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XL6/XL6M/XL6e OCS

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1. 59 11 7 60 4 2010 6 of 135 1037 0883 05 Table of Contents CHAPTER 12 SYSTEM SETTINGS AND 2 2 2 61 12 1 System Menu ESe II m 61 12 2 System Menu Navigation and 62 12 3 System M nu ESPECIE 63 12 4 74 CHAPTER 13 05 75 13 1 QUT EMEN SE EE 75 13 2 Displaying andentenng E ales ceo a a aaa 75 13 3 76 13 4 Screen Navigatio a 78 13 5 Ladder Based Screen Navigation ccccccccsseseccceeecceeeseeeeeeeeeseueeeeeeesessueeeseeeeeesessaeeeeeeeeeesaas 79 13 6 Beeper 79 13 7 Touch Slipy N ctus uisi 79 13 8 m UU E 80 13 9 Medid cic T 81
2. 2 2 2 126 March 4 2010 Page 134 of 135 1037 Table of Figures 0883 05 No part of this publication may be reproduced without the prior agreement and written permission of Horner Inc Information in this document is subject to change without notice March 4 2010 Page 135 of 135 1037
3. 115 Figure 16 4 Restore OCS Dal osi n Ore 115 Figure 16 5 Clear Backup og uM eese eU tte 116 Figure 16 6 Flow Chart for Automatic Restore 2 0 1 117 Figure 16 7 Autoboad Men oor e Aenea eerie rene eer 118 Figure 16 8 Flow Chart for AutoLoad 119 T6 9 AUtORUN dae se wna 120 Figure en E SY SOM MENU cA 121 Figure 17 2 Clone Unit Menu before 121 Figure 17 3 Clone Unit Confirm 122 Figure 17 4 Clone Unit Files eot Retos oid as cce be Load audi hamis 122 Figure 17 5 Cloning orbi oe LM ee a LU e Ede 123 Figure 17 6 System Men eea E 123 Figure 17 7 Clone Unit Menu after 124 Figure 17 8 Load Clone Confirm Screen 124 Figure 18 1 Back Cover Replacing the back up battery
4. 27 5 95 Serious IM 27 5 6 Cscape Programming via Serial 000 2 001 0000000000000000000000 0 00 000 27 5 7 Ladder Controlled Serial COMMUNICATION 002 000 0 27 5 8 Downloadable Serial Communication 8 27 March 4 2010 Page 5 of 135 1037 Table of Contents MANO883 05 EN CHAPTER 6 CAN 65 144444 29 CU RU 29 ST MM o a BI egeo 29 63 m T M 30 64 QGscape Programming Vid GQAN iile D agus tede steve lesa ute casos abuse uc Eu santa OVE 30 6 5 Ladder Controlled CAN Communication 2 0 30 6 6 Using CAN for I O Expansion Network 30 CHAPTER 7 ETHERNET COMMUNICATION XL6E 2 2 0 211 111 31 71 Ethernet Module Protocols and 31 7 2 Ethernet System 31 73 Ethernet Module 5 lt sen etes etel 31 7 4 Ethernet Module 31 C
5. 20 3 6 1 Glearance Adequate SO ACC sitet eco a 20 011 20 3 Temperature s coco i den ieee 20 9 4 NL OMM 21 9 5 9 NOO unii CR mop ADAM LAM M 21 9660 here ee 21 3 6 7 Panel Layout Design and Clearance 21 CHAPTER 4 ELECTRICAL INSTALLATION 23 Ad EOS o mI 23 42 around opeciliGCdllOfiS sen cos nen tuba iei uns Loc 23 429 Good 23 AA Ohio a 24 CHAPTER 5 SERIAL 5 0 4222222 44440000001 25 5 mE S 25 32 Es 25 castes 25 RS 485
6. 79 FOWE 13 3 Alarm OD GGL ac ote etn N e 80 Figure 13 4 Alarm VIeWDBE oou s 80 Figure 13 5 Removable Media oro adores ine 81 Figure 13 6 Removable media View CMs ooo ue us sete 82 Figure 13 7 Example application segment for safe removal of removable media 83 Figure 15 1 Front Panel and USB Programming 22 2 2 2 98 Figure 15 2 Digital Input HSC Configuration 6 107 Figure 15 3 Digital Output PWM Configuration 22142 2 109 Figure 15 4 Analog Input Configuration 1 nennen nnne nnn 110 Figure 15 5 Analog Output Configuration nnne nnne nnne 111 Figure 16 1 Fall Safe System Menu socio 2 2 era ge USE Ed ieee 113 Figure 16 2 Backup Restore Data n isa docte as 114 Figure 16 3 Registers io
7. TN 83 IS a 83 CHAPTER 14 REGISTER S iio icc dee dues dva 85 14 1 Rogister LI T M P 85 14 2 Useful 5 and SR registers areas daa 86 14 3 Register for XL6 XL6e 5 88 14 4 Resource 89 CHAPTER 15 CSCAPE CONFIGURATION siat ce deoc a uu cuia 91 15 1 AU 91 15 2 25 Slats T 91 15 3 Establishing 92 15 3 1 Communicating MJ1 Serial POr agosan a a a a eaa 105 15 3 2 Communicating On Board Ethernet Port For XL6e 106 15 4 Models SUDDONS Onia a 106 15 5 E 107 15 6 Digital Input HSC 107 15 7 Digital Output PWM 98 109 15 8 Analog Input ConfigurdtlOr 110 15 9 Analog Output 111
8. Comm Ports Maximum baud rate 5 600 z Timeout 000 m5 1 WAEDMTI Cancel Apply Help March 4 2010 Page 104 of 135 1037 MANO883 05 EN CH 15 If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above in this chapter section Cscape Status Bar User MONE XL Model Unknown Local 253 Target 25318 no Forces If the controller is not communicating you may need to set the target ID of the controller in the unit The Target ID allows directing communications to a particular unit when multiple units are connected 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 XL6 XL6e OCS press the system menu key The first item in the menu is Set Network ID Pressing Enter allows you to view or modify the ID of the unit Set Network ID Set Network Baud View OCS Status View OCS Diags View 1 0 Slots View Protocols Set Fkeys Mode 5 Set Serial Ports Set Time Date Set Beeper Set Screen Removable Media Press ESC to exit lj To change the Target ID of Cscape use the Controller Set Target Network ID dialog 15 3 1 Communicating via MJ1 Serial Port Start by configuring Cscape to use
9. is just dumb I O and its location RELATIVE to the map Enabled Contains the following 1 sec Frequency 100 msec Grayed out 10 msec Scan resolution Enabled Contains the following Enabled Value Totalize Hising edge can be 0 gt Falling edge Oxffffffff Hex Enabled Contains the following Width high Counts Pulse Width low 1usec Counts Grayed out Period rising edges 1usec Counts Period falling edges 1usec Counts Enabled Contains the following Enabled Value Quadrature 1 leads 2 count up can be 0 gt 1 leads 2 count down Oxffffffff Hex Enabled Only available in counter 3 and only when counter 1 is set to quadrature Contains the following Async reset on rising edge Async reset on falling edge Async reset on both edges Marker ub rising Grayed out OW reset on 1 rising High reset on 1 falling Low reset on 1 falling High reset on 2 rising Low reset on 2 rising High reset on 2 falling Low reset on 2 falling March 4 2010 Page 108 of 135 1037 MANO883 05 EN CH 15 15 7 Digital Output PWM Configuration The following figure illustrates the Digital Output PWM Configuration dialog Digital PWM Output Configuration E X 01 Normal C PAM H2 C HSC2 Output C HSC1 Output Stepper State on Controller Stop 1 Duty Cycle default Hold Last State Fuld 2 Duty Cycle default Hold Last State Presc
10. Table 14 2 SR Registers Register Name Min Val Max Val Read bit indicating Auto Restore of Register Data p L J Read bit indicating Backup of Register Data has a EE been performed Fail Safe SR164 5 Enable AUTORUN Fail Safe SR1646 Enable AUTOLOAD Fail Safe SR164 7 Backptiggebit SR1648 Clear Backup trigger bit CT SR164 9 2 MAKE CLONE trigger bit I SR164 10 LOAD_CLONE trigger bit Status indicating Make Clone Fail This bit goes mene high when Create clone fails Status indicating Load Clone Fail This bit goes NEN high when Load clone fails SR165 174 Reserved S e SR175 4 Current Removable Media interface status poo 6 o SR176 177 e movable Indicates free space on the Removable Media card o F Media in bytes SR178 179 D aad Indicates the total card capacity in bytes o FP Lee 9558180 Unacknowledged Alarm high bit indicates what 9058181 ALM UNACK group SR188 NET MIN Minimum Net Usage of all units on the CAN network SR189 NET MAX Maximum Net Usage of all units on the CAN network SR190 NT_TX_AVG Average Net Usage of this unit SR191 NT TX MIN Minimum Net Usage of this unit 9558192 Maximum Net Usage of this unit For additional information on system bits and registers refer to the o
11. 3 6 3 Temperature Ventilation Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient temperature range Consider the impact on the design of the panel layout if operating at the extreme ends of the ambient temperature range For example if it is determined that a cooling device is required allow adequate space and clearances for the device in the panel box or on the panel door March 4 2010 Page 20 of 135 1037 0883 05 3 6 4 When panel mounted there are no orientation restrictions on the XL6 XL6e OCS 3 6 5 Noise Consider the impact on the panel layout design and clearance requirements if noise suppression devices are needed Be sure to maintain an adequate distance between the XL6 XL6e OCS and noisy devices such as relays motor starters etc 3 6 6 Shock and Vibration The XL6 OCS has been designed to operate in typical industrial environments that may inflict some shock and vibration on the unit For applications that may inflict excessive shock and vibration please use proper dampening techniques or relocate the XL6 XL6e OCS to a location that minimizes shock and or vibration 3 6 7 Panel Layout Design and Clearance Checklist The following list provides highlights of panel layout design factors Meets the electrical code and applicable standards for proper grounding etc Meets the panel manufacturer s requirements for grounding etc
12. at run time Count The prescale 96AQ5 6 count sets the resolution of the internal counter used for generating the PWM output The prescale count 1 is a divisor applied to a 16MHz clock that drives the internal PWM counter For the highest resolution PWM output this value should be set as low as possible 0 provides a 1 16 micro second resolution Both the Period and Duty cycle pulse width are based on counts of the internal PWM counter The frequency of the PWM output is calculated using the following formula March 4 2010 Page 56 of 135 1037 0883 05 11 16 000 000 Frequency Pr escaleCount 1 xPeriodCount e Period Count This value AQ 7 8 sets the period of the output signal by specifying the number of internal PWM counter counts before the cycle is reset larger count results in a smaller frequency The duration of each count is determined by the prescaler value This parameter affects the Period of both PWM outputs See the previous formula to see how the prescale and period counts create an output frequency For example setting the PWM for 1 us resolution prescale 15 and a period count of 20 000 would result in a 50 Hz output LI Period e Duty Cycle Count This value PWM1 AQ1 2 PWM2 AQ3 4 sets the width of the output signal by specifying the number of internal PWM counter counts that the output is maintained high The duration of each count is determined
13. 14 2 1 2 Four main types of information are covered in the 14 2 153 Me c 14 ZK n Eom mmm 14 2 2 tothe KI 6 XLOC OCS reins coe seed ede ita e Scotia a did ass 15 23 Features or XLO XLOMXLOST OCS usquc tesa pelas al uo sia De 15 2 4 Required and Suggested 16 2 5 Usetul Docuiments and Referenc s o Uu te uh er cou dae eas Seite ces 16 CHAPTER 3 MECHANICAL 2 22222 2 17 pene ES 17 32 Mounting 17 3 2 1 Mounting Procedures Installed in a Panel 17 3 3 Mounting 9 18 3 3 1 XL6 XL6e OCS Mounting 18 3 9 2 XL6 XL6e OCS Mounting Orientation 18 T MEE Cue ME aac 19 So eXLOPXSEOMUXEOS DIMENSIONS os tee alte a 19 3 6 Factors Affecting Panel Layout Design and
14. Clone Unit can be accessed by going to the System Menu of the OCS A new menu Clone Unit has been added at the end of the main system menu as shown below set Network ID Set Hetunrk Baud Status Uiew Diags Slots Uiew Protocols set Fkeys Mode Set Serial Ports Set Time Date set Beeper Set Screen Removable Hedia Fail Safe System Clone Unit Figure 17 1 System Menu 2 Selecting Clone Unit menu will open the following menu screen Clone Unit Directory Empty Free 10805257280 Total 10054257280 Load Make Clone Clone Esc Figure 17 2 Clone Unit Menu before Cloning March 4 2010 Page 121 of 135 1037 17 0883 05 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 Clone Unit Hake Clone Files Are You Sure Ok Cancel Free 1004257280 Total 1004257280 Load Hake Clone Clone Esc Figure 17 3 Clone Unit Confirm Screen 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 Clone Unit 24570
15. User Manual for XL6 XL6M XL6e HE XL HEXT350 HEXT351 OCS HE XL100 HE XL1M0 HEXT350C100 HEXT280C100 HE XL102 HE XL1M2 HEXT350C112 HEXT280C112 HE XL103 HE XL1M3 HEXT350C113 HEXT280C113 104 HE XL1M4 HEXT350C114 280 114 105 HE XL1M5 HEXT350C115 HEXT280C115 1 0 HEXT351C100 1 2 HEXT351C112 HE XL1E3 HEXT351C113 1 4 HEXT351C114 HE XL1E5 HEXT351C115 0883 05 0883 05 Preface PREFACE This manual explains how to use the XL6 XL6e HE XL HEXT350 HEXT351 OCS Modules Copyright C 2008 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 and CsCAN are trademarks of Horner APG Ethernet is a trademark of Xerox Corporation Micro SD and CompactFla
16. 2010 Page 111 of 135 1037 15 0883 05 5 4 2010 112 135 1037 0883 05 16 CHAPTER 16 FAIL SAFE SYSTEM 16 1 Overview The Fail Safe System is a set of features that allow an application to continue running in the event of certain types of soft failures These soft failures include e Battery power loss e Battery Backed Register RAM or Application Flash corruption due to for example an excessive EMI event The Fail Safe System has the following capabilities e Manually backup the current Battery Backed RAM Register Settings into Flash memory Manually restore Register Settings from the values previously backed up in Flash to Battery Backed RAM Detect corrupted Register Settings at power up and then automatically restore them from Flash Detect corrupted or empty application in Flash memory at power up and then automatically load the AUTOLOAD PGM application file from Removable Media Compact Flash or MicroSD e f an automatic Register Restore or Application Load occurs the OCS can automatically be placed in RUN mode The fail safe system can be accessed by going to the system menu of the controller A new menu Fail Safe System has been added at the end of the main system menu for this Selecting Fail Safe System menu will open the following menu screen Backup Restore Data Enable AutoRun Enable AutoLoad ESC to exit F
17. 350000 Steps Decel Count Note The highest usable frequency is 65 KHz for the PWM output March 4 2010 Page 60 of 135 1037 0883 04 CHAPTER 12 SYSTEM SETTINGS AND ADJUSTMENTS 12 1 System Menu Overview 12 XL6 XL6e has a built in System Menu which lets user view System Settings and makes adjustments To start the System Menu press the SYSTEM key or set SR3 to 1 which will display the Main Menu Then use the 4 and 7 Up Arrow or Down Arrow keys to select a Main Menu item and press Enter Return Arrow to display the item s Sub Menu Sub Menus Network Yes Network ID 253 Network Baud 125 KB Use LT to adjust Model OCS Mode Scan Rate mS All Net Use Ladder Size Config Size Graphics Sz String Size Bitmap Size Text Tbl Size Font Tbl Size Protocol Size SMS File Size Firmware Rev 12 26 BIOS Rev 0 07 FPGA Rev 2 0 Self Test Ok OO CO OO CO N Logic Error User Program User Graphics W Dog Trips Net Errors Network State Network ID Dup Net ID Clock Error I O System Battery Slot 1 I O Empty Slot 2 I O Empty Slot 3 I O ETN300 March 4 2010 XL6 XL6M XL6e Main Menu Set Network ID Set Network Baud View OCS Status View OCS Diags View I O Slots View Protocols Set Fkeys Mode Set Serial Ports Set Time Date set Beeper set Screen Removable Media Fail Safe System Clone Unit
18. 5 6 7 8 Start the configuration by selecting the Controller Configure menu item If the XL6 XL6e OCS is connected to the PC press the Auto Config System button to automatically detect the Base model I O and any communication options If the XL6 XL6e OCS is not connected press the Config button to the right of the top of the unit This allows the base CPU to be selected Select either XL6 XL6e OCS Cscan or XL SERIES OCS No Net from the type drop down box Once the type of XL6 XL6e OCS is selected the model drop down box will provide the XL6 XL6e OCS model numbers from which to choose from Once the XL6 XL6e OCS CPU is selected press OK to exit the dialog and configure the I O that is present in the first slot The configure dialog Specifically the Module Setup tab provides 4 buttons to configure all of the I O Go through each area of I O and configure it Once done configuring the I O OK out of configuration dialogs Configuring the XL6 XL6e OCS I O has four main portions that are covered in this chapter For additional information on I O refer the chapters covering General I O or High Speed I O in this manual The four areas of I O configuration are 15 6 Digital in HSC Digital out PWM Analog in Analog out Digital Input HSC Configuration The following figure illustrates the Digital Input HSC Configuration dialog Digital Hsc Input Configuration Digital inputs active mode
19. 5 The correct product type should be selected if it is not select the type of controller from the drop down list and press the OK button Press the start button Wait for the firmware update to complete If there is a communication failure check the cable connections and comm port setting and try again 9 Firmware updates typically delete the user applications to ensure compatibility You will need to reload your application 10 Test the operation of the equipment with the new firmware before returning the XL6 XL6e OCS system to an operation mode NO 18 2 Backup Battery The XL6 XL6e OCS contains a run time battery monitor that checks the voltage of the internal lithium battery This battery is used to run the real time clock and maintains retentive registers when power 15 disconnected Under normal conditions the battery in the XL6 XL6e OCS should last 7 to 10 years Higher operating temperatures or variations in batteries may reduce this time 18 2 1 Indications the battery needs replacing The XL6 XL6e OCS indicates the battery is low failed or missing in a variety of ways At power up an error message is displayed indicating the low or missing battery The user program can monitor the battery using SR55 13 This bit will turn on if the battery is low or missing The system menu also contains a battery status message under the diagnostics sub menu see the chapter on System Settings and Adjustments March 4 2010 Pa
20. Active high Note This getting must match that of the jumpers Cancel C Active low on the product High Speed Counters Counts per Rew Mods LU Full 22 counts H Disabled 219 Disabled 410 fe H3 Disabled fani fe H4 Disabled 2112 Figure 15 2 Digital Input HSC Configuration Dialog March 4 2010 Page 107 of 135 1037 15 0883 05 The Active mode group box allows the user to select if inputs are active high 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 4 available high speed counters on the XL6 XL6e 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 Frequency Totalize Pulse Quadrature Marker Only available in counter 3 if counter 1 is set to quadrature The mode drop down items are set according to the type selection The Counts Per Rev window is enabled disabled according to the type selection as well The following table shows what is available with each type selection Table 15 1 Count Per Rev Type 9 c f Counts Rev Grayed out Displays lx to indicate to the user that the input devoted to the high speed counter
21. CHAPTER 16 FAIL SAFE SYSTEM o 113 cM eae ce UE 113 16 2 fe NH IET 114 16 3 sizes 2I EE 114 16 4 Uie Boro cc PIT 118 16 5 AWOR oe eet c 120 121 17 1 MEM 121 17 2 Meo M 9 121 17 3 UE 123 CHAPTER 18 MAINTENANCE ooo a 125 18 1 TEE 125 18 2 Bale RU Em e NI M 125 18 2 1 Indications the battery needs 125 19 2 2 Vd i Ga e ce ovt Ua oo da Va dua du Du A ET uM 126 March 4 2010 Page 7 of 135 1037 Table of Contents MANO883 05 EN CHAPTER 19 TROUBLESHOOTING TECHNICAL SUPPORT 2 22 11 1 127 19 1 Connecting to the XL6 XL6e OCS rerien nnn nnns nena arn nana nnns 127 19 1 1 Connecting Troubleshooting Checklist serial port MJ1 Programming 128 19 1 2 Connecting Troubleshooting Checkl
22. Count totalize Pulse width or period pulse and Quadrature measurement For some modes more than one HSC input may be consumed The measurement value is provided to ladder in a register see mapping below Note that while the high speed input circuitry has a resolution of 1 us measured edge transitions must not occur faster than 100 ps for accurate measurements Keep in mind that pulse width measurements utilize both the rising and falling edges of the waveform thus the pulse width must exist longer than 100 pS Note that the edge polarity selection in the mode parameter for totalize and pulse width functions Digital HSC Input Configuration assume Positive Logic regardless of the associated board s jumper setting for the Digital DC inputs polarity Negative logic is configured when using these functions the opposite edge polarity must be selected in the mode parameter 11 2 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 that selecting a shorter sample window provides a quicker measurement faster response but lowers the frequency accuracy resolution and increases the minimum frequency measurement limit 11 2 2 Totalize In totalize mode the accumulator is simply incremented each time the input transitions in a specific
