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HORNER HEXT251C216 User Manual

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User Manual for XL4 OCS
HE-XC1E0
HE-XC1E2
HE-XC1E3
HE-XC1E4
HE-XC1E5
HE-XC1E6
European: HEXT251C112, HEXT251C113, HEXT251C114, HEXT251C115, HEXT251C116, HEXT251C216
t h
O c t o b e r 2 9
, 2 0 1 9
MAN0964-12-EN_XL4_UserManual
HE-XC1E0-500
HE-XC1E2-500
HE-XC1E3-500
HE-XC1E4-500
HE-XC1E5-500
HE-XC1E6-500
MAN0964-12-EN_XL4_UserManual
HE-XC1E0-108
HE-XC1E2-108
HE-XC1E3-108
HE-XC1E4-108
HE-XC1E5-108
HE-XC1E6-108
P a g e 1 | 189

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  • Page 1 HE-XC1E3 HE-XC1E3-500 HE-XC1E3-108 HE-XC1E4 HE-XC1E4-500 HE-XC1E4-108 HE-XC1E5 HE-XC1E5-500 HE-XC1E5-108 HE-XC1E6 HE-XC1E6-500 HE-XC1E6-108 European: HEXT251C112, HEXT251C113, HEXT251C114, HEXT251C115, HEXT251C116, HEXT251C216 O c t o b e r 2 9 , 2 0 1 9 P a g e 1 | 189...

  • Page 2: Preface

    PREFACE This manual explains how to use the XL4 OCS. Copyright (C) 2012 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written permission of Horner APG, Inc.

  • Page 3: Limited Warranty And Limitation Of Liability

    MAN0964-12-EN_XL4_UserManual LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the XL4 (HE-XC/HEXT251) OCS module manufactured by HE-APG is free from defects in material and workmanship under normal use and service. The obligation of HE-APG under this warranty shall be limited to the...

  • Page 4: Visual Map Of Key Chapters

    MAN0964-12-EN_XL4_UserManual VISUAL MAP OF KEY CHAPTERS FIRST STEP of ANY TASK: DATASHEET The datasheet is the first document you need to refer to for model-specific information related to XL4 OCS models. Visit our website to obtain updates to datasheets, manuals, and user documentation. North America https://hornerautomation.com Europe...

  • Page 5: Table Of Contents

    MAN0964-12-EN_XL4_UserManual TABLE OF CONTENTS PREFACE ..............................2 LIMITED WARRANTY AND LIMITATION OF LIABILITY ................ 3 ABOUT PROGRAMMING EXAMPLES ....................... 3 VISUAL MAP OF KEY CHAPTERS......................4 TABLE OF CONTENTS ..........................5 CHAPTER 1: SAFETY/ COMPLIANCE ....................... 9 Safety Warnings and Guidelines ....................9 Grounding ............................
  • Page 6 MAN0964-12-EN_XL4_UserManual Port Description .......................... 27 CAN1 Port Wiring ........................28 Cscape Programming via CAN ....................28 Ladder-Controlled CAN Communication ................28 Using CAN for I/O Expansion (Network I/O) ................ 28 CHAPTER 7: ETHERNET COMMUNICATION ..................29 Ethernet Module Protocols and Features ................29 Ethernet System Requirements .....................
  • Page 7 MAN0964-12-EN_XL4_UserManual CHAPTER 12: HIGH SPEED I/O (HSC / PWM) ................... 82 12.1 Overview ............................82 12.2 Glossary ............................83 12.3 High Speed Counter (HSC) Functions ................... 84 12.4 HSC Functions Register Map ....................93 12.5 High Speed Output Functions ....................96 12.6 High Speed Output Functions Register Map ..............
  • Page 8 MAN0964-12-EN_XL4_UserManual 17.2 Storing Register Contents.......................155 17.3 Battery Life ..........................155 17.4 Lithium Battery Safety ......................155 17.5 Battery Charging Cycle ......................156 17.6 Battery Charging Status ......................156 17.7 Battery Charging State ......................156 17.8 Battery Status in System Registers ..................156 CHAPTER 18: FAIL – SAFE SYSTEM ....................157 18.1 Overview ............................

  • Page 9: Chapter 1: Safety/ Compliance

    MAN0964-12-EN_XL4_UserManual CHAPTER 1: SAFETY/ COMPLIANCE Safety Warnings and Guidelines When found on the product, the following symbols specify: Warning: Consult user documentation Warning: Electrical Shock Hazard. WARNING: EXPLOSION HAZARD – Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous. WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth) ground before making any other connections.

  • Page 10: Grounding

    MAN0964-12-EN_XL4_UserManual Adhere to the following safety precautions whenever any type of connection is made to the module. a. Connect the green safety (earth) ground first before making any other connections. b. When connecting to electric circuits or pulse-initiating equipment, open their related breakers.

  • Page 11: Chapter 2: Introduction

    MAN0964-12-EN_XL4_UserManual CHAPTER 2: INTRODUCTION Visual Overview of XL4 OCS Figure 2.1 - Visual Overview of XL4 OCS O c t o b e r 2 9 , 2 0 1 9 P a g e 11 | 189...
  • Page 12 MAN0964-12-EN_XL4_UserManual 2.1.1 Where to Find Information about the XL4 OCS Datasheets - The datasheets are the first documents you need to refer to for key information related to specific XL4 OCS models. The datasheets for all XL4 OCS models are available on our website and contain pin-outs, jumper settings and other model specific information.

  • Page 13: Connectivity To The Xl4 Ocs

    MAN0964-12-EN_XL4_UserManual Connectivity to the XL4 OCS The XL4 OCS has excellent capabilities for connecting to a variety of devices. The diagram below shows some examples of devices that can be used with the XL4 OCS. Other OCS Devices Other OCS Devices Smart Stix I/O Serial Drives...

  • Page 14: Features Of Xl4 Ocs

    MAN0964-12-EN_XL4_UserManual Features of XL4 OCS The XL4 OCS are all-in-one industrial control devices. They combine control, user interface, I/O and networking into a single, integrated package. Unique features of the XL4 OCS include: • Bright, 65,536 color graphical touch-sensing LCD display or a bright white touch-sensing LED backlit display capable of up to 16,777,216 colors.

  • Page 15: Accessories

    MAN0964-12-EN_XL4_UserManual Accessories Please visit the Horner Control Accessories website for communication, programming and I/O accessories. North America http://hornerautomation.com/product-category/home/control-accessories/ Europe http://horner-apg.com/en/products.aspx Useful Documents and References Visit our website to obtain user documentation, supplemental documents, certificates, and other documentation. North America https://hornerautomation.com Europe http://www.hornerautomation.eu...

  • Page 16: Chapter 3: Mechanical Installation

    MAN0964-12-EN_XL4_UserManual CHAPTER 3: MECHANICAL INSTALLATION NOTE: The datasheet is the first document to refer to for model-specific information related to XL4 OCS models such as pin-outs, jumper settings, and other key installation information. Visit our website to obtain datasheets, user documentation, and updates. North America https://hornerautomation.com Europe...

  • Page 17: Mounting Orientation

    MAN0964-12-EN_XL4_UserManual Mounting Orientation 3.3.1 XL4 OCS Mounting Clip Slot for Clip Clip Rail Figure 3.2 – XL4 OCS with Mounting Clips 3.3.2 XL4 OCS Mounting Orientation 001XLE056 CAUTION—For DIN Rail mounting: NOTE—For panel or DIN rail mounting: To prevent the unit from slipping off the DIN Rail, do The orientation shown above provides not install the unit on its sides as shown.

  • Page 18: Panel Cut-Out

    MAN0964-12-EN_XL4_UserManual Panel Cut-Out For installations requiring NEMA4X liquid and dust protection the panel cutout should be cut with a tolerance of +/- 0.005” (0.1mm). 3.622 [92mm] 001XLE002 Figure 3.4 – Panel Cutout Tolerances XL4 Dimensions Figure 3.5 – XL4 OCS Dimensions O c t o b e r 2 9 , 2 0 1 9 P a g e 18 | 189...

  • Page 19: Factors Affecting Panel Layout Design And Clearances

    MAN0964-12-EN_XL4_UserManual Factors Affecting Panel Layout Design and Clearances WARNING: It is important to follow the requirements of the panel manufacturer and to follow all applicable electrical codes and standards. The designer of a panel layout needs to assess the requirements of a particular system and to consider the following design factors 3.6.1 Clearance / Adequate Space Install devices to allow sufficient clearance to open and close the panel door.
  • Page 20 MAN0964-12-EN_XL4_UserManual 3.6.4 Orientation When panel-mounted, there are no orientation restrictions on the XL4 OCS. 3.6.5 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 XL4 OCS and noisy devices such as relays, motor starters, etc.

