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MAN0974-14-EN_XL7_XL7P_UM

July 6, 2022

Page 2 | 199

PREFACE

This manual explains how to use the XL7/XL7 PRIME OCS.

Copyright© 2013 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights
reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language or computer language, in any form by any means, electronic,
mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written
permission of Horner APG, Inc.

All software described in this document or media is also copyrighted material subject to the terms and
conditions of the Horner Software License Agreement.

Information in this document is subject to change without notice and does not represent a commitment
on the part of Horner APG.

Cscape, SmartStack, SmartStix, SmartRail, SmartMod, and CsCAN are trademarks of Horner APG.
Ethernet

™

is a trademark of Xerox Corporation.

microSD

™

and CompactFlash are registered trademarks of SanDisk Corporation.

For user manual updates, please visit our website:

North America

:

Tel: (+) (317) 916-4274
Fax: (+) (317) 639-4279
Website:

https://hornerautomation.com

Email:

[email protected]

Europe:

Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Website:

http://www.hornerautomation.eu

Email:

[email protected]

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Summary of Contents for HE-XPW1E0

Page 1: ...a Europe North America Europe HE XW1E0 HEXT391C100 HE XPW1E0 HEXP391C100 HE XW1E2 HEXT391C112 HE XPW1E2 HEXP391C112 HE XW1E3 HEXT391C113 HE XPW1E3 HEXP391C113 HE XW1E4 HEXT391C114 HE XPW1E4 HEXP391C114 HE XW1E5 HEXT391C115 HE XPW1E5 HEXP391C115 HE XW1E6 HEXT391C116 HE XPW1E6 HEXP391C116 ...

Page 2: ...ed 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 SmartMod and CsCAN are trademarks of Horner APG Ethernet is a trademark of Xerox Corporation microSD...

Page 3: ... 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 loss of use of th...

Page 4: ... user documentation visit a Horner website North America https hornerautomation com Europe http www hornerautomation eu QUICK START INSTALLATION PROGRAMMING TROUBLESHOOTING Safety Compliance Mechanical Installation System Settings Modbus Communications Introduction Electrical Installation Registers Back up Battery Cscape Configuration Maintenance General I O Troubleshooting High Speed I O Serial C...

Page 5: ...7 3 3 Mounting Orientation 18 3 4 XL7 XL7 PRIME Back Cover Dimensions 20 3 5 XL7 XL7 PRIME Dimensions 21 3 6 Installation Procedure 22 3 7 Factors Affecting Panel Layout Design and Clearances 23 CHAPTER 4 ELECTRICAL INSTALLATION 25 4 1 Grounding Definition 25 4 2 Ground Specifications 25 4 3 How to Test for Good Ground 26 4 4 Primary Power Port 27 CHAPTER 5 SYSTEM SETTINGS AND ADJUSTMENTS 28 5 1 S...

Page 6: ... 77 CHAPTER 8 GENERAL I O 78 8 1 Overview 78 8 2 Removing the XL7 XL7 PRIME OCS I O Cover 78 8 3 Model and I O Overview 80 8 4 Solid State Digital Outputs 81 8 5 Relay Outputs 82 8 6 Digital Inputs 84 8 7 Analog Inputs 85 8 8 Universal Analog Inputs 86 8 9 Analog Outputs 87 CHAPTER 9 HIGH SPEED I O HSC PWM 88 9 1 Overview 88 9 2 Glossary 89 9 3 High Speed Counter HSC Functions 90 9 4 HSC Functions...

Page 7: ...Config 125 13 3 Network Configuration 126 13 4 Device List and Device Configuration 128 13 5 Scan List 129 13 6 Data Mapping Configuration Scan List Entry 130 CHAPTER 14 USER INTERFACE 132 14 1 Overview 132 14 2 Screen Specifications 132 14 3 Displaying and Entering Data 133 14 4 Alpha numeric Keypad 134 14 5 Screen Navigation 136 14 6 Ladder Based Screen Navigation 137 14 7 Beeper Acknowledgement...

Page 8: ...14 System Registers used with RM 161 CHAPTER 18 CLONE UNIT 162 18 1 Overview 162 18 2 Clone 162 18 3 Load Clone 166 CHAPTER 19 FAIL SAFE SYSTEM 168 19 1 Overview 168 19 2 Settings 169 19 3 Backup Restore Data 169 19 4 AutoLoad 173 19 5 AutoRun 175 CHAPTER 20 MODBUS COMMUNICATIONS 176 20 1 Modbus Overview 176 20 2 Modbus Slave Overview 176 20 3 Modbus Master Overview 177 20 4 Modbus Addressing Tabl...

Page 9: ...9 199 24 1 Connecting to the XL7 XL7 PRIME OCS 190 24 2 Local Controller and Local I O 192 24 3 CsCAN Network 193 24 4 Removable Media Basic Troubleshooting 194 24 5 USB Interfaces 194 24 6 Technical Support Contacts 194 CHANGE LOG 195 INDEX 196 ...

