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1. waa 26 4 2 Ground SpeCificAatiONS ccccccsseeccecscsseeeeesccssececesccsseeceescceseeeeecccsseeceecccsseeeescccsseeeessccseeeesssccens 26 4 3 Howto Test for Good Ground 26 Aa Piman IUD EYES RU CEPR 27 CHAPTER 5 SERIAL COMMUNICATIONS 28 E nee 28 52 FO 28 Oso Serd POM PIM iei EE TUE 28 Do WO 28 5 6 Cscape Programming Serial Port 29 5 7 Ladder Controlled Serial Communication 29 58 Downloadable Serial Communication Protocols 29 CHAPTER 6 CAN COMMUNICATIONS 0 ccccccesssensseeeeceeeeccnnsseeeeeeeeeconaaseeeeeeeesoonaaseeeseeeeeoonsnseeeees 30 Page 5 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual MEG E eee ee eee 30 POM SS Ci OI PI TOTEM 30 6 3 Cscape Programming 31 6 4 Ladder Controlled CAN Communication
2. Base Selector 0 7 965864 SS STATUS SmartStack Base Status 0 2 SR65 76 SS INFO 1 0 Module 1 Information Eo tructure SR77 88 SS INFO 2 SN I O Module 2 Information eo tructure SR89 SmartStack I O Module 3 Information Smene 0 E _ SR101 SmartStack I O Module 4 Information ER Smene ue E _ GOBJ SIZE Graphics Object Table Size DN 256K cds GSTR SIZE Graphics String Table Size NE 128K GBMP_ SIZE Graphics Bitmap Table Size 256K GTXT SIZE Graphics Text Table Size NE 128K GFNT_SIZE Graphics Font Table Size E 256 PROT SIZE Protocol Table Size ee ee eee 9658126 Graphics String Table CRC 65535 9658127 GBMP Graphics Bitmap Table CRC O 65535 9658128 GTXT CRC _ Graphics Text Tabe CRC O 04 65535 9658129 GFNT GraphicsFontTableCRC O 65535 9658130 PROT Table CRC 0 X 1655385 LU mee Read bit indicating Auto Restore of Register pee Read bit indicating Backup of Register Data has been performed Fail Safe SR164 5_ Enable AUTORUN Fail Safe 95581646 AUTOLOAD Fail Safe 96581647 JBackptrggerbt 96581648 Clear Back
3. 46 10 2 System Menu Navigation and nennen 46 10 4 TOUGHT screen calibrati RR RETRO 56 CHAPTER 11 USERINTERFACE cor 57 11 1 OV OI VIE MEMT 57 11 2 Displaying and entering 57 11 3 Alpha numeric keypad ddim 58 11 5 Ladder Based Screen Navigation 60 11 6 Beeper 60 11 7 Touch Slip Sensitivity E M 60 11 8 TAN 61 1110 Sereen Savel shack 6 63 CHAPTER 12 REGISTERS cirine a i a a a a 64 12 1 Register 64 12 2 Useful 955 SR registers 64 12 4 Resource 67 CHAPTER 13 CSCAPE CONFIGURATION sesceeeeeecceccsnnssseeeeeeeeconsnseeeeeeeeeoonasseeeeseeseconssseeeees 69 13 1 COU CNW 9 O 69 13 2 O Cape BAT RR EE 69 13 3 Establishing Communications lssssssesssssessseeeeeeene nennen nennen nnne nnns nnn nnns 70 13 3 1 Co
4. 74 FIQUIC 16 5 Clear Backup Dala 74 Figure 16 6 Flow Chart for Automatic 75 16 7 76 Figure 16 8 Flow Chart for AutoLoad 78 Figure 16 9 SN 78 PIOUS YAN EE Ium 79 Figure 17 2 Clone Unit Menu before 79 Figure 17 3 Clone Unit Confirm Screen osise ncini eaei A ENE EE EAE EEE Taaa ai 80 Figure 17 4 Ee TBM 80 Figure NN T 81 Figure T70 3V3 NIU UERRMEREORE 81 Figure 17 7 Clone Unit Menu after 82 Figure 17 8 Load Clone Confirm 82 eonim Pm 83 Table 2 1 ZX OCS Y 15 Table 2 2 OCS Reference Document Numbers 15 Table 3 1 Minimum Clearance Requirements for Panel amp DOOF 19 Table 4 1
5. 31 6 5 Using CAN for I O Expansion Network I O sese 31 CHAPTER 7 ETHERNET _ 32 7 1 Ethernet Module Protocols and nnne nnne 32 7 2 Ethernet System 32 7 3 Ethernet Module Specifications 32 re MEE i 8 E TI 32 CHAPTER 8 REMOVABLE cine dn sun utc caule usu um uidetur sv UC 36 36 8 2 Removable Media File 36 8 3 Using the Removable Media Manager 37 8 4 Using Removable Media to Log 37 8 5 Using Removable Media to View and Capture Screens 38 CHAPTER 9 REMOTE I O __ 40 9 1 Configuration of ETX200 SmartRail Base and Modules 40 9 2 Configuring Other using SO AN eiut idees 42 CHAPTER 10 SYSTEM SETTINGS AND nnn nnn nnns 46 10 1 ex MI PERITI c