  • Page 21: Chapter 4: Electrical Installation

    The U.S. National Electrical Code (NEC) states the resistance to ground shall not exceed 25Ω. Horner APG recommends less than 15Ω resistance from our equipment to ground. Resistance greater than 25Ω can cause undesirable or harmful interference to the device.

  • Page 22: How To Test For Good Ground

    MAN0964-12-EN_XL4_UserManual How to Test for Good Ground In order to test ground resistance, a Ground Resistance Tester must be used. A typical Ground Resistance Meter Kit contains a meter, two or three-wire leads, and two ground rods. Instructions are supplied for either a two-point or a three-point ground test. Figure 4.1 shows a two-point ground connection test.

  • Page 23: Primary Power Port

    MAN0964-12-EN_XL4_UserManual Primary Power Port Table 4.1 – Primary Power Port Pins Signal Description Frame Ground Input power supply ground +24V Input power supply positive voltage 10-30VDC supply Figure 4.1 – Power Connector (Primary Power Port) D/C INPUT / FRAME Solid/Standard Wire: 12-24 awg (2.5 - 0.2mm). Strip Length: 0.28”...

  • Page 24: Chapter 5: Serial Communications

    MAN0964-12-EN_XL4_UserManual CHAPTER 5: SERIAL COMMUNICATIONS Overview All XL4 OCS models provide two serial ports, which are implemented with single 8-pin modular RJ45 connectors, are labeled MJ1 and MJ2. The MJ1 serial port is RS-232 while the MJ2 port is RS-485. MJ1 defaults to OCS programming by connecting it to the COM port of a PC running Cscape.

  • Page 25: Dip Switches

    MAN0964-12-EN_XL4_UserManual Dip Switches Figure 5.2 – Dip Switches RS-485 Termination Proper RS-485 termination minimizes reflections and improves reliability. The 485 serial port allows an internal RS-485 termination resistor to be placed across pins 1 and 2 by DIP Switch Setting. Only the two devices physically located at the endpoints of the RS-485 network should be terminated.

  • Page 26: Biasing

    XL4 OCS MJ1 serial port, Cscape can access the XL4 OCS for programming and monitoring. Programming can also be done via the CAN port, USB port or Ethernet. Successful communications with USB-to-serial adapters vary. If in doubt, Horner APG offers a USB to serial adapter. Part numbers HE-XCK and HE-CPK.

  • Page 27: Chapter 6: Can Communications

    MAN0964-12-EN_XL4_UserManual CHAPTER 6: CAN COMMUNICATIONS NOTE: For additional CAN information, refer to the CAN Networks manual (MAN0799) on our website. North America https://hornerautomation.com Europe http://www.hornerautomation.eu Overview All XL4 OCS models provide a CAN networking port, which is implemented with a 5-pin connector.

  • Page 28: Can1 Port Wiring

    MAN0964-12-EN_XL4_UserManual CAN1 Port Wiring CAN Connector CAN Network & Power Port Pin Assignments Use the CAN Connector Signal Signal Description when using CsCAN or CAN and Device Ground - Black other CAN network. CN_L CAN Data Low - Blue Torque Rating: SHLD Shield Ground - None 4.5 –...

  • Page 29: Chapter 7: Ethernet Communication

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

  • Page 30: Ethernet Module Configuration

    MAN0964-12-EN_XL4_UserManual Ethernet Module Configuration NOTE: The following configuration is required for all applications regardless of the protocols used. Additional configuration procedures must be performed for each protocol used. To configure the Ethernet Module, use Cscape Programming Software to perform the following steps: On the main Cscape screen, select the Controller menu and its Hardware Configuration sub-menu to open the Hardware Configuration dialog (Figure 7.1).
  • Page 31 MAN0964-12-EN_XL4_UserManual Click the Config button to the right of the LAN1 for LAN 1 or LAN2 for LAN 2, revealing the Ethernet Module Configuration dialog as shown in figure as shown in Figure 7.2. Figure 7.2 – Ethernet Module Configuration Configure the Ethernet Module parameters as follows: IP Address: Enter the static IP Address for the Ethernet Module being configured.
  • Page 32 MAN0964-12-EN_XL4_UserManual Table 7.3 - Ethernet Status Word Register Format High Byte Low Byte Bit 1 Link TCP Connections Status Values Status Bit(s) Status Indication Minimum Maximum Reserved Always 0 Link Duplex (Auto-Negotiated) 0 = Half Duplex 1 = Full Duplex Link Speed (Auto-Negotiated) 0 = 10MHz 1 = 100MHz...

  • Page 33: Ethernet Configuration - Ip Parameters

    Configure Selected Protocol button. This will open a new dialog with configuration options for the selected protocol. For detailed information on individual protocol configuration, refer to latest version of ETN 300 Manual SUP0740 on the Horner website. North America https://hornerautomation.com Europe http://www.hornerautomation.eu...

  • Page 34: Chapter 8: Downloadable Communication Protocols

    MAN0964-12-EN_XL4_UserManual CHAPTER 8: DOWNLOADABLE COMMUNICATION PROTOCOLS Overview Through loadable protocol device drivers, certain models of the OCS family can provide the ability to exchange data with remote devices such as variable-frequency drives, PLCs, and remote I/O devices. This feature greatly expands the OCS ’s control capability with negligible effect on the OCS ’s ladder scan time.
  • Page 35 (automatic) or controlled from ladder logic (manual) once a complex connection is programmatically created (i.e., dialup modem). The specific transaction-scanning mode is selected from the Network Config menu. The following Horner Automation websites offer OCS Protocol Software Downloads. North America http://hornerautomation.com/support-files/ Europe http://horner-apg.com/en/products/software/ocs-protocols.aspx...

  • Page 36: Protocol Config

    MAN0964-12-EN_XL4_UserManual Protocol Config After opening Cscape, choose Program → Protocol Config, and select the port drop-down box to select a protocol device driver. All protocol device drivers currently loaded in Cscape are displayed in the dropdown selection. Some OCS models can be limited in the number of ports or number of protocol device drivers that can be selected.

  • Page 37: Network Configuration

    MAN0964-12-EN_XL4_UserManual Network Configuration Network Configuration provides the required parameters to configure the network. Each protocol is different and may not require all the Network Config field. Please refer to the table below for the options in the Network Config field. See Table 8.1 below for Network Config details.
  • Page 38 MAN0964-12-EN_XL4_UserManual Table 8.1 – Network Protocols Baud Rate, Data Bits, Stop These field define the bit level transfer over the serial port. Bits, Parity None – No handshake lines are used Handshake Multidrop Full – Rx remains active while Tx is occurring. Multidrop Half –...

  • Page 39: Device List And Devices Configuration

    MAN0964-12-EN_XL4_UserManual Device List and Devices Configuration Device List The Device List is reached from the Device button on the Protocol Config screen and provides a list of the configured devices on the Network. Devices must be created and exist in this list before corresponding Scan List entries can be created for this device.

  • Page 40: Scan List

    MAN0964-12-EN_XL4_UserManual Scan List This can be accessed from the Scan List button on the Protocol Config screen or the Mapping button on the Device List screen and provides a Scan List of the Data Mapping entries. To transfer data between the OCS and remote target, a Scan List must be created that defines each transaction.

  • Page 41: Data Mapping Configuration (Scan List Entry)

    MAN0964-12-EN_XL4_UserManual Data Mapping Configuration (Scan List Entry) Update Type This field specifies the direction and what triggers the transfer of data between the OCS and target device for a mapping entry. Polled Read On every transaction scan, a read-only target device register(s) transaction occurs. Polled Read/Write On every transaction scan, a read target device register transaction occurs unless a local register value has changed.
  • Page 42 MAN0964-12-EN_XL4_UserManual Polled Read/Write/Init On every transaction scan, a read target device register transaction occurs unless a local register value has changed. The write transaction only updates those local registers that have changed in value. If several non-consecutive local registers (contained in a single mapping entry) change value between transaction scans, it takes several consecutive scans to write each changed register.