Page 10: ... 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 WARNING The USB parts are for operational maintenance only Do not leave permanently connected unless area is kn...

Page 11: ... circuit to be monitored d Route power wires in a safe manner in accordance 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 floors are dry before making any connection to a power line g Make sure the unit is turned OFF before making connection to terminals...

Page 12: ...MAN0974 14 EN_XL7_XL7P_UM July 6 2022 Page 12 199 CHAPTER 2 INTRODUCTION 2 1 Visual Overview of XL7 XL7 PRIME OCS Figure 2 1 Overview of the XL7 XL7 PRIME ...

Page 13: ...odel 5 MAN1165 MAN1344 Model 6 MAN1166 MAN1345 User Manual This manual provides general information that is common to XL7 XL7 PRIME OCS models and can be downloaded from our web Visit the Horner website to obtain user documentation and updates North America https hornerautomation comhttp www heapg com Europe http www hornerautomation eu 2 1 2 Four main types of information are covered in this manu...

Page 14: ... can be used with the XL7 XL7 PRIME OCS Figure 2 2 Visual Overview of Types of Devices that can be connected to XL7 XL7 PRIME OCS CAN Serial I O XL7 XL7 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 Server Ethernet Cscape OPC Server Modbus ...

Page 15: ...e media for 32GB of storage of programs data logging or screen captures CsCAN networking port for communication with remote I O other controllers or PCs High speed USB port for communication with PCs and programming of controller Configurable serial protocols for communication to drives PLCs or other serial peripherals Full featured built in I O including high resolution analog thermocouple RTD hi...

Page 16: ...rth America http hornerautomation com product category home control accessories Europe https www hornerautomation eu product overview 2 5 Useful Documents and References Visit our website to obtain user documentation supplemental documents certificates and other documentation North America https hornerautomation comhttp www heapg com Europe http www hornerautomation eu ...

Page 17: ...mentation and updates North America https hornerautomation comhttp www heapg com Europe http www hornerautomation eu 3 1 Overview The mechanical installation greatly affects the operation safety and appearance of the system Information is provided to mechanically install the unit such as cut out sizes mounting procedures and other recommendations for the proper mechanical installation of the unit ...

Page 18: ...t and debris Check that the corners of the gasket are secure 2 Pass the unit through the panel 3 Insert each of the four 4 mounting clips into the slots in the XL7 XL7 PRIME OCS case One clip should be installed on each corner Lightly tighten each screw so the clip is held in place 4 Tighten the screws on the clips such that the gasket is compressed against the panel Recommended torque is 7 10 in ...

Page 19: ...XL7 XL7 PRIME OCS Mounting Orientation Figure 3 3 Orientation of XL7 XL7 PRIME OCS NOTE There are no orientation restrictions on the XL7 XL7 PRIME OCS However the above orientation provides for optimum readability of the screen and ease of use of the keypad ...

Page 20: ...P_UM July 6 2022 Page 20 199 3 4 XL7 XL7 PRIME Back Cover Dimensions Standard Back Cover Dimensions Figure 3 4 Standard Back Cover Dimensions Extended I O Back Cover Dimensions Figure 3 5 Extended I O Back Cover Dimensions ...

Page 21: ...MAN0974 14 EN_XL7_XL7P_UM July 6 2022 Page 21 199 3 5 XL7 XL7 PRIME Dimensions Figure 3 6 XL7 XL7 PRIME OCS Dimensions ...

Page 22: ...te place to mount the XL7 XL7 PRIME Be sure to leave enough room at the top of the unit for insertion and removal of the microSD card 2 Carefully cut the host panel per the diagram creating a 131 2mm x 189 7mm with a 1 6mm 0mm panel cutout tolerance opening into which the XL7 Prime may be installed If the opening is too large water may leak into the enclosure potentially damaging the unit If the o...

Page 23: ...enough depth for the OCS 2 50 80mm 3 7 2 Grounding Panel box The panel box must 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 ventilation and ma...

Page 24: ...ing list 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 door ...

Page 25: ...nnection 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 Grounding is also for the safety of the user 4 2 Ground Specifications Ideally a ground resistance measu...

Page 26: ...ter must be used A typical Ground Resistance Meter Kit contains a meter two or three wire leads and two ground rods Instructions are supplied for either a two point or three point ground test 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 27: ... 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 28: ...elect a Main Menu item and press Enter Return Arrow to display the item s Sub Menu Figure 5 1 System Menu XL7 XL7 PRIME 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 indicates all self tests passed Flashing at 1 Hz indicates I O f...

Page 29: ...e 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 key is pre...

Page 30: ...r Ok User Program Ok User Graphics Ok W Dog Trips 2 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 Xex02 Slot 2 I O Empty Slot 3 I O ETN300 MJ1 None Loaded MJ2 None Loaded COM None Loaded MJ3 None Loaded Fkeys Momentary SYS Fn enable Yes Use to adjust Dflt Pgm Port MJ1 232 MJ2 RS485 Bias No MJ3 RS485 Bias No Use to adjust Time 14 58 03 ...