6. EAB 16 Digital Outputs Start 12 00001 M ame 0 BP x15 Analog Inputs Start zT M ame Andodnpul d BIT Analog Outputs Start 280001 M ame Andog upul 9 Note When configuring Initial I O start registers take into consideration other I O modules in the system and the registers they use If the SmartRail is the first added to the network as in above example then make 1 the starting register The modules added to the base will automatically assign registers for the inputs and outputs Click OK Now Add the appropriate modules to the bases Click Add Module 6 Select the appropriate module to add from the menu lists in order from first to last beginning with the first module added to the base on Note Total of up to 8 with less than 1500 mA of draw per base calculated in hardware configuration automatically allowed Analog modules and relay modules use more power so keep this in mind when configuring a bases Depending on the Modules added to the base the Registers will accumulate automatically as highlighted below Page 41 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Controller Local 1 0 CsCAN CAN2 CsCAN LAN1 1 0 LAN2 192 168 254 129 200 SE 200 606 607 Status Register AONT Base Information Input Map 10001 10016 Output 00001 00032 2AG001 2AG002 Curent
7. eene nennen 85 17 1 Connecting PM eee ere 85 17 1 3 Connecting Troubleshooting Checklist ETN port programming 86 17 2 ico ana keene een eee 86 17 2 1 Local Troubleshooting 86 17 3 COI SERERE 87 17 3 1 Network Troubleshooting 87 17 4 Removable Media Basic Troubleshooting 87 17 5 Techricaloupport COMACIS 87 EUAN a e e gt 88 Page 7 of 91 HORNER AUTOMATION GROUP ZX User Manual Visual map of major tasks and the key chapters FIRST STEP of ANY TASK DATASHEET Each ZX OCS unit is sent with a datasheet in the box The datasheet MAN0960 04 EN is the first document to refer to for model specific information related to ZX OCS models such as pin outs jumper settings and other key installation information To obtain updates to datasheets manuals and user documentation visit a Horner website US http www heapg com and Europe http www horner apg com QUICK START INSTALLATION PROGRAMMING TROUBLESHOOTING page 11 page 11 page 11 page 11 age 13 page 13 page 13 page 13 page 16 page 28 page 83 page 26 page 30 page 85
8. page 32 Media page 36 Remote I O e 40 Settings page 46 Interface page 5 page 64 Configuration page 69 Fail Safe page 2 Unit page 9 8 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual INTENTIONALLY LEFT BLANK Page 9 of 91 IM HORNER AUTOMATION GROUP ZX User Manual 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 a defective condition that will not clear by replacing the fuse WARNING EXPLOSION HAZARD Substitution of components may impair suitability for Class Division 2 WA
9. 4 Modbus ASCII 9eSR35 36 SERIAL NUM This Station s 32 bit Serial Number 0 27 1 9eSR37 MODEL NUM This Station s Binary Model Number 0 165535 9eSR39 CPLD REV BIOS Rev Number 100 000 255 9eSR40 FPGA_REV__ FPGA Image Rev Number 10 00 X 255 368841 LCD COLS Vertical Pixel 9eSR42 LCD ROWS HorizontalPixelCount o J 366843 KEY KeypadType 366844 SEC ReakTime Clock O0 59 9eSR45 0 159 9eSR46 HOUR Real Time Clock Hour 0 123 MON RealTime Clock Month __ 5 50 RTC DAY Real Time Clock Day 1 Sunday 1 7 NET CNT Network Ever fess SR52 WDOG_CNT Watchdog Tripped Error Count 0 165535 SR53 54 BAD_LADDER Bad Ladder Code Error Index 0 65534 SR55 ele Filtered Bit Mapped Self Test Result o 65535 Page 65 of 91 HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Table 14 3 SR Registers Register Description MinVal Max Val 95856 LAST KEY Key Code of Last Key Press or Release 0 255 LCD Backlight Dimmer Register BAK_LITE 0 0 25 25 100 255 100 ens 9eSR58 USER LEDS User LED Control Status 0 65535 SR59 60 Reseved 965863 SS