  • Page 43: Chapter 9: System Settings And Adjustments

    MAN0964-12-EN_XL4_UserManual CHAPTER 9: SYSTEM SETTINGS AND ADJUSTMENTS System Menu - Overview The XL4 has a built-in System Menu, which lets the user view System Settings and makes adjustments. To start the System Menu, press the SYSTEM key (or set %SR3 to 1), which will display the Main Menu.
  • Page 44 MAN0964-12-EN_XL4_UserManual Sub-Menus Sub-Menus CAN Ok? CAN ID: CAN Baud: 125KB Fkeys: Momentary SYS-Fn enable: MAC ID: 00:E0:C4:04:C7:35 ( Use ↑↓ to adjust ) 192.168.254.128 NetM: 255.255.255.0 GatW1 0.0.0.0 MAC ID2: Dflt Pgm Port MJ1-232 00:E0:C4:04:C0:35 MJ1 RS485 Bias IP2: 192.168.254.127 ( Use ↑↓...

  • Page 45: System Menu - Navigation And Editing

    MAN0964-12-EN_XL4_UserManual System Menu – Navigation and Editing  and  Keys Enter Key As mentioned above, the System Menu is started by pressing the System key on the XL4. Next press ESC to exit the System Menu, or use  and  to select an item and press Enter display the item’s Sub-Menu.

  • Page 46: System Menu - Details

    MAN0964-12-EN_XL4_UserManual System Menu – Details The following sections describe each of the Sub-Menus in detail. Set Networks This sub menu allows setting for the CAN and Ethernet network to be viewed or changed. Yes= CAN1 connected to a CAN network and functioning properly CAN Ok? No= Not ready to communicate on CAN network CAN ID...
  • Page 47 MAN0964-12-EN_XL4_UserManual View Status The View Status Sub-Menu displays up to 19 System Settings. Only the Mode System Setting is editable. Model: XL1yz = Model number of this XL4 OCS unit = indicates the installed I/O module = no I/O module Mode: Idle = XL4 OCS is in Idle mode...
  • Page 48 MAN0964-12-EN_XL4_UserManual View Diags The View Diags Sub-Menu displays up to 11 System Diagnostics, none of which are editable. The first two System Diagnostics are critical. If any of them indicate a Fault condition, the XL4 OCS will not enter or remain in Run mode, and the problem must be investigated and corrected.
  • Page 49 MAN0964-12-EN_XL4_UserManual View Battery Status The View Battery Status displays the following information. Waiting The charging system is waiting for voltages and temperatures to stabilize. Battery Charging The battery is charging. Battery Full Shows at the end of a charge cycle. Remains in this state until the battery is steadily discharging.
  • Page 50 MAN0964-12-EN_XL4_UserManual View I/O Slots The View I/O Slots Sub-Menu displays three System Settings, all of which are not editable. Internal to the XL4 OCS, there is a CPU board, and up to two installed modules. Model XE100 has no installed I/O or COM modules. All other models have an I/O module and can have a user- installed COM module.
  • Page 51 MAN0964-12-EN_XL4_UserManual View Protocols The View Protocols Sub-Menu displays three System Settings, none of which are editable. As mentioned in Downloadable Serial Communication Protocols section, both the MJ1 (Port 1) and MJ2 (Port 2) serial ports support downloadable protocols. To assign a downloadable protocol to an XL4 OCS serial port, select the Protocol Config item in Cscape’s Program menu and then setup a protocol for Port 1 or Port 2 (or both).
  • Page 52 MAN0964-12-EN_XL4_UserManual Set Fkeys Mode The Set Fkeys Sub-Menu displays two System Settings, both of which are editable. Momentary = %K1-5 bits go On & Off as F1-F5 are pressed & released Fkeys Toggle = %K1-5 bits toggle each time F1-F4 are pressed Yes = Reset and all clear system functions enabled SYS_Fn enable No = Reset and all clear system functions disabled...
  • Page 53 MAN0964-12-EN_XL4_UserManual Set Serial Ports The Set Serial Ports Sub-Menu displays three System Settings, all of which are editable, and one optional item. For the Dflt Pgm Port System setting, only MJ1-232 can be selected, unless a Modem (XMC) COM module is installed. MJ1-232 = MJ1 RS232 port is the default programming port Dflt Pgm Port Modem = Modem COM module is the default programming port...
  • Page 54 MAN0964-12-EN_XL4_UserManual Set Time/Date The following instructions are to set and display the real-time clock in the controller. More details can be found in the Help File in Cscape. Table 9.1 – Clock and Time Setting Terms Coordinated Universal Time Abbreviated to UTC, Coordinated Universal Time is the (UTC) primary time standard by which the world regulates clocks and time.
  • Page 55 MAN0964-12-EN_XL4_UserManual To Set Time Zone: The Time Zone setting is an hourly offset from UTC time. If using the Time Zone setting, set it first, then set the local time. UTC time will be automatically set based on the time zone and local time settings. If using NTP: NTP utilizes UTC time, therefore when using NTP, the appropriate hourly offset from UTC time must entered into the time zone setting.
  • Page 56 MAN0964-12-EN_XL4_UserManual Set Beeper The Set Beeper Sub-Menu displays one System Setting, which is editable. (default) = Enables beeper Beeper Enable (does NOT affect ladder access) No = Disables beeper O c t o b e r 2 9 , 2 0 1 9 P a g e 56 | 189...
  • Page 57 MAN0964-12-EN_XL4_UserManual Set Screen The Set Screen Sub-Menu displays four System Settings, all of which are editable. Yes = Enable screen saver Saver enable (default) = Disable screen saver 5 - 1200 = Amount of time in minutes to expire with NO touch Timeout (min) activity before activating screen saver (black screen) (default)
  • Page 58 MAN0964-12-EN_XL4_UserManual Removable Media The Removable Media Sub-Menu displays the Removable Media Manager. After selecting Removable Media from the Main Menu, one of four Sub-Menu screens will appear: Media Directory = No microSD card has been installed in the Memory slot No Card Media Directory = microSD card is installed, but it is still initializing...
  • Page 59 MAN0964-12-EN_XL4_UserManual If a directory name is highlighted, pressing Enter will switch to that directory showing its files and sub-directories. In a sub-directory, highlighting .. (dot dot) and pressing Enter will move up one directory. Fail – Safe System The Fail-Safe System is a set of features that allow an application to continue running in the event of certain types of "soft"...
  • Page 60 MAN0964-12-EN_XL4_UserManual Enable AutoRun “Enable AutoRun” displays the following options which can be selected: No = OCS will be in IDLE mode after AutoLoad or Automatic Restore. Enable AutoRun Yes = OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore. O c t o b e r 2 9 , 2 0 1 9 P a g e 60 | 189...
  • Page 61 MAN0964-12-EN_XL4_UserManual Enable AutoLoad “Enable AutoLoad” displays the following options which can be selected: No = Does not load AUTOLOAD.PGM automatically when application program is absent or corrupted. Enable AutoLoad Yes = Loads AUTOLOAD.PGM file automatically from RM when application program is absent or corrupted. O c t o b e r 2 9 , 2 0 1 9 P a g e 61 | 189...
  • Page 62 MAN0964-12-EN_XL4_UserManual Clone Unit ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” application program and unit settings stored in battery-backed RAM of an OCS into the RM. Refer to the Removable Media chapter for details on using RM.
  • Page 63 MAN0964-12-EN_XL4_UserManual Selecting Make Clone brings up the screen below for the user: After confirmation, the OCS will create two new files in the root directory of the Removable Media Drive as shown below: AUTOLOAD.PGM Application file CLONE.DAT File having all unit settings and register values from battery-backed RAM O c t o b e r 2 9 , 2 0 1 9 P a g e 63 | 189...
  • Page 64 MAN0964-12-EN_XL4_UserManual Load Clone Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone” (one of the virtual buttons beneath the screen). NOTE: For security enabled files, Load Clone asks for password validation before loading the application. O c t o b e r 2 9 , 2 0 1 9 P a g e 64 | 189...
  • Page 65 MAN0964-12-EN_XL4_UserManual WebMI License Details License details page displays the information about the WebMI license. Please refer to MAN1036 for the WebMI Manual. The information can also be viewed from Cscape using the following %SR registers: %SR209.3 WebMI server status %SR209.4 WebMI user logged in status %SR209.8 to SR209.16 Number of Users...

  • Page 66: Touch Screen Calibration

    MAN0964-12-EN_XL4_UserManual Touch Screen Calibration The touch screen is calibrated at the factory and rarely needs modification. However, if actual touch locations do not appear to correspond with responding objects on the display, field adjustment is available. Ensure SYS_fn Enable is set to YES in System Menu. To access the field adjustable touch screen calibration dialog, press and hold both the SYS and F1 key for longer than 2 seconds and a dialog similar to Figure 9.3 should appear.