Page 31: ...d 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 Gateway can be changed from the System Menu This is designed for commissioning or temporar...

Page 32: ...sed 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 of b...

Page 33: ... 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 node wa...

Page 34: ...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 35: ...odule 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 System Settings a...

Page 36: ...ort 1 and MJ3 Port 2 serial ports support downloadable protocols To assign a downloadable protocol to an XL7 XL7 PRIME OCS serial port select the Protocol Config item in Cscape s Program menu and then set up a protocol for Port 1 or Port 2 or both In the View Protocols Sub Menu the currently downloaded protocol if any and its version number are displayed for each of MJ1 MJ2 COM board and MJ3 ...

Page 37: ...enu displays two System Settings both of which may be edited 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 38: ...ing 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 MJ3 RS485 Bias No MJ3 R5485 bias resistors are not switched in Yes MJ3 R5485 bias resistors ...

Page 39: ...ency 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 daylight Selec...

Page 40: ...n 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 displays three s...

Page 41: ..._XL7_XL7P_UM July 6 2022 Page 41 199 5 11 Set Beeper The Set Beeper Sub Menu displays one System Setting which may be edited Beeper Enable Yes default Enables beeper No Disables beeper does NOT affect ladder access ...

Page 42: ...creen 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 update per...

Page 43: ...ighting dot dot and pressing Enter will move up one directory Media Directory No Card Media Directory 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 Shows size of highlighted file or shows DIR if directory is highlighted Shows the date...

Page 44: ...n 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 flash memory of the OCS Restore Copies the backed up data from onboard flash memory to the battery backed RAM Clear Bac...

Page 45: ... 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 46: ...nable 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 47: ...ame model This feature can be used when 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 NOTE Free Total displays number of free and total bytes in Removable Media Selecting Make Clone brings up the confirmation screen Upon confirmation the OCS will create two new files in the root di...

Page 48: ...UM July 6 2022 Page 48 199 5 18 Load Clone Selecting Clone Unit menu will open the following menu screen Select Load Clone NOTE For security enabled files Load clone asks for password validation before loading the application ...

Page 49: ...I license Refer to MAN1036 for the WebMI Manual for more details The information can also be viewed from Cscape using the following SR registers SR209 3 WebMI server status SR209 4 WebMI user logged in status SR209 9 to SR209 16 Number of Users SR218 Number of Webpages SR219 Number of Data Points SR220 SR222 Expiry Date of WebMI License ...

Page 50: ...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 move close...

Page 51: ...a unit which has the ability to display a screen If the bit is SET the screen is displayed I Digital Input Single bit input registers Typically an external switch is connected to the registers K Key Bit Single bit flags used to give the programmer direct access to any front panel keys appearing on a unit M Retentive Bit Retentive single bit registers Q Digital Output Single bit output registers Ty...

Page 52: ...0 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 RAM Error Read Only Read Only SR4 5 Self Test Results ...

Page 53: ...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 DeviceNet Mode 0 to 63 CANOpen Mode 1 to ...

Page 54: ...45 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 Read Only SR51 Network...

Page 55: ... 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 License Details WebMI user logged in status XL...

Page 56: ... 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 AUTORUN Sets Enable AutoRun to Yes or No Read Write Read Write SR164 6 EN_AUTO_LD Enable AUTOLOAD Sets Enable AutoLoad to Yes or Not Read ...

Page 57: ...it 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 Alarm Groups 1 16 Read Only Read Only SR183 SYS_BEEP Beep on Keypress Enable 0 Disabled 1 Enabled 0 to 1 Read Write Read Write SR184 USER_BEEP Internal Beeper 0 OFF 1 ON 0 to 1 Read Write Read Write SR185 Screen Saver Enabl...

Page 58: ...2V not charging 11 First 2 minutes Init Wait Not Charging 0 to 11 Read Only Read Only SR197 Charging Current Max mA Read Only Read Only SR198 Battery Voltage is mV Read Only Read Only SR199 Reserved SR200 InitRD Version 100 Read Only Read Only SR201 205 Linux Kernel version ASCII 10 characters Read Only Read Only SR206 208 Reserved SR209 3 WebMI Server Status Bit 3 is ON if server running Read Onl...

Page 59: ...escription Min Max Values Program Read Write Display Read Write SR218 Number of Webpages license detail XLE XLT X2 X4 X7 use SR101 SR108 112 for WebMI License Details Read Only Read Only SR219 Number of Data Points license detail XLE XLT X2 X4 X7 use SR101 SR108 112 for WebMI License Details Read Only Read Only SR220 222 Expiration Date of WebMI License license detail XLE XLT X2 X4 X7 use SR101 SR...

Page 60: ...utputs 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 registers...

