therefore, if several local registers (specified in a single mapping entry) change in value prior to a transaction scan, it takes SEVERAL transaction scans to complete all the write operations.
Page 126 User Interface Page 126...
Page 127: User Interface
Using Editable Screen Objects Ladder Based Screen Navigation Alarms Screen Saver Screen Brightness This chapter presents the user interface (or operator view) of the XLE/XLT and some of the model specific char- acteristics of the XLE/XLT 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. Screen Navigation The screen navigation on the XLE/XLT is quite flexible. Basic methods will be described here. C ontrol programming can be used to create complex screen navigation techniques. One form of screen navigation is the Jump Screen graphics object. This object is typically tied to a soft key (One of the four keys to the sides of the display for the XLE and at the bottom of the screen for the XLT). Pressing the soft key will switch to the screen that is programmed. XLE Typical Screen Jump Object XLT Typical Screen Jump Object Screen jumps can also be triggered on other keys or based on control logic for more advanced applications. To allow the operator to change screens, a screen jump object is generally used. T his object may be visually rep- resented as a button (responding to touch) or remain invisible and logically tied to an OCS register. An optional sys- tem ICON may be configured for display along with the legend, which aids in identifying the object as one that causes a screen change.
Page 128: Using Editable Screen Objects
User Interface Using Editable Screen Objects When a screen contains editable objects, one of the objects will be selected by default. Selected objects will be out- lined with a dotted line. The arrow keys can be used to navigate the editable objects and allow selection of an object to edit. When the object to be edited is selected press the Enter button. This enters the objects editing mode. The most common editable object is the numeric object. The value chosen by the operator cannot exceed the minimum or maximum set by the user program. If the user tries to exceed the maximum point or enter a value below the minimum point, the value will not change. NOTE: If the XLE/XLT displays >>>>>> in a numeric field, the value is too big to display in the field or is above the maximum for an editable field. If the XLE/XLT displays <<<<<< in a numeric field, the value is too small to display or is below the minimum for an editable field. XLE Specific - When in edit mode, a cursor appears on one digit of the editable field. Use the direction keys ← and → to move the cursor to the desired position. Use the ↑ and ↓ keys to increment or decrement the digit or enter the number/data with the alphanumeric keys. XLT Specific - The most common editable object is the numeric object. To edit, touch the object and the pop-up keypad will appear to allow editing of the value. 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. This is designed to show alarm conditions or to display other ladder-detected events. When the text coil is de-energized, the previous screen that was being viewed before the alarm is returned. The switch display coil switches to the associated screen when it is energized. Once it is de-energized the screen ...
Page 129: Alarms
User Interface Alarms Alarm presentation to the operator is highly configurable and beyond the scope of this document to describe fully. The alarm object is generally used to enunciate alarms to the operator. For more information, refer to the Graphics Editor Help File in Cscape. This section presents a typical con- figuration thereby providing an introductory description on what the operator should expect. To open the Alarm Configuration dialog, click on the Graphics Editor icon in the menu tool bar. Then select Config > Alarm from the tool menu bar to open the Alarm Configuration dialog. Page 129 of 174...
Page 130 User Interface To view, acknowledge, and/or clear alarms, the operator must access the alarm viewer. This is accomplished by selecting an alarm object. When accessed, the alarm object is displayed as pop-up alarm viewer dialog similar to that shown in Figure 14.5. 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. Once view operations are complete, simply touch the Esc button to remove the pop-up alarm viewer. NOTE: OCS registers %SR181 and %SR182 are available for ladder use, which indicate presence of unac- knowledged or acknowledged alarm (respectively). The screen designer may implement these registers to switch screens or activate the beeper to attract the operator’s attention. Page 130 of 174...