  • Page 67: Chapter 10: Removeable Media

    MAN0964-12-EN_XL4_UserManual CHAPTER 10: REMOVEABLE MEDIA 10.1 Overview All XL4 OCS models provide a Removable Media slot, labeled Memory Card, which supports standard microSD flash memory cards. microSD cards can be used to save and load applications, to capture graphics screens and to log data for later retrieval. Figure 10.1 –...

  • Page 68: Microsd File System

    MAN0964-12-EN_XL4_UserManual 10.3 microSD File System The microSD Memory Card slot uses the PC-compatible FAT32 File System. This means that a PC, with a microSD-compatible card reader, can read files that have been written by the XL4 OCS and can write files that can be read by the XL4 OCS. However, the XL4 OCS does not support long filenames, but instead implements the 8.3 filename format.

  • Page 69: Using Removable Media To Log Data

    MAN0964-12-EN_XL4_UserManual 10.5 Using Removable Media to Log Data Using Read and Write Removable Media function blocks, an application ladder program can read and write XL4 OCS register data in the form of comma-delimited files, with a .csv extension. These files are compatible with standard database and spreadsheet PC programs. In addition, an application ladder program can use Rename and Delete Removable Media function blocks to rename and delete files.

  • Page 70: Configuration Of The Removable Media Object

    MAN0964-12-EN_XL4_UserManual 10.8 Configuration of the Removable Media Object The configuration of the Removable Media Object that loads the Removable Media Viewer defines what buttons are enabled and available to the user. (Enter) button performs certain operations based on the selected file’s type: - change display to parent directory <DIR>...

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

    MAN0964-12-EN_XL4_UserManual 10.10 Removable Media (RM) Features—Program Features a. Datalog Configuration—This feature allows the controller to periodically log register values to Removable Media. The register data is stored in .csv (comma separated value) format, which is compatible with 3 party PC applications, such as Microsoft Excel. b.

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

    MAN0964-12-EN_XL4_UserManual 10.13 Filenames used with the Removable Media (RM) Function Blocks The RM function blocks support the flash with a Windows standard FAT-16 file system. All names must be limited to the “8.3” format where the filename contains eight characters a period then a three-character extension.

  • Page 73: System Registers Used With Rm

    MAN0964-12-EN_XL4_UserManual 10.14 System Registers used with RM %SR174 – Removable Media Protect. Write a one (1) to %SR174 to prohibit read/write access to the removable media card. Write a zero (0) to allow access. %SR175 Status – This shows the current status of the RM interface. %SR176 Free Space –...

  • Page 74: Chapter 11: General I/O

    MAN0964-12-EN_XL4_UserManual CHAPTER 11: GENERAL I/O NOTE: The datasheet is the first document you need to refer to for model-specific information related to XL4 OCS models such as pin-outs, jumper settings, and other key installation information. Visit our website to obtain datasheets, user documentation, and updates. 11.1 Overview The XL4 OCS is a compact unit that contains high density, very versatile I/O.

  • Page 75: Model And I/O Overview

    MAN0964-12-EN_XL4_UserManual Figure 11.2 – XL4 I/O Cover Removed (sample I/O board) Once the back is removed, the jumper selection can be changed. The jumper settings are documented on each data sheet using a diagram such as Figure 11.3 below and a description of the jumper settings.

  • Page 76: Solid-State Digital Outputs

    MAN0964-12-EN_XL4_UserManual 11.4 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 the XL4 OCS are “sourcing” outputs. This means the output applies a positive voltage to the output pin when turned ON.

  • Page 77: Relay Outputs

    MAN0964-12-EN_XL4_UserManual 11.5 Relay Outputs Relay outputs are designed to switch loads that typically have high voltage, current requirements, or require isolation that relays provide. NOTE: The design of the XL4 OCS does not require external coil power for the relays to function.

  • Page 78: Digital Inputs

    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.

  • Page 79: Analog Inputs

    MAN0964-12-EN_XL4_UserManual 11.7 Analog Inputs NOTE: See the Datasheet for the XL4 OCS model you are using for jumper settings and see the appropriate page in this manual (see Index) for details on how to use Cscape to configure the digital filtering. The analog inputs on the XL4 OCS allow voltage or current measurement from a variety of devices.

  • Page 80: Universal Analog Inputs

    The Universal Analog Inputs on the Model 6 I/O 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.

  • Page 81: Analog Outputs

    MAN0964-12-EN_XL4_UserManual 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 Figure 11.9 – Loop Power Requirements 11.9 Analog Outputs NOTE: Refer to the datasheet for XL4 OCS model you are using for details on jumper settings.

  • Page 82: Chapter 12: High Speed I/O (Hsc / Pwm)

    The XL4 ships with two high-speed counters, but a customer can contact Horner Technical Support to receive a file that will configure the unit to have four. These modes are not supported simultaneously. Two-counter mode supports quadrature mode and two stepper outputs, while four-counter mode does not support quadrature mode and supports only one stepper output.

  • Page 83: Glossary

    MAN0964-12-EN_XL4_UserManual 12.2 Glossary Table 12.1 – Glossary of High Speed I/O Terms Register used to accumulate or store up a sum or count of many items or Accumulator events. A special function to zero out the value in a specific register. (Not used with Clear Frequency or Period Measurement.) Disable...

  • Page 84: High Speed Counter (Hsc) Functions

    MAN0964-12-EN_XL4_UserManual 12.3 High Speed Counter (HSC) Functions The XL4 supports either two or four very high speed, configurable counters. There are four dedicated inputs that can be configures to a number of different options. Each of the counters can run in one of five modes. Those modes are Totalizer, Frequency Counter, Pulse Width Measurement, Period Measurement, and Quadrature measurement.
  • Page 85 MAN0964-12-EN_XL4_UserManual 12.3.2 Totalize In totalize mode, the accumulator is simply incremented or decremented each time the input transitions in a specific direction. The totalizer supports the following modes: Table 12.2 – Modes supported by Totalizer Internal This mode ties the input to the counter to an internal 10 MHz or 1 MHz clock.
  • Page 86 MAN0964-12-EN_XL4_UserManual NOTE: Counter triggers off the rising edge of the signal. Rising Edge Signal Falling Edge Signal Three different options are available to reset the current count. They are: • Configured reset value Counts per When configuring the Totalize function, a value may be specified under the column.
  • Page 87 MAN0964-12-EN_XL4_UserManual 12.3.3 Pulse Width Measurement In Pulse Width Measurement mode, the high-speed input can measure the width of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode, the Disable and Latch special functions are allowed. Please see section 12.2 for a description of these functions.
  • Page 88 MAN0964-12-EN_XL4_UserManual 12.3.4 Period Measurement In period measurement mode, the high-speed input can measure the period of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode, the Disable and Latch special functions are allowed. Please see section 12.2 for a description of these functions.
  • Page 89 MAN0964-12-EN_XL4_UserManual 12.3.5 Quadrature Quadrature mode uses two HSC inputs; any of the four HSC inputs can be assigned for this purpose. Quadrature mode works much like the totalizer except the accumulator will automatically increment or decrement based on the rotation phase of the two inputs. See the following example for more details.
  • Page 90 MAN0964-12-EN_XL4_UserManual 12.3.6 Register Match Totalizer & Quadrature counter modes support a register match function. When the accumulator value matches either the Match 1 or Match 2 value configured in the corresponding %AQ registers, a high-speed output can Turn On, Turn Off, or Toggle. An internal %I register mirrors the output state whether the high-speed output is configured or not.
  • Page 91 MAN0964-12-EN_XL4_UserManual 2.3.7 HSC Functions The high-speed input on the XL4 contains many optional tasks. All of which can be disabled, or set to an internal pre-assigned register (Assigned %Q) or to one of the external high speed inputs (External Input #1, 2, 3, or 4), or they can be set as an “overflow interrupt” or “underflow interrupt”...
  • Page 92 MAN0964-12-EN_XL4_UserManual 12.3.8 Status Bits There are three status bits (%I registers for each high-speed counter). Overflow Flag: This status bit turns high when the Accumulator “overflows”, it moves from 4,294,967,295 (-1 if Signed) to 0, this bit can be reset with the “Output Reset Bit”. See tables below.