Page 61: ...32 bit Run Count 32 bit AQ6 AQ7 PWM Period 32 bit Decel Count 32 bit AQ8 Q1 Run I30 Ready Done I31 Error Table 6 6 HSC Functions Register Map Register Frequency Totalize Pulse Quad AI5 6 HSC1 function Accumulator Quad 1 Acc AI7 8 HSC2 function Accumulator AI9 10 HSC3 function Accumulator Quad 2 Acc AI11 12 HSC4 function Accumulator AQ1 2 HSC1 Preset AQ3 4 HSC2 Preset Q17 Clear HSC1 Clear Quad 1 Q1...

Page 62: ...lave Ethernet IP FTP or HTTP 10MBd or 100MBd SR 448 CsCAN 125kBd 250kBd 500kBd or 1MBd T 16000 Serial Ports 1 RS232 1 RS485 Ports M 16000 IDs Per CsCAN Network 64 w o repeat 253 w 3 repeaters R 49999 Keypad 5 keys 4 fn keys and a System Key K 5 Display 800 x 480 7 TFT 65K colors D 1023 Screen Memory 64MB I 2048 User Screens 1023 Q 2048 Data Fields Per User Screen 1023 AI 512 Ladder Code 1024kB AQ ...

Page 63: ...dicates the current status of the pass through 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 un...

Page 64: ... on the Horner APG web site The drivers may be loaded from the HE XEC Ethernet Utility HTTP Web Server Demo Communications Drivers section of the support files page on the Horner website https hornerautomation com support files For XL7 XL7 PRIME use Cscape Version 9 30 SP6 or newer Next connect a PC s Personal Computer running a Windows Microsoft operating system USB port via USB cable to the USB ...

Page 65: ... The PC will detect a new device has been plugged into the USB port Now that the XL7 XL7 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 66: ...g for the first time we suggest connecting via USB Figure 7 3 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 reopened to ref...

Page 67: ...nection method in Add Target Figure 7 4 Cscape Alternative Connection Method Screenshot Figure 7 5 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 68: ...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 drop down U...

Page 69: ...it The Target ID allows directing communications to a particular unit when multiple units are connected via a CsCAN network Units without CsCAN network ports respond to any network ID and do not require the ID to be configured To check or change the ID on the XL7 XL7 PRIME OCS press the System Menu key The first item in the menu is Set Networks Pressing Enter allows the ID of the unit to be viewed...

Page 70: ...tion above If the controller is not communicating it may be required to set the target ID of the controller in Cscape or on the unit The Target ID allows directing communications to a particular unit when multiple units are connected via a CsCAN network Units without CsCAN network ports respond to any network ID and do not require the ID to be configured To check or change the ID on the XL7 XL7 PR...

Page 71: ...dule 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 6 LAN1 Configuration Dialog 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 Hardware Configuration Select Eth...

Page 72: ...OCS CsCAN from the type drop down box 5 Once the type of XL7 XL7 PRIME OCS is selected the model drop down box will provide the XL7 XL7 PRIME OCS model numbers from which to choose from 6 Once the XL7 XL7 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 Hardware configure dialog specifically the Module Setup tab provides four butto...

Page 73: ...MAN0974 14 EN_XL7_XL7P_UM July 6 2022 Page 73 199 To access the I O Setup Screen select Config from the Hardware Configuration Local I O dialog Then select the Module Setup tab see screenshot below ...

Page 74: ...tting 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 4 available high speed counters on the XL7 XL7 PRIME OCS In configuring a counter the user needs to set the type mode and counts per rev The type drop down includes the following options Disabled Totalizer Frequency Counter Pulse Width Measurement...

Page 75: ...low 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 State On Controller Stop group box contains items to allow the user ...

Page 76: ...nnels are outlined below Table 7 2 Analog In for Models 5 6 Model 5 Model 6 Channels 1 2 Channels 1 6 0 10V 0 10V 0 20mA 0 20mA 4 20mA 4 20mA 100mV Disable PT100 DIN RTD 1 20 C 0 60mV Type J Thermocouple 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 Ther...

Page 77: ...he 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 the analog outputs The modes include the following 0 10V 0 20mA 4 20mA Dis...

Page 78: ...RIME OCS I O Cover Some I O configurations require jumper settings to be changed in the XL7 XL7 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 XL7 XL7 PRIME OCS I O jumper is set to a factory default Refer to the XL7 XL7 PRIME datasheet to find the default setting to determine if a jumper change...

Page 79: ...the jumper settings Figure 8 3 Example Jumper Diagram To re install the cover place the I O cover back on the unit Place the screw back into the hole and turn the screw slowly counterclockwise until it clicks into the threads 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 excee...

Page 80: ...8 3 Model and I O Overview Table 8 1 I O and Model Overview XL7 XL7 PRIME Models DC In DC Out Relays HS In HS Out mA V In mA V RTD TC mA V Out Model 0 Model 2 12 6 4 4 Model 3 12 12 4 2 2 Model 4 24 16 4 2 2 Model 5 12 12 4 2 2 2 Model 6 12 12 4 2 6 4 ...