23. over current or the output driver overheats 10 5 Relay Outputs Relay outputs are designed to switch loads that typically have high voltage or current requirements or require isolation that relays provide Note The design of the XL6 XL6e OCS does not require external coil power for the relays to function The relays will activate anytime the XL6 XL6e OCS is powered March 4 2010 Page 46 of 135 1037 MANO883 05 EN CH 10 There are several factors that should be considered when using relays Relay Life Relays are mechanical devices that have a long but limited life Typically switching more current limits the life of relays Please check the data sheets at the end of this manual for expected relay life Current Temperature De Rating 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 de rating information for relays Fusing External fusing is generally required to protect the relays devices and wiring from shorts or overloads Warning To protect the module and associated wiring from load faults use external 5 A fuse s as shown Fuses of lower current or fusing for the entire system need to be in place to assure the maximum current rating of the unit is not exceeded Warning Connecting high voltage to any I O pin can cause high voltage to appear at other I O pins 230VAC OR 25VDC
24. 4 Insure 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 outputs set from a data watch window in Cscape without interference from the ladder program Some problems are only a result of a mistake in the ladder program 19 3 CsCAN Network For complete information on setting up a CSCAN network refer to CAN Networks manual 799 by visiting our website for the address to obtain documentation and updates Network status node ID errors and baud rate in the controller system menu are all in reference to the CsCAN network These indications can provide performance feedback on the CsCAN network and can also be used to aid in troubleshooting 10 11 12 13 19 3 1 CsCAN Network Troubleshooting Checklist Use the proper Belden wire type or equivalent for the network as specified in MANO799 The XL6 XL6e OCS does not provide 24VDC to the network An external voltage source must be used for other devices such as SmartStix 1 Check voltage at both ends of the network to insure that voltage meets specifications of attached devices Proper termination is required Use 121 ohm or 120 ohm resistors at each end of the network The resistors should be placed across the CAN and CAN LO terminals Measure the res
25. Digital Outputs oolid state digital outputs are generally used to activate lamps low voltage solenoids relays and other low voltage and low current devices Note The digital outputs used on the XL6 XL6e OCS are sourcing outputs This means the output applies a positive voltage to the output pin when turned ON When turned off the output applies approximately zero volts with respect to the I O ground 10 30VDC J2 Figure 10 5 Typical Output Wiring The digital outputs used in the XL6 XL6e OCS have electronic short circuit protection and current limiting While these electronic protections work in most applications some application may require external fusing on these outputs The digital outputs in the XL6 XL6e OCS are typically controlled 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 l O for additional information When the controller is stopped the operation of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state By default digital outputs turn off For more information on stop state see the Index to find pages referencing Cscape settings The digital outputs feature an output fault bit 965132 will turn on if any of the outputs experience a short circuit
26. File when triggered Enable AutoLoad 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 Clone Unit Clone Unit feature allows the user to clone the OCS of the exact same model This feature clones application program and unit settings stored in Battery backed RAM of an OCS into the RM refer Removable Media Chapter 9 for details on using RM It can then be used to clone a different OCS exact same model This feature can be used for e Replacing an OCS by another unit of the same model e Duplicating or clone units without a PC March 4 2010 Page 72 of 135 1037 MANO883 05 EN CH 12 Clone Selecting Clone Unit menu will open the following menu screen Clone Unit Directory Empty Free 1004257280 Total 1004257280 Load Hake Clone Clone ESC Note Free Total displays number of free and total bytes in Removable Media Selecting Make Clone brings up the screen below for the user Clone Unit Hake Clone Files Are You Sure Ok Cancel Free 10057572880 Total 1004257280 Load Hake Clone Clone Esc 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 Ba
27. March 4 2010 Page 116 of 135 1037 MANO883 05 EN The OCS follows the following sequence in execution of Automatic Restore L OCS Power Cycle P Battery Backed RAM Registers check failed Backup NO exists YES Y Controller placed in Application IDLE mode Program erased Y Data copied from Onboard FLASH to OCS Battery backed RAM Controller Resets NO v AutoRun 4 OCS put in IDLE Enabled Mode YES v OCS put in RUN Mode Figure 16 6 Flow Chart for Automatic Restore March 4 2010 Page 117 of 135 CH 16 1037 16 0883 05 16 4 AutoLoad This system menu option allows user to specify whether the OCS automatically loads the application AUTOLOAD PGM located in Removable Media When the AutoLoad setting is enabled set to YES it can either be manually initiated or automatically initiated at power up The automatic initiation will happen only in the following two cases e When there is no application program in the OCS and a valid AUTOLOAD PGM is available in the removable media of the device When the program residing in onboard memory is corrupted and a valid AUTOLOAD PGM is available in the removable media of the device AutoLoad can be manually initiated when the SYS F3 key is pressed OCS can be in any of the following mode Idle Run DOIO This also requ
28. Page 74 of 135 111037 0883 05 13 CHAPTER 13 USER INTERFACE 13 1 Overview This chapter presents the user interface or operator view of the XL6 XL6M XL6e and some of the model specific characteristics of the XL6 XL6e as compared to the rest of the OCS line This chapter does NOT cover building screens or using the CSCAPE graphics editor For instructions on creating screens and using the graphics editor refer to the graphics editor help file NOTE Most example images appearing in this chapter are for XL6 XL6e in case of XL6M grey scale colors will appear The following aspects are discussed Displaying and entering data Alpha numeric data entry Navigating around screens Beeper acknowledgement Touch slip sensitivity Alarm log dialog RM dialog Screen Saver Dimmer 13 2 Displaying and entering Data Roller 2 A Running Hours 1274 Cleaning Hours 34 Figure 13 1 Example Screen XL6 XL6e only March 4 2010 Page 75 of 135 1037 13 0883 05 Multiple objects provided for displaying data such as virtual panel lights push buttons numeric value displays bar graphs meters graphs and animated bitmaps On the XL6 XL6e these graphical objects through ladder manipulation of attribute bits can change color flash or change visibility to attract operator attention On objects that accept user input the input is provided by touching the object or alternately changin
29. Registers Restore OCS Data When initiated this will allow the user to manually copy the backed up data from the onboard FLASH to the Battery Backed RAM A restore operation will be automatically initiated if a backup has been previously created and on power up the Battery Backed RAM registers fail their check The following process will be followed for restoring data e The controller will be placed in IDLE mode Data will be copied from onboard FLASH to OCS Battery Backed RAM e controller will reset e The controller will be put in RUN mode if the AutoRun setting is Yes else it will remain in IDLE mode Backup Restore Data Restore Register Data Are You Sure This will cause System Resett Figure 16 4 Restore OCS Data 5 164 3 is set to 1 only when an automatic restore operation is performed not on a manual one This bit is reset to 0 when a new backup 15 created March 4 2010 Page 115 of 135 1037 16 MANO883 05 EN Restoring of data can be manually performed by selecting RESTORE option from the Backup Restore Data menu This will cause the controller to reset Clear Backup Data When initiated the backup data will be erased from the onboard Flash and no backup will exist 5 164 4 and SR164 3 is reset to 0 when backed up data is erased Backup Restore Data Clear Backup Are You Sure Figure 16 5 Clear Backup Data Exit Goes back to the previous screen
30. by the prescaler value Each PWM channel has its own duty cycle count parameter Setting the period count to 1000 and the duty cycle count to 500 results in a duty cycle of 50 percent Changing just the duty cycle count to a value of 250 results in a duty cycle of 25 percent Duty Cycle At controller power up or during a download the PWM output is maintained at zero until both the Period count and the Duty cycle count are loaded with non zero values When the controller is placed in stop mode the state of the PWM outputs is dependent on the PWM State on Controller Stop configuration This configuration allows for either hold last state or specific prescale period and duty cycle counts Specifying zero for either the period or duty causes the PWM output to remain low during stop mode Note that the nominal output driver turn on time delay to reach 50 output is 25 microseconds Therefore this limitation should be considered when determining both the minimum pulse width and the duty cycle accuracy of the application March 4 2010 Page 57 of 135 1037 11 0883 05 11 4 8 HSC High Speed Counter When either Q1 or Q2 is configured for HSC operation HSC1 or HSC2 totalize functions are extended to allow respective direct output control based on a comparison of the current count and a preset value PV See totalize in the HSC section above for more information 11 4 4 Stepper Function When Q1 is configu
31. defective condition that will not clear by replacing the fuse WARNING EXPLOSION HAZARD Substitution of components may impair suitability for Class 1 Division 2 WARNING The USB parts are for operational maintenance only Do not leave permanently connected unless area is known to be non hazardous WARNING EXPLOSION HAZARD BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE NON HAZARDOUS WARNING Battery May Explode If Mistreated Do Not Recharge Disassemble or Dispose Of In Fire WARNING Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life a All applicable codes and standards need to be followed in the installation of this product b For I O wiring discrete use the following wire type or equivalent Belden 9918 18 AWG or larger Adhere to the following safety precautions whenever any type of connection is made to the module Connect the green safety earth ground first before making any other connections a b When connecting to electric circuits or pulse initiating equipment open their related breakers Do not make connections to live power lines c Make connections to the module first then connect
32. direction Totalize mode is configurable to specify the edge rising or falling on which the accumulator is incremented IDEE Rising Edge Signal Falling Edge Signal March 4 2010 Page 51 of 135 1037 11 0883 05 Three different options are available to reset the current count They Configured reset value When configuring the Totalize function a value may be specified under the Counts per Hev column When the totalizer accumulator reaches this value 1 the accumulator will reset to zero on the next count Specifying zero for this value allows the totalizer to count through the full 32 bit range before resetting Ladder control Setting registers Q17 20 reset HSC1 4 respectively with no additional configuration When these registers are asserted the associated totalizer accumulator is reset and held at zero level sensitive See also Section 10 6 Direct digital input control HSC1 and HSC2 only HSC3 11 and HSC4 96112 may be configured as hardware digital reset signals for HSC1 and HSC2 respectively To enable these inputs as reset signals specify the type as Totalize Heset note that 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 100 ps The totalize function also supports an option which compares the current accu
33. of the XL6 XL6e OCS unit Please see the on line help provided with Cscape for additional details 15 2 Cscape Status Bar When the XL6 XL6e OCS is connected to a PC using Cscape software a Status Bar appears at the bottom of the screen The Cscape Status Bar can be used to determine if communications have been established between the XL6 XL6e OCS and the Cscape program Components of the Cscape Status Bar are explained below Message Line The contents of these messages stored in the Target Controller Equal Indicator indicates whether the current program in Cscape is equal to the program are context f Equal the program in Cscape is the same as the program stored in the Target Controller sensitive The e f Not Equal the program in Cscape is not the same as the program stored in the Target Message line can Controller be empty e If Unknown there may have been a change since the last time the program in Cscape was compared to the Target Controller Current User indicates who is logged for security purposes File Modified Indicator indicates that the file in the selected window has been modified but has not been saved User NONE Model Local 1 Target 2 R no forces MOD Controller Model Network Model Confirmation Communications Status indicates the current status of the pass through Connector Controller Model indicates the controller model for which the
34. of the gasket are secure 3 Pass the unit through the panel 4 Insert the each of the four 4 mounting clips into the slots in the XL6 XL6e OCS case One clip should be installed on each corner Lightly tignten each screw so the clip is held in place 5 Tighten the screws on the clips such that the gasket is compressed against the panel March 4 2010 Page 17 of 135 1037 MANO883 05 EN 3 3 Mounting Orientation 3 89 1 XL6 XL6e OCS Mounting Clip 001XLQX007 0010 5004 Figure 3 2 XL6 XL6e OCS with Mounting Clips 3 3 2 XL6 XL6e OCS Mounting Orientation 0010CS001 NOTE There are NO orientation restrictions on the OCS However the above orientation provides for optimum readability of the screen and ease of use of the keypad Figure 3 3 Orientation of XL6 XL6e OCS March 4 2010 Page 18 of 135 1037 MANO883 05 EN CH 3 3 4 Panel Cut Out For installations requiring NEMA4X liquid and dust protection the panel cutout should be cut with a tolerance of 0 005 0 1 mm 125 3 mm RADIUS CORNERS 5 156 131mm WHEN REQUIRING DUST OR WATER TIGHT SEAL PER NEMA 4 4X 12 es 175mm 0010CS003 R1 Figure 3 4 Panel Cutout Tolerances 3 5 XL6 XL6M XL6e Dimensions 5 653 143 6mm 1 Ex a nul b l M 3 030 77 0mm 7 326 186 1mm T Figure 3
35. pgm file and not a csp file XL6 XL6e OCS will not download project file In addition to file must be pgm the file s I O configuration must match the XL6 XL6e configuration for it to download 19 5 Technical Support Contacts For manual updates and assistance contact Technical Support at the following locations North America Tel 817 916 4274 Fax 317 639 4279 www heapg com Email techsppt heapg com Europe Tel 4 353 21 4321 266 Fax 353 21 4321826 www horner apg com Email tech support hornerapg com March 4 2010 Page 130 of 135 1037 0883 05 Index bits 47 Accessories 16 accumulator 51 52 53 54 55 88 89 Analog Inputs 49 Analog Outputs 50 Asynchronous 54 AutoLoad 118 AutoRun 120 Back Cover Replacing the back up battery 126 Backup Restore 114 Battery Backup 125 Replacement 126 Warnings 126 When to Replace 125 Battery backed RAM 72 121 CAN Comm Cscape Programming 30 Expansion Network I O 30 Ladder Controlled 30 Overview 29 Ports 29 Wiring 30 CAN Communications 29 CE 12 Clone Unit 72 121 CLONE DAT 73 122 COM 25 27 30 37 38 65 66 68 86 103 104 127 128 COM port 104 127 128 Communicating via MJ1 Serial Port 105 Communication options 31 37 Communication Options Ethernet COM Module XEC 37 Modem COM Module XMC 38 Overview 37 Communications Port 104 128 Compliance CE 12 Count 51 56 57 58 59 60
36. tado ia ode cu uds a uiuos 32 Figure 7 2 Ethernet Module 33 Figure 9 1 Removable Micro SD Memory Card 4 22 00 39 Figure 9 2 Installing Removable Memory 39 Figure 10 1 Removing the 43 Figure 10 2 XL6 XL6e I O Cover sample 44 Figure 10 4 Example Jumper Diagram 45 Figure 10 5 Typical Output WINO iren eee eo o ett aeuo een 46 Figure 10 7 Positive and Negative 5 48 Figure 11 1 Sync pulse mode Illustration IR es eed ened Saeco 55 Figure 12 1 System Menu 61 Figure 12 2 System Menu XL6 XL6e Screenshot 00 00 62 Figure 13 1 Example Screen ista dale acetate taser tsa rca 75 Figure 13 2 Alpha numeric Keypad 77 Figure 13 3 Typical Screen Jump Object 6 78 Figure 13 4 Force and Switch Coils in Ladder
37. the Local Area Network or to the Internet After installing and configuring the Ethernet COM module Cscape or OPC Server software should be set up to communicate to one of the virtual serial ports at which point they should function as if a real PC serial port was connected to the XL6 OCS serial port March 4 2010 Page 37 of 135 1037 CH 8 MANO883 05 EN 8 3 Modem COM Module XMC Option A Modem COM module can be installed to allow Cscape programming of an XL6 OCS over a dial up network In addition the application ladder program can take control of the modem for application specific modem communication The Modem COM module supports the standard AT command set and can connect to the dial up network at speeds up to 14 4 KBaud Connection speed is auto negotiated The Modem COM module connects to the dial up network phone line via a cable with a standard RJ11 modular plug To enable Cscape programming via a dial up network the Modem COM module should first be configured as the Default Programming Port using the XL6 OCS System Menu Doing this puts the Modem COM module in auto answer mode so Cscape can call the XL6 OCS via a remote modem To program the ladder application to communicate via the Modem COM module standard Cscape Serial and Modem function blocks can be used March 4 2010 Page 38 of 135 1037 MANO883 05 EN CH 10 CHAPTER 9 REMOVABLE MEDIA 9 1 Overview All XL6 XL6M XL6e OCS models provide a Rem
38. the correct communications port This can be done using the Tools Options Communication Port dialog in Cscape Next connect the PC s serial port to the port labeled MJ1 on the XL6 XL6e If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above If the controller is not communicating you may need to set the target ID of the controller in Cscape or on the unit The Target ID allows directing communications to a particular unit when March 4 2010 Page 105 of 135 1037 15 MANO883 05 EN multiple units are connected a CSCAN network Units without CSCAN network ports respond to any network ID and do not require the ID to be configured To check or change the ID on the XLe XLt press the UP and DOWN keys on the XLe XLt simultaneously to enter the system menu The first item in the menu is Set Network ID Pressing Enter allows you to view or modify the ID of the unit To change the Target ID of Cscape use the Controller Set Target Network ID dialog 15 3 2 Communicating via On Board Ethernet Port For XL6e Only 15 4 From Cscape go to Controller gt I O Configure and do auto configuration for the connected controller XL6e Click on Config of Ethernet amp go to Module Setup In Module configuration dialog go to IP Address field enter unused IP Address and configure unused registers in Register field amp then click OK Screen s
39. the operator on the current state of the removable media device and allow access to its file structure The removable media object is displayed as a button that changes colors to indicate the current state of the removable media device The following indicates the device states and the default colors associated with these states Highest Red Device Error Yellow Device Full threshold adjustable Lowest Green Device Figure 13 5 Removable Media Object To view and perform file operations 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 similar to that shown in Figure 13 8 Note that the removable media object can be configured to open the removable media viewer at a certain directory complete with restrictions on transversing back up the file path This may be used to restrict operator access to non critical files March 4 2010 Page 81 of 135 1037 13 MANO883 05 EN Media Directory SCREEN61 153654 61 13 96 1213p SCREENZ6 153654 61 13 96 1268p Free 002247808 Total 992739328 V Del For Save 4 Del 111 Esc Figure 13 6 Removable media viewer The currently selected entry is indicated by a yellow highlight which can be moved up or down by touching the arrow bu
40. to occur within the run phase The frequency of the cycles within this mode is constant at the specified Run frequency The Run count may be any value Setting this value to zero disables this phase Deceleration Count This value AQ 7 8 sets the number of cycles to occur within the deceleration phase The frequency of the cycles within this phase will vary linearly between the specified Run and Stop frequency The Decel count must not equal 1 or an error is generated Setting this value to zero disables this phase The stepper provides two Boolean registers to provide stepper status Ready Done A high indication on this register 130 indicates the stepper sequence can be started i e not currently busy March 4 2010 Page 58 of 135 1037 0883 05 11 Error A high indication on this register 96131 indicates that one of the analog parameters specified above is invalid or the stepper action was aborted before the operation was complete This register is cleared on the next start command if the error was corrected The stepper requires one discrete register Q1 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 that setting the PLC mode to Stop while the stepper is in operation causes the stepper output to immediately drop to z
