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HORNER HE-XC1E0, User Manual

The HORNER HE-XC1E0 User Manual is a comprehensive guide that provides essential instructions for operating and maximizing the potential of the product. Available for free download from our website, this manual ensures you can easily set up and utilize the HORNER HE-XC1E0 to its fullest potential.

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MAN0964-14-EN_XL4_XL4P_UM 

 

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20.5  OCS Battery Charging Cycle 

 
There are various charging states that are executed based on battery temperature, level 
of battery charge, and self-test results. The battery temperature can be determined by 
checking the CPU temperature in the controller System Menu: View Battery Status or by 
monitoring System Register %SR195.  
 
The battery temperature is equal to the CPU temperature minus 30°C. 
 
NOTE: Refer to Table 20.1 for charge states and definitions. 

 

1.

 

When power is applied to the OCS, the unit always goes to State 11; Waiting, for the 
first two minutes. 

2.

 

After two minutes have expired, the OCS will begin charging the battery based on 
battery temperature. In this step, charging will ensue even if the battery is already 
fully charged. 
In this step charging does not ensue if the battery temperature is outside of the 
acceptable hot or cold limits. 

3.

 

The battery is charged fully to 4.2 volts in the Normal Charging or Cold Charging 
states or to 4.1 volts in the Hot Charging state. 

4.

 

Once fully charged to 4.2 volts, state 0, the Wait Discharging state is executed, 
state 12.  The battery is allowed to discharge to 4.0 volts for however long that 
takes. Powering up the OCS will reset the charge cycle to step 1. 

5.

 

If the battery was charged to 4.1 volts under state 2, Hot Charging; 4.1 volts is 
maintained until Normal or Cold Charging can be executed. 
 

Note: If the battery voltage is too low, less than 2.5 volts, or if the battery is missing, 

charging is suspended.  In this condition, the OCS unit fails self-test. Diagnostics will 
show a battery warning.  %SR55.13 will be ON. 

 
Note: If the battery is not missing and the voltage is 2.5 volts or greater but will not fully 

charge in 8 to 40 hours, the charge cycle is suspended for 5 minutes and then tried 
again. 

 
Note: Because the OCS is designed to maintain the Real Time Clock for a year or more in a 

powered down state, this translates as; the battery requires up to 8 to 40 hours of 
recharging time in a year. 

 

 

Summary of Contents for HE-XC1E0

Page 1: ...a Europe North America Europe HE XC1E0 HEXT251C100 HE XPC1E0 HEXP251C100 HE XC1E2 HEXT251C112 HE XPC1E2 HEXP251C112 HE XC1E3 HEXT251C113 HE XPC1E3 HEXP251C113 HE XC1E4 HEXT251C114 HE XPC1E4 HEXP251C114 HE XC1E5 HEXT251C115 HE XPC1E5 HEXP251C115 HE XC1E6 HEXT251C116 HE XPC1E6 HEXP251C116 ...

Page 2: ...l 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 Corporatio...

Page 3: ...OM THE XL4 XL4 PRIME 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 los...

Page 4: ... Europe http www hornerautomation eu QUICK START INSTALLATION PROGRAMMING TROUBLESHOOTING Safety Compliance Safety Compliance Safety Compliance Safety Compliance Introduction Introduction Introduction Introduction Mechanical Installation Serial Communications Back Up Battery Electrical Installation CAN Communications Fail Safe System Ethernet Communications Clone Unit Downloadable Communication Pr...

Page 5: ... 16 3 1 Overview 16 3 2 Mounting Requirements 16 3 3 Mounting Orientation 17 3 4 Dimensions 18 3 6 Installation Procedure 19 3 7 Factors Affecting Panel Layout Design and Clearances 20 CHAPTER 4 ELECTRICAL INSTALLATION 22 4 1 Grounding Definition 22 4 2 Ground Specifications 22 4 3 How to Test for Good Ground 23 4 4 Primary Power Port 24 CHAPTER 5 SYSTEM SETTINGS AND ADJUSTMENTS 25 5 1 System Menu...

Page 6: ... Inputs 77 CHAPTER 8 GENERAL I O 78 8 1 Overview 78 8 2 Removing the XL4 XL4 Prime OCS I O Cover 78 8 3 Model and I O Overview 79 8 4 Solid State Digital Outputs 80 8 5 Relay Outputs 81 8 6 Digital Inputs 82 8 7 Analog Inputs 83 8 8 Universal Analog Inputs 84 8 9 Analog Outputs 85 CHAPTER 9 HIGH SPEED I O HSC PWM 86 9 1 Overview 86 9 2 Glossary 87 9 3 High Speed Counter HSC Functions 88 9 4 HSC Fu...

Page 7: ... Protocol Config 123 13 3 Network Configuration 124 13 4 Device List and Devices Configuration 126 13 5 Scan List 127 13 6 Data Mapping Configuration Scan List Entry 128 CHAPTER 14 USER INTERFACE 130 14 1 Overview 130 14 2 Screen Specifications 130 14 3 Displaying and Entering Data 131 14 4 Alpha Numeric Keypad 132 14 5 Screen Navigation 134 14 6 Ladder Based Screen Navigation 134 14 7 Beeper Ackn...

Page 8: ... Settings 163 18 3 Backup Restore Data 163 18 4 AutoLoad 168 18 5 AutoRun 170 CHAPTER 19 MODBUS COMMUNICATIONS 171 19 1 Modbus Overview 171 19 2 Modbus Slave Overview 171 19 3 Modbus Master Overview 172 19 4 Modbus Addressing Table 173 CHAPTER 20 XL4 RECHARGEABLE BACK UP BATTERY 174 20 1 Overview 174 20 2 Storing Register Contents 174 20 3 Battery Life 174 20 4 Lithium Battery Safety 174 20 5 OCS ...

Page 9: ...MAN0964 14 EN_XL4_XL4P_UM N o v e m b e r 1 0 2 0 2 1 P a g e 9 194 CHANGE LOG 190 INDEX 191 ...

Page 10: ...urce as possible WARNING Replace fuse with the same type and rating to provide protection against risk of fire and shock hazards WARNING In the event of repeated failure do not replace the fuse again as a repeated failure indicates a defective condition that will not clear by replacing the fuse WARNING EXPLOSION HAZARD Substitution of components may impair suitability for Class I Division 2 WARNIN...

Page 11: ...e with good practice and local codes e Wear proper personal protective equipment including safety glasses and insulated gloves when making connections to power circuits f Ensure hands shoes and floor are dry before making any connection to a power line g Make sure the unit is turned OFF before making connection to terminals Make sure all circuits are de energized before making connections h Before...

Page 12: ...MAN0964 14 EN_XL4_XL4P_UM N o v e m b e r 1 0 2 0 2 1 P a g e 12 194 CHAPTER 2 INTRODUCTION 2 1 Visual Overview of XL4 XL4 P OCS Figure 2 1 Visual Overview of XL4 XL4 P OCS ...

Page 13: ... Model 4 MAN1146 MAN1322 Model 5 MAN1147 MAN1323 Model 6 MAN1148 MAN1324 User Manual This manual provides general information that is common to XL4 XL4 P OCS models and can be downloaded from our web Visit our website to obtain user documentation and updates North America https hornerautomation com Europe http www hornerautomation eu 2 1 2 Four main types of information are covered in the manual a...

Page 14: ... devices that can be used with the XL4 XL4 P OCS Figure 2 2 Visual Overview of Types of Devices that can be connected to XL4 XL4 P OCS CAN Serial I O XL4 XL4 Prime OCS Other OCS Devices Drives PLCs Bar Code Readers Printers SCADA OPC Servers Serial I O Sensors Indicators Alarms Encoders Pumps Relays Solenoids Other OCS Devices Smart Stix I O RCX116 I O Base OPC Ethernet Cscape OPC Server Modbus TC...