Page 81: ...plication may require external fusing on these outputs The digital outputs in the XL7 XL7 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 stopped the ...

Page 82: ...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 001XLE015 0V ON J1 12 24VDC R2 C2 R3 C3 R6 C6 R4 C4 R5 C5 R1 C1 H4 H2 H3 LOAD 230VAC OR ...

Page 83: ...om inductive load consult Horner Automation Technical Support Details on devices that may protect outputs can be found in the Spark Quencher Datasheet MAN0962 Output State on Controller Stop When the controller is stopped the operation of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state By default relay ou...

Page 84: ...ositive voltage applied to the input will turn the input The internal design of this mode is basically a resistor from the input to I O ground This mode is sometimes called sourcing In negative logic mode connecting the input to the I O ground or zero volts will turn the input on The internal design of this mode is basically a resistor from the input to the positive I O voltage usually 12V or 24V ...

Page 85: ...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 Thermistor...

Page 86: ... 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 input output cards in that they are configurable through the mod...

Page 87: ...ovide 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 before the controller stopped or they can go to a predeterm...

Page 88: ...ilability 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 XL7 XL7 PRIME to be programmed to have either two high speed counters or four high speed counters The XL7 XL7 PRIME ships with two high speed counters but a customer can contact ...

Page 89: ... 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 a specifi...

Page 90: ...med 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 provides ...

Page 91: ...n 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 clock signal t...

Page 92: ...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 through a A...

Page 93: ...mpled 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 1 9 2 Pulse Wi...

Page 94: ... 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 edge of th...

Page 95: ... 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 to determi...

Page 96: ...nters 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 dependent 5 The Hi...

Page 97: ...ion 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 the marker f...

Page 98: ...is 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 high speed output...

Page 99: ...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 Counter 2...

Page 100: ...nter 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...

Page 101: ...ounter 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 Sp...

Page 102: ...es 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 cycle a value ...

Page 103: ...nts 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 0MHz Th...

Page 104: ...y 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 phase T...

Page 105: ...t 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 the steppe...

Page 106: ...433 434 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 PWM 1 Dut...

Page 107: ... 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 Value Tabl...

Page 108: ... 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 150 000 step...

Page 109: ...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 the HSC accumulator is affected by any change The state high or low of the high speed input is sampled with every...

Page 110: ...t 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 Dotted lines in the Figure 2 after 2 samples the state of input signal changes to 1 so the counter is again started ...

Page 111: ...MAN0974 14 EN_XL7_XL7P_UM July 6 2022 Page 111 199 Figure 3 Input signal before filtering Figure 4 Input signal after filtering This delay will be 4μs ...

Page 112: ...tocols The second 8 pin modular RJ45 connector which is labeled MJ3 provides a multiplexed serial port which can be configured for either RS232 or RS485 MJ3 can be optionally set for OCS programming via the System Menu for connection to the COM port of a PC running Cscape 10 2 Port Descriptions The MJ1 serial port contains an RS232 interface with RTS CTS handshaking The MJ2 serial port contains a ...

Page 113: ...iasing RS485 biasing passively asserts a line idle state when no device is actively transmitting which is useful for multi drop RS485 networking Both the MJ2 and MJ3 serial ports allow internal bias resistors to be switched in pulling pin 1 up to 3 3 V and pulling Pin 2 down to ground The Set Serial Ports item in the System Menu can be used to enable RS485 biasing Also an application graphics scre...

Page 114: ...rotocols In addition external modems can be connected and accessed using Init Dial and Answer Modem function blocks 10 8 Configuration via Mini B USB NOTE The unit must be connected via the mini USB port to the PC or laptop It is possible to load the program and monitor data via the Mini B USB To load via Mini B USB configure the communications port in Cscape as follows Select Tools from the toolb...

Page 115: ...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 CAN2 port supports CsCAN CANopen J1939 and DeviceNet Master layer 3 as a selectable option one only 11 2 Port Description The XL7 XL7 PRIME OCS CAN ports implemen...

Page 116: ...Ladder Controlled CAN Communication Using Put and Get Network Words function blocks the CAN 1 port can exchange digital and analog global data with other XL7 XL7 PRIME OCS or OCS RCS devices nodes attached to the CAN1 port network In addition Put and Get Network Heartbeat function blocks allow nodes on the CAN 1 port network to regularly announce their presence and to detect the presence or absenc...

Page 117: ... Features Protocol Feature 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 ASCII over TCP IP ASCI...

Page 118: ...ble 12 2 Ethernet Module Specifications Speeds 10 BaseT Ethernet 10Mbps 100 BaseTx Fast Ethernet 100Mbps Modes Half or Full Duplex Auto Negotiation Both 10 100Mbps and Half Full Duplex Connector Type Shielded RJ 45 Cable Type Recommended CAT5 or better UTP Port Auto MDI MDI X Auto Crossover ...