41. two System Settings of which only Network ID is editable Network Ok Yes NET1 connected to a CAN network and functioning properly No Not ready to communicate on CAN network Network ID 1 253 This node s CsCAN Network ID must be unique on network Set Network Baud Hetwork Baud 125 Use 117 to adjust The Network Baud Sub Menu only appears for XL6 XL6e OCS models that have CAN ports XE1xx This Sub Menu displays just one System Setting and it is editable Network Baud 125 KB 125 KBaud CAN network 250 KB 250 KBaud CAN network 500 KB 500 KBaud CAN network 1 MB 1 MBaud CAN network March 4 2010 Page 63 of 135 1037 12 0883 04 View Status OCS Het lUse 2 All Het Use Ladder Size Config Size Graphics Size String Size Bitmap Size Size Size Size Size Reu The View Status Sub Menu displays up to 17 System Settings Only the Mode System Setting is editable Model XLiyz Model number of this XL6 XL6e OCS unit indicates the installed I O module 00 I O module OCS Mode Idle XL6 XL6e OCS is in Idle mode DolO XL6 XL6e OCS is in Do I O mode Run XL6 XL6e OCS is in Run mode Scan Rate mS 0 0 2XL6 XL6e OCS is not in Run mode 0 1 to 999 9 Average number of mS for each ladder scan OCS Net Use 0 0 100 0 CAN network bandwidth used by this XL6 XL6e OCS node All Net Use 0 0 to 100 0 CAN network bandwidth 96 used by all n
42. unit must be configured to the same mode Positive Logic vs Negative Logic Wiring The XL SERIES OCS can be wired for Positive Logic inputs or Negative Logic inputs 12 24VDC 001 6 Positive Logic In Negative Logic In Figure 10 7 Positive and Negative Inputs In positive logic mode a positive voltage applied to the input will turn the input The internal design of this mode is basically a resistor from the input 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 voltage usually 12 or 24 volts This mode is sometime called sinking Some of the digital inputs may support high speed input functional such as counting or frequency measurement 10 7 Analog Inputs Note See the data sheet for the XL6 XL6e OCS model you are using for jumper settings and see the appropriate page in this manual see Index for details on how to use Cscape to configure the digital filtering March 4 2010 Page 48 of 135 1037 0883 05 10 The analog inputs on the XL6 XL6e OCS allow voltage or current measurement from a variety of devices The voltage or current mode is set though jumpers on the unit and settings in Cscape Each channel can be separately configured for voltage or current mode The analog inputs
43. 07 14 09 12 11a Free 1004208128 Total 1004257280 Load Clone Clone V Esc Figure 17 4 Clone Unit Files NOTE Make Create clone operation automatically includes the security in AUTOLOAD PGM file for security enabled files 4 Once the cloning is successful OCS gives a message as below March 4 2010 Page 122 of 135 1037 0883 05 17 Clone Unit Cloning Status SUCCESS MAKE CLONE operation Ok Free 1004224512 Total 1004257280 Load Hake Clone Clone Esc Figure 17 5 Cloning Status Make Create clone can also be triggered by setting SR164 9 bit to 1 from Ladder program or graphics Once the operation is completed this bit is made zero by the firmware When Make clone operation is triggered by this SR bit it does not ask the user for confirmation for making clone 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 If user desires Backup should be done as explained in Chapter 16 Fail Safe System 17 3 Load Clone This option loads the application all unit settings and register values from Removable media to the Battery backed RAM Regardless of AutoLoad settings and then resets the OCS for the settings to take effect User needs to
44. 08 Free 511672320 Total 51195904 A V Del For Save 4 Del 11 Esc The Removable Media Sub Menu displays the Removable Media Manager After selecting Removable Media from the Main Menu one of four Sub Menu screens will appear Media Directory No Card Media Directory Initializing Media Directory Dir Empty No Micro SD card has been installed in the Memory slot Micro SD card is installed but it is still initializing Micro SD card is installed and initialized but contains no files Media Directory 44272 07 10 08 12 46 SCROBO1 JPG SCR808002 JPG 15209 07 10 08 12 46 SCR80003 JPG 29708 07 10 0725 SCROGO4 JPG 29582 07 10 08 12 57 SCR0O005 JPG 23263 SCRO606 JPG SCR0007 JPG 14643 07 10 08 12 14976 07 10 08 12 47 5 80008 JPG 15994 07 10 08 12 47 SCR80009 JPG 17561 Free 511672326 Total 511959040 07 10 08 12 57 v Micro SD card is installed and initialized and it contains files Shows size of highlighted file or shows DIR if directory is highlighted Shows the date file or directory was created or last modified hows the time file or directory was created or last modified Scrollbar If a directory name is highlighted pressing Enter will switch to that directory showing its files and sub directories In a sub directory highlighting dot dot and pressing Enter will move up one directory March 4 2010 Page 70 of 135
45. 096 On 25 2596 On 100 255 100 On 9eSR58 USER LEDS User LED Control Status 0 65535 SR61 NUM 105 This Station s Number of Network IDs 1 29 9656862 NUM IDS This Station s Number of NetworkIDs 1 253 9eSRe3 SS BASE SmarStackl OBaseSeletor 0 7 9656864 SS STATUS SmarStack I O Base Status 0 2 9eSR65 76 SS INFO 1 SmartStack I O Module 1 Information Structure 6 77 8 SS INFO 2 SmartStack I O Module 2 Information Structure 9eSR89 100 SS INFO SmartStack I O Module 3 Information Structure 6 101 11 2 SS INFO 4 SmartStack I O Module 4 Information Structure 6 113 114 SIZE Graphics Object Table Size 8 256K SR115 116 GSTR SIZE Graphics String Table Size 8 128K 6 119 120 GTXT SIZE Graphics Text Table Size 8 128K 6 121 122 GFNT SIZE Graphics Font Table Size 7 8 256 9658125 GOBJ CRC Graphics Object Table 0 65535 9658126 GSTR GraphicsString Table O 65535 9688127 Graphics BitmapTableCRC 0 65535 9658128 GTXT CRC Graphics Text Table 0 65535 9688129 GFNT Graphics Font Table CRC 70 65535 9eSR130 PROT ProtocolTableCRC 0 65535 SR131 March 4 2010 Page 87 of 135 1037 14 0883 05
46. 1 Primary Power Port Pins Description Signal Input power supply ground Input power supply positive voltage Pin 10 30 VDC supply T Power Connector Power Up Figure 4 2 Power Connector Primary Power Port Connect to Earth Ground Apply 10 30 VDC Screen lights up Torque rating 4 5 7 Lb In 0 50 0 78 N m ES d lt 5 E 1 2 PIN 3 Figure 4 3 Primary Power Port as Viewed Looking at the XL6 XL6e OCS March 4 2010 Page 24 of 135 111037 0883 05 5 CHAPTER 5 SERIAL COMMUNICATIONS 5 1 Overview All XL6 XL6M XL6e OCS models provide two serial ports which are implemented with 8 pin modular RJ45 connectors and are labeled MJ1 and MJ2 The MJ1 serial port is normally used although MJ2 can also be used for 6 6 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 5 2 Port Descriptions The MJ1 serial port contains both a half duplex RS 485 interface and an RS 232 interface with RTS CTS handshaking Note MJ1 shares its serial port with the optional COM module so when an optional Ethernet or Modem COM module is installed and active the MJ1 connector is inactive The MJ2 serial port contains both a full duplex RS 485 interface and an RS 232 interface with no handshaking Both the MJ
47. 1 170 Empty slot 2 170 Empty Slot 3 170 0883 04 Backup battery operating properly Backup battery needs to be replaced The View Slots Sub Menu displays three System Settings all of which are not editable Internal to the XL6 XL6e OCS there is a CPU board and up to two installed modules Model XE100 has no installed or COM modules All other models have an module and can have a user installed COM module Depending on which I O module is installed and which I O module has been configured by Cscape one of the following six System Settings should appear for Slot 1 Slot 1 I O Empty Slot 1 Unsupported Slot 1 I O Missing Slot 1 41 O Slot 1 I O XExyy Slot 1 I O XExyy No I O module installed or configured Unsupported module installed No I O module installed but an I O module is configured yy I O module installed but no I O module configured yy I O module installed but another I O module configured 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 appears for Slot 2 Slot 2 I O Empty Slot 2 Unsupported Slot 2 I O Missing Slot 2 1 0 XzC Slot 2 1 O XzC Slot 2 I O XzC Slot 3 I O ETN300 March 4 2010 No COM module installed or configured Unsupported COM module installed No COM
48. 1 and MJ2 RS 485 interfaces provide switchable termination and bias resistors internally 5 3 Wiring Figure 5 1 along with Table 5 1 and Table 5 2 show how the MJ1 and MJ2 serial port pins are assigned Note MJ1 and MJ2 look the 8 same but have different pin assignments and functions Figure 5 1 MJ Serial Port Connector Pin Signal Signal Description Direction 2 5 RD RS232ReceveDaia e 5 on XLe Rev E and later e 5 on all revisions XLt and XL6 and QX351 2 RX TX IN OUT 1 IN OUT Signals are labeled for connection to a DTE device March 4 2010 Page 25 of 135 1037 5 0883 05 Pin Mu2Pins Siona Direction Table 5 2 MJ2 Serial Port Pin Assignments Pin Signa Signal Description Direction 6 ov Ground 2 RX RS 485 Receive Negative In RS 485 Transmit Positive 4 TX HS 485 Transmit Negative Out 5 VDC 60mA max Le Y 6 w Ground RS 232 Transmit Data ES Hee 8 RD RS 282 Receive Data Signa Direction MJ2 Half Duplex Mode Position 4 Figure 5 2 MJ Serial Port Connectors and DIP Switches for RS 485 Port Termination March 4 2010 Page 26 of 135 111037 0883 05 Switches are used for termination of the RS 485 ports The XL6 is shipped un terminated To terminate select one of t
49. 1037 0883 05 12 Fail Safe System The Fail Safe System is a set of features that allow an application to continue running in the event of certain types of soft failures These soft failures include e Battery power loss e Battery Backed Register RAM or Application Flash corruption due to for example an excessive EMI event Selecting Fail Safe System menu will open the following menu screen Backup Restore Data Enable AutoRun Enable AutoLoad ESC to exit Selecting Backup Restore Data displays the following screen in Backup Restore Data Clear Backup Backup Copies Battery Backed RAM contents on to the onboard FLASH memory of the OCS Restore Copies the backed up data from onboard FLASH to the battery backed RAM Clear Backup The backup data will be erased from the onboard FLASH Exit Goes back to previous menu Enable AutoRun displays the following options which can be selected March 4 2010 Page 71 of 135 1037 12 0883 04 Enable AutoRun Ho AUT IUH sx Auto Enters RUH after AutoLoad or Battery Fail Enable AutoRun NO OCS will be in IDLE mode after AutoLoad or Automatic Restore Yes OCS will be automatically placed into RUN mode after AutoLoad or Automatic Restore Enable AutoLoad displays the following options which can be selected Enable AutoLoad Ho AutoLoad from Removable lt AUTOLOAD PGH
50. 108 Counts per Rev 52 54 Csape Program Via Serial Port 27 Cscape 3 15 16 25 27 29 30 37 38 41 42 43 47 49 50 51 66 67 79 88 91 92 101 105 106 125 127 128 129 Analog In Configuration 110 Analog Out Configuration 111 Configuration Procedures 107 Count per Rev 108 Digita In HSC Configuration 107 Digital Out PWM Configuration 109 Establishing Communications 92 March 4 2010 Page 131 of 135 Index Models Supported 106 Overview 91 Status Bar 91 CSCAPE CONFIGURATION 91 datasheet 9 14 17 23 43 49 50 Default Gateway 33 Device Manager 103 128 Devices to Connect to XL6 15 Digital Inputs 49 Dimensions 19 DIP Switches 26 Duty Cycle 57 59 89 Duty Cycle Examples 59 60 ELECTRICAL INSTALLATION 23 Ethernet 25 37 86 92 128 Ethernet COM Module XEC 37 Ethernet Communication 31 Ethernet Module Default Gateway 33 IP Address 33 Net Mask 33 Status Register 33 Version Register 34 Ethernet Module Configuration 31 Ethernet Module Protocol Configuration 35 Ethernet Module Protocols and Features 31 Ethernet Module Specifications 31 Ethernet System Requirements 31 Fail Safe System Overview 113 Fail Safe System Settings 114 Features 15 Firmware Updates 125 Frequency 51 56 57 58 59 60 108 Front Panel and USB Programming Connector 98 fusing 47 48 General I O Overview 43 GENERAL I O 43 Ground Specification 23 Grounding Locations of Inf
51. 230VAC 230VAC OR 25VDC 230VAC 230VAC OR 25VDC 230VAC 12 24VDC OV ON J1 001XLEO15 Figure 10 6 Relay Fusing March 4 2010 Page 47 of 135 1037 10 MANO883 05 EN Protection for Inductive Loads Inductive loads can cause reverse currents when they shut off that can shorten the life of relay contacts Some protective measures need to be determined by an engineer Below you will find recommendations that will work for many applications If you have additional questions on protection from inductive load consult an application engineer or HEAPG Technical Support DC Loads General purpose diode IN4004 in reverse bias across the load AC Load MOV Harris V140xxx for 120V V275xx for 220V Output State on Controller Stop When the controller is stopped the operation of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state By default relay outputs turn off For more information on stop state see the Index for Cscape settings pages 10 6 Digital Inputs Note Refer to the datasheet for XL6 XL6e OCS model you are using for details on jumper settings Note The digital inputs on the XL6 XL6e OCS are designed for low voltage DC inputs The inputs are designed to support both positive and negative input modes The mode is set by a jumper setting and a configuration parameter in Cscape All the inputs on the
52. 26 Upgrade For XL6 The InstallShield RE Wizard will install Cscape 8 526 Upgrade For 6 on your computer To continue click Next WARMING This program is protected by copyright law and international treaties z Back Cancel March 4 2010 Page 94 of 135 1037 MANO883 05 EN CH 15 i Cscape 8 52B Upgrade For XL6 InstallShield Wizard License Agreement Please read the Following license agreement carefully END USER LICENSE AGREEMENT FOR HORNER APG LLC SOFTWARE CAREFULLY This Homer APG End User License Agreement EULA is a legal agreement between you either an Individual or a single entity and Horner APG LLC for the Homer APG LLC software product identified above which includes computer software and associated media and printed materials and may include online or electronic documentation SOFTWARE PRODUCT ar SOF IVVARE By installing copying or otherwise using the SOFTWARE PRODUCT you agree to be bound by the terms of Ido not accept the terms in the license agreement Installshield lt Back Cancel im Cscape 8 52B Upgrade For XL6 InstallShield Wizard Destination Folder Click to install to this Folder or click Change bo install to a different Folder Install Cscape 8 526 Upgrade For 16 to Files scape Change Installshield z Back March 4 2010 Pag
53. 37 13 0883 05 The key generates the following mathematical character sequence repeat sequence The key generates the following punctuation character sequence 42 5 5 5 repeat Sequence gt Once the desired alpha numeric character is obtained use the left or right arrow to select a new position Alternately pressing different key moves to the next position Text Table Object When editing a Text Table Object all the keys except the Up and Down arrow keys are grayed and disabled The next text selection is made by pressing either the Up or Down arrow Time Date Object When editing a Time Date Table Object all the keys except the Up Down Left and Right arrow keys are grayed and disabled The specific field i e hour or minutes is selected using the Left and Right arrows The value in the selected field is changed by pressing either the Up or Down arrow 13 4 Screen Navigation To allow the operator to change screens a screen jump object is generally used This object may be visually represented as a 3 D button responding to touch or remain invisible and logically tied to an OCS register An optional system ICON may be configured for display along with the legend which aids in identifying the object as one that causes a screen change shown below in figure 13 3 Reactor Temper ature Reactor Trend Figure 13 3 Typical Screen Jump Object XL6 XL6e Screen
54. 5 10 Once the back is removed jumper selection be changed The jumper settings are documented each data sheet using a diagram such as Figure 9 4 below and a description of the jumper settings Figure 10 4 Example Jumper Diagram To re install the cover place the cover back on the unit Place the screw back into the hole and turn the screw slowly counter clockwise until it clicks into the threads This prevents the screw from being cross threaded Now turn the screw clock wise until the cover is firmly secured Repeat this process for all four 4 screws 10 3 Model and Overview Table 10 1 I O and Model Overview Model io ia Relay Digital Analog Universal Analog XL6 XL6e Outputs Inputs Inputs Analog Inputs Outputs 1 0 100 1 0 51 100 HE XL1x2 HEXTxxxC112 HE XL1E2 HEXT351C112 HE XL1x3 HEXTxxxC113 HE XL1E3 HEXT351C113 HE XL1x4 HEXTxxxC114 HE XL1E4 HEXT351C114 HE XL1x5 HEXTxxxC115 1 5 HEXT351C115 Table 10 1 shows the different types of I O included with the various XL6 XL6M XL6e OCS models Specific specifications jumper settings and wiring diagrams can be found on the data sheets attached at the end of the manual Descriptions and applications of the different type of can be found below March 4 2010 Page 45 of 135 1037 10 MANO883 05 EN 10 4 Solid State
55. 5 XL6 XL6e OCS Dimensions March 4 2010 Page 19 of 135 111037 0883 05 3 6 Factors Affecting Panel Layout Design and Clearances Warning is important to follow the requirements of the panel manufacturer and to follow all applicable electrical codes and standards The designer of a panel layout needs to assess the requirements of a particular system and to consider the following design factors 3 6 1 gt Clearance Adequate Space Install devices to allow sufficient clearance to open and close the panel door Table 3 1 Minimum Clearance Requirements for Panel Box and Door Minimum Distance between base of device and 2 inches 50 80mm sides of cabinet Minimum Distance between base of device and 1 5 inches 38 10mm wiring ducts If more than one device installed in panel box or on Minimum Distance between bases of each device 101 60mm When door is closed Minimum distance between device and closed door 2 inches 50 80mm Be sure to allow enough depth for the XL6 OCS 3 6 2 Grounding Warning Be sure to meet the ground requirements of the panel manufacturer and also meet applicable electrical codes and standards 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
56. 60 Frequency Formula 56 58 Registers 59 Quadrature 51 53 54 88 89 108 References Useful documents 16 register mapping 43 47 registers 85 Registers March 4 2010 Page 132 of 135 0883 05 96S SR 86 Definitions 85 88 Resource Limits 89 Relay Outputs 47 Removable Media Load Save Applications 42 Log Data 41 Overview 39 Save Applications XL6 42 View Capture 42 REMOVABLE MEDIA 39 Removable Media Manager 41 Removable Media Manager Submenu 41 Removable Media XL6 70 Removable Memory Card Slot Photograph 39 RS 485 Biasing 27 RS 485 Termination 27 safety compliance 11 Safety Warnings Guidelines 1 1 Serial Comm Cscape Programming 27 Downloadable Protocols 27 Ladder Controlled 27 Overview 25 Ports 25 Wiring 25 SERIAL COMMUNICATIONS 25 Set Network ID 63 105 106 Solid State Digital Outputs 47 sourcing 47 49 stepper 51 52 58 59 stop state 47 49 Sub Menus 61 Synchronous 55 System Menu 61 Details 63 Navigate Edit 62 System Menu XL6 Screenshot 62 SYSTEM SETTINGS AND ADJUSTMENTS 61 System Menu Overview 61 Table of Contents 5 target ID 105 Target ID 105 106 target indicator 105 106 Technical Support 3 16 49 106 126 127 130 Contacts 130 Testing for Good Ground 23 totalize 51 52 58 Totalize 51 Totalize Heset 52 Troubleshooting Common problems 127 1037 0883 05 Connecting Checklist 128 CsCAN Check
57. APG cannot assume responsibility or liability for actual use based on the examples and diagrams It is the sole responsibility of the system designer utilizing the XL6 XL6e OCS module to appropriately design the end system to appropriately integrate the XL6 XL6e OCS module and to make safety provisions for the end equipment as is usual and customary in industrial applications as defined in any codes or standards which apply Note The programming examples shown in this manual are for illustrative purposes only Proper machine operation is the sole responsibility of the system integrator March 4 2010 Page 4 of 135 1037 0883 05 Table of Contents TABLE OF CONTENTS PREFACE a P 3 LIMITED WARRANTY AND LIMITATION OF nnmnnn 4 VISUAL OF MAJOR TASKS AND THE KEY CHAPTERS TO ASSIST YOU 9 CHAPTER 1 SAFETY 11 Warnings and ied eae 11 0 Cree Rm 12 125 CR testers 12 CHAPTER 27 INTRODUCTION S 13 21 Visual Overview of XL6 XL6e 5 13 2 1 1 Where to Find Information about the XL6 XL6e 5