10. 5 v Shift Space Enter Figure 11 2 Alpha numeric Keypad and ASCII 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 unchanged and the alpha numeric keypad disappears Page 58 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 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 alt
11. Once the panel design has been completed using the criteria and suggestions in the following sections use the following steps to panel mount the ZX OCS 1 Remove all connectors from the ZX OCS unit 2 Make sure the gasket is installed on the ZX OCS and is free from dust and debris Check that the corners of the gasket are secure 3 Pass the unit through the panel 4 Insert each of the four 4 mounting clips on the ZX452 or a minimum of 8 mounting clips on the ZX752 and 10 ZX1152 into the slots in the ZX OCS case Lightly tighten 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 in a criss cross pattern start with top left corner then move to bottom right corner etc Recommended torque is 7 10 Ib in 0 8 1 13 Nm Page 16 of 91 IM HORNER AUTOMATION GROUP 3 3 Mounting Orientation PRELIMINARY ZX User Manual 3 3 1 ZX OCS Mounting Clip Slot Locations VESA Mount Option 969 e L e oe 8 Clips fit in to parallel slots on the unit The clips tighten the unit against the inside of the panel Tighten the screws on the clips such that the gasket is compressed against the panel Recommended torque is 7 10 Ib in 0 8 1 13 Nm The screw should be level and the mount should be perpendicular to controller If the screw is angled or not flush with panel when tightened to spec ensure proper
12. Primary Power Port 8 23 Table 7 1 Ethernet Module Protocols amp Features 28 Table 7 2 Ethernet Module nennen nennen nnne nnn 28 Table 7 3 Ethernet Status Word Register 33 Table 8 1 XL Series COM Options nennen nnnm nnn nnns nsn naar nnn nnns nena 33 Table 9 1 Filename Special 33 Table 9 2 Status e Erie CR 37 Table 10 1 O amp Model OVeVIGW coute tea nosque iue tes 40 Table 11 1 Glossary of Speed l O Terms 44 Table 11 2 HSC Functions Register Map iiie teta plaisance tian le ae 48 Table 11 3 PWM Functions Register Map sccccccccsssssecceceeessceeeceeeeeceeesseaeeeeessaaaeceeessaaseeeessaaaeeeees 51 Table 14 1 Type of Registers found in the ZX 74 Table 14 2 Common S Register Definitions nennen nennen 74 Table 14 3 74 Table 14 4 Register for ZX 77 Page 90 of 91 IM HORNER AUTOMATION GROUP ZX User Manual Table 14 5 Resource 77 Tab
13. No CAN network bus off errors have occurred x Number of CAN network bus off errors that have occurred Network State Warning No other nodes wore ound on he CAN network Warning No other nodes were found on the CAN network Network Warning This node s GAN Network ID was out of range at powerup _ 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 another node Page 48 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Ok Time and date have been set Warning Time and date need to be set Svstem Ok 1 0 configuration matches the installed I O COM modules y Warning configuration needs updating to match installed modules Batter Ok Backup battery operating properly d Warning Backup battery needs to be replaced View Protocols System Menu Port 1 a None Loaded lt gt Esc Enter 1 LN E E qn geo o The View Protocols Sub Menu displays two System Settings neither of which may be edited As mentioned in 0 both the MJ1 MJ2 Port 1 and MJ3 Port 2 serial ports support downloadable protocols To assign a downloadable protocol to an ZX OCS serial port select the Protocol Config item in Cscape s Program menu and then set up a protocol for Port 1 or Port 2