Page 119: ...l used To configure the Ethernet Module use Cscape Programming Software to perform the following steps 1 On the main Cscape screen select the Controller 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 desired OCS Model an...

Page 120: ...g 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 the local network To pr...

Page 121: ... 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 Settings From Get settings from allows the programmer to configure either the IP Address Net Mask o...

Page 122: ... any edits made from System Menu Set Networks is not retained through a power cycle After power cycle the unit reverts to the last downloaded Cscape LAN Config that was loaded into non volatile RAM at power down Cscape LAN Config Get Settings from Register When Get settings from is set to Register the IP parameters are retrieved from the OCS registers assigned in LAN Config Configured registers mu...

Page 123: ... 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 configured to match...

Page 124: ...mote 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 automatic ...

Page 125: ...layed 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 configured af...

Page 126: ...3 Network Configuration Network Configuration provides the required parameters to configure the network Each protocol is different and may not require all the Network Config field Please refer to the table below for the options in the Network Config field ...

Page 127: ...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 that a sing...

Page 128: ...col 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 129: ...pping 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 identifying...

Page 130: ...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 is a read...

Page 131: ...e 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 as retriev...

Page 132: ...OCS line This chapter does NOT cover building screens or using the Cscape graphics editor For instructions on creating screens and using the graphics editor refer to the graphics editor help file 14 2 Screen Specifications Display Type 7 TFT Color Screen Brightness 800cd m nits Resolution QVGA 800x480 Color 16 bit 65 535 Screen Memory 17MB User Programmable Screens 1023 Backlight LED 50 000 hour l...

Page 133: ...own 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 example the ...

Page 134: ...displays the current value with all the digits being highlighted Once the first digit is entered the current value is erased from the display and the new digit is placed in the first location Thereafter no digits are highlighted and new digits are added to the rightmost position while the other digits are shifted left Edit value Mode Edit value mode may be entered from the initial new value mode b...

Page 135: ...e or a signed value Password Object When editing a password value the arrow keys and the keys are disabled Additionally overwrite mode is disabled When entering digits the pop up keypad hides the value by displaying alternately for each digit ASCII Object When editing an ASCII value an ASCII keypad is displayed as shown figure 13 2 The ASCII keypad has 3 modes numeric symbols and alpha In Alpha mo...

Page 136: ...he object as one that causes a screen change shown below in Figure 14 3 Screen jumps can also be triggered on other keys or based on control logic for more advanced applications To allow the operator to change screens a screen jump object is generally used This object may be visually represented as a button responding to touch or remain invisible and logically tied to an OCS register An optional s...

Page 137: ... de energized the screen remains until it is switched by the user or ladder Figure 14 4 Force and Switch Coils in Ladder Programming There is also a system register that can be used to for control based screen navigation SR1 can be read to determine the current screen or written to change the current screen Refer to the on line help in Cscape for more information on control based screen navigation...

Page 138: ...h 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 sensitivity To increase the amount of tolerable slip and prevent false releases of the button the XL7 XL7 PRIME allows adjustment of the allowable slide up to 5x the default value To enable the touch slip sensitivity first an OCS data register must b...

Page 139: ...ristics 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 Exist To view ack...

Page 140: ...iated 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 pop up alarm view...

Page 141: ...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 similar to that shown in Figure 14 8 NOTE The removable media object can be configured to open the removable media viewer at a certain directory complete with restrictions on tran...

Page 142: ...le 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 is attempting to write t...

Page 143: ...backlight is otherwise ignored by the XL7 XL7 PRIME Any additional touch activity is also ignored by the XL7 XL7 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 acknowledgem...

Page 144: ...ure Minimum Firmware Version 15 xx or later 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 controllers ...

Page 145: ...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 interface featur...

Page 146: ...ampling Rate Supported 24000Hz to 44100Hz Audio Playback Only one audio file can be played at a time If multiple bits are simultaneously triggered only the least significant bit will be acted upon After completing playback the next least significant bit will be acted upon File Location Files must be present in Removable Media for playback and are NOT downloaded from Cscape 15 2 Audio Configuration...

Page 147: ...r gives the status of the audio files see table below Table 15 1 1st and 2nd Status Registers Bit Number Description 1st Status Register Bit 1 to Bit 8 Volume Control 0 100 Bit 9 Play Control 1 Pause 0 Play Bits 10 16 Not Used 2nd Status Register Bit 1 Cannot open ALSA Lib Bit 2 Cannot open MP3 Lib Bit 3 Audio output device cannot be setup Bit 4 Cannot open input Audio Stream Bit 5 Memory allocati...

Page 148: ...the list Add Selecting this button display the following window where an audio filename with full path needs to be configure The Modify and Delete button are also available in the Audio Config dialog IMPORTANT 1 Audio files are not downloaded from Cscape they must be present 2 Only one audio file can be played at a time If multiple bits are simultaneously triggered only the least significant bit w...

Page 149: ... 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 16 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 20 24 30 ...