Page 131: Screen Saver
User Interface Screen Saver The XLE/XLT screen backlight life remains sufficiently bright for five (5) years. It will dim to 70% brightness if it is left on continuously for five (5) years. If the application does not require interaction with the OCS 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 activity on the screen. When the screen saver shuts off the backlight, any key or button reactivates the backlight. It is possible for the application to temporarily disable the screen saver by generating a positive transition to %SR57.16 (coil only) at a rate faster than the screen saver timeout value. This may be desired while waiting for alarm acknowledgment. NOTE: The backlight life can be extended by dimming or powering off the backlight. Screen Brightness The XLT provides a feature that allows screen dimming for night operation. To enable this feature, the application must access and control system register %SR57 (Display Backlight Brightness). Screen brightness is continuously variable by driving %SR57 through the range of 100 (full bright) to 0 (full off). It is left to the screen designer on if and how to present a Screen Brightness control to the user. NOTE: Only the XLT offers a screen dimming function. NOTE: The backlight life can be extended by dimming or powering off the backlight. Page 131 of 174...
Page 132 Removable Media Page 132...
Page 133: Removable Media
Removable Media (RM) Function Blocks in Cscape Filenames and Function Blocks System Registers used with RM microSD Cards All XLE/XLT models provide a Removable Media slot, labeled Memory, which supports standard microSD memory cards. microSD cards can be used to save and load applications, to capture graphics screens and to log data for later retrieval. microSD card Flash memory (aka a thumb drive) Format a microSD Card 1. Select Removable Media in the System Menu of the controller. 2. Place card in the “Memory” slot. 3. Final Step: a. For XLE, press the bottom right soft key to get the submenu that includes “format”, select format. b. For XLT, press the bottom left and right keys to get the sub menu that includes “format”, select format. Page 133...
Page 134 Install & Remove a microSD card The XLE/XLT Memory slot is equipped with a “push-in, push-out” connector and a microSD card can be safely inserted into the Memory slot when the XLE/XLT is powered On or Off. To install a microSD card: Align its 8-pin gold edge connector down, facing the front of the XLE/XLT unit as shown in Figure 15.1; then carefully push it all the way into the Memory slot. Ensure that it clicks into place. To remove the microSD card: Push down on the top of the card gently to release the spring. The card pops up for removal. microSD File System XLE/XLT prior to Rev TA supported the FAT16 file system which allows up to 2.0 GB of memory, while XLE/XLT with REV TA and higher support the FAT32 file system which allows up to 2TB of memory. FAT microSD cards are compatible in REV TA units and higher. The XLEe and XLTe also support the FAT32 file system. This means that a PC, with a microSD-compatible card reader, can read files that have been written by the XLE/XLT and can write files that can be read by the XLE/XLT. The XLE/XLT supports the 8.3 filename format. This means that all file and directory names must consist of up to eight (8) characters, followed by an optional dot, and an optional extension with up to three (3) characters.
Page 135 Page 135...
Page 136: Load And Save Applications
Using the Removable Media Manager The Removable Media Manager is an interactive XLE/XLT screen that performs the following functions: Display number of total and free bytes Browse file and directory lists Delete files and directories Format a microSD card Load and save application programs View screen capture bitmaps The Removable Media Manager can be accessed via the System Menu or by using Cscape to place a Remov- able Media Manager object on an application graphics screen. Log Data Using Read and Write Removable Media function blocks, an application ladder program can read and write XLE/XLT 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. Load and Save Applications A special file type, with a .PGM extension, is used to store XLE/XLT application programs on microSD. To load an application from microSD to the XLE/XLT, use the Removable Media Manager to find and highlight the desired .PGM file, and then press Enter. ...
Page 137 Cscape can also save an application directly to a microSD card, which is plugged into the PC’s microSD com- patible card reader by selecting the Export to Removable Media item on the File menu. Page 137...