  • Page 93: Hsc Functions Register Map

    MAN0964-12-EN_XL4_UserManual 12.4 HSC Functions Register Map The register assignments for the high speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below. Table 12.4 –...
  • Page 94 MAN0964-12-EN_XL4_UserManual NOTE: Four Count Mode requires FPGA update. Table 12.5 – HSC Functions Register Map for 4 HSC Configuration Register Frequency Pulse Totalize %AI401-402 Accumulator - Counter 1 %AI403-404 Latch Value – Counter 1 %AI405-406 Accumulator – Counter 2 %AI407-408 Latch Value –...
  • Page 95 MAN0964-12-EN_XL4_UserManual %Q1651 Clear – Counter 4 %Q1652 Disable – Counter 4 %Q1653 Direction – C4 %Q1654 Output Reset – Counter 4 %Q1655 Preload Disable – Counter 4 %Q1656 Latch Disable – Counter 4 %Q1657-1664 Reserved %I1601 Overflow Flag – Counter 1 %I1602 Underflow Flag –...

  • Page 96: High Speed Output Functions

    MAN0964-12-EN_XL4_UserManual 12.5 High Speed Output Functions On units that support High-Speed Output functions, two dedicated outputs are available that can be configured for one of four modes of operation. Those modes are Normal, PWM, HSC Match, and Stepper. 12.5.1 Normal When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives that respective output.
  • Page 97 MAN0964-12-EN_XL4_UserManual At controller power-up or during a download, the PWM output is maintained at zero until both the Frequency and the Duty cycle are loaded with non-zero values. When the controller is placed in Stop Mode, the state of the PWM outputs is dependent on the PWM State on Controller Stop configuration.
  • Page 98 MAN0964-12-EN_XL4_UserManual 12.5.4 High-Speed Counter Match When either Q1 or Q2 is configured for HSC Output operation, their output state is based on a comparison between the counter accumulator and match registers. See details above in the High-Speed Output section. 12.5.5 Stepper Function The XL4 supports two stepper functions, one on each high-speed output when in two counter mode.
  • Page 99 MAN0964-12-EN_XL4_UserManual The stepper provides two Boolean registers to provide stepper status: A high indication on this register indicates the stepper sequence can Ready/Done be started (i.e. not currently busy) and when the move is completed. A high indication on this register indicates that one of the analog parameters specified above is invalid, or the stepper action was Error aborted before the operation was complete.

  • Page 100: High Speed Output Functions Register Map

    MAN0964-12-EN_XL4_UserManual 12.6 High Speed Output Functions Register Map The register assignments for the high speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below.
  • Page 101 MAN0964-12-EN_XL4_UserManual Table 12.9 – PWM Functions Register Map, Four Counter Register Stepper %AQ451-452 PWM 1 Duty Cycle(32 bit) Start Frequency – Stepper 1 %AQ453-454 PWM 1 Frequency Run Frequency – Stepper 1 %AQ455-456 Acceleration Count – Stepper 1 %AQ457-458 Run Count – Stepper 1 %AQ459-460 Deceleration Count –...

  • Page 102: Pwm Examples

    MAN0964-12-EN_XL4_UserManual 12.7 PWM Examples Example 1 Duty Cycle Frequency To get a 50% Duty Cycle @ Set %AQ421-422 = 16,000 Set %AQ423-424 = 10,000 10kHz waveform on PWM1: Example 2 Duty Cycle Frequency Set %AQ421-422 = 16,000 To get a 50% Duty Cycle on Set %AQ423-424 = 1,000 PW1 and 90 % Duty Cycle on Set %AQ431-432 = 28,800...

  • Page 103: Stp Examples

    MAN0964-12-EN_XL4_UserManual 12.8 STP Examples Example 1 Start Accel Count Run Count Decel Count Frequency Frequency 10,000,000 Set %AQ423- Set %AQ425- Set %AQ427-8 steps Set %AQ421 Set %AQ422 4 = 1,000,000 6 = 8,000,000 = 1,0000,000 control = 2500Hz = 5000Hz (Steps) (Steps) (Steps)

  • Page 104: Hsc I/O Filtering

    MAN0964-12-EN_XL4_UserManual 12.9 HSC I/O Filtering This feature is used to enable digital Filter for HSC Inputs. Selecting Digital In/HSC configuration opens up the following dialog where in HSC I/O Filtering is available. Input signal is filtered based on the filter frequency and Number of samples selected. User has to select Filter Frequency and Number of samples based on the frequency of the Input signal.
  • Page 105 MAN0964-12-EN_XL4_UserManual The state (high or low) of the high-speed input is sampled with every rising input edge of the filter frequency. The rising edges of the filter frequency are totaled in a sample counter, and when that total equals the number of samples configured, the sample counter is reset. If the high-speed input state did not change by the time of the sample counter reset, that state, high or low, is passed on to the high-speed accumulator.
  • Page 106 MAN0964-12-EN_XL4_UserManual Figure 3: Input signal before filtering Figure 4: Input signal after filtering This delay will be 4μs. O c t o b e r 2 9 , 2 0 1 9 P a g e 106 | 189...

  • Page 107: Chapter 13: User Interface

    MAN0964-12-EN_XL4_UserManual CHAPTER 13: USER INTERFACE 13.1 Overview This chapter presents the user interface (or operator view) of the XL4 and some of the model specific characteristics of the XL4 as compared to the rest of the OCS line. This chapter does NOT cover building screens or using the CSCAPE graphics editor.

  • Page 108: Displaying And Entering Data

    MAN0964-12-EN_XL4_UserManual 13.3 Displaying and Entering Data Figure 13.1 – Example Screen Multiple objects are provided for displaying data such as virtual panel lights, push buttons, numeric value displays, bar graphs, meters, graphs and animated bitmaps. On the XL4, these graphical objects (through ladder manipulation of attribute bits) can change color, flash, or change visibility to attract operator attention.

  • Page 109: Alpha-Numeric Keypad

    MAN0964-12-EN_XL4_UserManual 13.4 Alpha-Numeric Keypad To allow entry of a specific number or text, several of the input objects invoke a pop-up alpha- numeric keypad when the object is touched. An example of the alpha-numeric keypad invoked from a numeric input object is shown below in Figure 13.2. Once invoked, the operator may touch the appropriate keys to enter a specific value.
  • Page 110 MAN0964-12-EN_XL4_UserManual Since the alpha-numeric keypad services several different graphical objects, certain keys on the alpha-numeric keypad may be disabled (grayed) when the keypad is invoked for certain objects. The following describes the alpha-numeric keypad variation based on object. Numeric Object When editing a numeric value, the [+/-] or the [.] key are disabled (grayed) if the object is NOT configured for floating-point value or a signed value.

  • Page 111: Screen Navigation

    MAN0964-12-EN_XL4_UserManual 13.5 Screen Navigation To allow the operator to change screens, a Screen Jump Object is generally used. This object may be visually represented as a 3-D button (responding to touch) or remain invisible and logically tied to an OCS register. An optional system ICON may be configured for display along with the legend, which aids in identifying the object as one that causes a screen change (shown below in Figure 13.3).

  • Page 112: Beeper Acknowledgement

    MAN0964-12-EN_XL4_UserManual 13.7 Beeper Acknowledgement The XL4 contains an internal beeper that provides an audible acknowledgment when an operator touches a graphic object that accepts touch input. When the graphic object is enabled, a short 5ms tone is emitted. When the graphic object is disabled, a longer 100ms tone is emitted to enounce that graphical object is not currently accepting the touch input.

  • Page 113: Alarms

    MAN0964-12-EN_XL4_UserManual 13.9 Alarms Alarm presentation to the operator is highly configurable and beyond the scope of this document to describe fully. For more information, refer to the graphics editor help file in CSCAPE. This section presents a typical configuration thereby providing an introductory description on what the operator should expect.
  • Page 114 MAN0964-12-EN_XL4_UserManual Alarm Viewer Figure 13.6 – Alarm Viewer The currently selected entry is indicated by a yellow highlight which can be moved up or down by touching the arrow buttons or by directly touching an entry. If more entries exist than can fit on the page, a scroll bar is displayed on the right side that also indicates the current relative position.

  • Page 115: Removable Media

    MAN0964-12-EN_XL4_UserManual 13.10 Removable Media The Removable Media Object is generally used to inform the operator on the current state of the removable media device and allow access to its file structure. The Removable Media Object is displayed as a button that changes colors to indicate the current state of the removable media device.
  • Page 116 MAN0964-12-EN_XL4_UserManual File operations are accomplished by pressing the appropriate button at the bottom of the Removable Media Viewer. The configuration of the removable media object that invokes the Removable Media Viewer defines what buttons are enabled and available to the user. A button is grayed and does not respond to touch if configured as disabled.