Page 15: ... multiple auto tuning PID loops and string handling capabilities Removable media for 32 gigabytes of storage of programs data logging or screen captures CsCAN networking port for communication with remote I O other controllers or PCs USB port for communication with PCs and programming of controller Configurable serial protocols for communication to drives PLCs or other serial peripherals Full feat...

Page 16: ...nical installation of the unit 3 2 Mounting Requirements 3 2 1 Mounting Procedures Installed in a Panel Door Figure 3 1 Panel Mounting of an XL4 XL4 Prime Series OCS Once the panel design has been completed using the criteria and suggestions in the following sections use the following steps to panel mount the XL4 XL4 Prime OCS 1 Remove all connectors from the XL4 XL4 Prime OCS unit 2 Make sure the...

Page 17: ...g Orientation Figure 3 3 Orientation of XL4 XL4 Prime OCS Slot for Clip DIN Rail Clip CAUTION For DIN Rail mounting To prevent the unit from slipping off the DIN Rail do not install the unit on its sides as shown Be sure the DIN Rail is in the horizontal position NOTE For panel or DIN rail mounting The orientation shown above provides for optimum readability of the screen and ease of use of the ke...

Page 18: ...MAN0964 14 EN_XL4_XL4P_UM N o v e m b e r 1 0 2 0 2 1 P a g e 18 194 3 4 Dimensions Figure 3 5 XL4 XL4 P OCS Dimensions ...

Page 19: ...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 XL4 XL4 Prime may be installed If the opening is too large water may leak into the enclosure potentially damaging the unit If the opening is too small the OCS may not fit through the hole without damage 3 Remove any burrs and or sharp ...

Page 20: ...llow enough depth for the OCS 2 50 80mm 3 7 2 Grounding Panel Box The panel box needs to be properly connected to earth ground to provide a good common ground reference 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 3 7 3 Temperature Ventilation Ensure that the panel layout design allows for adequate ventilati...

Page 21: ...st provides highlights of panel layout design factors ____Meets the electrical code and applicable standards for proper grounding etc ____Meets the panel manufacturer s requirements for grounding etc ____Is the panel box properly connected to earth ground Is the panel door properly grounded Has the appropriate procedure been followed to properly ground the devices in the panel box and on the panel...

Page 22: ...s a conductive connection between a circuit or piece of equipment 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 frequency interference RFI 4 2 Ground Specifications Ideally a ground resistance measurement from equipment to ear...

Page 23: ...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 Figure 4 1 Two Point Ground Connection Test METAL WATER PIPE OR OTHER GOOD GROUND GROUND ROD GROUND DISCONNECTED FROM SERVICE GROUND RESISTANCE METER ...

Page 24: ...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 2 Connect to earth ground 3 Apply recommended power ...

Page 25: ... display the Main Menu Then use the and Up Arrow or Down Arrow keys to select a Main Menu item and press Enter Return Arrow to display the item s Sub Menu Figure 5 1 System Menu Screenshot Table 5 1 OCS LEDs RUN OFF indicates OCS is in IDLE STOP mode Flashing indicates DO IO mode or RUN with no ladder program ON indicates ladder code running OK OFF indicates one or more self tests failed ON indica...

Page 26: ...v 14 10 FPGA Rev 0 0 InitRD Rev 1 06 OS Ver 2 6 35 43 Self Test Ok Logic Error Ok User Program Ok User Graphics Ok W Dog Trips 0 Net Errors 0 Network State Ok Network ID Ok Dup Net ID Ok Clock Error Ok I O System Ok Battery Ok Slot 1 I O Xex06 Slot 2 I O Empty Slot 3 I O ETN300 MJ1 None Loaded MJ2 None Loaded COM None Loaded Fkeys Momentary SYS Fn enable Yes Use to adjust Dflt Pgm Port MJ1 232 MJ1...

Page 27: ...o edit the highlighted 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 appropriate 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 k...

Page 28: ...1 to 253 This node s CsCAN Network ID must be unique on network CAN Baud 125kB 125kBd CAN network 250kB 250kBd CAN network 500kB 500kBd CAN network 1MB 1MBd CAN network MAC ID Displays the Ethernet MAC ID of the unit IP Displays the Ethernet IP address of the unit NetM Displays the Ethernet net mask of the unit GatWy Displays the Ethernet gateway of the unit NOTE The IP address Net Mask and Gatewa...

Page 29: ...dth used by all nodes Ladder Size x Number of bytes in application ladder program Config Size x Number of bytes in application I O configuration Graphics Size x Number of bytes in application graphic screens String Size x Number of bytes in application string table Bitmap Size x Number of bytes in application bitmaps Text Tbl Size x Number of bytes in application text tables Font Tbl Size x Number...

Page 30: ...rrected User Graphics Ok Application graphics objects loaded successfully Fault Application graphics objects not loaded or load failed W Dog Trips 0 Watchdog timer has not tripped since the last power up x Number of times watchdog timer has tripped Net Errors 0 No CAN network bus off errors have occurred x Number of CAN network bus off errors that have occurred Network State Ok At least one other ...

Page 31: ...plays 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 Battery Discharging The battery is steadily discharging ...

Page 32: ...sing 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 Slot 1 I O XExyy yy I O module installed but another I O module configured Slot 1 I O XExyy yy I O module installed and configured properly Depending on the COM module that is installed and the COM module that has been configured by Cscape one of the following six Syst...

Page 33: ... an XL4 XL4 Prime OCS serial port select the Protocol Config item in Cscape s Program menu and then setup a protocol for Port 1 or Port 2 or both 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 Name None Loaded or name of the protocol assigned to MJ1 Protocol Version Blank or version of the prot...

Page 34: ...keys Sub Menu displays two System Settings both of which are editable Fkeys Momentary K1 5 bits go On Off as F1 F5 are pressed released Toggle K1 5 bits toggle each time F1 F4 are pressed SYS_Fn enable Yes Reset and all clear system functions enabled No Reset and all clear system functions disabled ...

Page 35: ...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 Dflt Pgm Port MJ1 232 MJ1 RS232 port is the default programming port Modem Modem COM module is the default programming port MJ2 RS485 Bias No MJ2 RS485 bias resistors are not switched in Yes MJ2 RS485 bias resistors are switched in ...

Page 36: ...ariable latency data networks Daylight Saving Time Time as adjusted to achieve longer evening daylight especially in summer by setting the clocks an hour ahead of the standard time Apply Daylight Saving DST Daylight Saving Time DST is the practice of setting the clocks forward one hour from standard time during the summer months and back again in the fall in order to make better use of natural day...

Page 37: ...m logic can be written to accomplish an automatic switchover using system register SR211 In program logic move a 1 INT into SR211 to enable Daylight Saving Time Move a 0 INT into SR211 to disable Daylight Saving Time Trigger the move to SR211 based on a compare function to the RTC date according to daylight saving practices in your desired region To Set Local Time The Set Time Date sub menu displa...

Page 38: ...P_UM N o v e m b e r 1 0 2 0 2 1 P a g e 38 194 5 12 Set Beeper The Set Beeper Sub Menu displays one System Setting which is editable Beeper Enable Yes default Enables beeper No Disables beeper does NOT affect ladder access ...

Page 39: ...Disable screen saver Timeout min 5 1200 Amount of time in minutes to expire with NO touch activity before activating screen saver black screen Popup Status Off default Disable popup status Warning Display popup status only if controller status changes to NOT Ok or NOT Run mode On Display popup status on any controller status change Update Time mS 2 50 Maximum amount of time to allow for graphics u...

Page 40: ...ory Dir Empty Media Directory Initializing No microSD card has been installed in the Memory slot microSD card is installed but it is still initializing microSD card is installed and initialized but contains no files Scrollbar Shows size of highlighted file or shows DIR if directory is highlighted Shows the date file or directory was created or last modified Shows the time file or directory was cre...

Page 41: ...tain 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 Electromagnetic Interference event Selecting Fail Safe System menu will open the following menu screen Selecting Backup Restore Data displays the following screen in Backup Copies battery backed RAM contents on to the onboard fla...