Page 138: View And Capture Screens
View and Capture Screens The XLE/XLT File System uses bitmap files with the .BMP (.bmp) extension to store XLE/XLT graphic screen captures. To view a captured XLE/XLT screen, use the Removable Media Manager to find and highlight the desired .BMP file, and then press Enter. To capture an XLE/XLT screen, turning on the assigned Screen Capture Control Register will capture the cur- rent XLE/XLT graphics screen and write it to the microSD card using the assigned Screen Capture Filename. Before capturing an XLE/XLT screen, Cscape must first be used to assign a Screen Capture Control Register and Filename in the application. To do this, first open the Graphics Editor by selecting the View / Edit Screens item on the Cscape Screens menu. Next, select the Screen Capture item of the Graphics Editor Config menu and then enter a Control Register and Filename. Removable Media (RM) Function Blocks in Cscape NOTE: For detailed information regarding RM function blocks and parameters, refer to the Help File in Cscape. The following RM functional blocks are available in Cscape Software. These function blocks will reference: a. microSD when filename is prefixed with ‘A:’ or nothing b. USB A Flash Drive when filename is prefixed with ‘B:’ RM Function Blocks Allows reading ...
Page 139 Program Features 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 3rd party PC applications, such as Microsoft Excel. Report Editor—This feature allows the OCS to be configured to generate text printouts which incorporate data from the registers embedded in the text. The reports can be printed using a serial interface printer through any of the serial ports of the OCS or can be saved on the removable media of the device. Graphic/Screen Editor Trends—The historic support feature in the trend object utilizes Removable Media. Removable Media—This is a graphic object used to access files and functions pertaining to Removable Media. Recipes—This is a graphic object that is used in conjunction with the recipe editor which is mentioned above. Additional Configuration Alarms - Alarm data can be logged to a .csv file stored on Removable Media. Screen Capture - The screen capture function allows a bitmap or jpeg image of the displayed OCS screen to be written to the Removable Media card. Filename Counters - The filename counters can be accessed wherever Removable Media functions require a path name. A typical application is the auto-incrementing of a file name when doing screen captures. File Select - File Select is used to specify the register block that is used with the Removable Media Manager object ‘Write Selected Filename’ option. Page 139...
Page 140: Filenames And Function Blocks
Filenames and Function Blocks The RM function blocks support the flash with a Windows standard FAT-16 file system. All names must be lim- ited to the “8.3” format where the filename contains eight characters a period then a three-character exten- sion. The entire filename including any path must be less than or equal to 147 characters. When creating filenames and directories, it is sometimes desirable to include parts of the current date or time. There are six special symbols that can be entered into a filename that are replaced by the OCS with current time and date information. Filename Special Symbols Symbol Description Example Substitutes t he current 2-digit year 2022 = 22 Substitutes t he current month with a 2-digit code March = 03 Substitutes t he current day 22nd = 22 Substitutes t he current hour in 24-hour format 5 ...
Page 141 RM Status Values RM i nterface OK Card p resent but unknown format No c ard in slot Card p resent, but not supported Card s wapped before operation was complete Unknown e rror Page 141...
Page 142 Clone Unit Page 142...
Page 143: Clone Unit
Clone Unit Clone Unit Clone Load Clone The ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” applic- ation program and unit settings stored in Battery backed RAM of an OCS into the RM. Refer to"Removable Media" on page 133 for more details on using RM. It can then be used to clone a different OCS (same model). This feature can be used for: Replacing an OCS by another unit of the same model. Duplicating or “clone” units without a PC. Clone User must perform the following sequence of action to Clone a unit: Step 1: The ‘Clone Unit’ can be accessed by going to the ‘System Menu’ of the OCS. A new menu “Clone Unit” has been added at the end of the main system menu as shown below: Page 143 of 174...
Page 144 Clone Unit Step 2: Selecting “Clone Unit” menu will open the following menu screen: NOTE: a. In the above Figure 16.2, F3 and F4 are inactive in the Clone Unit. b. DSK – when selected shows the number of total and free bytes in Removable Media. Step 3 - Make/Create Clone option enables the user to duplicate / Clone an application file, all unit settings and all register values from Battery Backed RAM. Selecting Make Clone brings up the screen below: 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 - F ile having all unit settings and register values from Battery Backed RAM Page 144 of 174...