  • Page 117: Screen Saver

    MAN0964-12-EN_XL4_UserManual 13.11 Screen Saver The XL4 screen backlight life is typically five (5) years when in continuous use. If the application does not require interaction with the XL4 for long periods of time, the backlight life can be extended by using the screen saver function. When enabled through the System Menu, the backlight is shut off (screen goes black) after a specified time of no touch activity on the screen.

  • Page 118: Touch Screen Pressure

    With a unique change to the touch monitoring firmware user can measure the pressure being exerted on the touch screen. This feature has been added in some Horner XL series controllers. This allows the OCS programmer to be notified of the touch pressure and it can configure the pressure required to accept a touch event.
  • Page 119 MAN0964-12-EN_XL4_UserManual There are two system registers that provide this touch feature: %SR9 (I/O Name - TCH_PRESSURE) Records the highest-pressure level of the last touch on the screen that exceeds the threshold value set in %SR10. This is a range of 0 to 3000. Zero (0) indicates no pressure and 3000 is the maximum amount of pressure that can be measured.

  • Page 120: Chapter 14: Registers

    MAN0964-12-EN_XL4_UserManual CHAPTER 14: REGISTERS 14.1 Register Definitions When programming the XL4 OCS, data is stored in memory that is segmented into different types. This memory in the controller is referred to as registers. Different groups of registers are defined as either bits or words (16 bits). Multiple registers can usually be used to handle larger storage requirements.

  • Page 121: Useful %S And %Sr Registers

    MAN0964-12-EN_XL4_UserManual %QG Global Digital Output Specially defined single-bit outputs that go to the network. %R General Purpose Register Retentive 16-bit registers. %S System Bit Single-bit bit coils predefined for system use. %SR System Register 16-bit registers predefined for system use. %T Temporary Bit Non-retentive single-bit registers.
  • Page 122 MAN0964-12-EN_XL4_UserManual Table 14.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values 6= View OCS Diagnostics 7= View I/O Slots 8= Set Function Key Mode (%SR33) 9= Set Serial Ports (%SR34) 10= Set Time/Date (%SR44-%SR50) 11= Set Beeper (%SR183) 12= Set Screen (%SR185)
  • Page 123 MAN0964-12-EN_XL4_UserManual Table 14.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values I/O Configuration Table Size (32-Bit %SR17-18 Read Only Read Only DINT) %SR19-20 Network Config Table Size (32-Bit DINT) Read Only Read Only %SR21-22 Security Data Table Size (32-Bit DINT)
  • Page 124 MAN0964-12-EN_XL4_UserManual Table 14.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values Keypad Type %SR43 Read Only Read Only *Excludes RCC Units %SR44 RTC_SEC Real-Time-Clock Second 0 to 59 Read Only Read Only %SR45 RTC_MIN...
  • Page 125 MAN0964-12-EN_XL4_UserManual Table 14.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values Soft Key 7 = 40 Soft Key 8 = 41 Release = 255 (Keys pressed since power-up but not currently) *Excludes RCC Units LCD Backlight Dimmer Register 0-100 = 0% to 100% On...
  • Page 126 MAN0964-12-EN_XL4_UserManual Table 14.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values MJ2 Termination Enable %SR152.1 Read / Write Read / Write *Excludes RCC972 MJ3 Termination Enable *XL+ Only %SR152.2 Read / Write Read / Write RS485 Termination Enable * X4 &...
  • Page 127 MAN0964-12-EN_XL4_UserManual Table 14.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values %SR168-170 Reserved %SR171 X-Coordinate Touched Read Only Read Only %SR172 Y-Coordinate Touched Read Only Read Only %SR173 System-Function Disable, 0 to 1 Read / Write Read / Write...
  • Page 128 MAN0964-12-EN_XL4_UserManual Table 14.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values Battery Charge Temp High %SR195 Read Only Read Only *XL+ Only – in degree centigrade Charging State NOTE: Refer to MAN1142 for more details on Rechargeable Batteries 0=Waiting 1=Normal Charging...

  • Page 129: Resource Limits

    MAN0964-12-EN_XL4_UserManual Table 14.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values Number of Webpages, license detail %SR218 (XLE/XLT, X2, X4, & X7 use %SR101 & Read Only Read Only %SR108-112 for WebMI License Details.) Number of Data Points, license detail.

  • Page 130: Register Map For Xl4 Ocs I/O

    MAN0964-12-EN_XL4_UserManual 14.4 Register Map for XL4 OCS I/O Table 14.4 – I/O Register Map Description Registers XL4 with XL4 with XL4 with XL4 with XL4 with XL4 with no I/O 102 I/O 103 I/O 104 I/O 105 I/O 106 I/O %I1-%I12 Unused Digital Inputs...
  • Page 131 MAN0964-12-EN_XL4_UserManual Table 14.5 – PWM Function Registers Map Register Stepper %AQ1 PWM1 Duty Cycle (32- HSC1 Start Frequency bit) Preset Value %AQ2 Run Frequency %AQ3 PWM2 Duty Cycle (32- HSC2 Accel Count bit) Preset Value (32-bit) %AQ4 %AQ5 PWM Prescale Run Count (32-bit) (32-bit)

  • Page 132: Chapter 15: Cscape Configuration

    MAN0964-12-EN_XL4_UserManual CHAPTER 15: CSCAPE CONFIGURATION 15.1 Overview XL4 OCS 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 XL4 OCS unit. Please see the Online Help provided with Cscape for additional details. 15.2 Cscape Status Bar When the XL4 OCS is connected to a PC using Cscape software, a Status Bar appears at the bottom of the screen.

  • Page 133: Establishing Communications

    MAN0964-12-EN_XL4_UserManual 15.3 Establishing Communications The XL4 OCS can communicate with Cscape using USB to USB, USB to serial adapters, serial port communications via MJ1 Port, Ethernet (with an Ethernet adapter board), onboard Ethernet Port, CAN (CsCAN), or modems. If a direct USB connection is to be used, connect the Mini-USB port on the OCS (only on select models) to an open USB port on the PC.
  • Page 134 MAN0964-12-EN_XL4_UserManual The PC will detect a new device has been plugged into the USB port. Now that the XL4 is plugged in, go to Cscape → Controller → Connection Wizard. If you are just opening Cscape, Connection Wizard usually opens by default. Select USB and click Next >>.
  • Page 135 MAN0964-12-EN_XL4_UserManual If the Connection Wizard does not pop up upon opening Cscape, then select Controller (in the Cscape tool bar) → Connection Wizard, choose your connection method. If you are connecting for the first time, we suggest connecting via USB. Figure 15.2 –...
  • Page 136 MAN0964-12-EN_XL4_UserManual An alternate way to select the COM setting is to go to Cscape → Tools → Application Settings → Communications → Configure and choose connection method in Add Target. Figure 15.3 – Cscape: Alternative Connection Method Screenshot Figure 15.4 – Add Target Screenshot in Cscape NOTE: The following fields, Target Name, Connection Medium, Connected Device, and Connection Settings, need to be filled for communication configuration if Cscape Connection Wizard was not used.
  • Page 137 NOTE: Cscape will do necessary initialization for the selected internal modem. Select this option to communicate over USB. Now Horner devices and Horner USB to serial converters are recognized and can be specifically selected.
  • Page 138 MAN0964-12-EN_XL4_UserManual If communications are successful, the message line should show “USB (COM8)” for this example, and an (R) should follow the Target number. For more information on the status bar, see the Cscape Status Bar Section. When connected directly to the controller to which Cscape communications are required, the Local ID Local ID and Target ID and the Target ID should match.
  • Page 139 Adapter, which comes as part of the HE-XCK and HE-CPK programming kits. 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 XL4.
  • Page 140 MAN0964-12-EN_XL4_UserManual 15.3.2 Communicating via On Board Ethernet Port From Cscape go to Controller → Hardware Configuration and do auto configuration for the connected controller, Click on Config of Ethernet and select Module Setup. The IP address, Net Mask, and Gateway of the controller may be temporarily set from the System Menu under the Set Networks menu item.

  • Page 141: Configuration

    MAN0964-12-EN_XL4_UserManual 15.4 Configuration An overview of configuration: (1) Start the configuration by selecting the Controller → Hardware Configuration menu item. (2) If the XL4 OCS is connected to the PC, press the Auto Config System button to automatically detect the Base model, I/O, and any communication options. (3) If the XL4 OCS is not connected, press the Config button to the right of the top of the unit.