Page 42: ...e 42 194 5 15 Enable AutoRun Enable AutoRun displays the following options which can be selected Enable AutoRun No OCS will be in IDLE mode after AutoLoad or Automatic Restore Yes OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore ...

Page 43: ...AutoLoad Enable AutoLoad displays the following options which can be selected Enable AutoLoad No Does not load AUTOLOAD PGM automatically when application program is absent or corrupted Yes Loads AUTOLOAD PGM file automatically from RM when application program is absent or corrupted ...

Page 44: ...into the RM Refer to the Removable Media chapter for 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 Make Clone Selecting Clone Unit menu will open the following menu screen Load Clone and Make Clone virtual buttons are below the screen NOTE Free Total...

Page 45: ...ake 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 ...

Page 46: ...a g e 46 194 5 18 Load Clone Selecting Clone Unit menu will open the following menu screen Select Load Clone one of the virtual buttons beneath the screen NOTE For security enabled files Load Clone asks for password validation before loading the application ...

Page 47: ... about the WebMI license Please refer to MAN1036 for the WebMI Manual The information can also be viewed from Cscape using the following SR registers SR209 3 WebMI server status SR209 4 WebMI user logged in status SR209 9 to SR209 16 Number of Users SR218 Number of Webpages SR219 Number of Data Points SR220 SR222 Expiry Date of WebMI License ...

Page 48: ...bration dialog press and hold both the SYS and F1 key for longer than 2 seconds and a dialog similar to Figure 5 3 should appear 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 crosshair as exactly as possible and release A small should appear and will mo...

Page 49: ...Q Analog Output 16 bit output registers used to send analog information such a voltages levels or speed settings to an attached device AIG Global Analog Input Specially defined 16 bit input registers that come from the network AQG Global Analog Output Specially defined 16 bit output registers that go to the network D Display Bit These are digital flags used to control the displaying of screens on ...

Page 50: ...d for system use T Temporary Bit Non retentive single bit registers 6 2 Useful S and SR Registers Table 6 1 Common S Register Definitions Register Name Description S1 FST_SCN Indicate First Scan S2 NET_OK Network is OK S3 T_10MS 10mS timebase S4 T_100MS 100mS timebase S5 T_1SEC 1 second timebase S6 IO_OK I O is OK S7 ALW_ON Always ON S8 ALW_OFF Always OFF S9 PAUSING_SCN Pause n Load soon S10 RESUM...

Page 51: ...p Restore Data 18 Enable AutoRun 19 Enable AutoLoad 20 Clone Unit 21 Touch Calibration 24 License Details Excludes RCC Units 0 to 24 Read Write Read Write SR4 SELF_TST Self Test Results Read Only Read Only SR4 1 Self Test Results BIOS Error Read Only Read Only SR4 2 Self Test Results Engine Error Read Only Read Only SR4 3 Self Test Results Ladder Error Read Only Read Only SR4 4 Self Test Results R...

Page 52: ...Data Table Size 32 Bit DINT Read Only Read Only SR23 Ladder Code CRC Read Only Read Only SR24 User Text CRC Read Only Read Only SR25 System Text CRC Read Only Read Only SR26 I O Configuration Table CRC Read Only Read Only SR27 Network Configuration Table CRC Read Only Read Only SR28 Security Data Table CRC Read Only Read Only SR29 NET_ID Network ID Read Only Read Write CsCAN Mode 1 to 253 DeviceNe...

Page 53: ...Read Only Read Only SR45 RTC_MIN Real Time Clock Minute 0 to 59 Read Only Read Only SR46 RTC_HOUR Real Time Clock Hour 0 to 23 Read Only Read Only SR47 RTC_DATE Real Time Clock Date 1 to 31 Read Only Read Only SR48 RTC_MON Real Time Clock Month 1 to 12 Read Only Read Only SR49 RTC_YEAR Real Time Clock Year 1996 to 2095 Read Only Read Only SR50 RTC_DAY Real Time Clock Day 1 Sunday 1 to 7 Read Only ...

Page 54: ...8 USER_LEDS User LEDs Read Write Read Write SR59 Engine Build Number Only last three numbers displayed Read Only Read Only SR60 Build Option Build Test 0 Build Beta 1 Build Product 2 0 to 2 Read Only Read Only SR61 NUM_IDS Number of CsCAN Network IDs Read Only Read Only SR62 100 Reserved SR101 3 WebMI License Details WebMI server status XLEe XLTe X2 X4 X7 only Read Only Read Only SR101 4 WebMI Lic...

Page 55: ... Read Write Read Write SR153 163 Reserved SR164 FailSafe Clone SR164 1 RS485 Port Biasing 1 MJ1 or MJ2 Read Write Read Write SR164 2 RS485 Port Biasing 2 MJ2 or MJ3 Read Write Read Write SR164 3 AUTO_RESTRD Indicates Automatic Restore Operation has been performed Read Only Read Only SR164 4 BCKUP_TAKN Indicates Backup of Registers has been taken Read Only Read Only SR164 5 EN_AUTO_RN Enable AUTORU...

Page 56: ...SR174 2 Indicates safe to remove Media Read Write Read Write SR175 Removable Media Status Read Only Read Only SR176 177 Removable Media Free Space 32 Bit DINT Read Only Read Only SR178 179 Removable Media Total Space 32 Bit DINT Read Only Read Only SR180 Reserved SR181 ALM_UNACK Bits 1 16 indicate Unacknowledged in Alarm Groups 1 16 Read Only Read Only SR182 ALM_ACT Bits 1 16 indicate Active in Al...

Page 57: ...rge Temp High XL Only in degree centigrade Read Only Read Only SR196 Charging State 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 charging 9 CPU Hot not charging 10 Battery voltage 2V not charging 11 First 2 minutes Init Wait Not Charging ...

Page 58: ...ing is enabled one hour will be added to the local time Read Write Read Write SR212 UTC Seconds Read Only Read Only SR213 UTC Minutes Read Only Read Only SR214 UTC Hours Read Only Read Only SR215 UTC Date Read Only Read Only SR216 UTC Month Read Only Read Only SR217 UTC Year Read Only Read Only SR218 Number of Webpages license detail XLE XLT X2 X4 X7 use SR101 SR108 112 for WebMI License Details R...

Page 59: ...32 per ID AQG 32 per ID Ethernet CsCAN Ping EGD SRTP Modbus TCP Master Downloadable protocol Slave Ethernet IP FTP or HTTP 10MBd or 100MBd CsCAN 125kBd 250kBd 500kBd or 1MBd Serial Ports 1 RS 232 1 RS 485 Ports IDs Per CsCAN Network 64 w o repeat 253 w 3 repeaters Keypad 5 keys 4 Function keys and a System Key Display 320 x 240 3 5 TFT 64K colors Screen Memory 64MB User Screens 1023 Data Fields Pe...

Page 60: ... Digital Outputs Q13 Q16 Unused Reserved Digital Outputs Reserved Q17 Q20 Unused Link HSC Table Q21 Q24 Unused Reserved AI1 AI4 Unused Analog Inputs AI1 AI2 for Analog Input Channels AI3 AI4 Unused Mirror of first four analog channels AI33 AI38 Unused Analog Inputs for all 6 channels AQ1 AQ8 Unused PWM Table Below AQ9 AQ10 Unused Analog Outputs Unused These registers can be used as general purpose...

Page 61: ...uency Totalize Pulse Quad AI5 6 HSC1 function Accumulator Quad 1 Acc AI7 8 HSC2 function Accumulator AI9 10 HSC3 function Accumulator Quad 2 Acc AI11 12 HSC4 function Accumulator AQ1 2 HSC1 Preset AQ3 4 HSC2 Preset Q17 Clear HSC1 Clear Quad 1 Q18 Clear HSC2 Set Quad 1 Q19 Clear HSC3 Clear Quad 2 Q20 Clear HSC4 Set Quad 2 ...