Page 145 Clone Unit NOTE: Make/Create clone operation automatically includes the security in AUTOLOAD.PGM file for security enabled files. Step 4: Once the cloning is successful, the OCS gives a message as below: 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 to make the clone. The success / failure of the operation is also not notified on screen to the user. In case of failure of “Make Clone” operation, %SR164.11 bit is set to “1” by the firmware and never reset. NOTE: Backup of registers in flash memory is not performed by the Clone Feature. If user desires, Backup should be done as explained in the Fail-Safe System chapter. Page 145 of 174...
Page 146: Load Clone
Clone Unit 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 must perform the following to Load the Clone: Step 1: Select “Clone Unit” from main system menu of OCS as shown below: Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”. Page 146 of 174...
Page 147 Clone Unit Step 2: User must confirm Load Clone as shown below: Step 3: After confirmation, all unit settings and register values will be loaded from the Removable media to the Bat- tery backed RAM (Regardless of AutoLoad settings) and then the OCS resets at which stage the settings take effect. NOTE: For security enabled files, Load clone asks for password validation before loading the application. Load clone can also be triggered by setting %SR164.10 bit to “1” from Ladder program or graphics. Once the oper- ation is completed, this bit is made zero by the firmware. When the Load clone operation is triggered by this SR bit, it does not ask the user for confirmation to load the clone. The success / failure of the operation is not notified on the screen to the user. In case of failure of the “Load Clone” operation, %SR164.12 bit is set to “1” by the firmware and never reset. Page 147 of 174...
Page 148 Fail-Safe System Page 148...
Page 149: Fail-Safe System
Fail-Safe System Fail-Safe System Fail-Safe Features Settings Backup / Restore Data Flow Chart for Automatic Restore AutoLoad AutoRun Fail-Safe Features The Fail-Safe System is a set of features that allows 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, Elec- tromagnetic Interference, event. The Fail-Safe System has the following capabilities: Manually backup the current Battery-Backed RAM Register Settings into Flash memory. Manually restore Register Settings from the values previously backed up in Flash to Battery-Backed RAM. Detect corrupted Register Settings at power-up and then automatically restore them from Flash. Detect corrupted or empty application in Flash memory at power-up and then automatically load the AUTOLOAD.PGM application file from Removable Media (Compact Flash or microSD). ...
Page 150: Settings
Fail-Safe System Settings To use the Fail – Safe feature, the user must do the following: 1. 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. Set the ‘Enable AutoRun’ option to YES if the controller needs to be placed in RUN mode automatically after automatic restore of data or AutoLoad operation. 5. Backup the current Battery-Backed RAM Register contents in On-Board Flash memory using System Menu options. Backup / Restore Data Selecting this option brings up a screen having four operations: Backup OCS Data. Restore OCS Data. Clear Backup Data. Exit 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 150 of 174...
Page 151 Fail-Safe System 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 a backup has been previously created and on power-up the Bat- tery-Backed RAM registers fail their check. The following process is implemented to restore data: 1. The controller will be placed in IDLE mode. 2. Data will be copied from onboard FLASH to OCS Battery-Backed RAM 3. The controller will reset. 4. The controller will be put in RUN mode if the AutoRun setting is ‘Yes’ else it will remain in IDLE mode. %SR164.3 is set to 1 only when an automatic restore operation is performed - not on a manual one. This bit is reset to the value of 0 when a new backup is created. Restoring of data can be manually performed by selecting RESTORE option from the Backup / Restore Data menu. This will cause the controller to reset. 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 the value of 0 when backed up data is erased. Exit: Goes back to the previous screen. Page 151 of 174...
Page 152: Flow Chart For Automatic Restore
Fail-Safe System Flow Chart for Automatic Restore The OCS follows the following sequence in execution of Automatic Restore: Page 152 of 174...