  • Page 142: Digital / Hsc Input Configuration

    MAN0964-12-EN_XL4_UserManual 15.5 Digital / HSC Input Configuration The following figure illustrates the Digital / HSC Input Configuration dialog. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 15.6 – Digital / HSC Input Configuration Dialog The Active mode group box allows the user to select if inputs are active high (Positive logic) or active low (Negative logic).

  • Page 143: Digital / Pwm Output Configuration

    MAN0964-12-EN_XL4_UserManual 15.6 Digital / PWM Output Configuration The following figure illustrates the Digital / PWM Output Configuration dialog. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 15.7 – Digital / PWM Output Configuration Dialog The Q1 and Q2 group boxes allow the user to specify the operation of the multi-function outputs.

  • Page 144: Analog Input Configuration

    MAN0964-12-EN_XL4_UserManual 15.7 Analog Input Configuration The following figure illustrates the Analog Input Configuration dialog of a Model 2. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 15.8 – Analog Input Configuration Dialog The Channel x drop down windows allow the user to specify the mode for each analog input to operate.
  • Page 145 MAN0964-12-EN_XL4_UserManual On Model 5 and Model 6 I/O, other options on channels are outlined below: Table 15.2 – Analog In for Models 5 & 6 Model 5 Model 6 Channels 1 & 2 Channels 1-6 0..10V 0..10V 0..20mA 0..20mA 4..20mA 4..20mA 100mV Disable...

  • Page 146: Analog Output Configuration

    MAN0964-12-EN_XL4_UserManual 15.8 Analog Output Configuration The following figure illustrates the Analog Output Configuration dialog. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 15.9 – Analog Output Configuration Dialog (Model 6) The Output value on STOP group box contains items that allow the user to specify how the analog output channels behave when the controller is stopped.

  • Page 147: Scaling Analog Inputs

    MAN0964-12-EN_XL4_UserManual 15.9 Scaling Analog Inputs To access the Advanced Math Scaling function, select Tools → Project Toolbox. This will open a side bar, and then select Advanced Math → Scale. Figure 15.10 –Scaling Analog Inputs O c t o b e r 2 9 , 2 0 1 9 P a g e 147 | 189...
  • Page 148 MAN0964-12-EN_XL4_UserManual 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. With the analog channel set to the 4-20mA range, the raw analog input value, which is in INT format ranges from 0-32,000 for 4mA-20mA.

  • Page 149: Chapter 16: Video Object

    MAN0964-12-EN_XL4_UserManual CHAPTER 16: VIDEO OBJECT 16.1 Video Object Overview The Video Object feature allows two options for video type: Stream and Playback. The Video Object trigger is used to start, stop, and pause video, and the System Register provides the status of the video object, which supports various resolutions and frames per second.

  • Page 150: Opening Video Object In Cscape

    MAN0964-12-EN_XL4_UserManual 16.2 Opening Video Object in Cscape NOTE: Video Object requires Firmware 14.03 or newer to use with the XL4 devices. In Cscape, select the XL4 and model number by selecting Controller → Hardware Configuration from the toolbar. Open the Graphics Editor by selecting the “T” button from the toolbar. In Graphic Editor, select the video button from the toolbar.
  • Page 151 MAN0964-12-EN_XL4_UserManual Then double click on the icon in the middle to open the Video Properties dialog. O c t o b e r 2 9 , 2 0 1 9 P a g e 151 | 189...

  • Page 152: Video Properties: Video Type

    MAN0964-12-EN_XL4_UserManual 16.3 Video Properties: Video Type Figure 16.1 – Configuring Video Type There are two options for video type: Stream and Playback Stream – This option can be selected to view live video from a web cam. Four channels are supported through the USB hub.

  • Page 153: Video Properties: Control

    MAN0964-12-EN_XL4_UserManual 16.4 Video Properties: Control Figure 16.2 – Configuring Control Trigger The Video Properties: The video control trigger is used to start, stop and pause video. Video trigger is done by bit level addressing. The trigger reserves eight (8) bits and uses the first two (2) bits.

  • Page 154: Configuring Display Properties

    MAN0964-12-EN_XL4_UserManual 16.5 Configuring Display Properties Figure 16.3 – Configuring Display Properties Resolution Options 320x240 (QVGA) Frames per Seconds 10, 15, 20, 24, 30 & MAX_FPS 16.6 Video Object Performance 1. When Video Object is active, navigating to System Menu or any popup window, causes Video Object to be inactive.

  • Page 155: Chapter 17: Back-Up Battery

    The OCS has safety circuitry built into the charging IC and additional external protection including fusing. These circuits were closely evaluated by UL and Horner engineering for use in hazardous environments. O c t o b e r 2 9...

  • Page 156: Battery Charging Cycle

    MAN0964-12-EN_XL4_UserManual 17.5 Battery Charging Cycle The battery is charged at unit power up. The first two minutes after boot there is a wait period before charging begins. 2. In all charge cycles, battery is charge fully to 4.2V (4200mV). 3. Charging mA should be 100mA. 4.

  • Page 157: Chapter 18: Fail - Safe System

    MAN0964-12-EN_XL4_UserManual CHAPTER 18: FAIL – SAFE SYSTEM 18.1 Overview The Fail-Safe System is a set of features that allow an application to continue running in the event of certain types of "soft" failures. These "soft" failures include: • Battery power loss •...

  • Page 158: Settings

    MAN0964-12-EN_XL4_UserManual 18.2 Settings To use the Fail-Safe feature, the user needs to do the following: From Cscape, create AUTOLOAD.PGM for the application program using ‘Export to Removable Media’. 2. Place the Removable Media with AUTOLOAD.PGM in the device. 3. Set the ‘Enable AutoLoad’ option in the device to YES. 4.
  • Page 159 MAN0964-12-EN_XL4_UserManual 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 160 MAN0964-12-EN_XL4_UserManual Restore OCS Data: When initiated, this will allow the user to manually copy the backed-up data from the onboard flash to the battery-backed RAM. A restore operation will be automatically initiated if 1) a backup has been previously created and 2) on power-up the battery-backed RAM registers fail their check.
  • Page 161 MAN0964-12-EN_XL4_UserManual Clear Backup Data: When initiated, the backup data will be erased from the onboard flash and no backup will exist. %SR164.4 and %SR164.3 is reset to 0 when backed up data is erased. Figure 18.5 – Clear Backup Data Exit: Goes back to the previous screen.
  • Page 162 MAN0964-12-EN_XL4_UserManual The OCS follows the following sequence in execution of Automatic Restore: OCS Power Cycle Battery Backed RAM Registers check failed Backup exists? Controller placed in Application IDLE mode Program erased Data copied from Onboard FLASH to OCS Battery backed Controller Resets AutoRun OCS put in IDLE...

  • Page 163: Autoload

    MAN0964-12-EN_XL4_UserManual 18.4 AutoLoad This System Menu option allows the user to specify whether the OCS automatically loads the application AUTOLOAD.PGM located in Removable Media. When the AutoLoad setting is enabled (set to YES), it can either be manually initiated or automatically initiated at power-up.
  • Page 164 MAN0964-12-EN_XL4_UserManual The OCS follows the following sequence in execution of AutoLoad: Power up OCS Application Program absent Application Program corrupted AutoLoad OCS put in IDLE mode Enabled? AutoLoad run sequence AUTOLOAD.PGM present in failed (with reasons for the RM of the device ? failure) AutoLoad initiated.

  • Page 165: Autorun

    MAN0964-12-EN_XL4_UserManual 18.5 AutoRun This System Menu option, when enabled (YES), allows the user to automatically place the OCS into RUN mode after the AutoLoad operation or automatic Restore Data operation. When the AutoRun setting is disabled (NO), the OCS remains in the IDLE mode after a Restore Data or AutoLoad operation.