58. Address register s Direction can set to Read only or Read Write If the register is Read only the Default IP Address becomes the unit s IP Address and is loaded into the assigned register where it can be read by the application Note In this case the low octet of the IP Address can be replaced with the units CAN Network ID by checking the Use CAN ID for last Octet checkbox If the register is Read Write the application should write an IP Address to the assigned register and this value will then be the units IP Address In this case the Default IP Address is used only if communication is lost during an I O configuration download otherwise the Default IP Address is ignored Ethernet Module Register Usage Enhanced Configuration To perform Enhanced Configuration first check the Enhanced Configuration checkbox In this case IP Address Net Mask Gateway Status and Version can all be optionally assigned to OCS registers By default the register edit boxes are empty indicating that no registers are assigned As with the IP Address register described in the Standard Configuration section above Net Mask and Gateway register Directions can be set to Read Only or Read Write Ethernet Module Register Usage General For the Status and Version registers if configured the Direction settings are always Read Only March 4 2010 Page 34 of 135 1037 0883 05 7 The Use CAN ID for last Octet checkbox does not aff
59. Cscape Make sure the COM port of the PC is functioning An RS 232 serial loopback and Microsoft HyperTerminal can determine positively if the COM port is working Or connect to an alternate device to determine if the port is working Successful communications with USB to serial adapters vary If in doubt Horner APG offers a USB to serial adapter Part number 50005 600 XL6 XL6e OCS units without Ethernet must use MJ1 or the Mini B USB Port for programming and debugging If Ethernet is installed it can be selected as the programming port The selection is made in the controllers System Menu If there are difficulties connecting make sure that the default programming port is set correctly with the connection method being attempted 19 1 2 Connecting Troubleshooting Checklist USB Port Mini B Programming Programming and debugging must use Mini B USB Port or MJ1 2 Controller must be powered up 3 Ensure that the correct COM port is selected in Cscape Tools Editor Options Communications Port 4 Be sure that the USB cable is connected between the PC and controller and check the Windows Device Manager to find out if the USB driver is properly installed and which port it set itself up on 5 Make sure the USB port of the PC is functioning and or connect to an alternate device to determine if the port is working 6 XL6 XL6e OCS units without Ethernet must use the Mini B USB Port or MJ1 for programming and debugging If Ethernet
60. E XExxx XLe and XLt LX Series e g LX xxx also covers RCS116 755 Color Touch OCS e g OCSxxx 465 OCS Operator Control Station e g OCS1xx 2xx Graphic OCS250 Wiring Accessories and Spare Parts Manual March 4 2010 Page 16 of 135 1037 0883 05 CHAPTER 3 MECHANICAL INSTALLATION Note Each XL6 XL6e OCS unit is sent with a datasheet in the box The datasheet is the first document you need to refer to for model specific information related to XL6 XL6e OCS models such as pin outs jumper settings and other key installation information Visit our website to obtain datasheets user documentation and updates 3 1 Overview 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 3 2 Mounting Requirements 3 2 1 Mounting Procedures Installed in a Panel Door 0010CS001 0010CS002 Figure 3 1 Panel Mounting of an XL6 XL6e 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 XL6 XL6e OCS 1 Remove all connectors from the XL6 XL6e OCS unit 2 Make sure the gasket is installed on the XL6 XL6e OCS and is free from dust and debris Check that the corners
61. F1 F10 are pressed SYS Fn enable Yes Reset and all clear system functions enabled No Reset and all clear system functions disabled March 4 2010 Page 67 of 135 1037 12 0883 04 Set Serial Ports Dflt Port HJ1 232 1 RS485 Bias No HJ2 RS485 Bias No Use 1t to adjust The Set Serial Ports Sub Menu displays three System Settings all of which are editable and one optional item For the Dflt Port System setting only MJ1 232 can be selected unless a Modem COM module is installed Port MJ1 232 MJ1 RS232 port is the default programming port Modem Modem COM module is the default programming port MJ1 RS485 Bias No MJ1 RS485 bias resistors are not switched in Yes MJ1 RS485 bias resistors are switched in MJ2 RS485 Bias No MJ2 5485 bias resistors are not switched in Yes MJ2 RS485 bias resistors are switched in Set Time Date 16 06 59 Date 10 Jul 2008 Day Thursday Use 11 to adjust each field The Set Time Date Sub Menu displays three System Settings Time and Date are editable and Day is automatically calculated from the Date setting Note that Time and Date are split into three editable fields each Use lt or gt to select a field and then use 4 or 7 to edit the field Time 16 09 49 Current time hours minutes seconds in 24 hour format Date 10 Jul 2008 Current date day month year Day Thursday Current day of week calcu
62. HAPTER 8 COMMUNICATION 6 2222244 4 4 000001 37 SENE Si cmi 37 98 2 Ethernet COM Module 37 8 3 Modem COM Module Option eessseseeeeeeeneenennnnnn nnne nnn nennen nnn 38 39 39 92 EE 39 9 9 Miro SD File 40 9 4 Using the Removable Media 40 9 5 Using Removable Media to Log 40 9 6 Using Removable Media to Load and Save Applications 41 9 7 Using Removable Media to View and Capture Screens 41 98 Removable Media RM Function Blocks in 41 9 9 Filenames used with the Removable Media RM Function 22 2 42 9 10 System Registers used gati 42 CHAPTER 10 GENERAL risen icut ire tera educ ceti cauto oec 43 10 1 QI m ET 43 10 2 Remo
63. Is the panel box properly connected to earth ground Is the panel door properly grounded the appropriate procedure been followed to properly ground the devices in the panel box and on the panel door Are minimum clearance requirements met Can the panel door be easily opened and closed 15 there adequate space between device bases as well as the sides of the panel and wiring ducts Is the panel box deep enough to accommodate the XL6 XL6e OCS Is there adequate ventilation Is the ambient temperature range maintained Are cooling or heating devices required Are noise suppression devices or isolation transformers required 15 there adequate distance between the base of the XL6 XL6e OCS and noisy devices such as relays or motor starters Ensure that power and signal wires are not routed in the same conduit Are there other requirements that impact the particular system which need to be considered March 4 2010 Page 21 of 135 1037 0883 05 5 4 2010 Page 22 of 135 1037 0883 05 4 CHAPTER 4 ELECTRICAL INSTALLATION Note Each XL6 XL6M XL6e OCS unit is sent with a datasheet in the box The datasheet is the first document you need to refer to for model specific information related to XL6 XL6e OCS models such as pin outs jumper settings and other key installation information Visit our website to obtain datasheets user documentation and updates 4 1 Grounding Defini
64. MEN Country Email I am please select rhe please select M 72 Yes please add my name to your e mail list for Cscape software updates Cscape FREE training programs and product introductions Your confidential information will not be sold or distributed to other third parties Request cant be processed if these fields are not completed Download Cscape New User Reset Submit Create New User Done 7 If you have already registered enter your Login User name and Password If you have not yet registered please enter your information Submit and you will be taken to the page http www heapg com Pages TechSupport Cscape Cscape php Where you can download Cscape 8 52B if you have not already installed this version of Cscape and the Cscape 8 52B upgrade for XL6 For XL6e use Cscape Ver 8 7 Upgrade For XL6M use Cscape 9 1 and onwards Software Date Version Release Notes o version 8 528 latest zeme Download Notes IET m BD Download the Cscape 8 52B Upgrade for XL6 once Cscape 8 52B has been installed iCscapeB5zBllp igradeForxL6 e xe March 4 2010 Page 93 of 135 111037 15 MANO883 05 EN Run double click this exe file once it has downloaded InstallShield Welcome to the InstallShield Wizard for Cscape 8 5
65. Press ESC to Exit Backup Restore Data Enable AutoRun Enable AutoLoad ESC to exit Beeper Enable Yes Use LT to adjust Figure 12 1 System Menu Page 61 of 135 Sub Menus Port 13 None Loaded Port 2 None Loaded Fkeys Momentary Sys Fn enable Yes Use LT to adjust Pom Port 01 232 21 RS485 Bias NO MJ2 RS485 Bias NO Use LT to adjust Time 10 21 36 Date 28 Jun 2009 Day Thursday Use LT to adjust each field Saver enable Yes Timeout min 15 Popup Status Off Update Time mS 5 Update time sets the maximum time used by graphics the logic Scan Media Directory Media Card Not Present Clone Unit Directory Empty 1037 12 0883 04 Set Hetunrk ID Set Hetwork Baud Status View Diags Uiew I O Slots Uiewu Protocols set Fkeys 1 and J keys Set Serial Ports Set Time Date set Beeper Set Screen Removable Fail Safe System Clone Unit Enter key Figure 12 2 System Menu 6 Screenshot 12 2 System Menu Navigation and Editing As mentioned above the System Menu is started by pressing the System key on the XL6 XL6e Next press ESC to exit the System Menu or use and to select an item and press Enter P to display the item s Sub Menu A Sub Menu generally shows a list of System Settings and their values After opening a Sub Menu if any of its S
66. Temporary Bit Non retentive single bit registers 14 2 Useful S and SR registers Table 14 1 Common 96S Register Definitions Register Name Descripion MinVal Max Val 9eSR2 ALRM SCR Current Alarm Screen Number O none O 1023 SYS SCR Current System Screen Number O none O 14 4 SELF TEST BitMappedSel TestResut O 65535 96685 CS MODE Control Station Mode 0 Idle 1 Do lO 2 Run 0 2 9eSR6 SCAN RATE Average ScanRate 10 1000 SR7 MIN RATE MinimumScanRate 10 1 1000 SR8 MAX RATE MaximumScanRate 10 1000 9eSR9 10 EDIT BUF Data Field Edit Buffer 0 2714 9658 13 16 Reserved S 2 14 oc 9eSR21 22 SD SIZE Security Data Table Size 9eSR23 LADDER Ladder Code 0 65535 9658 24 25 Reserved o y 9656826 10 CRC l OConfiguration Table 0 65535 9eSR27 NET Network Configuration Table 20 65535 9656828 SD SecurityDataTableCRC 0 65535 Network Baud Rate CsCAN DE ORASI 0 125KB 1 250KB 2 500KB 3 1MB March 4 2010 Page 86 of 135 1037 0883 05 14 Table 14 2 SR Registers Register Description Min Val Max Val Network Mode 0 network not required 1 network SR31 NET MODE required 2 networ
67. XL6 XL6e OCS 15 Figure 3 1 Panel Mounting of an XL6 XL6e Series OCS 2 2 17 Figure 3 2 XL6 XL6e OCS with Mounting Clips 18 Figure 3 3 Orientation of XL6 XL6e OCS oae etes iet sese sais unns ve enc rede cH e usa pe ss Ode sa ge eee 18 Figure 3 4 Panel Cutout Tolerances 25 0n dore c ote 19 Figure 3 5 XL6 XL6e OCS Dimensions 19 Figure 4 1 Two Point Ground Connection 0 23 Figure 4 2 Power Connector Primary Power 24 Figure 4 3 Primary Power Port as Viewed Looking at the XL6 XL6e 24 Figure 5 1 MJ Serial Port Connector eon me eet orte ede dud e 25 Figure 5 2 MJ Serial Port Connectors and Switches for RS 485 Port Termination 26 Figure 6 1 COHReCIOEL oe D ai to mei rates oak tegen 29 Figure 6 2 NET1 Port Connetti ioo Ie e o tue tec io e Ak 30 Figure 7 1 LO Configuration Dialogs eerte t n tod ioo vet
68. a USB Figure 2 2 Front View of XL6 XL6M XL6e type OCS Where to Find Information about the XL6 XL6e OCS a Datasheets The datasheets are the first documents you need to refer to for key information related to specific XL6 XL6e OCS models A datasheet is provided in the box with your unit The datasheets for all XL6 XL6e OCS models are available on our website Datasheets contain pin outs jumper settings and other model specific information User Manual This manual provides general information that is common to XL6 XL6e OCS models and can be downloaded from our web Visit our website at http www heapg com to obtain user documentation and updates Four main types of information are covered in the manual a b C d Safety and Installation guidelines instructions Mechanical and Electrical Descriptions of hardware features Serial ports Removable Media Communication Options etc Configuration and Use of the XL6 XL6e OCS Maintenance and Support Manual Index Index Major topics of interest may be found in the Index towards the end of this manual Table of Figures Page 14 of 135 1037 0883 05 2 Table of Figures Location of important drawing illustrations etc may be found in the Table of Figures 2 2 Connectivity to the XL6 XL6e OCS The XL6 XL6e OCS has excellent capabilities for connecting to a variety of devices The diagram below shows some examples of devices th
69. a This prevents corruption to the file system if the removable media is removed during a file write sequence The graphic objects should set OCS register SR174 1 when requesting the card be removed and provide an indicator based on OCS register SR174 2 which indicates that it is safe to remove the removable media March 4 2010 Page 82 of 135 1037 0883 05 13 Halt RM Activity for Removal Figure 13 7 Example application segment for safe removal of removable media 13 10 Screen Saver The XL6 XL6e screen backlight life is typically 5 years when in continuous use If the application does not require interaction with the XL6 XL6e for long periods of time the backlight life can be extended by using the screen saver function When enabled through the system menu the backlight is shut off screen goes black after a specified time of no touch activity on the screen When the screen saver shuts off the backlight any operator touch on the screen or function keys reactivates the backlight Note that when the screen saver is active backlight shut off any initial touch activity on the screen or function key to reactivate the backlight is otherwise ignored by the XL6 XL6e Any additional touch activity is also ignored by the XL6 XL6e 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 onl
70. ale default Do Hold Last State Period default Hold Last State Output State on Controller Stop Legend A or S on Bf Hod Last state Cancel Figure 15 3 Digital Output PWM Configuration Dialog The Q1 and Q2 group boxes allow the user to specify the operation of the multi function outputs 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 that 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 March 4 2010 Page 109 of 135 1037 15 MANO883 05 EN The Output State On Controller Stop group box contains items to allow the user to specify how the remaining digital outputs behave when the controller is stopped These items can either hold their value or default to some value when the controller is stopped 158 Analog Input Configuration The following figure illustrates the Analog Input Configuration dialog Analog Input Configuration X Channel 1 z 0 10 Cancel Channel 2 0 10 Channel 3 Channel 4 zl Filter Constant Figure 15 4 Analog Input Configuration Dialog The Channel x drop down windows allow the user to specify the mode for each analog input to operat
71. appropriate keys to enter a specific value When entering a value the alpha numeric keypad is in one of two modes new value or edit value New value mode Generally when the alpha numeric keypad is first invoked it is placed in new value mode Initially the alpha numeric keypad 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 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 respectively from the selected digit The user may then use the left or right arrow keys to select a new position March 4 2010 Page 76 of 135 1037 MANO883 05 EN CH 13 Figure 13 2 Alpha numeric Keypad Once the desired value is entered pressing the Enter key moves that value into the object and the corresponding OCS register and the alpha numeric keypad disappears Alternately pressing the ESC key any time before the Enter key cancels the operation leaves the objects current value unchang
72. ar04 Month0O3 aa01_15 csv Filename Month_ M Day_ D h_ m_ s csv Month_03 Day_01 15 45 34 csv 9 10 System Registers used with RM SR175 Status 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 bytes Possible status values are shown in the table Table 8 2 RM Status Values RM interface OK Card present but unknown format Card present but not supported Card swapped before operation was complete Unknown error O 0 No card in slot March 4 2010 Page 42 of 135 1037 MANO883 05 EN CH 10 CHAPTER 10 GENERAL I O Note Each XL6 XL6e OCS unit is sent with a datasheet in the box The datasheet is the first document you need to refer to for model specific information related to XL6 XL6e OCS models such as pin outs jumper settings and other key installation information Visit our website to obtain datasheets user documentation and updates 10 1 Overview XL6 XL6e OCS is a compact unit that contains high density very versatile I O Using the I O properly requires wiring to the proper terminals configuring jumpers inside the XL6 XL6e OCS unit and configuring Cscape properly This section will offer some tips and suggestions to configure the I O properly For the register mapping of the I O refer to the Index at the end of this manual for the pa
73. are was found User Program Ok Ladder program and I O configuration loaded successfully Fault Ladder program or I O configuration not loaded or load failed The last nine System Diagnostics are informational If any of them indicate a Warning condition the XL6 XL6e OCS can still enter and remain in Run mode but the problem should be investigated and corrected 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 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 was found on the CAN network Warning No other nodes were found on the CAN network Network ID Ok _ This node s CAN Network ID is in the range 1 to 253 Warning This node s CAN Network ID was out of range at power up Dup Net ID Ok This node s Network ID is unique on the CAN network Warning This node s Network ID is duplicated in another node Clock Error Ok Time and date have been set Warning Time and date need to be set I O System Ok configuration matches the installed COM modules Warning I O configuration needs updating to match installed modules March 4 2010 Page 65 of 135 1037 12 Battery Ok Warning View I O Slots slot
74. at can be used with the XL6 XL6e OCS XL6 XL6e OCS Sensors Indicators lt gt Alarms Encoders Pumps Relays Flash Drive Solenoids Cscape Figure 2 3 Visual Overview of Types of Devices that can be connected to XL6 XL6e OCS Other OCS Devices Serial gt Drives PLCs Bar Code Readers Other OCS Devices Smart Stix I O RCS116 I O Base kt amp OPC Server Printers SCADA OPC Servers Serial I O Sy Cscape XL6e Models OPC Server Only Modbus TCP Devices Ethernet USB 2 3 Features of XL6 XL6M XL6e OCS The XL6 XL6e OCS are all in one industrial control devices They combine control user interface and networking into a single integrated package Unique features of the XL6 XL6e OCS include Bright 32768 color graphical touch sensing LCD display in all models of XL6 XL6e XL6M has 16 shade grey scale display e Display of complex graphical objects including trends gauges meters and animations e Advanced control capabilities including floating point multiple auto tuning PID loops and string handling capabilities e Removable media for up to two gigabytes of storage of programs data logging or screen Captures CsCAN networking port for communication with remote I O other controllers or PCs USB networking port for communication with PCs and programming of controller Configurable serial protocols for communication to drives PLCs or other serial peripherals Full
75. ation 1 2 XL6e controller with onboard Ethernet port FTP amp HTTP protocols 7 3 Ethernet Module Specifications Speeds 10 BaseT Ethernet 10 Mbps 100 Fast Ethernet 100 Mbps Half or Full Duplex Auto Negotiation Both 10 100 Mbps and Half Full Duplex Shielded RJ 45 Connector Type Shielded RJ 45 Cable Type CAT5 or better UTP Recommended Auto MDI MDI X 7 4 Ethernet Module Configuration Note The following configuration is required for all applications regardless of the protocols used Additional configuration procedures must be performed for each protocol used To configure the Ethernet Module use Cscape Programming Software to perform the following steps 1 On the main Cscape screen select the Controller menu and its Configure sub menu to open the Configuration dialog Figure 7 1 2 If configuring a different OCS Model than the one shown in the Configuration dialog click on the topmost Config button select the desired OCS Model and then click OK March 4 2010 Page 31 of 135 1037 7 MANO883 05 EN Configuration LPU Slots Base 2 Base 3 Base 4 Base 5 Base E Network 1 0 ALB E theret 300 Ethernet Auto Config System Cancel Figure 7 1 I O Configuration Dialog 3 Click the Config button to the right of the Ethernet Module and then select the Module Setup tab revealing the Etherne