Page 153: Autoload
Fail-Safe System 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 be manually or automatically initiated at power-up. The automatic initiation will happen only in the following two cases: When there is no application program in the OCS and a valid AUTOLOAD.PGM is available in the removable media of the device. When the program residing in onboard memory is corrupted and a valid AUTOLOAD.PGM is available in the removable media of the device. AutoLoad can be manually initiated when the SYS-F3 key is pressed (OCS can be in any of the following mode – Idle / Run / DOIO). This also requires a valid AUTOLOAD.PGM to be present in the removable media of the device. When the AutoLoad setting is not enabled (set to NO), OCS will be in IDLE mode and the application is not loaded. If the AUTOLOAD.PGM is security enabled, the user will be prompted to enter the password before loading the application. The application will be loaded from the Removable media only after getting the correct password. %SR164.6 can be set to enable AutoLoad feature. Page 153 of 174...
Page 154 Fail-Safe System The OCS implements the following sequence to execute the AutoLoad function: Page 154 of 174...
Page 155: Autorun
Fail-Safe System 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. %SR164.5 can be set by putting the system into RUN mode automatically, once an AutoLoad has been performed or an Automatic Restore has occurred. If for any reason the AutoLoad-Run (Loading the AUTOLOAD.PGM automatically and OCS put in RUN mode) sequence does not succeed, a pop-up message box saying "AUTO-LOAD-RUN SEQUENCE FAILED" will be dis- played. It will also show the reason for its failure. On acknowledging this message box the AutoLoad-Run sequence will be terminated, controller will return to the first user-screen and will be placed in IDLE mode. Page 155 of 174...
Page 156 Modbus Communications Page 156...
Page 157: Modbus Communications
Modbus Communications Modbus Communications Modbus Slave Modbus Master Modbus Addressing Tables for XLE/XLT Units 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 XLE/XLT 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. Only the addressed slave will send a response when the request is com- pleted. Should the slave be unable to complete the request, it returns the appropriate error response. Should the slave be unable to respond, the master’s timeout timer expires to provide an indication of No Response. Modbus Slave For complete Modbus Slave instructions, please refer to the Help file in Cscape. The Modbus slave function block, when used with the appropriate Modem and/or Open function blocks, allows the primary serial port on the controller to act as a Modbus slave. The Modbus function supports both ASCII and RTU modes of operation across a range of baud rates and protocol frames. Also supported is port activity status, an inactivity timer, support for call-on exception, and support for store and forward (repeater) operation for radio modems. ...
Page 158: Modbus Master
Modbus Communications Modbus Master 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 XLE/XLT to allow the user to spe- cify the data to be read/written from/to the slaves. Modbus Master Function Block—This is for serial only. This is an advanced feature that should only be used in rare occasions. Protocol Config—The Protocol Config is configured in the Hardware Configuration dialog box in Cscape (serial) This is the preferred method in most applications. After the protocol has been selected from the dropdown menu, the Network, Devices, and Scan List become avail- able. The Protocol Config is configured on three different levels: Network—Parameters, such as the polling rate of the data scan, are specified along with timeout values, retry, and re-acquisition settings. Serial configuration, baud rate, parity, etc. are also set here. Devices—For every slave to be polled, configuration details are added in the Devices dialog box. This includes Slave ID (serial). Under Device Type, the Modbus addressing style matching that specified in the slave’s user documentation may be selected. For instance, some slaves specify Modbus addresses (i.e. 40,001), and others specify offsets (i.e. 0000). Hex or Decimal—Some specify addresses in hex, and others in decimal. By allowing the user to select the 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 alto- gether. Scan List—This is where the specific Modbus addresses to be read/written from/to each slave are specified. ...
Page 159: Modbus Addressing Tables For Xle/Xlt Units
Modbus Communications Modbus Addressing Tables for XLE/XLT Units To access XLE/XLT 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). Since only four register types can be represented in this manner, XLE/XLT Modbus Function Blocks pack several XLE/XLT register types into each Modbus register type. Starting addresses of each XLE/XLT register type are shown in the Traditional Mod- bus Reference column of the tables below. Method 2: The second method requires the Modbus Master to be configured with a specific Modbus Command and Modbus Offset. The supported Modbus commands and the associated offsets are also illustrated in the tables below. XLE/ XLEe Modbus Master Mapping Trad. Modbus Refer- Expanded Modbus Maximum Modbus Command...