Page 150: ...14 03 or newer to use with the XL7 XL7 PRIME devices In Cscape select the XL7 XL7 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 Then click in the grid ...

Page 151: ...MAN0974 14 EN_XL7_XL7P_UM July 6 2022 Page 151 199 4 Then double click on the icon in the middle to open the Video Properties dialog ...

Page 152: ...e 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 Target Path field ...

Page 153: ...s 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 number c...

Page 154: ...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 16 7 Web Cameras If multiple web cameras are directly connected to the XL7 XL7 PRIME then only one web cam will be considered If user needs t...

Page 155: ...S power is On or Off To install a microSD card Align its 8 pin gold edge connector down facing the front of the XL7 XL7 PRIME OCS unit then carefully push it all the way into the Memory slot Ensure that it clicks into place To remove the microSD card Push in on the top of the card gently to release the spring The card pops out for removal 17 3 microSD File System The microSD memory card slot uses ...

Page 156: ...edia Manager can be accessed via the System Menu or by using Cscape to place a Removable Media Manager object on an application graphics screen Figure 17 2 Removable Media Submenu 17 5 Using Removable Media to Log Data Using Read and Write Removable Media function blocks an application ladder program can read and write XL7 XL7 PRIME OCS register data in the form of comma delimited files with a CSV...

Page 157: ...rd reader by selecting the Export to Removable Media item on the Cscape File menu 17 7 Using Removable Media to View and Capture Screens The XL7 XL7 PRIME OCS File System uses bitmap files with the BMP extension or JPEG files with the JPG extension to store XL7 XL7 PRIME OCS graphic screen captures To view a captured XL7 XL7 PRIME OCS screen use the Removable Media Manager to find and highlight th...

Page 158: ...sc button to remove the pop up removable media viewer 17 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 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 blocks will ref...

Page 159: ... 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 17 12 Removable Media RM Features Additional Configuratio...

Page 160: ...y the OCS with current time and date information Table 17 2 Filename Special Symbols 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 4 pm 16 m Substitutes the current minute 45 45 s Substitutes the current second 34 34 NOTE Al...

Page 161: ...rent 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 For additional status information consult the Cscape Help file Table 17 5 RM Status Values 0 RM interface OK 1 Card present but unknown format 2 No card in...

Page 162: ...r 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 18 2 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 has been ad...

Page 163: ...Unit Menu before Cloning Free Total displays number of free and total bytes in Removable Media 3 Make Create Clone option enables user to duplicate Clone application file all unit settings and all register values from Battery Backed RAM Selecting Make Clone brings up the screen below for the user Figure 18 3 Clone Unit Confirm Screen ...

Page 164: ...t 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 18 4 Clone Unit Files NOTE Make Create clone operation automatically includes the security in AUTOLOAD PGM file for security enabled files ...

Page 165: ...t 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 Clone Feature I...

Page 166: ... 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 18 6 System Menu Selecting Clone Unit menu will open the following menu screen Select Load Clone Figure 18 7 Clone Unit Menu after Cloning ...

Page 167: ...r 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 failure of the...

Page 168: ...agnetic Interference event The Fail Safe System has the following capabilities Manually backup the current Retentive Register Settings into flash memory 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 fl...

Page 169: ...a or AutoLoad operation 5 Backup the current Battery Backed RAM Register contents in On Board flash memory using System Menu options 19 3 Backup Restore Data Selecting this option brings up a screen having four operations Backup OCS Data Restore OCS Data Clear Backup Data Exit Figure 19 2 Backup Restore Data Backup OCS Data When initiated this will allow the user to copy manually Battery Backed RA...

Page 170: ... followed 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 else it will remain in IDLE mode Figure 19 4 Restore OCS Data SR164 3 is set to the value of 1 only when an automatic restore operation is performed not on a man...

Page 171: ... Clear Backup Data When initiated the backup data will be erased from the onboard flash memory and no backup will exist SR164 4 and SR164 3 is reset to 0 when backed up data is erased Figure 19 5 Clear Backup Data Exit Goes back to the previous screen ...

Page 172: ...re Figure 19 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 173: ...e program residing in onboard memory is corrupted and a valid AUTOLOAD PGM is available in the removable media of the device AutoLoad can be manually initiated when the SYS F3 key is pressed OCS can be in any of the following mode Idle Run DOIO This also requires a valid AUTOLOAD PGM to be present in the removable media of the device When the AutoLoad setting is not enabled set to NO OCS will be i...

Page 174: ...low 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 175: ... 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 acknowledging this me...

Page 176: ...ble 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 20 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 allows the pri...

Page 177: ...ery 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 decimal By ...

Page 178: ...n in the Traditional Modbus Reference column of the table Method 2 The second method requires the Modbus Master to be configured with a specific Modbus Command and Modbus Offset Table 20 1 Modbus Master Mapping XL7 XL7 PRIME Reference Maximum Range Trad Modbus Ref 5 Digits Expanded Modbus Ref 6 Digits Modbus Commands Modbus Offset I1 2048 10001 010001 Read Input Status 2 0 IG1 256 13001 013001 300...