76. cked RAM Clone Unit 10 i 1 24570 07 14 09 12 11a Free 1004208128 Total 1004257280 Load Hake Clone Clone V Esc March 4 2010 Page 73 of 135 1037 12 0883 04 Load Clone Selecting Clone Unit menu will open the following menu screen Select Load Clone Clone Unit DAT 24570 07 15 09 12 11a Free 1004208128 Total 1004257280 Load Hake Clone Clone V Esc NOTE For security enabled files Load clone asks for password validation before loading the application 12 4 Touch screen calibration The touch screen is calibrated at the factory and rarely needs modification However if actual touch locations do not appear to correspond with responding objects on the display field adjustment is available To access the field adjustable touch screen calibration dialog press and hold both the SYS and F1 key for longer than 2 seconds and a dialog similar to figure 9 2 should appear Thereafter use a plastic tip stylus and follow the dialog instructions Note that special system keys may be locked out from user access If the SYS F1 combination does NOT respond verify that the system menu s Set Fkeys sub menu s parameter SYS Fn is enabled Touch Calibration Screen Touch crosshair with stylus calculated touch point will appear and will auto align with crosshair Repeat until touch point and crosshairs no longer need alignment to match March 4 2010
77. duty cycle count Set AQ5 6 Any value prescale count Set AQ7 8 Any value or 0 period count STP Examples Example 1 10 000 000 steps control sequence The following example starts at 2 5 kHz and ramps up to 5 kHz during the first 1 000 000 steps Then it runs at 5 kHz for the next 8 000 000 steps Finally during the last 1 000 000 steps it slows to a stop Set AQ1 2500 Hz Start Frequency Set AQ2 5000 Hz Run Frequency Set AQ3 4 1000000 Steps Accel Count Set AQ5 6 8000000 Steps Run Count Set AQ7 8 1000000 Steps Decel Count Example 2 5 000 000 steps control sequence The following example starts at 0 5 kHz and ramps up to 1 kHz during first 2 000 000 steps Then it runs at 1 kHz for the next 2 000 000 steps Finally during the last 1 000 000 steps it slows to a stop Set AQ1 500 Hz Start Frequency Set AQ2 1000 Hz Run Frequency Set AQ3 4 2000000 Steps Accel Count Set AQ5 6 2000000 Steps Run Count Set AQ7 8 1000000 Steps Decel Count Example 3 6 000 000 steps control sequence The following example starts at 50 Hz and ramps up to 250 Hz during the first 150 000 steps Then it runs at 250 Hz for the next 5 500 000 steps Finally during the last 350 000 steps it slows to a stop Set AQ1 50 Hz Start Frequency Set AQ2 250 Hz Run Frequency Set AQ3 4 150000 Steps Accel Count Set AQ5 6 5500000 Steps Run Count Set AQ7 8
78. e The Channel x drop down windows are enabled disabled according to which model is being configured All of the models have the following modes available 0 10V 0 220 4 20mA On model 005 channels 3 and 4 also have the following modes available 100mV PT100 DIN RTD 1 20 C Type J Thermocouple 1 20 C Type K Thermocouple 1 20 Type N Thermocouple 1 20 C Type T Thermocouple 1 20 C Type E Thermocouple 1 20 C Thermocouple 1 20 Type S Thermocouple 1 20 C Type B Thermocouple 1 20 C The Filter Constant provides filtering to all channels March 4 2010 Page 110 of 135 111037 MANO883 05 EN CH 15 15 9 Analog Output Configuration The following figure illustrates the Analog Output Configuration dialog Analog Output Configuration X Output value on S 1 Gata 0 v Hold Last Value 2 Goto 0 Hold Last Value Output Mode 10 Cancel Figure 15 5 Analog Output Configuration Dialog 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 the analog outputs The modes include the following 0 10V 0 220 4 20mA March 4
79. e XL6 XL6e OCS serial port the XL6 XL6e OCS can act as a pass through gateway allowing Cscape to access all XL6 XL6e OCS and OCS RCS devices that are attached to the CAN network 6 5 Ladder Controlled CAN Communication Using Put and Get Network Words function blocks the NET1 port can exchange digital and analog global data with other XL6 XL6e 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 6 6 Using CAN for I O Expansion Network I O Connecting Network I O devices SmartStix Modules to XL6 XL6e OCS port allows the XL6 XL6e OCS I O to be economically expanded and distributed A variety of SmartStix Modules is available for this purpose March 4 2010 Page 30 of 135 1037 0883 05 7 CHAPTER 7 ETHERNET COMMUNICATION XL6E ONLY Note Models namely HE XL1Ex HEXT351Cxxx support onboard built in Ethernet port It provides advanced Ethernet Communication capabilities 7 1 Ethernet Module Protocols and Features The following table describes the Ethernet Module Protocols and features supported by XL6e Modbus over Ethernet 7 2 Ethernet System Requirements Full Ethernet functionality requires PC running Cscape Programming Software Version 8 7 with upgrade or later for configur
80. e 95 of 135 111037 15 MANO883 05 EN 5 Cscape 8 52B Upgrade For XL6 InstallShield Wizard Ready to Install the Program The wizard is ready to begin installation IF au want to review or change any of your installation settings click Back Click Cancel exit Ehe wizard Current Settings Setup Type Destination Folder C Program FilesCcscapel User Information Name harner Company horner Installshield i 8 52B Upgrade For XL6 InstallShield Wizard Installing Cscape 8 52B Upgrade For XL6 The program features vau selected are being installed Please wait while Ehe InstallShield Wizard installs Cscape 8 52B Upgrade For sL This may take several minutes Status Installshield Back Mex gt 1037 March 4 2010 Page 96 of 135 MANO883 05 EN CH 15 The InstallShield Wizard has successfully installed Cscape 6 526 Upgrade For 6 Click Finish to exit the wizard Back Gancel March 4 2010 Page 97 of 135 1037 15 MANO883 05 EN Next connect a PC s Personal Computer running a Windows Microsoft operating system USB port via USB cable to the USB mini B port on the XL6 XL6e OCS Removable Media User Interface Figure 15 1 Front Panel and USB Programming Connector The PC will detect a new device has been plugged into the USB port Found Hew Hardware Wizard Welcome to the Found New Hardware Wizard Window
81. e Manager and Ports m ing Device Manager Action View Help T Se Disk drives Display adapters xi DYDICD ROM drives 4c Floppy disk controllers Floppy disk drives 43 IDE ATAJATAPI controllers Keyboards Mice and other pointing devices P Monitors BB Network adapters EI a Ports COM amp LPT E d Communications Port COMI E d Communications Port COM OCS USB COM Port COMIS 0 Jw Printer Port LPT1 m e Processors DE Sound video and game controllers 52 System devices Universal Serial Bus controllers Note that in this example the XL6 XL6e is on This COM number may vary from PC to EL Ports COM amp LPT bet in Communications Pork COM Bee EA Communications Pork COM be me OCS USE COM Port COM3 f Printer Port LPT1 March 4 2010 Page 103 of 135 111037 15 MANO883 05 EN Now that you know which COM port the XL6 XL6e is plugged to go to Cscape Tools Editor Options Communications Port and choose the correct COM port in this example Com 3 Toole Screens View Window Help Search Network i e 3 THR Security d Of Connect Via Modern StpLalc Strip Chart Update Smart Stack Module View Data List Project Havigator Backup Register Contents Restore Register Contents Editor Options 2 X Editor Uptions Ladder Ladder Numbering Colors Communications
82. e for HSC input 3 The marker input is typically part of an encoder or motion system that signals when a cycle of motion is complete When the marker input is triggered the accumulator is reset to zero or to Counts per rev 1 based on rotation direction Marker reset operation is enabled when HSC3 is configured for Markertype Once selected one of several modes is available for marker operation These modes can be sub divided into two groups of marker operation Asynchronous modes ignore the quadrature inputs and reset the quadrature accumulator to zero on the configured edge rising falling or both These are the most common settings used When configuring asynchronous mode selections are prefixed with the word Async March 4 2010 Page 54 of 135 1037 0883 05 11 Synchronous modes synchronize the reset set to the selected quadrature input and selected marker polarity Figure 10 1 below indicates which mode to select based on the markers timing diagram Consult the documentation provided with your encoder to determine the marker pulse timing Note that the Marker input is sampled within 50 micro seconds of the associated quadrature edge It is left to the user to determine if this meets the time constraints of the measured drive Note that if the Marker input pulse consecutively spans more than one of the specified edges quadrature decoding operation is unpredictable oync mode selection Waveforms Clock
83. ect Net Mask Gateway Status or Version configuration Ethernet Module Protocol Configuration The Protocol Support area contains a list of all the protocols supported by the platform being configured To activate a protocol check its checkbox For protocols that require additional configuration click on a listed protocol to select it and then click the Configure Selected Protocol button This will open a new dialog with configuration options for the selected protocol For detailed information on individual protocol configuration refer latest version of ETN 300 Manual SUP0740 March 4 2010 Page 35 of 135 1037 7 0883 05 5 4 2010 36 135 1037 0883 05 CH 8 CHAPTER 8 COMMUNICATION OPTIONS 8 1 Overview To supplement the built in MJ1 and MJ2 serial ports additional communication options are available This is accomplished by installing a COM module internal to the XL6 OCS controller 8 1 1 shares its serial port with the optional COM module so when an Ethernet or Modem COM module is installed and active the MJ1 connector is inactive Internal to the XL6 OCS there is a CPU board and up to two installed modules Models HE 100 HEXT350C100 have no installed I O or COM modules All other models have an I O module in Slot 1 and could have a user installed COM module in Slot 2 This chapter briefly describes both the Ethernet and Modem COM module opt
84. ed and the alpha numeric keypad disappears Note Each numeric entry object has a configured minimum and maximum value If the operator enters a value outside of the configured range the new value is ignored when Enter is pressed and the current object value is NOT changed Since the alpha numeric keypad services several different graphical objects certain keys on the alpha numeric keypad may be disabled grayed when the keypad is invoked for certain objects The following describes the alpha numeric keypad variation based on object Numeric Object When editing a numeric value the or the key are disabled grayed if the object is NOT configured for floating point value or a signed value 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 each press of the same key generates a different value For example the QZ key generates the following sequence space 2 q z 1 repeat sequence The digit keys except zero sequence the corresponding 3 alphabetical characters first in upper case followed by the same 3 characters in lower case followed by the corresponding numeric digit Thereafter continued presses of the same key repeat the sequence March 4 2010 Page 77 of 135 1110
85. enames but instead implements the 8 3 filename format This means that all file and directory names must consist of up to 8 characters followed by an optional dot and an optional extension with up to 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 9 4 Using the Removable Media Manager The Removable Media Manager is an interactive XL6 XL6e OCS screen that performs the following functions Display number of total and free bytes Browse file and directory lists Delete files and directories Format a Micro SD card Load and save application programs View screen capture bitmaps The Removable Media Manager can be accessed System Menu by using to place Removable Media Manager object on an application graphics screen Directory SEROBDO1 14272 07 10 08 SEROBDU 15209 07 10 08 s SERUBDUS 29708 07 10 08 SERBOBDUA 29582 07 10 08 SCROGG5 23263 07 10 08 SCROO0G6 14643 07 10 08 SCROOO 14976 07 10 08 SERBBBS 15994 07 10 08 SEROUBDUS 17561 07 10 08 Free 511672328 Total 511959080 aj pd ad e d Figure 9 3 XL6 Removable Media Submenu 9 5 Using Removable Media to Log Data Using Read and Write Removable Media function blocks an application ladder program can read and write XL6 XL6e OCS register data in the form of comma delimited files with a CSV exten
86. eras Add remove and configure A Scheduled Tasks Schedule computer tasks ta L Security Center View your current security 5 Dlsoundmax 3 0 Control Panel See Also Sounds and Audio Devices Change the sound scheme indows Update Speech Change settings text to Bem LiveUpdate This applet allows you to cn Help and Support stem See information about your see and Start Menu Customize Ehe Start Menu a 88 User Accounts Change user account settim g windows Firewall Configure the Windows Fire xz Wireless Network Setup Setuporaddtoawireless March 4 2010 Page 101 of 135 1037 15 System Properties System Restore Automatic Updates Remote General Computer Mame Hardware l Advanced Device Manager The Device Manager lists all the hardware devices installed an your computer Use the Device Manager to change the properties of any device Device Manager Driver Signing lets you make sure that installed drivers are compatible with Windows Windows Update lets you set up how Windows connects to Windows Update for drivers Driver Signing Windows Update Hardware Protiles Hardware profiles provide way for to set up and store different hardware configurations Hardware Profiles March 4 2010 Page 102 of 135 MANO883 05 EN 1037 MANO883 05 EN CH 15 Next go to the PC s Devic
87. ero and the current stepper count to be lost Note that stepper output level may cause damage or be incompatible with some motor driver inputs Consult drive documentation to determine if output level and type is compatible 11 5 PWM functions register map Regser HSC 2 1 PWM1 Duty Cycle 32 HSC1 Start Frequency 2 bit Preset Value Run Frequency 4 bit Preset Value 32 bit _______ _ _ 32 bit 32 bit 7 PWM Period Decel Count 96AQ8 32 bit 32 bit 9Q1 Run 130 Ready Done 9131 116 PWM Examples All of the PWM examples use the following formula 16 000 000 Frequency Pr escale41 xPeriodCount Example 1 To get a 50 Duty Cycle 10 kHz waveform on PWM1 Set AQ1 2 50 duty cycle count Set AQ5 6 15 prescale count Set AQ7 8 100 period count Example 2 To get a 5096 Duty Cycle on PW1 and 90 Duty Cycle 2 1 kHz waveform Set AQ1 2 500 duty cycle count Set AQ3 4 900 duty cycle count Set AQ5 6 15 prescale count Set 7 8 1000 period count March 4 2010 Page 59 of 135 1037 11 0883 05 Example 3 To turn PWM 1 output ON all the time Set AQ1 2 Same value as AQ7 8 duty cycle count Set AQ5 6 Any value prescale count Set AQ7 8 Non Zero value period count Example 4 To turn PWM 1 output OFF all the time Set AQ1 2 0
88. featured built in I O including high resolution analog thermocouple RTD high speed counters PWM outputs and relays depending upon the XL6 XL6e OCS model used e Cscape programming software that allows all aspects of the XL6 XL6e OCS to be programmed and configured from one integrated application Optional communication add on modules that allow additional capabilities such as Ethernet modems On board Ethernet port 10 100Mbps for Cscape programming and application defined communication with Auto MDI MDI X XL6e only March 4 2010 Page 15 of 135 1037 2 0883 05 2 4 Required and Suggested Accessories The following list contains a sampling of required and suggested XL6 XL6e OCS accessories Visit our website to view updates on new products and accessories Note The XL6 XL6M XL6e OCS is not shipped with a programming cable in the box To obtain a programming cable order 500 300 Table 2 1 XL6 OCS Accessories Part Number Description HE XEC 10 100 Ethernet option kit field installable Kit includes all parts necessary for internal installation within the XL6 OCS case including a deeper plastic back cover adapted for Ethernet operation HE XMC 14 4 k Telephone modem option kit field installable Kit includes all parts necessary for internal installation within the XL6 OCS case including a deeper plastic back cover adapted for modem operation HE MC1 Removable Media card compa
89. g an OCS register i e Function key registers Objects that allow input generally have a raised 3D appearance exception is the binary type objects such as buttons which 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 example the slider object requires the operator to touch and s ide the control in the direction desired Alternately alpha numeric entry objects invoke a pop up alpha numeric keypad for additional user input The alpha numeric keypad is discussed below Note that if the numeric entry object displays gt gt gt gt gt gt gt the value is too big to display in the field or is above the maximum for an editable field Likewise if the numeric entry object displays in a numeric field the value is too small to display or is below the minimum for an editable field 133 A Alpha numeric keypad To allow entry of a specific number or text several of the input objects invoke a pop up alpha numeric keypad when the object is touched An example of the alpha numeric keypad invoked from a numeric input object is shown in Figure 13 2 Once invoked the operator may touch the
90. ge 125 of 135 1037 18 MANO883 05 EN 18 2 2 Battery Replacement Warning Lithium Batteries may explode or catch fire if mistreated Do not recharge disassemble heat above 100 deg C 212 deg F incinerate or puncture Warning Disposal of lithium batteries must be done in accordance with federal state and local regulations Be sure to consult with the appropriate regulatory agencies before disposing batteries In addition do not re charge disassemble heat or incinerate lithium batteries Warning Do not make substitutions for the battery Be sure to only use the authorized part number to replace the battery The XL6 XL6e OCS uses a coin lithium battery available from Horner Below are the steps to replace the battery 1 Make sure the user program and any data stored in retentive memory is backed up 2 Disconnect all power from the XL6 XL6e OCS unit including power 3 Remove the battery cover 4 Note there are two connectors X1 and X2 in the battery compartment that can accommodate the battery connector 5 Plug the new battery into the empty connector X1 or X2 before removal of the old battery 6 Remove the old battery 7 Dispose of the old battery properly see the above warning on disposal regulations 8 Place the battery cover back on the unit 9 Apply power to the unit Check that the battery error is no longer reported If the unit still reports the error remove the battery immediatel
91. ges referencing register mapping 10 2 Removing the XL6 XL6e OCS I O Cover Warning Power including I O power must be removed from the unit prior to removing the back cover Failure to do so could result in electrocution and or damage to equipment Some configurations require jumper settings to be changed inside the XL6 XL6e OCS unit Examples of these settings are setting positive or negative logic on digital inputs or setting current or voltage on analog inputs Each XL6 XL6e OCS I O jumper is set to a factory default Refer to the data sheet for your XL6 XL6e OCS model to find the default setting to determine if a jumper change is necessary for your application To remove the cover of the XL6 XL6e OCS remove the four 4 Phillips screws from the back It may help to place the XL6 XL6e OCS unit face down on a clean work surface Once the four screws are removed the cover can be lifted straight off Figure 10 1 Removing the Cover March 4 2010 Page 43 of 135 1037 10 MANO883 05 EN Figure 10 2 XL6 XL6e Cover sample 0028 2 1 2 2 Eu Teh tee DE 4 4 n mia Res i 111111 HHE 4 m i om pm 2 e Figure 10 3 XL6 I O Cover Removed sample I O board March 4 2010 Page 44 of 135 1037 0883 0
92. gh 0 41 Counter Falling High CPR 1 Low Reseton2rising Clockwise Rising Low po 0 Counter _ Falling Low CPR 1 High Reseton2faling Clockwise Rising High CPR 1 41 Counter Falling High 0 Reset on 2 falling Clockwise Rising Low CPR 1 po Falling Low 0 11 3 HSC Functions Register Map 1 Accumulator 96AQ1 2 HSC1 Preset Preset 4 HBCT Preset Preset Clear HSC1 Clear Quad 1 L 298 8 OlearHSC2 9 Q20 O HSC3 Clear Quad 2 E HSC4 114 Pulse Width Modulation PWM Functions On units that support the PWM two dedicated outputs are available that can be configured for one of four modes of operation Those modes are Normal PWM HSC count PV and Stepper 11 4 1 Normal When either Q1 or Q2 is configured for Normal operation the digital output registers Q1 and Q2 drives that respective output 11 4 2 PWM When either Q1 or Q2 is configured for PWM the PWM function drives that respective output Both PWM channels may be individually enabled however when both PWM outputs are enabled both share the same output frequency with the low going pulses synchronized Otherwise each PWM s pulse width can be independently adjusted The PWMs require three parameters AQs to be set for operation These parameters may be
93. 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 10 8 X Universal Analog Inputs Note See the data sheet for the XL6 XL6e OCS model you are using for jumper settings and see the appropriate pages in this manual see Index for details on how to use Cscape to configure the digital filtering The universal analog inputs provide a high resolution very flexible interface for a variety of analog inputs These inputs include voltage current thermocouple RTD and millivolt Each channel can be configured separately using jumpers and configuration settings in Cscape Like the standard analog inputs these inputs have a digital filter that can be used to filter electrical noise that may be unavoidable in some installations The downside to digital filtering is the inputs will respond more slowly to sudden changes in the actual input 10 9 Analog Outputs Note Refer to the datasheet for XL6 XL6e OCS model you are using for details on jumper settings The analog outputs on XL6 XL6e OCS devices provide high resolution voltage or current outputs The voltage or current selection is controlled with jumpers and configuration settings in Cscape Note that each channel can be separately configured for voltage or current mode When the controller is stopped the operation of each output i