Page 160 Modbus Communications XLT/ XLTe Modbus Master Mapping Expanded Mod- XLT/XLTe Maximum Trad. Modbus Ref. (5 Modbus Command Modbus Reference bus Ref. Range Digits) Offset (6 Digits) 2048 10001 10001 %IG1 13001 13001 3000 Read I nput Status (2) 14001 14001 4000 15001 15001 5000...
Page 161 Backup Battery Page 161...
Page 162: Backup Battery
Backup Battery Backup Battery Precautions & Safety Steps for Battery Replacement Precautions & Safety The XLE/XLT contains an internal lithium battery that is used while power is disconnected for the following func- tions: Run the real-time clock Maintain retentive registers Maintain the application program Under normal conditions the battery in the XLE/XLT should last seven (7) to ten (10) years. Higher operating tem- peratures or variations in batteries may reduce this time. Preventing Program Loss: A n available option to prevent the loss of program should the battery be drained is to use the Backup/Restore function which is part of the Fail-Safe System. This feature is highly recommended and is accessible from the System Menu and from program logic. Backup/Restore DOES NOT require the installation of a microSD card in order to prevent program loss. Refer to "Fail-Safe System" on page 149 for complete details. The battery will generally last seven (7) to ten (10) years. Environmental conditions, including extreme tem- peratures and humidity, can affect battery life. If the battery is older than seven (7) to ten (10) years old, it is recom- mended that it be replaced as preventative maintenance.
Page 163: Steps For Battery Replacement
Backup Battery Steps for Battery Replacement Below are the steps to replace the battery: 1. Make sure the user program and any data stored in retentive memory is backed up. 2. Disconnect all power from the XLE/XLT unit including I/O power. 3. Using a Phillips screwdriver, remove the four (4) screws on the back of the XLE/XLT unit by turning the four (4) corner screws counterclockwise. Remove the back cover. 4. Carefully remove the I/O board (if present) by lifting it straight up. 5. Remove the old battery. It may require a small flat blade screwdriver to lift it from the holder. 6. Dispose of the battery properly; see the above warning on disposal regulations. 7. Slide the new battery into the holder. Make sure the battery is inserted with the proper polarity. The top tab of the battery holder should contact the positive (+) terminal of the battery. 8. Replace the I/O circuit board by aligning the edges with the guideposts. Align the I/O board bus connector to bus pins, and then gently press on the I/O circuit board until it is seated. 9. Place the back cover back on the unit. 10. Place the screw back into the hole and turn the screw slowly counterclockwise until “clicks” into the threads. This will prevent the screw from being cross threaded. Now turn the screw clockwise until the cover is firmly secured. Repeat this process for all four (4) screws. Recommended torque is 3 - 4 in-lbs (0.34 – 0.45 Nm). Page 163 of 174...
Page 164 Firmware Update Page 164...
Page 165: Firmware Update
Method A: Removable Media Method The controller firmware is updated by a bootloader, using a microSD card or USB Flash drive (not through the Cscape Firmware Update Wizard). To update or change firmware: 1. Download desired Firmware set from the Horner APG website. (Verify CsCAN or CANopen com- munications.) 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: F iles 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. Method B: RS232 Serial Connection Serial firmware updates are done from Cscape software to the controller’s primary serial port, MJ1 in most cases. Method C: Mini USB Port – The mini USB port can be used to update firmware in the XLE and XLT series. T his is quicker than doing so via MJ1. Page 165 of 174...