  • Page 166: Chapter 19: Clone Unit

    MAN0964-12-EN_XL4_UserManual CHAPTER 19: CLONE UNIT 19.1 Overview ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” application program and unit settings stored in battery-backed RAM of an OCS into the RM. Refer to the Removable Media Chapter for details in using RM.
  • Page 167 MAN0964-12-EN_XL4_UserManual 2. Selecting “Make Clone” will open the following menu screen: Figure 19.2 – Make Clone Menu before Cloning NOTE: Free/Total – displays number of free and total bytes in Removable Media. 3. Make/Create Clone option enables user to duplicate / Clone application file, all unit settings and all register values from battery-backed RAM.
  • Page 168 MAN0964-12-EN_XL4_UserManual After confirmation, the OCS will create two new files in the root directory of the Removable Media Drive as shown below: AUTOLOAD.PGM Application file CLONE.DAT File having all unit settings and register values from battery-backed RAM Figure 19.4 – Clone Unit Files NOTE: Make/Create clone operation automatically includes the security in AUTOLOAD.PGM file for security enabled files.
  • Page 169 MAN0964-12-EN_XL4_UserManual 4. Once the cloning is successful, OCS gives a message as below: Figure 19.5 – Cloning Status Make/Create clone can also be triggered by setting %SR164.9 bit to “1” from Ladder program or graphics. Once the operation is completed, this bit is made zero by the firmware. When Make Clone operation is triggered by this SR bit, it does not ask the user for confirmation for making clone.

  • Page 170: Load Clone

    MAN0964-12-EN_XL4_UserManual 19.3 Load Clone This option loads the application, all unit settings and register values from Removable media to the battery-backed RAM (Regardless of AutoLoad settings) and then resets the OCS for the settings to take effect. User needs to perform the following to Load Clone: Select “Clone Unit”...
  • Page 171 MAN0964-12-EN_XL4_UserManual 3. User needs to confirm Load Clone as shown below: Figure 19.8 – Load Clone Confirm Screen 4. After confirmation, all unit settings and register values will be loaded from Removable Media to the Battery backed RAM (Regardless of AutoLoad settings) and then OCS resets for the settings to take effect.

  • Page 172: Chapter 20: Maintenance

    MAN0964-12-EN_XL4_UserManual CHAPTER 20: MAINTENANCE 20.1 Firmware Updates The XL4 OCS products contain field updatable firmware to allow new features to be added to the product. Firmware updates should only be performed when a new feature or correction is required. WARNING: Firmware updates are only performed when the equipment being controlled by the XL4 OCS is in a safe, non-operational state.

  • Page 173: Replacing Backup Battery

    MAN0964-12-EN_XL4_UserManual 20.2 Replacing Backup Battery The XL4 has an advanced battery system that uses a rechargeable lithium-ion battery. The battery powers the real time clock when power is removed. To store registers, the battery continues to power the OCS for less than a second after external power is removed. In this time the registers and other retentive data is saved to internal flash memory.
  • Page 174 MAN0964-12-EN_XL4_UserManual Below are the steps to replace the lithium-ion battery, part no. BAT00019, available from Horner APG. Make sure the user program and any data stored in retentive memory is backed up. 2. Disconnect all power from the XL4 OCS unit including I/O power. Unplug I/O connections.

  • Page 175: Chapter 21: Modbus Communications

    MAN0964-12-EN_XL4_UserManual CHAPTER 21: MODBUS COMMUNICATIONS 21.1 Modbus Overview For complete Modbus instructions, please refer to the Help file in Cscape. Modbus (serial) is a popular, de-facto standard protocol that allows industrial devices from multiple manufacturers to easily share data in real-time. For Modbus serial communications, the XL4 can act as either a Master or a Slave.

  • Page 176: Modbus Master Overview

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

  • Page 177: Modbus Addressing Table

    MAN0964-12-EN_XL4_UserManual 21.4 Modbus Addressing Table To access XL4 registers, a Modbus Master must be configured with the appropriate register type and offset. This is usually accomplished with one of two methods: Method 1: The first method uses Traditional Modbus References, in which the high digit represents the register type and the lower digits represent the register offset (starting with Register 1 for each type).

  • Page 178: Chapter 22: Troubleshooting / Technical Support

    MAN0964-12-EN_XL4_UserManual CHAPTER 22: TROUBLESHOOTING / TECHNICAL SUPPORT Chapter 22 provides commonly requested troubleshooting information and checklists for the following topics. • Connecting to the XL4 OCS controller • Local controller and local I/O • CsCAN Network • Removable media In the event that this information is not what you need, please contact Technical Support at the locations indicated at the end of this chapter.
  • Page 179 Run Mode from the System Menu on the controller will make MJ1 available to Cscape. 5. Successful communications with USB-to-serial adapters vary. If in doubt, Horner APG offers a USB to serial adapter. Part numbers HE-XCK and HE-CPK.

  • Page 180: Local Controller And Local I/O

    MAN0964-12-EN_XL4_UserManual 22.2 Local Controller and Local I/O The System Menu provides the following status indications that are useful for troubleshooting and system maintenance. • Self-test results, diagnostics. • RUN and OK status • Network status and usage • Average logic scan rate •...
  • Page 181 MAN0964-12-EN_XL4_UserManual 22.3.1 CsCAN Network Troubleshooting Checklist Use the proper Belden wire type or equivalent for the network as specified in MAN0799. 2. The XL4 OCS does not provide 24VDC to the network. An external voltage source must be used for other devices such as SmartStix I/O. 3.

  • Page 182: Basic Troubleshooting

    Tel: (317) 916-4274 Fax: (317) 639-4279 Website: http://www.hornerautomation.com Email: techsppt@heapg.com Europe: Tel: (+) 353-21-4321-266 Fax: (+353)-21-4321826 Website: www.horner-apg.com Email: technical.support@horner-apg.com O c t o b e r 2 9 , 2 0 1 9 P a g e 182 | 189...

  • Page 183: Index Of Contents

    MAN0964-12-EN_XL4_UserManual INDEX OF CONTENTS %Q bits, 76 Compliance Accessories, 15 CE, 10 accumulator, 84, 85, 87, 89 Configuration of a Removable Media, 70 Add Target Screenshot in Cscape, 131 Configuration via Mini-B USB, 26 Alarms, 112 Configured reset value, 86 Alpha-numeric keypad, 108 Configuring Video Properties, 147 Analog Input Tranzorb Failure, 79...
  • Page 184 MAN0964-12-EN_XL4_UserManual ELECTRICAL INSTALLATION, 21 HSC, 82, 89, 92, 95, 97, 136, 137 Ethernet, 128 HSC Functions Register Map for 2 HSC Ethernet Communication, 29 configuration, 92 Ethernet Configuration HSC Functions Register Map for 4 HSC IP Parameters, 33 configuration, 93 Ethernet Module I/O Configuration Dialog, 30 Default Gateway, 31...
  • Page 185 MAN0964-12-EN_XL4_UserManual Panel Box Shock and Vibration, 20 REMOVABLE MEDIA, 67 Panel Cut-out, 18 Removable Media Manager, 68 Panel Cutout Tolerances, 18 Removable Media Manager Submenu, 68 Panel Design Checklist, 20 Removable Media XL4, 58 Panel Layout / Clearances, 19 Removable Memory Card Slot Photograph, Panel Mounting of an XL4 Series OCS, 16 Password Object, 109 Removing the I/O Cover, 74...
  • Page 186 MAN0964-12-EN_XL4_UserManual Sytem Menu Two-Point Ground Connection Test, 22 Overview, 43 Types of Devices that can be connected to target ID, 133, 134 XL4, 13 Target ID, 133, 134 Typical Output Wiring, 76 target indicator, 134, 135 Typical Screen Jump Object (XL4), 110 Technical Support, 2, 78, 173, 177 Universal Analog Inputs, 80 Contacts, 177...

  • Page 187: Index Of Figures And Tables

    MAN0964-12-EN_XL4_UserManual INDEX OF FIGURES AND TABLES Figure 02.1 - Visual Overview of XL4 OCS, 11 Figure 02.2--Types of Devices that can be connected to XL4, 13 Figure 03.1 – Panel Mounting of an XL4 Series OCS, 16 Figure 03.2 – XL4 OCS with Mounting Clips, 17 Figure 03.3 –...
  • Page 188 MAN0964-12-EN_XL4_UserManual Figure 15.02 – Cscape Connection Wizard Screenshots, 130 Figure 15.03 – Cscape Alternative Connection Method Screenshot, 131 Figure 15.04 – Add Target Screenshot in Cscape, 131 Figure 15.05 – LAN1 Configuration Screen, 135 Figure 15.06 – Digital / HSC Input Configuration Dialog, 137 Figure 15.07 –...
  • Page 189 Table 9.1 - Clock and Time Setting Terms, 54 No part of this publication may be reproduced without the prior agreement and written permission of Horner APG, Inc. Information in this document is subject to change without notice. O c t o b e r 2 9...

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