94. he DIP Switches and configure it based upon the option that is desired wee in CH 5 SWl ON enables MJ2 RS485 port termination 121 Ohms OFF disables MJ2 RS485 port termination SW2 amp SWS ON places MJ2 RS485 port in half duplex mode OFF places MJ2 RS485 port in full duplex mode SWA ON enables MJ1 RS485 port termination 121 Ohms OFF disables MJ1 RS485 port termination 5 4 RS 485 Termination Proper RS 485 termination minimizes reflections and improves reliability Both serial ports allow 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 5 5 RS 485 Biasing RS 485 biasing passively asserts a line idle state when no device is actively transmitting which is useful for multi drop RS 485 networking Both serial ports allow internal RS 485 bias resistors to be switched in pulling pin 1 up to 3 3V and pulling pin 2 down to ground The Set Serial Ports item in the System Menu can be used to enable RS 485 biasing Also an application graphics screen that writes to SR164 can do the same thing Setting SR164 1 enables MJ1 biasing and setting SR164 2 enables MJ2 biasing If biasing is used it should be enabled in only one of the devices attached to the RS 485 network 5 6 Cscape Programming via Serial Port XL6 XL6e OCS Mu1 serial port supports CSCAN Prog
95. hot for the same as follows Module Configuration Map Module Setup Register Usage Default Settings Register Direction IP Address 192 168 5 175 28100 eem Read Only Use ID for last Octet Met Mask 255 255 255 0 E BIT 2 0 0 0 0 gam 200 Read Ony 00 Version xR30 ReadOnly Enhanced Configuration Protocol Support 2 Configure Selected Protocol SATF Slave 90 30 Service Request Modbus TCP Slave EthemetzlP FTP File Server CJ HTTP web Server Download the configuration in to Controller XL6e Connect LAN cable to the Controller in default LAN Port From Cscape go to Tools gt Editor Options gt Communication Port gt configure Select Ethernet and enter IP address which is configured in the file Select mode as XL Series mode from drop down list The controller should get connected to Cscape If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above Models supported Cscape 8 7 with upgrade supports all models and options offered in the XL6 XL6e OCS line For the latest version of Cscape or compatibility information contact Technical Support March 4 2010 Page 106 of 135 1037 MANO883 05 EN CH 15 15 5 Configuration An overview of configuration 1 2 3 4
96. igure 16 1 Fail Safe System Menu March 4 2010 Page 113 of 135 1037 16 0883 05 16 2 Settings To use the fail safe feature the user needs to do the following 1 Backup the current Battery Backed RAM Register contents in On Board Flash memory using System Menu options 2 From Cscape create AUTOLOAD PGM for the application program using Export to Removable Media Place the Removable Media with AUTOLOAD PGM in the device Set the Enable AutoLoad option in the device to YES 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 16 3 Backup Restore Data Selecting this option brings up a screen having four operations e Backup OCS Data Restore OCS Data Clear Backup Data e Exit Backup Restore Data Clear Backup Figure 16 2 Backup Restore Data Backup OCS Data When initiated this will allow the user to manually copy Battery Backed RAM contents on to the onboard FLASH memory of the OCS This will have the effect of backing up all the registers and controller settings Network ID etc that would otherwise be lost due to a battery failure SR164 4 is set to 1 when backup operation is performed March 4 2010 Page 114 of 135 1037 0883 05 16 Backup Restore Data Backup Register Data Overwrite Backup Figure 16 3 Backup
97. ing the software for E OCS USB COM Part Click Finish to close the wizard Finish Cancel March 4 2010 Page 100 of 135 1037 MANO883 05 EN CH 15 Next configure Cscape to use the correct communications port This can be done using the Tools Editor Options Communication Port dialog in Cscape In order to find the Comm Port number that the XL6 XL6e is using go to the PC s Control Panel and System System Properties Hardware My Computer E x Edit wiew Favorites Tools Help C9 Bm sect 27 Folders Address 72 My Computer Name Type 00000 System Tasks Hard Disk Drives View system information Sa Local Disk 0 7 Local Disk 4 Add or remove pragrams gt Change a setting Devices with Removable Storage didis Floppy l 3 Inch Floppy Disk Other Places 4 CD RW Drive D CD Drive Network Places Network Drives Lj My Documents 3 Doc Manuals Disconnected Network Drive ontrol Pane gt 3 kmecloud Disconnected Network Drive Other Details Control Panel System Folder Computer System Folder E Control Panel Edit View Favorites Tools Help E m NE gt Folders Address Control Panel dd 2 Mame Comments Control Panel A Regional and Language Customize settings Ehe d Scanners and Cam
98. ions For detailed information regarding these modules please refer to the individual documents provided with the modules 8 2 Ethernet COM Module XEC Option An Ethernet COM module can be installed to allow Cscape programming of an XL6 OCS over a Local Area Network or over the Internet In addition the Horner OPC Server can be installed on a PC to allow other standard PC applications such as database and spreadsheets programs access to XL6 OCS register data The Ethernet COM module supports 10 BaseT 10 MHz and 100 BaseTx 100 MHz as well as both half and full duplex communication Both the connection speed and the duplex are auto negotiated Although the physical connection between the Ethernet COM Module and the Local Area Network is done using a standard Ethernet cable CAT5 or better with RJ45 modular plug a Serial Port Tunnel protocol is employed that makes the Ethernet COM Module appear as a serial port to Cscape or OPC Server software running on the PC On the XL6 OCS end of the Serial Port Tunnel the Ethernet COM module should be properly configured using the XL6 OCS System Menu This configuration consists of making Ethernet the Default Programming Port and setting its target IP Address Net Mask and optionally the Gateway IP Address The Gateway IP Address is required if the XL6 OCS will be accessed from outside the Local Area Network e g the Internet On the PC end of the Serial Port Tunnel the PC should be connected to
99. ires a valid AUTOLOAD PGM to be present in the removable media of the device When the AutoLoad setting is not enabled set to NO OCS will be in IDLE mode and the application is not loaded If the AUTOLOAD PGM is security enabled the user will be prompted to enter the password before loading the application The application will be loaded from the Removable media only after getting the correct password SR164 6 be set to enable AutoLoad feature Enable AutoLoad Ho AutoLoad from Removable AUTOLOAD PGH file when triggered Figure 16 7 AutoLoad Menu March 4 2010 Page 118 of 135 1037 MANO883 05 EN 4 Power up OCS y The OCS follows the following sequence in execution of AutoLoad Application Program absent or Application Program corrupted AutoRun NO AutoLoad Enabled gt OCS put in IDLE mode NO UTOLOAD PGM present iri s the RM of the device AECA W failure YES AutoLoad initiated NO M Enabled YES OCS put in RUN Mode March 4 2010 OCS put in IDLE Mode Figure 16 8 Flow Chart for AutoLoad Page 119 of 135 CH 16 1037 16 0883 05 16 5 AutoRun This system menu option when enabled YES allows the user to automatically place the OCS into RUN mode after the AutoLoad operation or automatic Rest
100. is installed it can be selected as the programming port The selection is made in the controllers System Menu If there are difficulties connecting make sure that the default programming port is set correctly with the connection method being attempted 19 1 3 Connecting Troubleshooting Checklist ETN port programming For XL6e only 1 Programming and debugging must use MJ1 or Ethernet Port 2 Controller must be powered up 3 Ensure that correct IP address is given in the Ethernet field and correct Mode is selected in Cscape Tools Editor Options Communications Port 4 Ensure that the Ethernet Cable is connected between the controller and the Ethernet Hub 5 Make sure the Ethernet cable is functioning properly 19 2 Local Controller and Local I O The system menu provides the following status indications that are useful for troubleshooting and system maintenance Self test results diagnostics RUN and OK status Network status and usage Average logic scan rate Application memory usage March 4 2010 Page 128 of 135 1037 0883 05 19 Loaded firmware versions Loaded protocols e Removable media access To view the system menu press the System key 19 2 1 Local I O Troubleshooting Checklist Verify the controller is in RUN mode Check diagnostics to insure controller passed self tests View diags in System Menu or in Cscape click Controller Diagnostics 3 Check data sheets to insure proper wiring
101. ist USB Port Mini B Programming 128 19 1 3 Connecting Troubleshooting Checklist ETN port programming For XL6e only 128 19 2 local Gonttoll randibocal en a 128 19 2 1 Local I O Troubleshooting 129 19 3 ITI TET 129 19 3 1 CsCAN Network Troubleshooting 129 19 4 Removable 130 19 4 1 Basic 130 19 5 Technical Support 00002000000000 0 nennen nennen nnn nnne nnns nnn nan nnns 130 lafe qme 131 Table OF FiIQureS mt T 134 March 4 2010 Page 8 of 135 1037 0883 05 Visual Visual of major tasks and the key chapters to assist you FIRST STEP of ANY TASK DATASHEET Each XL6 XL6e OCS unit is sent with a datasheet in the box The datasheet is the first document you need to refer to for model specific information related to XL6 XL6e OCS models such as pin outs jumper settings and other key installation information Visit our website http www heapg com to obtain updates to datasheets manuals and user documentation QUICK START PROGRAMMING TROUBLESHOOTING Safety Compliance Safety Compliance Safety Compliance page 11 page 11 page 9 page 11 Introduction Introduction Introductio
102. istance between CAN and CAN LO f the network is properly wired and terminated there should be around 60 ohms Check for duplicate node ID s Keep proper wires together One twisted pair is for V and V and the other twisted pair is used for CAN Hl and CAN LO Make sure the baud rate is the same for all controllers on the network Assure shields are connected at one end of each segment they are not continuous through the network Do not exceed the maximum length determined by the baud rate and cable type Total drop length for each drop should not exceed 6m 20 feet A drop may include more than one node The drop length adds to the overall network length Network should be wired in straight line fashion not in a star pattern In applications requiring multiple power supplies make sure the V of all supplies is connected together and to earth ground at one place only March 4 2010 Page 129 of 135 1037 19 0883 05 14 In some electrically noisy environments it may be necessary to add repeaters to the network Repeaters can be used to add additional nodes and or distance to the network and protect the signal against noisy environments The Horner APG repeater is part HE200CGM 100 19 4 Removable Media 19 4 1 Basic Troubleshooting _ media card should be formatted with the XL6 XL6e OCS does not read media card XL6 XL6e OCS Make sure the project file is saved as a
103. 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 system ICON may be configured for display along with the legend which aids in identifying the object as one that causes a screen change March 4 2010 Page 78 of 135 1037 0883 05 13 13 5 Ladder Based Screen Navigation Ladder logic can use several techniques to control screen navigation Coils can be tied to D registers to make them screen coils These coils have two modes switch and alarm If the ladder program energizes an alarm display coil the screen associated with this coil is displayed and overrides the normal user screens This is designed to show alarm conditions or to display other ladder detected events When the text coil is de energized the previous screen that was being viewed before the alarm is returned The switch display coil switches to the associated screen when it is energized Once it is de energized the screen remains until it is switched by the user or ladder Input 1 Force Screen 1 4 Screen 1 Input 2 Switch Screen 2 zT O00 Screen 2 Figure 13 4 Force and Switch Coils in Ladder Programming There is also a system register that can be u
104. k optimized 3 3 network required and optimized 9eSR32 LCD CONT LCD Display Contrast setting 0 255 Function Key Mode O Momentary 1 Toggle 0 1 RS232 Serial Protocol Mode O Firmware Update RISM 12 CsCAN 2 Generic Ladder Controlled 3 Modbus RTU 4 Modbus ASCII SR35 36 SERIAL_NUM _ This Station s 32 bit Serial Number 0 2 4 SR37 MODEL NUM This Station s Binary Model Number 0 65535 SR38 ENG REV Firmware Rev Number 100 0000 9999 SR39 CPLD_REV BIOS Rev Number 100 000 255 9556840 FPGA REV FPGA Image Rev Number 10 000 255 9 SR41 LCD COLS Vertical Pixel Count es SR42 LCD ROWS Horizontal Pixel Count LE SR43 KEY_TYPE Keypad Type rr ee SR44 Real Time Clock Second 0 59 SR45 RTC_MIN Real Time Clock Minute 0 59 SR46 RTC_HOUR Real Time Clock Hour 0 23 9556847 RTC DATE Real Time Clock Date SR48 RTC_MON Real Time Clock Month 1 12 9 SR49 RTC YEAR Real Time Clock Year 1996 2095 SR50 RTC_DAY Real Time Clock Day 1 Sunday a a SR51 Network Error Count 0 65535 9556852 WDOG CNT Watchdog Tripped Error Count 0 65535 SR53 54 BAD LADDER Bad Ladder Code Error Index 0 65534 9556855 SELF TEST Filtered Bit Mapped Self Test Result 0 65535 SR56 LAST KEY Key Code of Last Key Press or Release 0 255 o SR57 BAK LITE LCD Backlight Dimmer Register 255 0
105. lated from the Date setting March 4 2010 Page 68 of 135 1037 MANO883 05 EN CH 12 Set Beeper ves Use 11 to adjust 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 Set Screen The Set Screen Sub Menu displays four System Settings all of which are editable Saver enable Timenut min Popup Status Update 5 Update time sets the maximum time used by graphics in the logic scan Saver enable Yes Enable screen saver No default 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 update per scan March 4 2010 Page 69 of 135 1037 12 Removable Media MANO883 04 EN Media Directory J 3sERBBU 1 sERBaBU sCROOOJ sCROOOH sCROOOS sCROOGO SCROOGOZ sCROOOH 15272 15209 20708 29582 23283 14653 14976 15994 17561 JPG JPG JPG JPG JPG JPG JPG JPG JPG t 07 10 08 07 10 08 07 10 08 07 18 08 02 10 08 07 10 08 07 10 08 07 10 08 07 18
106. list 129 CsCAN Network 129 Local Controller I O 128 Local Checklist 129 Removable Media 130 troubleshooting technical support 127 Troubleshooting Checklist serial port MJ1 Programming 128 Troubleshooting Checklist USB Port Mini B Programming 128 Troubleshooting Checklist Ethernet port Programming For XL6e only 128 Two Point Ground Connection Test 23 Types of Devices that can be connected to XL6 15 Universal Analog Inputs 50 USB 15 16 30 92 98 128 User Interface March 4 2010 Page 133 of 135 Index Ladder Based Navigation 79 Screen Navigation 78 USER INTERFACE 75 Using Removable Media to View and Capture Screens 42 Visual Overview of XL6 and Topics 13 Where to Find Information 14 XEC 37 XL6 Dimensions 19 XL6 I O Cover Photograph 44 XL6 I O Cover Removed sample board Photograph 45 XL6 Manual PREFACE 3 XL6 OCS Accessories 16 XL6 OCS Dimensions 19 XL6 OCS Mounting Clip 18 XL6 OCS Mounting Orientation 18 XL6 OCS with Mounting Clips 18 XMC 38 1037 MANOS883 05 EN Table of Figures Table of Figures Figure 2 1 Visual Overview of XL6 XL6e type OCS Side and Rear 13 Figure 2 2 Front View of XL6 XL6e type 2 2 2 2 14 Figure 2 3 Visual Overview of Types of Devices that can be connected to
107. module installed but a COM module is configured 2 COM module installed but no COM module configured 2 COM module installed but another COM module configured 2 COM module installed and configured properly ETN300 has been configured through Cscape Page 66 of 135 1037 MANO883 05 EN CH 12 View Protocols Port 1 None Loaded Port 2 None Loaded The View Protocols Sub Menu displays two System Settings neither of which are editable As mentioned in O both the MJ1 Port 1 and MJ2 Port 2 serial ports support downloadable protocols To assign a downloadable protocol to an XL6 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 protocol assigned to MJ1 Port 2 Protocol name None Loaded or name of the protocol assigned to MJ2 Protocol version Blank or version of the protocol assigned to MJ2 Set Fkeys Mode Momentary 5 5 enable Yes Use 1T to adjust The Set Fkeys Sub Menu displays two System Settings both of which are editable Fkeys Momentary 1 10 bits go On amp Off as F1 F10 are pressed amp released Toggle 1 10 bits toggle each time
108. mulator value with a supplied Preset Value PV which is provided through a AQ and drives a physical digital output based on the that comparison This option available for HSC1 and HSC2 only drives Q1 or Q2 output point respectively once the associated totalizer accumulator reaches or exceeds the PV value To enable this function the corresponding PWM function output Q1 or Q2 must be configured for HSCx Output Note that Q1 and Q2 are PWM function outputs that may be configured independently as one of the following standard digital output PWM HSCx or stepper output Preset values may be modified during run time A preset value of zero disables resets the totalizer compare function output causing the output to remain low 11 2 3 Pulse In pulse mode the high speed input can measure the width or period of a pulse stream in one of four modes and provides a continuous indication of the last sampled value Width High 1 us Counts In this sub mode the accumulator value will contain the number of 1 us counts the pulse is high March 4 2010 width High Jide Page 52 of 135 1037 0883 05 11 Width Low 1 us Counts In this sub mode the accumulator value will contain the number of 1 us counts the pulse is low L width Low Period Rising Edges 1 us Counts In this sub mode the period of the input signal is reported in one 1 us units The period measurement will start on the rising edge of the inpu
109. n page 13 page 13 page 11 page 13 Serial Communications Maintenance page 17 Page 25 page 125 CAN Communications Troubleshooting page 23 page 29 page 127 Clone Unit Page 121 Ethernet XL6e only Page 31 Communication Options page 37 Removable Media page 39 High Speed page 51 System Settings page 61 User Interface page 75 Registers page 85 Cscape Configuration page 91 Fail Safe System Page 113 March 4 2010 Page 9 of 135 1037 Visual Map MANOS883 05 EN NOTES March 4 2010 Page 10 of 135 1037 0883 05 1 CHAPTER 1 SAFETY COMPLIANCE 1 1 Safety Warnings and Guidelines When found on the product the following symbols specify Warning Consult user documentation Warning Electrical Shock Hazard WARNING EXPLOSION HAZARD Do not disconnect equipment unless power has been switched off or the area is known to be non hazardous WARNING To avoid the risk of electric shock or burns always connect the safety or earth ground before making any other connections WARNING To reduce the risk of fire electrical shock or physical injury it is strongly recommended to fuse the voltage measurement inputs Be sure to locate fuses as close to the source as possible WARNING Replace fuse with the same type and rating to provide protection against risk of fire and shock hazards WARNING In the event of repeated failure do not replace the fuse again as a repeated failure indicates
110. n line help found in Cscape 14 3 Register Map for XL6 XL6e OCS I O Table 14 3 I O Register Map Description 1 Description 024 March 4 2010 Page 88 of 135 1037 0883 05 14 018 Totalizer Clear HSC2 Quadrature Set Quad Table 14 3 I O Register Map Description 1 1 Description 02 iiid 019 HSC1 Accumulator 7 8 9 10 Unused These registers can be used as general purpose registers 14 4 Resource Limits Table 14 4 Resource Limits Resource Value 13 R 208 2048 102 7 i 1 1023 AAI AIG WAQG Ethernet XL6e CsCAN Ping EGD SRTP Modbus TCP Master Downloadable protocol amp Slave Ethernet Only IP FTP or HTTP 10 MBd or 100 MBd 125 kBd 250 kBd 500 kBd or CsCAN 1 Serial Ports 2 RS 232 RS 485 Ports Software Selectable IDs Per CSCAN Network 64 w o repeat 253 w 3 repeaters Keypad Display Screen Memory User Screens Data Fields Per 50 User Screen Ladder Code 5 5 K D Q March 4 2010 Page 89 of 135 1037 14 0883 05 5 4 2010 90 135 1037 MANO883 05 EN CH 15 CHAPTER 15 CSCAPE CONFIGURATION 15 1 Overview XL6 XL6e OCS hardware is programmed with a Windows based PC application called Cscape This application can be used to program configure monitor and debug all aspects