Page 179: ... 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 21 3 Battery Life The battery is designed to last 300 full charges to 1000 partial charge cycles or 7 to 10 years ...

Page 180: ... 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...

Page 181: ...perature 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 has fully...

Page 182: ... Charge State Refer to Table 21 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 the unit it ...

Page 183: ...tures 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 RECHARGE DISASSEMBLE ...

Page 184: ...l regulations 7 Insert new battery by aligning the positive end of the battery with the positive sign on the board 8 Slide battery plate cover back on the unit from the bottom up and re tighten the screw in place 9 Apply power and restore program and registers if necessary 10 Allow the unit to remain powered near room temperature 10 35 C for 6 to 8 hours This will ensure the battery is fully charg...

Page 185: ... 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 CHANGED IN A A...

Page 186: ...ll power from the XL7 Prime unit including I O power 3 On the back of the XL7 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 battery error ...

Page 187: ... for Current Firmware Revision To check the firmware revision on a controller open System Menu View Status Warning Firmware updates should only be performed when the equipment being controlled by the XL7 XL7 PRIME 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 equipme...

Page 188: ... 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 recent firmware set wit...

Page 189: ...nstall Bootloader button and then press 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 ...

Page 190: ...r 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 not present or that another program has control of the COM port Only one Cscape window can access a port at a time Subsequent instances of Cscape opened will indicate No Port Local No Com Csc...

Page 191: ...ers a USB to serial adapter Part numbers HE XCK and HE CPK 24 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 driver is...

Page 192: ...eck diagnostics to ensure controller passed self tests View Diags in System Menu or in Cscape 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 monitored and ...

Page 193: ...s should be placed across the CAN_HI and CAN_LO terminals 5 Measure the resistance between CAN_HI and CAN_LO If the network is properly wired and terminated there should be around 60Ω 6 Check for duplicate node ID s 7 Keep proper wires together One twisted pair is for V and V and the other twisted pair is used for CAN_HI and CAN_LO 8 Make sure the baud rate is the same for all controllers on the n...

Page 194: ...guaranteed Larger USB devices such as hard drives etc should only be attached and removed when the OCS is powered down The resets are caused by short sharp current spikes when devices are added or removed from the OCS these spikes can exceed the USB specification but are usually very short and mostly do not cause problems Some devices however draw a longer larger current as they power up causing a...

Page 195: ...ughout Cscape Config Analog In Table 7 2 8 10 2020 12 Added back cover dimensions for standard and extended Mantis 3487 3 4 XL7 XL7 PRIME Back Cover Dimensions 8 13 2021 13 4845 Updated WebMI Register 4802 4802 WebMI Max of Connections 6483 Updated Install Procedure 6319 USB Interfaces 6442 Battery Charging Cycle SR Table Ethernet Overview Installation Procedure USB Interfaces Battery Status in SR...

Page 196: ...eo Properties 152 Count 102 104 Csape Program Via Serial Port 114 Cscape 2 15 35 36 59 63 69 78 81 83 84 85 86 87 88 112 114 116 137 156 157 190 191 192 Alternative Connection Method Screenshot 67 Analog In Configuration 76 Analog Out Configuration 77 Configuration Procedures 72 Digita In HSC Configuration 74 Digital Out PWM Configuration 75 Establishing Communications 64 Overview 63 Status Bar 63...

Page 197: ...NTY 3 Lithium Battery Safety 179 Load Clone 48 166 Maintenance 187 Make Clone 162 Manual Index 13 MECHANICAL INSTALLATION 17 micro SD Cards 155 Installing Removing 155 micro SD System 155 Minimum Clearance Requirements for Panel Box and Door 23 Modbus Addressing Table 178 Modbus Communications 176 Modbus Master 177 Modbus Master Mapping 178 Modbus Slave 176 Model I O Overview 80 Mounting Orientati...

Page 198: ...tate 81 83 Storing Register Contents 179 STP Examples 108 Sub Menus 28 System Menu Details 50 Navigate Edit 29 System Menu Map 30 System Registers with RM 161 SYSTEM SETTINGS AND ADJUSTMENTS 28 Sytem Menu Overview 28 Table of Contents 5 target ID 69 70 Target ID 69 70 target indicator 70 71 Technical Support 2 83 194 Contacts 194 Testing for Good Ground 26 Thermistor Option 85 totalize 91 Totalize...

Page 199: ...36 View Status 32 Visual Overview of XL7and Topics 12 Where to Find Information 13 XL4 PRIME BACK UP BATTERY 185 XL7 I O Cover Photograph 78 XL7 I O Cover Removed sample I O board Photograph 79 XL7 Manual PREFACE 2 XL7 OCS Dimensions 21 XL7 OCS Mounting Clip 18 XL7 OCS Mounting Orientation 19 XL7 OCS with Mounting Clips 18 ...

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