Page 166: Obtain Firmware
a. In North America, visit https://hornerautomation.com Then click Support > Downloads >Controller Firm- ware and download the most recent firmware set with the correct communication protocol. b. In Europe, visit http://www.hornerautomation.eu and click Support > Firmware tab and download the desired firmware (an account is required to access firmware updates, create one if necessary). Update Firmware Steps 1. Establish communication between Cscape and the controller using a direct serial connection to MJ1. 2. Make sure your application is available on your PC or upload the application. 3. Make sure the machinery connected to the XLE/XLT is in a safe state for firmware update (see warning above). 4. Start the firmware update by selecting File à Firmware Update Wizard. 5. The correct product type should be selected, if it is not select the type of controller from the drop-down list. 6. Press the Start button. 7. Wait for the firmware update to complete. 8. If there is a communication failure check the cable, connections and comm. port setting and try again. 9. Firmware updates typically delete the user applications to ensure compatibility. You will need to reload your application. 10. Test the operation of the equipment with the new firmware before returning the XLE/XLT system to an oper- ation mode.
Page 167: Firmware Update Via Microsd Card
Firmware Update Firmware Update via microSD card NOTE: Applies to XLEe and XLTe (ethernet models) only. Method 1 Placing “.s19” file in the root of microSD card and loading firmware manually and automatically. Manual firmware update by selecting “.s19” file - Place “.s19” file in the root of microSD card and insert the card. Go to System menu | Removable media and select “.s19” file that needs to be loaded. Device displays the fol- lowing message “Do not power Cycle Until FW is updated”, select OK. Firmware update will be started, and a busy symbol will be displayed on the device until firmware will be loaded. When firmware update will start %SR154.16 bit will be set to high. Once firmware update is completed %SR154.16 bits will be set to low. Set %SR154.12 bit to high before selecting “.s19” file / before loading firmware if user program and register data should be cleared after the update. Set %SR154.12 bit to low before selecting “.s19” file / before loading firmware if user program should be present, register values should be retained and status of the device needs to be retained after the update. Auto firmware update via %SR’s - Place “.s19” file in the root of microSD card and insert the card. When %SR154.9 is set to high, %SR154.16 bit goes high and controller will update the firmware which is placed in the root directory of SD Card. Once firmware update process is successful, %SR154.9 and %SR154.16 bits are reset (goes low).
Page 168: Manual Firmware Update Via %Sr's
Firmware Update Manual Firmware Update via %SR’s With proper folder structure placed in microSD card, insert the card to device. Set %SR154.10 high. If firmware version folder inside update directory is greater than the firmware version on the device, then %SR154.16 will go high indicating firmware update process have started. Once firmware update pro- cess will be completed, %SR154.10 and %SR154.16 bits goes low. NOTE: There will be no busy symbol indication for this method. User should monitor %SR’s for the updates. Set %SR154.12 bit to high if user program and register data should be cleared after the update. Set %SR154.12 bit to low if user program should be present, register values should be retained and status of the device needs to be retained after the update. Auto firmware update via %SR’s Setting %SR154.10 and %SR154.11 high, whenever new firmware folder is placed in the microSD card, firmware update will happen automatically setting %SR154.16 bit high. Once firmware update process will be completed, %SR154.16 bit will be reset but %SR154.10 and %SR154.11 will remain high (for auto update of firmware). NOTE: There will be no busy symbol indication for this method. User should monitor %SR’s for the updates. Set %SR154.12 bit to high if user program and register data should be cleared after the update. Set %SR154.12 bit to low if user program should be present, register values should be retained and status of the device needs to be retained after the update. In all the methods, device will reset automatically after firmware update process is completed. Page 168 of 174...
Page 169 Troubleshooting & Tech Support Page 169...
Page 170: Troubleshooting
Troubleshooting Troubleshooting Connecting to the XLE/XLT Local Controller and Local I/O CsCAN Network Removable Media Troubleshooting Technical Support Contacts Connecting to the XLE/XLT 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. In general, the Target number should match the Local number. The exception to this is when the controller is being used as a "pass through" unit where other controllers on a CsCAN network could be accessed through the local con- troller. Determine connection status by examining feedback next to Local & Target in the status bar of Cscape.