111. net with an Ethernet adapter board onboard Ethernet Port XL6e only CAN or modems For communications other than USB or the MJ1 port please refer to the manual which ships with the communications adapter hardware being used for programming To communicate with the XL6 XL6e via USB you will need the automated driver installer located on the Horner APG web site http www heapg com Pages TechSupport CscapeSoftware html Click this button This will take you to the registration page March 4 2010 Page 92 of 135 111037 MANO883 05 EN CH 15 Cscape Download Registration Form Mozilla Firefox File Edit History Bookmarks Tools Help gt ir S a http www heapg com Pages TechSupport Cscape CscapeRegistration php gt HOME PRODUCTS HOWTOBUY MANUALS TECH SUPPORT NEWS amp BROCHURES ABOUTUS CONTACT TECH SUPPORT Manuals Cscape DOWNLOAD REGISTRATION FORM Please Login or complete the registration form to download Cscape at no charge We will contact you in the event of a safety matter important upgrade Cscape Software Product Certifications Login Help Desk User name Password FAQs Submit RMA Submissions If you have forgotten your login information click here Training Application Notes Product Notices New User First name 7 Last Compay Job addres cep State Province
112. ng and 2 is low 1 is high and 2 is rising 1 is falling and 2 is high and when 1 is low and 2 is falling This results in 4 counts per revolution So in order to determine the number of cycles the accumulator would have to be divided by 4 Three different options are available to reset or set the current count They are Configured Counts per Hev value When configuring the quadrature function a value may be specified under the Counts per Hev column When rotation produces an increasing count the quadrature accumulator resets to zero on reaching the Counts per Hev count Alternately when rotation produces a decreasing count the quadrature accumulator is set to Counts per Rev 1 on the count following zero Specifying zero for this value allows the totalizer to count through the full 32 bit range before resetting For example if your encoder outputs 1024 counts per revolution the value of 1024 can be entered into the configuration for Counts per rev This will result in a counter that produces counts in the range of 0 to 1023 Ladder control Setting registers 9017 Q19 resets quadrature HSC 1 or quadrature HSC respectively with no additional configuration Setting registers Q18 or Q20 sets quadrature HSC 1 or quadrature HSC 3 respectively to Counts per Hev 1 Direct digital input control HSC3 Marker When HSC input 1 and 2 are used for quadrature inputs an additional choice of marker input becomes availabl
113. odes 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 Size x Number of bytes in application font tables Protocol Size x Number of bytes in application downloaded protocols SMS File Size x Number of bytes in application SMS protocol configuration Firmware Rev Current firmware version BIOS Rev X yz Current CPLD Complex Programmable Logic Device version FPGA Rev x y FPGA Floating Point Gate Array version March 4 2010 Page 64 of 135 1037 0883 05 12 Self Test Ok power on self tests passed Fault 2 One or more power on self tests failed View Diags Logic Error User Program User Graphics System Battery The View Diags Sub Menu displays up to 14 System Diagnostics none of which are editable The first two System Diagnostics are critical If any of them indicate a Fault condition the XL6 XL6e OCS will not enter or remain in Run mode and the problem must be investigated and corrected Logic Error Ok All executed ladder instructions are legal for loaded firmware Fault _ A ladder instruction not supported by firmw
114. odule THIS WARRANTY SHALL NOT APPLY TO THIS XL6 XL6e OCS module OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT NEGLIGENCE ALTERATION ABUSE OR MISUSE HE APG MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE APG THE TERM ORIGINAL PURCHASER AS USED IN THIS WARRANTY SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM THE XL6 XL6e HE XL HEXT350 HEXT351 OCS module IS ORIGINALLY INSTALLED THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES In no event whether as a result of breach of contract warranty tort including negligence or otherwise shall HE APG or its suppliers be liable of any special consequential incidental or penal damages including but not limited to loss of profit or revenues loss of use of the products or any associated equipment damage to associated equipment cost of capital cost of substitute products facilities services or replacement power down time costs or claims of original purchaser s customers for such damages To obtain warranty service return the product to your distributor with a description of the problem proof of purchase post paid insured and in a suitable package ABOUT PROGRAMMING EXAMPLES Any example programs and program segments in this manual or provided on accompanying diskettes are included solely for illustrative purposes Due to the many variables and requirements associated with any particular installation Horner
115. on is triggered by this SR bit it does not ask the user for confirmation for loading clone The success failure of the operation is also not notified on screen to the user In case of failure of Load Clone operation SR164 12 bit is set to 1 by the firmware and never reset March 4 2010 Page 124 of 135 1037 0883 05 18 CHAPTER 18 MAINTENANCE 18 1 Firmware Updates The XL6 XL6e OCS products contain field updatable firmware to allow new features to be added to the product at a later time Firmware updates should only be performed when a new feature or correction is required Warning Firmware updates are only performed when the equipment being controlled by the XL6 XL6e QX351 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 mode Steps for updating the firmware 1 Establish communication between Cscape and the controller using a direct serial connection to MJ1 2 Make sure your application is available on your PC or upload the application 3 Make sure the machinery connected to the XL6 XL6e OCS is in a safe state for firmware update see warning above 4 Start the firmware update by selecting File Firmware Update Wizard
116. on to store XL6 XL6e OCS graphic screen captures To view a captured XL6 XL6e OCS screen use the Removable Media Manager to find and highlight the desired BMP file and then press Enter To capture 6 OCS screen turning On assigned Screen Capture Control Register will capture the current XL6 XL6e OCS graphics screen and write it to the Micro SD card using the assigned Screen Capture Filename Before capturing an XL6 XL6e OCS screen Cscape must first be used to assign a Screen Capture Control Register and Filename in the application To do this first open the Graphics Editor by selecting the View Edit Screens item on the Cscape Screens menu Next select the Screen Capture item of the Graphics Editor Config menu and then enter a Control Register and Filename 9 8 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 reference Micro SD when filename is prefixed with or nothing OR USB A Flash Drive when filename is prefixed with B a Read RM csv This function allows reading of a comma separated value file from the Micro SD interface into the controller register space b Write RM csv This function allows
117. ore Data operation When the AutoRun setting is disabled NO the OCS remains in the IDLE mode after a Restore Data or AutoLoad operation 9o9H164 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 acknowledging this message box the AutoLoad Run sequence will be terminated controller will return to the first user screen and will be placed in IDLE mode Enable AutoRun Ho xxx DAT IDHessxxx Auto Enters after AutoLoad or Battery Fail Figure 16 9 AutoRun Menu March 4 2010 Page 120 of 135 1037 MANO883 05 EN CH 17 CHAPTER 17 CLONE UNIT 17 1 Overview Clone Unit feature allows the user to clone the OCS of the exact same model This feature clones application program and unit settings stored in Battery backed RAM of an OCS into the RM refer Removable Media Chapter 9 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 e Duplicating or clone units without a PC 17 2 Clone User needs to perform the following to Clone 1 The
118. ormation 12 Grounding Definition 23 High Speed Configure Inputs 51 Frequency 51 High Speed PWM Overview 51 High Speed Counting 51 HIGH SPEED I O 51 HSC 51 52 53 54 56 58 59 107 Cover Removal 43 IP Address 33 1037 Index Jumpers Example 46 LIMITED WARRANTY 4 Load Clone 74 123 Maintenance 121 125 Make Clone 121 Manual Index 14 Mechanical installation 17 Micro SD Cards 39 Installing Removing 39 Micro SD System 41 Minimum Clearance Requirements for Panel Box and Door 20 MJ Serial Port Connector 25 MJ Serial Port Connectors and DIP Switches for RS 485 Port Termination 26 MJ Serial Port Connectors Photograph 27 Model I O Overview 46 Modem COM Module Option 38 Mounting Orientation 18 Mounting Requirements 17 Panel Door Mounting 17 Net Mask 33 OCS Reference Document Numbers 16 Orientation of XL6 OCS 18 Panel Box Clearances 20 Grounding 20 Noise 21 Orientation 21 Temperature 20 Panel Box Shock and Vibration 21 Panel Cut out 19 Panel Cutout Tolerances 19 Panel Design Checklist 21 Panel Layout Clearances 20 Panel Mounting of an XL6 Series OCS 17 Power Connector Primary Power Port 24 Primary Power Port 24 Primary Power Port As Viewed Looking at the XL6 OCS 24 Primary Power Port Pins 24 PROGRAMMING EXAMPLES 4 Pulse 52 pulse mode 52 55 pulse stream 52 Pulse Width Modulation 51 56 PWM 15 47 51 52 56 57 59 60 89 107 109 Examples 59
119. ovable Media slot labeled Memory Card which supports standard Micro SD Flash memory cards Micro SD cards can be used to save and load applications to capture graphics screens and to log data for later retrieval Figure 9 1 Removable Micro SD Memory Card Slot 9 2 Micro SD Cards When the Micro SD card format was introduced it was originally called TransFlash Cards labeled either Micro SD or TransFlash with up to 2 0 GB of Flash memory are compatible with the XL6 XL6e OCS Memory slot The Memory slot is equipped with a push in push out connector and a Micro SD card can be safely inserted into the Memory slot whether the XL6 XL6e OCS power is On or Off To install a Micro SD card Align its 8 pin gold edge connector down facing the front of the XL6 XL6e OCS unit as shown in Figure 9 2 then carefully push it all the way into the Memory slot Ensure that it clicks into place To remove the Micro SD card Push down on the top of the card gently to release the spring The card pops up for E Figure 9 2 Installing Removable Memory Card March 4 2010 Page 39 of 135 1037 10 0883 05 9 3 Micro SD File System The Micro SD Memory slot uses the PC compatible FAT16 File System This means that a PC with a Micro SD compatible card reader can read files that have been written by the XL6 XL6e 5 and can write files that can be read by the XL6 XL6e OCS However the XL6 XL6e OCS does not support long fil
120. perform the following to Load Clone 1 Select Clone Unit from main system menu of OCS as shown below Set Hetwork ID Set Hetwork Baud Uiewu Status View Diags Uiew I O Slots Uiew Protocols set Fkeys Set Serial Ports Set Time Date set Beeper Set Screen Removable 11 System Clone Unit Figure 17 6 System Menu March 4 2010 Page 123 of 135 1037 17 0883 05 2 Selecting Clone Unit menu will open the following menu screen Select Load Clone Clone Unit DAT 24570 07 14 09 12 11a Free 1805208128 Total 1004257280 Load Hake Clone Clone V Esc Figure 17 7 Clone Unit Menu after Cloning 3 User needs to confirm Load Clone as shown below Clone Unit Load Clone Files Are You Sure Ok Cancel Free 1805208128 Total 1004257280 Load Clone Clone V Esc Figure 17 8 Load Clone Confirm Screen 4 After confirmation all unit settings and register values will be loaded from Removable media to the Battery backed RAM Regardless of AutoLoad settings and then OCS resets for the settings to take effect 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 operati
121. prevent false releases of the button the XL6 XL6e allows adjustment of the allowable slide up to 5x the default value To enable the touch slip sensitivity first an OCS data register must be allocated through the Graphics editor Configuration menu for Display Settings Once a Touch Sensitivity register is assigned that register may be modified range 1 Low to 5 High to the desired slide amount If a value outside the valid range is entered in the touch sensitivity register it is ignored and the last valid value is used 13 8 Alarms Alarm presentation to the operator is highly configurable and beyond the scope of this document to describe fully For more information refer to the graphics editor help file This section presents a typical configuration thereby providing an introductory description on what the operator should expect The alarm object is generally used to enunciate alarms to the operator While the display 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 Exist TE Figure 13 3 Alarm Object To view acknowledge and or clear alarms the operator must acce
122. program in Cscape is configured Network indicates the type of network that the program in Cscape expects to use e g CSCAN Model Confirmation provides the following e indications Modelz the actual Target Controller matches the configured Controller Model and Network Model Notz the actual Target Controller does not last time the Target Controller was compared to the Local xx indicates the Network ID of the XL6 QX351 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 following are status indicators Cscape is not communicating with the remote unit match the configured Controller Model and Network R Running D Do l o e Model there may have been a change since the l Idle 4 2010 configured Controller Model and Network Page 91 of 135 no forces indicates no has been forced 1037 15 MANO883 05 EN 15 3 Establishing Communications The preferred method of communicating between Cscape and an XL6 OCS is via USB port The XL6 OCS can communicate with Cscape using USB to USB USB to serial adapters serial port communications via MJ1 Port Ether
123. ramming Protocol but MJ2 does If a PC COM port is connected to the XL6 XL6e OCS serial port Cscape can access the XL6 XL6e OCS for programming and monitoring 5 7 Ladder Controlled Serial Communication Using Serial Communication function blocks both MJ1 and MJ2 support Generic Modbus Master and Modbus Slave Protocols In addition external modems can be connected and accessed using Init Dial and Answer Modem function blocks 5 8 Downloadable Serial Communication Protocols Both MJ1 and MJ2 also support downloadable protocols such as Allen Bradley DF1 CSCAN Master GE Fanuc SNP and Modbus Master March 4 2010 Page 27 of 135 1037 5 883 05 Note Refer download section of website for the list of latest supported protocols http www heapg com Pages TechSupport Downloads html March 4 2010 Page 28 of 135 111037 MANO883 05 EN CH 6 CHAPTER 6 CAN COMMUNICATIONS Note For additional CAN information refer to the CAN Networks manual 0799 on our website 6 1 Overview All XL6 XL6M XL6e OCS models provide a CAN networking port which is implemented with a 5 pin connector The connector is labeled NET1 p i m Figure 6 1 NET 1 Connector Like the MJ1 serial port the NET1 port can be used for XL6 XL6e OCS programming by connecting it to the CAN port of a PC running Cscape port also allows the XL6 XL6e OCS to exchange global data with other OCS RCS cont
124. red for Stepper the stepper function is enabled at the Q1 output Only one stepper function and output is available Note that when Q1 is configured for stepper operation Q2 operation is limited to direct digital output The Stepper requires five parameters AQs to be set for operation These parameters may be set at run time but are latched when the stepper is commanded to start Start Frequency cycles per second This value 1 sets the frequency for the first cycle during the acceleration phase and the frequency of the last cycle during the deceleration phase When an acceleration or deceleration count is specified the Start Frequency must be greater than 0 and must not exceed the run frequency or an error is generated Run Frequency cycles per second This value 2 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 5000 cycles sec or an error is generated Acceleration Count This value AQ3 4 sets the number of cycles to occur within the acceleration phase The frequency of the cycles within this mode will vary linearly between the specified Start and Run frequency The Accel count must not equal 1 or an error is generated Setting this value to zero disables this phase Run Count This value 96AQ5 6 sets the number of cycles
125. rollers and to access remote Network devices SmartStix Modules 6 2 Port Description The XL6 XL6e OCS port implements the ISO 11898 2 physical layer and the CAN 2 0 data link layer standards Also since the NET1 port is powered by an internal isolated power supply external CAN power is not required March 4 2010 Page 29 of 135 1037 6 0883 05 63 NET1 Port Wiring Note The connection is required on the XL6 XL6e OCS The XL6 XL6e OCS network port is self powered Supporting devices require this connection and this pin can be used to land the extra wire required for those devices CAN Connector Use the CAN Connector when using CsCAN network Torque rating 4 5 7 Lb In 0 50 0 78 N m Figure 6 2 NET1 Port Connector Table 6 1 NET1 Port Pin Assignments Signal Description Direction CAN Ground CAN Data Low In Out Shield Ground CAN Data High Lx ej No Connect 6 4 Cscape Programming via CAN The port supports CSCAN Programming Protocol If a PC has a CAN interface installed PCI or USB and the PC CAN port is connected to the XL6 XL6e OCS port Cscape can access the XL6 XL6e OCS for programming and monitoring In addition the XL6 XL6e OCS supports single point programming of all XL6 XL6e OCS and other OCS RCS devices that are connected to a CAN network the PC COM port is connected to th
126. s configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined value By default analog outputs are set to a value of zero For more information on Stop State refer to the appropriate pages see Index for the configuration chapter for Cscape settings March 4 2010 Page 49 of 135 1037 10 0883 05 5 4 2010 50 135 1037 MANO883 04 EN CH 11 CHAPTER11 HIGH SPEED HSC PWM 11 1 Overview In addition to the compliment of simple analog and digital I O several of the XL6 XL6e OCS I O modules support High Speed Counting HSC I O functions and may also support Pulse Width Modulation PWM Output functions HSC functions include frequency totalizing pulse width and quadrature measurement PWM functions include traditional PWM with variable rate and duty and a stepper limited functionality with variable acceleration and deceleration rates To determine function availability refer to the associated model s Specification Installation sheet Digital DC Input Output sections This chapter describes the operation of these high level I O functions For configuration details of these functions see Cscape Configuration 11 2 High Speed Counter HSC Functions On units that support the HSC four dedicated inputs are available than can be configured for one of four modes of operation Those modes are Frequency
127. s will search for current and updated software by looking on your computer on the hardware installation or on the Windows Update Web site with pour permission Read aur privacy policy Can Windows connect to Windows Update to search for s ftware CO Yes this time only now and every time connect a device Click Next to continue Cancel March 4 2010 Page 98 of 135 1037 MANO883 05 EN CH 15 Found Hew Hardware Wizard This wizard helps you install software for OCS USB COM Port If your hardware came with an installation CD lt nr floppy disk insert it now What want the wizard to C Install fram a list or specific location Advanced Click Next to continue Hardware Installation The software you installing for this hardware OLS USE COM Port has not passed Windows Logo testing to verify its compatibility with Windows me why this testing is important Continuing your installation of this software may impair destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing STOP Installation March 4 2010 Page 99 of 135 1037 15 MANO883 05 EN Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has finished install
128. sed to for control based screen navigation SR1 can 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 136 Acknowledgement XL6 XL6e contains an internal beeper that provides an audible acknowledgment when an operator touches a graphic object that accepts touch input When the graphic object is enabled a short 5ms tone is emitted When the graphic object is disabled a longer 100ms tone is emitted to enounce that graphical object is not currently accepting the touch input If beep acknowledgement is not desired the beeper function can be disabled from the system menu 13 7 Touch Slip Sensitivity Touch s ip sensitivity is preset to meet most applications however adjustment is available to reduce the sensitivity for touch release That is once a graphical object button is touched and held by a finger the default touch slip sensitivity allows for a slight slip of the finger on the graphical object before the XL6 XL6e assumes touch been released equates to approximately a quarter inch of movement with a stylus March 4 2010 Page 79 of 135 1037 13 MANO883 05 EN In some applications such as jog buttons where the operator is pushing a button for a period of time the amount of s ip while holding a button pressed may exceed the default sensitivity To increase the amount of tolerable s ip and