Page 62: ...rough Connector Local xx Indicates the Network ID of the OCS to which the Cscape program is physically connected through its serial port It can serve as a pass through device to other nodes on the network Target yy R Indicates the Network ID of the device with which the Cscape program is exchanging data NOTE The Local unit and Target unit can be the same unit or they can be separate units The foll...

Page 63: ...rt on the OCS only on select models to an open USB port on the PC A cable for doing this is included in the HE XCK and HE CPK programming kits The OCS will install as a device once plugged in 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 HE XEC Ethernet Utility HTTP Web S...

Page 64: ...g e 64 194 The PC will detect a new device has been plugged into the USB port Now that the XL4 XL4 Prime is plugged in go to Cscape Controller Connection Wizard If you are just opening Cscape Connection Wizard usually opens by default Select USB and click Next ...

Page 65: ... connecting for the first time we suggest connecting via USB Figure 7 2 Cscape Connection Wizard Screenshots If Controller USB COM Port is not present in the dropdown list the Windows operating system has not yet recognized 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 reope...

Page 66: ...hoose connection method in Add Target Figure 7 3 Cscape Alternative Connection Method Screenshot Figure 7 4 Add Target Screenshot in Cscape NOTE The following fields Target Name Connection Medium Connected Device and Connection Settings need to be filled for communication configuration if Cscape Connection Wizard was not used Table 7 1 below explains the information needed in each field ...

Page 67: ...nterface Select this option to communicate over CAN This option requires additional hardware to be installed with the PC to be able to do so Select the type of hardware installed from the dropdown Installed Modem Select this option to communicate to the device through the internal modem of the computer Cscape will automatically detect the internal modem attached with PC and list in the attached dr...

Page 68: ...arget 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 XL4 XL4 Prime OCS press the System Menu key The first item in the menu is Set Networks Pressing Enter allows you to view or modify the ID of the uni...

Page 69: ...port files Connect the PC s serial port or the USB to Serial adaptor to the port labeled MJ1 on the XL4 XL4 Prime 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 in the Cscape Status Bar section If the controller is not ...

Page 70: ...t 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 Figure 7 5 LAN1 Configuration Screen 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 ...

Page 71: ...he type of XL4 XL4 Prime OCS is selected the model drop down box will provide the XL4 XL4 Prime OCS model numbers from which to choose 6 Once the XL4 XL4 Prime OCS CPU is selected press OK to exit the dialog and configure the I O that is present in the first slot 7 The I O configure dialog specifically the Module Setup tab provides four 4 buttons to configure all of the I O Go through each area of...

Page 72: ...oup box allows the user to select if inputs are active high Positive logic or active low Negative logic It is important that this setting match what the jumper settings are on the hardware The High Speed Counters group box contains all of the windows that are used for configuring the four 4 available high speed counters on the XL4 XL4 Prime OCS In configuring a counter the user needs to set the ty...

Page 73: ...uts The PWM State On Controller Stop group box contains items that allow the user to specify how the PWM outputs behave when the controller is stopped 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 The Output...

Page 74: ...tion dialogs select Controller Hardware Configuration Local I O Config top button Module Setup Figure 7 8 Analog Input Configuration Dialog The Channel x drop down windows allow the user to specify the mode for each analog input to operate The Channel x drop down windows are enabled disabled according to which model is being configured All the models have the following modes available 0 10V 0 20mA...

Page 75: ...ouple 1 20 C PT100 DIN RTD 1 10 C Type K Thermocouple 1 20 C PT1000 DIN RTD 1 10 C Type N Thermocouple 1 20 C Type J Thermocouple 1 10 C Type T Thermocouple 1 20 C Type K Thermocouple 1 10 C Type E Thermocouple 1 20 C Type N Thermocouple 1 10 C Type R Thermocouple 1 20 C Type T Thermocouple 1 10 C Type S Thermocouple 1 20 C Type E Thermocouple 1 10 C Type B Thermocouple 1 20 C Type R Thermocouple ...

Page 76: ...tton Module Setup Figure 7 9 Analog Output Configuration Dialog Model 6 The Output value on STOP group box contains items that allow the user to specify how the analog output channels behave when the controller is stopped The outputs can either hold their value or default to a value when the controller is stopped The Output Mode group box allows the user to select the operating modes for each of t...

Page 77: ... e m b e r 1 0 2 0 2 1 P a g e 77 194 7 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 7 10 Scaling Analog Inputs ...

Page 78: ...or the pages referencing register mapping 8 2 Removing the XL4 XL4 Prime OCS I O Cover Some I O configurations require jumper settings to be changed inside the XL4 XL4 Prime OCS unit Examples of these settings are setting positive or negative logic on digital inputs or setting current or voltage on analog inputs Each XL4 XL4 Prime OCS I O jumper is set to a factory default Refer to the data sheet ...

Page 79: ...reads This prevents 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 Ensure not to exceed the recommended max torque of 7 10 in lbs 0 8 1 13 N m 8 3 Model and I O Overview Table 8 1 Built In Digital Analog I O Digital Analog DC In DC Out Relay Out HSC In Pulse Out mA V In mA V RTD TC Universal mA V Out Mode...

Page 80: ...s some application may require external fusing on these outputs The digital outputs in the XL4 XL4 Prime OCS are typically controlled via Q bits in the register mapping Some of the outputs are designed for high speed applications and can be used for PWM or frequency output applications Please see the data sheet and the chapter on High Speed I O for additional information When the controller is sto...

Page 81: ...ating Products containing relays often have total current limits based on the ambient temperature of the application Please see the product data sheet for current temperature derating information for relays Fusing External fusing is generally required to protect the relays devices and wiring from shorts or overloads Figure 8 5 Relay Fusing 001XLE015 0V ON J1 12 24VDC R2 C2 R3 C3 R6 C6 R4 C4 R5 C5 ...

Page 82: ... on jumper settings NOTE The digital inputs on the XL4 XL4 Prime OCS are designed for low voltage DC inputs The inputs are designed to support both positive and negative input modes For most models the mode is set by a jumper setting and a configuration parameter in Cscape The HE XC1E6 does not require jumpers and only requires a configuration parameter in Cscape All the inputs on the unit must be...

Page 83: ... downside to digital filtering is the inputs will respond more slowly to sudden changes in the actual input 8 7 1 Thermistor Option for Special Orders NOTE The standard unit does NOT support thermistor Thermistor support is a factory option for Models 2 3 and 4 only Model 2 can support a two channel and four channel thermistor Models 3 4 support the two channel thermistor only Please refer to the ...

Page 84: ...a configuration parameter 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 sudden changes in the actual input The Universal Analog Inputs on the Model 6 I O board are unique from other Horner XL series inpu...

Page 85: ...scape The analog outputs on XL4 XL4 Prime OCS devices provide high resolution voltage or current outputs The voltage or current 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 bef...

Page 86: ...nction availability refer to the associated model s Specification Installation sheet Digital DC Input Output sections The OCS contains a Field Programmable Gate Array FPGA which is an integrated configurable circuit that allows the XL4 XL4 PLUS to be programmed to have either two high speed counters or four high speed counters The XL4 XL4 PLUS ships with two high speed counters but a customer can ...

Page 87: ... latch has a data input a clock input and an output When the clock input is active data on the input is latched or stored and transferred to the output register either immediately or when the clock input goes inactive The output retains its value until the clock goes active again Marker Input into the OCS that indicates a particular position Typically an encoder has a marker output that represents...

Page 88: ... be consumed The measurement values are provided to ladder in a AI register Refer to the Registers chapter for more details 9 3 1 Frequency In frequency mode the frequency of the input signal is written to the accumulator in terms of Hertz cycles second When using frequency mode four update selections are provided which specify the width of the sample window NOTE Selecting a shorter sample window ...

Page 89: ...ulator when the input is enabled NOTE Two inputs can be assigned Either input can cause the counter to decrement The second input can also be disabled Up Down Input 1 Up Input 2 Down In this mode Input 1 assigned to any of the four inputs increments the counter while Input 2 also assigned to any of the 4 inputs decrements the counter Clk Dir Input 1 Clk Input 2 Dir This mode uses input 1 as a cloc...