Page 171: Local Controller And Local I/O
1. Programming and debugging can use MJ2 if it is set as the default programming port. 2. Controller must be powered up. 3. Assure that the correct COM port is selected in Cscape. 4. Tools > Application Settings > Communications . 5. Check that a Loaded Protocol or ladder is not actively using MJ1/MJ2. Taking the controller out of run mode from the System Menu on the controller will make MJ1/MJ2 available to Cscape. 6. Make sure the COM port of the PC is functioning. An RS-232 serial loopback and Microsoft HyperTerminal can determine positively if the COM port is working. Or connect to an alternate device to determine if the port is working. 7. Successful communications with USB-to-serial adapters vary. If in doubt, Horner Automation offers a USB to serial adapter. Part number: HE-XCK. 8. XLE/XLT units with built-in Ethernet or installed HE-XEC module can be programmed and debugged via the Ethernet port. If the HE-XEC is installed, it can be selected as the programming port. The selection is made in the controller's System Menu under the Serial Port settings. If there are difficulties connecting, make sure that the default programming port is set correctly with the connection method being attempted. Local Controller and Local I/O The System Menu provides the following status indications that are useful for troubleshooting and system main- tenance. Self-test results, diagnostics. ...
Page 172: Cscan Network
Troubleshooting CsCAN Network For complete information on setting up a CsCAN network, refer to CAN Networks manual (MAN0799) by visiting our website. Network status, node ID, errors, and baud rate in the controller system menu are all in reference to the CsCAN net- work. These indications can provide performance feedback on the CsCAN network and can also be used to aid in troubleshooting. Refer to the "System Settings and Adjustments" on page 24 chapter for full details. CsCAN Network Troubleshooting Checklist 1. Use the proper Belden wire type or equivalent for the network as specified in MAN0799. 2. The XLE/XLT does not provide 24VDC to the network. An external voltage source must be used for other devices such as SmartStix I/O. 3. Check voltage at both ends of the network to ensure that voltage meets specifications of attached devices. 4. Proper termination is required. Use 121Ω (or 120Ω) resistors at each end of the network. The resistors should be placed across the CAN_HI and CAN_LO terminals. 5. Measure the resistance between CAN_HI and CAN_LO. If the network is properly wired and terminated there should be around 60Ω. 6. Check for duplicate node ID’s. 7. Keep proper wires together. One twisted pair is for V+ and V- and the other twisted pair is used for CAN_HI and CAN_LO. 8. Make sure the baud rate is the same for all controllers on the network. 9. Assure shields are connected at one end of each segment -- they are not continuous through the network. 10. Do not exceed the maximum length determined by the baud rate and cable type. 11. Total drop length for each drop should not exceed 6m (20’). A drop may include more than one node. The ...
Page 173: Removable Media Troubleshooting
Troubleshooting Removable Media Troubleshooting RM Troubleshooting Description Action XLE/XLT does not read media card. The media card should be formatted with t he XLE/XLT. XLE/XLT will not download project file. Make sure the project file is saved as a . pgm file and not a .csp file. Technical Support Contacts For manual updates and assistance, contact Technical Support at the following locations: North America: Tel: (317) 916-4274 Fax: (317) 639-4279 Website: https://hornerautomation.com Email: techsppt@heapg.com Europe: Tel: (+) 353-21-4321-266 Fax: (+353)-21-4321826 Website: https://www.hornerautomation.eu Email: technical.support@horner-apg.com Page 173 of 174...
Page 174: Change Log
Change Log Change Log Change Log Date Rev # Description of Revision with Mantis # Location in Doc #2801 – How to Format m icroSD card Format a microSD card #2831 – Add Change Log Change Log 3-18-2021 12 #3343 – microSD v. F lash Memory RM Overview #3467 – 121 ohm r esistor CAN Termination #4567 – EMI definition Fail-Safe System #4845 – Updated WebMI r egister SR Table #4802 – WebMI – Max # ...

This manual is also suitable for:

Xlee Xlt Xlte

HORNER XLE User Manual

Quick Links

Troubleshooting

Need help?

Questions and answers

Related Manuals for HORNER XLE

Summary of Contents for HORNER XLE

This manual is also suitable for:

Table of Contents