129. sh are registered trademarks of SanDisk Corporation For user manual updates contact Technical Support North America Tel 817 916 4274 Fax 817 639 4279 Web www heapg com Email techsppt heapg com Europe Tel 353 21 4321 266 Fax 353 21 4321 826 Web www horner apg com Email tech support horneraog com March 4 2010 Page 3 of 135 1037 MANOS883 05 EN Limited Warranty and Liability LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner APG LLC HE APG warrants to the original purchaser that the XL6 XL6e HE XL HEXT350 HEXT351 OCS module manufactured by HE APG is free from defects in material and workmanship under normal use and service The obligation of HE APG under this warranty shall be limited to the repair or exchange of any part or parts which may prove defective under normal use and service within two 2 years from the date of manufacture or eighteen 18 months from the date of installation by the original purchaser whichever occurs first such defect to be disclosed to the satisfaction of HE APG after examination by HE APG of the allegedly defective part or parts THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE APG NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE APG ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS XL6 XL6e OCS m
130. sion These files are compatible with standard database and spreadsheet PC programs In addition an application ladder program can use Rename and Delete Removable Media function blocks to rename and delete files March 4 2010 Page 40 of 135 1037 0883 05 10 9 6 Using Removable Media to Load and Save Applications A special file type with a PGM extension is used to store XL6 XL6e OCS application programs on Micro SD To load an application from Micro SD to the XL6 XL6e OCS use the Removable Media Manager open the Removable Media Manager in the System Menu to find and highlight the desired PGM file and then press the Enter key To save an application from XL6 XL6e to Micro SD open the Removable Media Manager in the Save System Menu and press the Save 9 function key The application will be saved in a file called DEFAULT PGM in the Micro SD root directory Note Saving an application to Micro SD can only be done from the Removable Media 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 Micro SD card which is plugged into the PC s Micro SD compatible card reader by selecting the Export to Removable Media item on the Cscape File menu 9 7 Using Removable Media to View and Capture Screens The XL6 XL6e OCS File System uses bitmap files with the BMP bmp extensi
131. ss the alarm viewer This is accomplished by touching an enabled alarm object When accessed the alarm viewer is displayed as pop up alarm viewer dialog similar to that shown in Figure 13 6 Figure 13 4 Alarm Viewer March 4 2010 Page 80 of 135 1037 0883 05 13 The currently selected entry is indicated by a yellow highlight which be moved up down by touching the arrow buttons or by directly touching an entry If more entries exist than can fit on the page a scroll bar is displayed on the right side that also indicates the current relative position The current state of the displayed alarm is indicated by its color and optionally by an abbreviated indicator after the date time stamp ALM RTN 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 viewer Note that OCS registers SR181 and SR182 are available for ladder use which indicate presence of unacknowledged or acknowledged alarm respectively The screen designer may implement these registers to switch screens or activate the beeper to attract the operator s attention 13 9 Removable Media The removable media object is generally used to inform
132. t FL Period from Rising Edge Period Falling Edges 1 us Counts In this sub mode the period of the input signal is reported in one 1 us units The period measurement will start on the falling edge of the input _ _ Period from Falling Edge 11 2 4 Quadrature Two HSC inputs are consumed for each of the two possible Quadrature counters For example selecting quadrature mode for HSC 1 will use HSC inputs 1 and 2 which correspond to A and B quadrature signals Therefore HSC 1 and 3 may be configured for quadrature input Alternately HSC 3 may be configured to reset HSC1 quadrature count on a marker input Quadrature mode works much like the totalizer except the accumulator will automatically increment or decrement based on the rotation phase of the two inputs See the following example for more details Quadrature inputs are typically used for reporting the value of an encoder Two modes are available for quadrature that select whether the accumulator counts up or down when the phase of input 1 leads input 2 Check your encoder s documentation to determine the output form it uses or try both modes to determine if the encoder counts up when expected March 4 2010 Page 53 of 135 1037 11 0883 05 1 leading _ lagging 90 phase TM Using the above waveforms and a HSC input configuration of Quadrature 1 leads 2 count up the accumulator will count up when 1 is risi
133. t Module Configuration dialog as shown in figure 7 2 March 4 2010 Page 32 of 135 111037 MANO883 05 EN CH 7 Module Configuration Register Usage Default Settings Register Direction IP Address 182 168 254 128 segr Read Only Use CAN ID for last Octet Met Mask 255 255 255 0 e Gatewy 0 0 0 0 i Status ReadOnly 00 Version PO ReadOnly Enhanced Configuration Protocol Support 21 T Configure Selected Protocol C SATF Slave 90 30 Service Request Modbus TCP Slave Ethernet IP C FTF File Server web Server Cancel Figure 7 2 Ethernet Module Configuration 4 Configure the Ethernet Module parameters as follows IP Address Enter the static IP Address for the Ethernet Module being configured Note IP Addresses are entered as four numbers each ranging from 0 to 255 These four numbers are called octets and they are always separated by decimal points Net Mask Enter the Net Mask sometimes called Subnet Mask being used by all nodes on the local 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 Address of a Gateway Server on the local network that allows for communication outside of the local network To pre
134. t data such as voltages temperatures and speed settings coming from an attached device Analog Output 16 bit output registers used to send analog information such a voltages levels or speed settings to an attached device Global Analog Input opecially 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 a unit which has the ability to display a screen If the bit is SET the screen is displayed l Digital Input Single bit input registers Typically an external switch is connected to the registers IG Global Digital Input Specially defined single bit inputs that come from the network 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 Typically these bits are connected to an actuator indicator light or other physical outputs QG Global Digital Output Specially defined single bit outputs that go to the network R General Purpose Register Retentive 16 bit registers March 4 2010 Page 85 of 135 1037 14 0883 05 S System oingle bit bit coils predefined for system use SR System Register 16 bit registers predefined for system use
135. that is not present or that another program has control of the Local No Port COM port Only one Cscape window can access a port at a time Subsequent instances of Cscape opened will indicate No Port Cscape has accessed a PC COM port but is not communicating with the controller This Local No Com typically occurs when the controller is not physically connected Unknown communication error Close Cscape power cycle the controller and reopen Local Cscape with a blank project Check Local If idle run or D do I O shows next to Target number then communication is established to the target controller Target I R D Communication is not established to the target controller Check node ID of controller and H Target set Target to match Make sure local connection is established March 4 2010 Page 127 of 135 1037 19 0883 05 19 1 1 Connecting Troubleshooting Checklist serial port MJ1 Programming 1 3 Programming and debugging must use MJ1 or USB Mini B Port Controller must be powered up Ensure that the correct COM port is selected in Cscape Tools Editor Options Communications Port Ensure that a straight through non null modem serial cable is being used between PC and controller port MJ1 Check that a Loaded Protocol or ladder is not actively using MJ1 Taking the controller out of run mode from the System Menu on the controller will make MJ1 available to
136. tible with XL6 OCS Card capacity is 256 MB or larger 1 Media Card Reader for HE MC1 Portable device allows 1 to be plugged into the USB port of personal computers as a portable hard drive HE X24 AS Power supply 100 240VAC or 140 340VDC Switching supply that outputs 1 5 HE X24 AS AL at 24 VDC Mounts on Standard DIN rail Designed for X Family products HE X24 AL Power supply 100 240 VAC or 140 340 VDC Switching supply that outputs 1 5 A 3A HE X24 AS AL at 24VDC Mounts on Standard DIN rail Designed for X Family products HE5000SW232 Cscape Software Package Includes Cscape E 9 pin OCS Programming Cable RJ 45 Programming Cable ocumentation HE500CBL300 OCS Programming Cable 9 pin female PC to RJ 45 OCS 6 feet HE500USB600 USB programming kit Includes USB to RS 232 adapter and 6 foot RS 232 cable with D sub connections Requires HE500CBL300 to program the XL6 OCS 2 5 Useful Documents and References The following information serves as a general listing of Horner controller products and other references of interest with their corresponding manual numbers Visit our website to obtain user documentation and updates Table 2 2 OCS Reference Document numbers Note This list is not intended for users to determine which products are appropriate for their application controller products differ in the features that they support If assistance is required refer to Technical Support Controllers H
137. tion Ground The term Ground is defined as 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 earth ground is 0 ohms In reality it typically is higher The U S National Electrical Code NEC states the resistance to ground shall not exceed twenty five 25 ohms Horner APG recommends ess than fifteen 15 ohms resistance from our equipment to ground Resistance greater than twenty five 25 ohms can cause undesirable or harmful interference to the device 4 3 How to Test for Good Ground In order to test ground resistance a Ground Resistance Tester must be used A typical Ground Resistance Meter Kit contains a meter two or three wire leads and two ground rods Instructions are supplied for either a two point or three point ground test Figure 4 1 shows a two point ground connection test GROUND RESISTANCE METER GROUND DISCONNECTED us E7 se ae T GROUND ROD METAL WATER PIPE OR OTHER GOOD GROUND Figure 4 1 Two Point Ground Connection Test March 4 2010 Page 23 of 135 1037 4 0883 05 4 4 Primary Power Port Table 4
138. to the 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 floor is 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 each use inspect all cables for breaks or cracks in the insulation Replace immediately if defective March 4 2010 Page 11 of 135 1037 CH 1 0883 05 1 2 Grounding Grounding is covered in various chapters within this manual 1 3 CE Compliance To check for compliance and updates visit our website at http www heapg com Pages T echSupport ProductCert html March 4 2010 Page 12 of 135 1037 MANO883 05 EN CH 2 CHAPTER 2 INTRODUCTION 2 1 Visual Overview of XL6 XL6e OCS USB Mini B USB 5 pin Removable Media programming port Memory 5 Mot present 100 HEXL350C 100 Ethernet XL6e only Figure 2 1 Visual Overview of XL6 XL6e type OCS Side and Rear Views Serial Comm Ethernet only March 4 2010 Page 13 of 135 1037 2 User Interface 2 1 1 2 1 4 March 4 2010 MANO883 05 EN Removable Medi
139. ttons or by directly touching an entry If more entries exist than can fit on the page a scroll bar is displayed on the right side that also indicates the current relative position File operations are accomplished by pressing the appropriate button at the bottom of the removable media viewer The configuration of the removable media object that invokes the removable media viewer defines what buttons are enabled and available to the user A button is grayed and does not respond to touch if configured as disabled The 4 Enter button if enabled performs certain operations based on the selected 5 type change display to parent directory DIR change display to child directory bmp jpeg display bitmap if compatible format pgm load application if compatible model and version Alternately the enter button can be configured to simply load the ASCII 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 is attempting to write to the removable media when it is removed the screen designer should create objects that allow the operator to temporally halt access to the removable medi
140. vent the Ethernet Module from communicating outside the local network set the Default Gateway IP Address to 0 0 0 0 the default setting Status Register Enter an OCS Register reference such as R100 to indicate which 16 bit OCS register will have the Ethernet Status word written to it Table 7 1 shows how this register value is formatted and explains the meaning of each bit in the Status Word March 4 2010 Page 33 of 135 1037 7 0883 05 Table 7 1 Ethernet Status Word Register Format High Byte Low Byte Bit Bit Bn 8 7 o JD Re m unc TOP Connections Status Bit s Status Indication Status Values Minimum Maximum Reserved 60 TCP Connections Total Number of Active TCP Connections 40 CsCAN SRTP Modbus EIP HTTP Version 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 Ethernet Module Register Usage Standard Configuration To perform Standard Configuration simply leave the Enhanced Configuration checkbox unchecked In this case Net Mask and Gateway cannot be assigned to OCS registers while IP Address Status and Version must be assigned to OCS registers Note that the assigned IP
141. ving the XL6 XL6e OCS 43 10 3 Model and Overview PR 45 10 4 Solid Slate Digital OUMU 46 10 5 46 10 6 HM 48 10 7 JArialodg Ipulsa22 dte di Haee vedo etd ene erea ia 48 10 8 Unversal Analog 49 10 9 Analog cr 49 CHAPTER11 HIGH SPEED I O HSC 51 11 1 51 11 2 High Speed Counter ASG Functions 51 ME Leo 51 Lee ne Me 51 UE CEN LU Ice rr T 52 uL Ee eir E US 53 11 3 HSO FUNCIIONS sedan aae esee ete ee t 56 11 4 Pulse Width Modulation PWM 56 AT oU Um 56 A2 PWN 56 1 4 HS0 High speed Counter sisi uii ho pe 58 TAA Mn cL 58 11 5 6 59 11 6 PANNEE XADI 6
142. wise Rotation 3 1 2 High Reset on 2 rising SYNC High Reset on 1 falling SYNC High Reset on 2 falling SYNC High Reset on 1 rising SYNC While not displayed in this figure modes for low level inverse logic are also supported for each state Figure 11 1 Sync pulse mode illustration The accumulator is reset to zero on the specified edge if rotation is clockwise as shown in figure 10 1 above However if rotation is reversed the accumulator is alternately set to Counts per rev 1 on that same physical edge When direction is reversed that same physical edge is seen by the internal decoder as having the opposite edge polarity as shown below EEN EENLIIC GR HSC1 HSC2 HSC3 Value Async Reset on rising edge 1 Async Resetonfalingedge Falig 0 Async Reset on both edge Boh 0 High Reset on 1 rising Clockwise Rising 0 ee Counter Falling 1 High CPR 1 Low Resetonirising Clockwise Rising Low 0 1 Counter Falling Low CPR 1 High Reset on 1 falling Clockwise Rising 1 High CPR 1 Counter Falling High 0 Low Reseton 1 falling Clockwise Rising Low CPR 1 March 4 2010 Page 55 of 135 1037 11 0883 05 po Falling Low 0 High Reseton2rising Clockwise Rising Hi
143. writing of a comma separated value file to the Micro SD interface from the March 4 2010 Page 41 of 135 1037 10 0883 05 controller register space c Rename RM csv This function allows renaming a file on the RM card The data in the file is not changed d Delete RM csv This function allows deleting a file on the RM card e Copy RM csv This function allows copying a file on the RM card The data in the file is not changed 9 9 Filenames used with the Removable Media RM Function Blocks The RM function blocks support the flash with a DOS Windows standard FAT 16 file system All names must be limited to the 8 3 format where the filename contains eight characters a period then a three character extension The entire filename including any path must be less than or equal to 147 characters When creating filenames and directories it is sometimes desirable to include parts of the current date or time There are six special symbols that can be entered into a filename that are replaced by the OCS with current time and date information Symbol Descipion 22 22 Note that all the symbols start with the dollar sign character Date symbols are in upper case time symbols are in lower case The following are examples of the substituted time date filenames Current date and time March 1 2004 3 45 34 PM Filename Data M D csv Data0301 csv Filename Year Y Month M aa D_ h csv Ye
144. y at a rate faster than the screen saver timeout value This be desired while waiting for alarm acknowledgement 13 11 Screen Brightness The XL6 XL6e provides a feature that allows screen dimming for night operation To enable this feature the application must access and control system register SR57 Display Backlight Brightness Screen brightness is continuously variable by driving SR57 through the range of 100 full bright to O full off is left to the screen designer on if and how to present a Screen Brightness control to the user Note that backlight life may be shorted when screen is dimmed or screen brightness is varied on a repetitive basis March 4 2010 Page 83 of 135 1037 13 0883 05 INTENTIONALLY LEFT BLANK March 4 2010 Page 84 of 135 1037 0883 05 14 CHAPTER 14 REGISTERS 14 4 Register Definitions When programming the XL6 XL6e OCS data is stored in memory that is segmented into different types This memory in the controller is referred to as registers Different groups of registers are defined as either bits or words 16 bits Multiple registers can usually be used to handle larger storage requirements For example 16 single bit registers can be used to store a Word or two 16 bit registers can be used to store a 32 bit value Below is a list of the type of registers found in the XL6 XLeM XL6e OCS 1 Analog Input 16 bit input registers used to gather analog inpu
145. y and contact Technical Support Battery Cover Figure 18 1 Back Cover Replacing the back up battery March 4 2010 Page 126 of 135 111037 0883 05 19 CHAPTER 19 TROUBLESHOOTING TECHNICAL SUPPORT Chapter 18 provides commonly requested troubleshooting information and checklists for the following topics Connecting to the XL6 OCS controller Local controller and local I O CsCAN Network Removable media In the event that this information is not what you need please contact Technical Support at the locations indicated at the end of this chapter 19 1 Connecting to the XL6 XL6e OCS Cscape connects to the local controller automatically when the serial connection is made The status bar below shows an example of a successful connection This status bar is located in the bottom right hand corner of the Cscape window Local 253 Target 25318 Forces In general the Target number should match the Local number The exception to this is when the controller is being used as a pass through unit where other controllers on a CSCAN network could be accessed through the local controller Determine connection status by examining feedback next to Local amp Target in the status bar of Cscape Local If a number shows next to Local then communication is established to the local controller Cscape is unable to access the COM port of the PC This could mean that Cscape is configured for a COM port
146. ystem Settings are editable the first System Setting that can be edited is highlighted If desired the 4 and 7 keys can be used to select a different System Setting to be edited At this point either press ESC to exit the Sub Menu returning to the Main Menu or press Enter to edit the 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 oetting s value use either the arrow keys TM t lt 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 pressed a new possible value is displayed When the desired value appears press the Enter key to save it otherwise press the ESC key to cancel the edit The numeric keys are normally used to enter numeric System Settings In addition to edit a single numeric digit use the lt or key to select the digit and then either press numeric key or use J 7 to modify the digit In any case after entering the new desired value press the Enter key to save it otherwise press the ESC key to cancel the edit March 4 2010 Page 62 of 135 1037 0883 05 12 12 3 System Menu Details The following sections describe each of the Sub Menus in detail Set Network ID Hetwork ID This Sub Menu displays

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