Page 90: ...e 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 configurable Maximum direct digital reset latency is 100μs The totalize function also supports an option which compares the current accumulator value with a supplied Preset Value PV which is provided t...

Page 91: ...of the last sampled value In this mode the Disable and Latch special functions are allowed Refer to the HSC Glossary for a description of these functions Width High 1 μs Counts In this sub mode the accumulator value will contain the number of 1 μs counts the pulse is high Width Low 1 μs Counts In this sub mode the accumulator value will contain the number of 1 μs counts the pulse is low Figures 9 ...

Page 92: ...owed Refer to the HSC Glossary for a description of these functions Period Rising Edges 1 μs 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 1 μs Counts In this sub mode the period of the input signal is reported in 1 μs units The period measurement will start on the falling ...

Page 93: ...utput form it uses or try both modes to determine if the encoder counts up when expected Figure 9 5 Quadrature 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 ...

Page 94: ...t only for counters 1 and 2 3 The High Speed Outputs are Q1 for Counter 1 and Q2 for Counter 2 They operate as high speed outputs independent of the controller scan rate when configured as HSC Output in the Digital Out PWM configuration in Cscape 4 The High Speed Output state reflects in the status register High Speed Out e g I1603 for Counter 1 the update speed of the status bit is scan rate depe...

Page 95: ...e Latch function is active it takes the current value of the Accumulator and moves it into the Latch Value register Preload When the pre load function is active it will take the value from the Preload register and put it into the Accumulator for the corresponding Counter Clear When the clear function is active it will move a value of 0 into the Accumulator for the corresponding counter Marker When...

Page 96: ...1 if Signed this bit can also be reset with the Output Reset Bit NOTE For the Overflow and Underflow flag registers if using some sort of counter that counts both up and down going over the threshold to go negative triggers the underflow and then going back over the threshold back into positive numbers will trigger the positive register to go active High Speed Out This register will follow the hig...

Page 97: ...r 2 AQ411 412 Match2 Counter 2 AQ413 424 Reserved Q1601 Latch Counter 1 Q1602 Preload Counter 1 Q1603 Clear Counter 1 Q1604 Disable Counter 1 Q1605 Direction C 1 Q1606 Output Reset Counter 1 Q1607 Preload Disable Counter 1 Q1608 Latch Disable Counter 1 Q1609 Disable Marker C1 Q1610 Latch Marker C1 Q1611 Preload Marker C1 Q1612 Clear Marker C1 Q1613 1616 Reserved Q1617 Latch Counter 2 Q1618 Preload...

Page 98: ...r 3 AQ415 416 Match1 Counter 3 AQ417 418 Match2 Counter 3 AQ419 420 Preload Counter 4 AQ421 422 Match1 Counter 4 AQ421 424 Match2 Counter 4 Q1601 Latch Counter 1 Q1602 Preload Counter 1 Q1603 Clear Counter 1 Q1604 Disable Counter 1 Q1605 Direction C1 Q1606 Output Reset Counter 1 Q1607 Preload Disable Counter 1 Q1608 Latch Disable Counter 1 Q1609 1616 Reserved Q1617 Latch Counter 2 Q1618 Preload Co...

Page 99: ...ter 4 Q1657 1664 Reserved I1601 Overflow Flag Counter 1 I1602 Underflow Flag Counter 1 I1603 High Speed Out 1 I1604 Reserved I1605 Overflow Flag Counter 2 I1606 Underflow Flag Counter 2 I1607 High Speed Out 2 I1608 Reserved I1609 Overflow flag Counter 3 I1610 Underflow flag Counter 3 I1611 High Speed Out 3 I1612 Reserved I1613 Overflow flag Counter 4 I1614 Underflow flag Counter 4 I1615 High Speed...

Page 100: ...ction drives that respective output Both PWM channels may be individually enabled and can have independent frequency and duty cycles The PWMs require two parameters AQs to be set for operation These parameters may be set at run time Duty Cycle The Duty Cycle is a 32 bit value from 0 to 32 000 indicating the relative duty cycle of the output For example a value of 8000 would indicate a 25 duty cycl...

Page 101: ...e counts Specifying zero for either the period or duty causes the PWM output to remain low during stop mode NOTE For standard I O models 1E3 1E4 1E5 and 1E6 the maximum recommended PWM frequency is 10kHz due to the limitations of built in output circuitry The HE XHSQ generates 24V pulse outputs with a recommended max of 400kHz The HE XHSQ 5 generates 5V pulse outputs with a recommended max of 1 0M...

Page 102: ...Frequency pulses per second Sets the frequency for the last cycle during the acceleration phase the consistent frequency during the run phase and the frequency of the first cycle during the deceleration mode The Run Frequency must be greater than 0 and must not exceed 5000Hz standard 400 000Hz HE XHSQ or 1 0MHz HE XHSQ 5 Acceleration Count Sets the number of cycles to occur within the acceleration...

Page 103: ...on the next start command if the error was corrected Table 9 7 Boolean Registers 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 ...

Page 104: ...epper 2 AQ433 434 PWM 2 Frequency Run Frequency Stepper 2 AQ435 436 Acceleration Count Stepper 2 AQ437 438 Run Count Stepper 2 AQ439 440 Deceleration Count Stepper 2 Q1 Start Move Bit Stepper 1 Q2 Start Move Bit Stepper 2 I1617 Ready Done Stepper 1 I1618 Error Stepper 1 I1619 Ready Done Stepper 2 I1620 Error Stepper 2 Table 9 9 PWM Functions Register Map Four Counter Register PWM Stepper AQ451 452...

Page 105: ...Frequency To get a 50 Duty Cycle on PW1 and 90 Duty Cycle on PWM2 1kHz waveform Set AQ421 422 16 000 Set AQ431 432 28 800 duty cycle 32000 0 9 Set AQ423 424 1 000 Set AQ433 434 1 000 Example 3 Duty Cycle Frequency To turn PWM 1 output ON all the time Set AQ421 422 32 000 Set AQ423 424 Any Value Example 4 Duty Cycle Frequency To turn PWM 1 output OFF all the time Set AQ421 422 0 Set AQ423 424 Any V...

Page 106: ... 000 steps Finally during the last 1 000 000 steps it slows to a stop Example 3 Start Frequency Run Frequency Accel Count Run Count Decel Count 6 000 000 steps control sequence Set AQ421 50 Hz Set AQ422 250 Hz Set AQ423 4 150 000 Steps Set AQ425 6 5 500 000 Steps Set AQ427 8 350 000 Steps When the start bit is energized the following example starts at 50Hz and ramps up to 250Hz during the first 15...

Page 107: ...tering 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 Filter Frequency To set the filter choose a value that is 4 Number of Samples Expected Max Hz on the high speed inputs Number of samples The input must be stable for this many samples before th...

Page 108: ... Example 1MHz Number of samples 4 If user selects filter frequency as 1MHz and Number of samples as 4 then Input signal is sampled for 4 samples and if the signal is stable for 4 samples i e 4μs then the signal is passed to Accumulator If the Input state is changed in between the sampling counts then the count is reset and the Input state is again checked for given number of samples Refer to Dotte...

Page 109: ...MAN0964 14 EN_XL4_XL4P_UM N o v e m b e r 1 0 2 0 2 1 P a g e 109 194 Figure 3 Input signal before filtering Figure 4 Input signal after filtering This delay will be 4μs ...

Page 110: ... is RS 485 MJ1 defaults to OCS 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 10 2 Port Descriptions The MJ1 serial port contains a RS 232 interface with RTS CTS handshaking The MJ2 serial port contains half duplex RS 485 interface with no handsha...

Page 111: ... 5 RS 485 Termination Proper RS 485 termination minimizes reflections and improves reliability The 485 serial port allows an internal RS 485 termination resistor to be placed across pins 1 and 2 by DIP Switch Setting Only the two devices physically located at the endpoints of the RS 485 network should be terminated ...

Page 112: ... 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 10 8 Ladder Controlled Serial Communication Using Serial Communication function blocks both MJ1 and MJ2 support Generic Modbus Master and Modbus Slave Protocols In addition ...

Page 113: ... 11 1 CAN1 Connector The CAN1 port allows the XL4 XL4 Prime OCS to exchange global data with other OCS RCS controllers and to access remote Network I O devices SmartStix Smart Blocks and Smart Rail Modules The CAN1 port also supports pass through communications for programming multiple OCS controllers over the CsCAN network 11 2 Port Description The XL4 XL4 Prime OCS CAN1 port implements the ISO 1...

Page 114: ...AN Communication Using Put and Get Network Words function blocks the CAN1 port can exchange digital and analog global data with other XL4 XL4 Prime OCS 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 1...

Page 115: ... Protocol Feature Description ICMP Ping Internet Control Message Protocol EGD Ethernet Global Data SRTP Slave 90 30 Service Request Service Request Transfer Protocol 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 File Transfer Protocol HTTP Web Server HyperText Transfer Protocol Web ...

Page 116: ...ations Speeds 10 BaseT Ethernet 10Mbps 100 BaseTx Fast Ethernet 100Mbps Modes Half or Full Duplex Auto Negotiation Both 10 100Mbps and Half Full Duplex Connector Type Shielded RJ 45 Cable Type Recommended CAT5 or better UTP Port Auto MDI MDI X Auto Crossover Table 12 2 Ethernet Module Specifications ...

Page 117: ...ocol used To configure the Ethernet Module use Cscape Programming Software to perform the following steps 1 On the main Cscape screen select the Controller menu and its Hardware Configuration sub menu to open the Hardware Configuration dialog Figure 12 1 2 If configuring a different OCS Model than the one shown in the Hardware Configuration dialog click on the topmost Config button select the desi...

Page 118: ...called Subnet Mask being used by all nodes on the local network 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 outside of ...

Page 119: ... Register Enter an OCS Register reference such as R101 to indicate which 16 bit OCS register will have the Ethernet Firmware Version written to it The value stored in the Version Register is Ethernet Firmware Version 100 For example for Ethernet Firmware Version 4 30 the Version register will contain 430 Get Setting From Get settings from allows the programmer to either configure the IP Address Ne...

Page 120: ...s 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 parameters are retrieved from the OCS registers assigned in LAN Config Configured registers must be populated with the desired IP paramete...

Page 121: ...ncluded 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 Program Protocol Config menu Only one protocol device driver can be associated with a serial port though some OCS models support multiple protocols on a single Ethernet port Once the protocol is selected for a specific port that port must be configure...

Page 122: ...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 This transaction scanning can be on a continual basis automati...

Page 123: ... 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 Once a protocol is selected the Network Devices and Data Scan List must be configured through corresponding dialogs accessible through the respective buttons Network Device and Scan List Figure 13 1 Protocol Config Dialog Three fields must be conf...

Page 124: ...iguration Network Configuration provides the required parameters to configure the network Each protocol is different and may not require all the Network Config field Please refer to the table below for the options in the Network Config field See Table 13 1 below for Network Config details ...

Page 125: ... times a transaction is retried on a failed response Timeout Specifies the amount of time for a device to wait for a valid response Update Scan Automatic Update Interval Specifies the update interval at which all the mapped entries are executed Reacquire Time Specifies the amount of time to wait before attempting communications with an offline device Manual Trigger Specifies the binary register th...

Page 126: ... 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 Typically the number of entries is limited to 64 devices Device Configuration This configuration is reached from the Device List when adding or modifying an existing device ...

Page 127: ...n Each mapping entry transaction contains the source and destination registers the number of consecutive registers transferred the direction of the transfer 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 Sort functions are provided to change the order of the list Each entry also has an id...

Page 128: ...rs 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 transaction scans to write each changed register When the OCS is placed in RUN mode the initial action for this mapping type...

Page 129: ...can of the OCS This allows registers to be initialized locally before Writing to the target device register s Triggered Read A read transaction is triggered by a high level on a separately designated OCS binary trigger register Once the read transaction is complete or the device is offline the OCS trigger register is cleared by the OCS This update type can be used for occasion data accesses such a...

Page 130: ...apter 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 14 2 Screen Specifications Display Type 3 5 TFT Color Screen Brightness 640cd m nits Resolution QVGA 320x240 Color 16 bit 65 535 User Programmable Screens 1023 Backlight LED 50 000 hour life Brightness Control ...

Page 131: ...ich are shown in a depressed 3D appearance when in the ON state Objects that normally accept touch input may be disabled through program control through ladder manipulation of an attribute bit If an object is disabled the object s representation changes to a 2D appearance On objects that represent non discrete information more action may be required beyond that of simply touching the object For ex...

Page 132: ...st position while the other digits are shifted left Edit Value Mode Edit value mode may be entered from the initial new value mode by pressing either the left or right arrow key before any digit key is pressed The result will be a single character highlighted The user may then either touch a key to change the digit at the selected position or the up and down arrows may be used to add or subtract r...

Page 133: ...pad is displayed as shown Figure 14 2 The ASCII keypad has three 3 modes numeric symbols and alpha In Alpha mode the Caps Lock button may be pressed to access capital letters When you first enter this editor typing a character will overwrite the entire old string and start a new entry You may press the back space arrow to delete the previous character Pressing Enter will save the entry pressing ES...

Page 134: ... 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 ...

Page 135: ... finger the default touch slip sensitivity allows for a slight slip of the finger on the graphical object before the XL4 XL4 Prime assumes touch been released equates to approximately a quarter inch of movement with a stylus In some applications such as jog buttons where the operator is pushing a button for a period of time the amount of slip while holding a button pressed may exceed the default s...

Page 136: ...splay characteristics of this object is configurable it is generally displayed as a button that changes colors to indicate the highest state of the alarm s in the alarm group it is monitoring The following indicates the priority of the alarm states and the default colors associated with these states Highest Red Unacknowledged Alarms Exist Yellow Acknowledged Alarms Exist Lowest Green No Alarms Exi...

Page 137: ...lly by an abbreviated indicator after the date time stamp ALM ACK RTN The operator can acknowledge an alarm by selecting it from the list and touching the ACK button The operator can also clear an alarm if that function is enabled in the alarm object If not enabled the Clear buttons are grayed and do not respond to touch Once view operations are complete simply touch the Esc button to remove the p...

Page 138: ...the operator must access the removable viewer This is accomplished by either touching an enabled removable media object or through the System Menu When accessed the removable media viewer is displayed as pop up removable media dialog like that shown in Figure 14 7 NOTE The Removable Media Object can be configured to open the removable media viewer at a certain directory complete with restrictions ...

Page 139: ... representation of the file path including the file name to a group of OCS registers That pathname can then be used by ladder for opening and manipulating that file Once view operations are complete simply touch the Esc button to remove the pop up removable media viewer If the removable media is used in an application the Removable Media Device requires changing by the operator and the application...

Page 140: ...ctivate the backlight is otherwise ignored by the XL4 XL4 Prime Any additional touch activity is also ignored by the XL4 XL4 Prime for approximately one second thereafter 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 ...

Page 141: ...for this feature Minimum Firmware Version 15 xx o Minimum OS Version 2 6 35 49 Minimum Cscape Version 9 80 SP1 Figure 14 10 Touch Screen Pressure NOTE Touch creates contact between resistive circuit layers closing a switch 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 contro...

Page 142: ...ange of 0 to 3000 Zero 0 indicates no pressure and 3000 is the maximum amount of pressure that can be measured SR10 I O Name TCH_PRESSURE_TSH This register sets the pressure threshold to indicate a touch A value of 200 is typically the lightest touch 600 is moderate and 1000 is a heavy touch These new features allow customizing the feel of the touch screen and can be used to add unique user interf...

Page 143: ...t 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 Table 15 1 Features and Specifications of Video Properties Streaming Channels 4 channels supported through USB hub 1 channel can be viewed at a time Playback Formats mp4 mov mpg wmv Resolution 320x240 QVGA Frames per Seconds 10 15 ...

Page 144: ...es Firmware 14 03 or newer to use with the XL4 XL4 Prime devices In Cscape select the XL4 XL4 Prime and model number by selecting Controller Hardware Configuration from the toolbar 1 Open the Graphics Editor by selecting the T button from the toolbar 2 In Graphic Editor select the video button from the toolbar 3 Click in the grid ...

Page 145: ...MAN0964 14 EN_XL4_XL4P_UM N o v e m b e r 1 0 2 0 2 1 P a g e 145 194 4 Then double click on the icon in the middle to open the Video Properties dialog ...

Page 146: ...be viewed at a time Enter Channel Number directly or through registers in the Enter Channel No field Playback This option can be selected to view videos that are stored in Removable Media on the controller Videos present in both A microSD and B USB drives are supported and can be viewed Supported formats including mp4 mov mpg and wmv can be played Select Playback and enter video name in the Enter ...

Page 147: ...two 2 bits NOTE The least significant bit is Bit 1 Definitions are as follows Bit 1 High Start Low Stop Bit 2 High Pause Low Play System Register The Video Control System Register provides the status of the Video Object The status word is 16 bits and should be viewed in hexadecimal format The status definitions are as follows 0x0001 Video is currently playing 0x0002 Video is paused 0x00010 Channel...

Page 148: ...ny popup window causes Video Object to be inactive 2 Video Object can be made active in both Idle and Run modes 3 If actual Frames Per Second of the configured video is different from the one that is configured in Cscape few frames will be missed when video is played 15 7 Web Cameras If multiple web cameras are directly connected to the XL4 XL4 Prime then only one web cam will be considered If use...

Page 149: ...sh Cards labeled either microSD or TransFlash with up to 32GB of flash memory are compatible with the XL4 XL4 Prime OCS Memory Card slot The Memory Card slot is equipped with a push in push out connector and a microSD card can be safely inserted into the Memory Card slot whether the XL4 XL4 Prime OCS power is On or Off To install a microSD card Align its 8 pin gold edge connector down facing the f...

Page 150: ...wed by an optional dot and an optional extension with up to three 3 characters Directories and sub directories can be nested up to 16 levels deep as long as each pathname string does not exceed 147 characters 16 4 Using the Removable Media Manager The Removable Media Manager is an interactive XL4 XL4 Prime OCS screen that performs the following functions a Display number of total and free K bytes ...

Page 151: ... microSD can only be done from the Removable Media in the System Menu and is not available on a Removable Media Manager object that was placed on an application graphics screen by Cscape Cscape can also save an application directly to a microSD card which is plugged into the PC s microSD compatible card reader by selecting the Export to Removable Media item on the Cscape File menu 16 7 Using Remov...

Page 152: ... touch the Esc button to remove the pop up removable media viewer 16 9 Removable Media RM Function Blocks in Cscape NOTE For detailed information regarding RM function blocks and parameters refer to the Help File in Cscape Software Refer to USB flash Media support for RM Functions for USB flash drive access details The following RM functional blocks are available in Cscape Software These function ...

Page 153: ... Removable Media RM Features Graphic Screen Editor a Trends The historic support feature in the trend object utilizes Removable Media b Removable Media This is a graphic object used to access files and functions pertaining to Removable Media c Recipes This is a graphic object that is used in conjunction with the recipe editor which is mentioned above 16 12 Removable Media RM Features Additional Co...

Page 154: ...eplaced by the OCS with current time and date information Table 16 2 Filename Special SymbolsError Bookmark not defined Symbol Description Example Y Substitutes the current 2 digit year 2015 15 M Substitutes the current month with a 2 digit code March 03 D Substitutes the current day 22nd 22 h Substitutes the current hour in 24 hour format 5 pm 17 m Substitutes the current minute 45 45 s Substitut...

Page 155: ...tus This shows the current status of the RM interface SR176 Free Space This 32 bit register shows the free space on the RM card in bytes SR178 Card Capacity This 32 bit register shows the total card capacity in kilobytes Possible status values are shown in the table Table 16 3 RM Status Values 0 RM interface OK 1 Card present but unknown format 2 No card in slot 3 Card present but not supported 4 ...

Page 156: ...RM Refer to the Removable Media Chapter for details in using RM 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 17 2 Make Clone User needs to perform the following to Clone 1 The Clone Unit can be accessed by going to the System Menu of the OCS A new menu Clone Unit...

Page 157: ...ke 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 Selecting Make Clone brings up the screen below for the user Figure 17 3 Clone Unit Confirm Screen ...

Page 158: ...in the root directory of the Removable Media Drive as shown below AUTOLOAD PGM Application file CLONE DAT File having all unit settings and register values from battery backed RAM Figure 17 4 Clone Unit Files NOTE Make Create clone operation automatically includes the security in AUTOLOAD PGM file for security enabled files ...

Page 159: ...ted 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 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 Clon...

Page 160: ...ia 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 1 Select Clone Unit from main System Menu of OCS as shown below Figure 17 6 System Menu 2 Selecting Clone Unit menu will open the following menu screen Select Load Clone Figure 17 7 Clone Unit Menu after Cloning ...

Page 161: ...t 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 operation is completed this bit is made zero by the firmware When Load Clone operation is triggered by this SR bit it does not ask the user for confirmation for loading clone The success failu...

Page 162: ...y Manually restore Register Settings from the values previously backed up in flash memory 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 If an automatic Regi...

Page 163: ...vice 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 onboard flash memory using System Menu options 18 3 Backup Restore Data Selecting this option brings up a screen having four...

Page 164: ...er 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 Figure 18 3 Backup Registers ...

Page 165: ...ollowed for restoring data The controller will be placed in IDLE mode Data will be copied from onboard flash memory to OCS battery backed RAM The controller will reset The controller will be put in RUN mode if the AutoRun setting is Yes or else it will remain in IDLE mode Figure 18 4 Restore OCS Data SR164 3 is set to 1 only when an automatic restore operation is performed not on a manual one This...

Page 166: ...a g e 166 194 Clear Backup Data When initiated the backup data will be erased from the onboard flash and no backup will exist SR164 4 and SR164 3 is reset to 0 when backed up data is erased Figure 18 5 Clear Backup Data Exit Goes back to the previous screen ...

Page 167: ...tic Restore Figure 18 6 Flow Chart for Automatic Restore OCS Power Cycle Battery Backed RAM Registers check failed Backup exists Controller placed in IDLE mode Data copied from Onboard FLASH to OCS Battery backed RAM Controller Resets AutoRun Enabled OCS put in RUN Mode OCS put in IDLE Mode NO YES YES NO Application Program erased ...

Page 168: ...e 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 ...

Page 169: ...ure 18 8 Flow Chart for AutoLoad Power up OCS Application Program absent or Application Program corrupted AutoLoad Enabled AUTOLOAD PGM present in the RM of the device AutoLoad initiated OCS put in IDLE mode AutoLoad run sequence failed with reasons for failure NO NO YES YES AutoRun Enabled OCS put in RUN Mode OCS put in IDLE Mode NO YES ...

Page 170: ...R164 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 displayed It will also show the reason for its failure On acknowledgi...

Page 171: ...ave 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 19 2 Modbus Slave Overview 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 allo...

Page 172: ...es 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 o Hex or Decimal Some specify addresses in hex and others in de...

Page 173: ...olumn of the Table 19 1 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 Table 19 1 Table 19 1 Modbus Master Mapping XL4 XL4 Prime Reference Maximum Range Trad Modbus Ref 5 Digits Expanded Modbus Ref 6 Digits Modbus Commands Modbus Offset I1 2048 1...

Page 174: ...out 1 10 of a second During this time register and other retentive data is saved away to flash memory The clock continues to run on the battery at a much lower power The battery is designed to last well over a year in this state Once power is restored the battery recharges in eight 8 hours or less 20 3 Battery Life The battery is designed to last 300 full charges to 1000 partial charge cycles or 7...

Page 175: ...old limits 3 The battery is charged fully to 4 2 volts in the Normal Charging or Cold Charging states or to 4 1 volts in the Hot Charging state 4 Once fully charged to 4 2 volts state 0 the Wait Discharging state is executed state 12 The battery is allowed to discharge to 4 0 volts for however long that takes Powering up the OCS will reset the charge cycle to step 1 5 If the battery was charged to...

Page 176: ...ttery temperature falls to 60 C or less 5 Cold Charging Battery is slow charging Tb 0 10 C 20mA to 4200mV Up to 40hrs charge time 6 Battery Too Cold Not Charging Tb 0 C Charging cycle resumes when battery temperature climbs to 0 C or greater 7 Error No Battery No battery was detected at power up It will not attempt to charge until the next power cycle SR55 13 ON 8 Final Charge to 4 1V The battery ...

Page 177: ...in C SR196 Charge State Refer to Table 20 1 SR197 Charging Current mA SR198 Battery Voltage in mV IMPORTANT The battery voltage shown in the System Menu and in SR198 is ONLY valid if the battery is not in the Charging State To check battery voltage power cycle the controller and check the battery voltage within the first two minutes of power up In the first two minutes after power is applied to th...

Page 178: ...uding extreme temperatures and humidity can affect battery life If the battery is older than seven 7 to ten 10 years old it is recommended that it be replaced as preventative maintenance NOTE Do not use an alkaline AA battery only use the proper battery type listed WARNING DO NOT USE IF BATTERY IS LEAKING OR HAS BEEN DAMAGED WARNING LITHIUM BATTERIES MAY EXPLODE OR CATCH FIRE IF MISTREATED DO NOT ...

Page 179: ... board Reinstall the Kevlar patch and tape that was removed in Step 6 8 Gently replace the I O circuit board by aligning the edges with the guideposts Align the XL Bus Connector and then gently press on the I O circuit board until it is seated If an insert came off be sure to slide it back into the cover before replacing 9 After the I O circuit board is replaced replace the I O back cover by align...

Page 180: ...ended that it be replaced as preventative maintenance NOTE Use only the proper battery type listed NOTE Use only the proper battery type listed WARNING DO NOT USE IF BATTERY IS LEAKING OR HAS BEEN DAMAGED WARNING LITHIUM BATTERIES MAY EXPLODE OR CATCH FIRE IF MISTREATED DO NOT RECHARGE DISASSEMBLE HEAT ABOVE 100 C 212 F INCINERATE OR PUNCTURE WARNING EXPLOSION HAZARD BATTERIES MUST BE ONLY BE CHAN...

Page 181: ...sconnect all power from the XL4 Prime unit including I O power 3 On the back of the XL4 Prime model slide off the battery plate cover 4 Connect the new battery into the adjacent connector first and then remove the old battery 5 Dispose of the old battery properly see the above warning on disposal regulations 6 Slide battery plate cover back on the unit 7 Apply power to the unit Check that the batt...

Page 182: ...are updates should only be performed when the equipment being controlled by the OCS is in a safe non operational state Communication or hardware failures during the firmware update process can cause the controller to behave erratically resulting in injury or equipment damage Make sure the functions of the equipment work properly after a firmware update before returning the device to an operational...

Page 183: ... 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 STEP ONE In North America visit https hornerautomation com Then click Support Downloads Controller Firmware and download the most recen...

Page 184: ...ess Yes NOTE DO NOT press the Install Firmware option This has the potential to create a scenario where the unit will not boot up If this is pressed by mistake contact Tech Support for the recovery procedure e When Operation Completed appears press OK f Power cycle the OCS controller and wait for it to boot up g Press SYSTEM key select View Status and press the Enter button h Scroll down to see th...

Page 185: ...essed through the local controller Determine connection status by examining feedback next to Local Target in the status bar of Cscape Table 23 1 Cscape Target Local Numbers Local If a number shows next to Local then communication is established to the local controller Local No Port Cscape is unable to access the COM port of the PC This could mean that Cscape is configured for a COM port that is no...

Page 186: ...r APG offers a USB to serial adapter Part numbers HE XCK and HE CPK 23 1 2 Connecting Troubleshooting Checklist USB Port Mini B Programming 1 Controller must be powered up 2 Ensure that the correct COM port is selected in Cscape Tools Applications Settings Communications 3 Be sure that the USB cable is connected between the PC and the controller Check Windows Device Manager to ensure that the USB ...

Page 187: ...de 2 Check diagnostics to ensure controller passed self tests View Diags in System Menu or in Cscape click Controller Diagnostics 3 Check data sheets to ensure proper wiring 4 Ensure that hardware jumpers and software configuration for I O match 5 Check data sheets for voltage and current limits 6 Take ladder out of the picture From Cscape set controller to Do I O mode In this mode inputs can be m...

Page 188: ...istors 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 ...

Page 189: ...p in the OCS internal supplies leading to a reset Standard SanDisk and Kingston ranges with read times less than 120MB sec should not cause resets The display will flicker when a device is added or removed 23 5 Basic Troubleshooting Description Action XL4 XL4 Prime OCS does not read media card The media card should be formatted with the XL4 XL4 Prime OCS XL4 XL4 Prime OCS will not download project...

Page 190: ...onnections Added latest Firmware Update steps 6482 Updated Install Procedure 6319 USB Interfaces 6442 Battery Charging Cycle SR Table Ethernet Overview Firmware Updates Installation Procedure USB Interfaces Battery Status in SR 11 5 2021 14 6984 Added XL4 Prime Added Backup Battery for XL4 Prime 6429 Revised Register Map Throughout CHAPTER 21 XL4 Prime BACK UP BATTERY 6 4 Register Map for XL4 XL4 ...

Page 191: ... Port 65 66 186 Compliance CE 11 Configuration of a Removable Media 152 Configuration via Mini B USB 112 Configured reset value 90 Configuring Video Properties 146 Count 100 102 Csape Program Via Serial Port 112 Cscape 2 15 32 33 58 62 68 69 70 78 80 82 83 84 85 86 110 112 114 134 150 151 185 186 187 Alternative Connection Method Screenshot 66 Analog In Configuration 74 Analog Out Configuration 76...

Page 192: ...O 86 HSC 71 72 86 88 93 97 100 102 HSC Functions Register Map for 4 HSC configuration 98 I O Configuration Dialog 117 I O Cover Removal 78 Installing Removable Memory Card 149 IP Address 118 Jumpers Example 79 Ladder control 90 LIMITED WARRANTY 3 Lithium Battery Safety 174 Load Clone 46 160 Maintenance 182 Make Clone 156 Manual Index 13 Mechanical installation 16 microSD Cards 149 Installing Remov...

Page 193: ...unction Blocks 154 Function Blocks 152 Graphic Screen Editor 153 Program Features 153 System Registers 155 RM Status Values 155 RS 485 Biasing 112 RS 485 Termination 111 safety compliance 10 Safety Warnings Guidelines 10 Scan List 127 Scan List Entry 128 Screen Brightness 140 Screen Saver 140 Serial Comm Cscape Programming 112 Ladder Controlled 112 Overview 110 Ports 110 Wiring 110 111 SERIAL COMM...

Page 194: ...ump Object XL4 XL4 Prime 134 Universal Analog Inputs 84 USB 15 63 64 112 114 186 User Interface 130 Ladder Based Navigation 134 Screen Navigation 134 USER INTERFACE 130 Using Removable Media to View and Capture Screens 151 Video Object Playback 146 Stream 146 View Battery Status 31 View Diags 30 View I O Slots 32 View Protocols 33 View Status 29 Visual Overview of XL4 XL4 Prime and Topics 12 Where...

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