14. Total Number of Active TCP Connections e CSCAN SRTP Modbus EIP FTP HTTP Page 35 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 8 REMOVABLE MEDIA 8 1 Overview All ZX OCS models provide dual USB drives for increased storage and functionality Flash storage drives can be used to save and load applications to update firmware to capture graphics screens and to log data for later retrieval Note The USB ports on the ZX units are not designed for Programming with Cscape The drives Drive A and Drive B serve different primary functions for the controller Drive A is the primary port for data logging program or application saving and loading cloning firmware updating and screen shot saving Drive B is mainly used for alternate Removable Media Function Blocks in ladder logic USB USBB USBA Figure 8 1 Removable MicroSD Memory Card Slot ZX452 top and ZX752 1152 bottom 8 2 Removable Media File System The MicroSD Memory slot uses the PC compatible FAT32 File System This means that a PC with the USB driver for the storage device installed can read files that have been written by the ZX OCS and can write files that can be read by the ZX OCS However the ZX OCS does not support long filenames 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 chara
15. Signal Description Direction CD Carrier Detect IN GND DSR ON _ Ground DSR Data Set Ready O N Ceartosend IN m Ringindicate N _ Serial Port 2 Pin Assignments RS 485 Signal Signal Description Direction In Out DoNotConet NC DoNotConnect GND gt DSR DataSetReady RIS RequesttoSend OUT S RTS S CleartoSend IN 5 5 RS485 Biasing RS485 biasing passively asserts line idle state when no device 15 actively transmitting which is useful for multi drop RS485 networking The Set Serial Ports item in the System Menu can be used to enable RS485 biasing Also an application graphics screen that writes to SR164 can do the same thing Setting SR164 1 enables MJ2 biasing and setting SR164 2 enables MJ3 biasing Page 28 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual If biasing is used it should be enabled in only one of the devices attached to the RS485 network 5 6 Cscape Programming via Serial Port The ZX Supports CSCAN Programming Protocol If a PC COM port is connected to the ZX OCS RS232 serial port 1 Cscape can access the ZX OCS for programming and monitoring If connecting via Serial Port for programming it is important to use a Null Modem connection Programming can also be done via the CAN port or Ethernet port as covered in the following chapters 5 7 Ladder Controlled Se
16. set Beeper Set Screen Removable Hedia Fail Safe System Clone Unit Figure 17 6 System Menu 2 Selecting Clone Unit menu will open the following menu screen Select Load Clone Page 81 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Clone Unit DAT 24570 092 14 09 12 11a Free 1004208128 Total 1004257280 Load 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 180805208128 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 operation 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
17. 13 3 Reactor Temper ature screen jumps can also be triggered on other keys or based on control logic for more advanced applications To allow the operator to change screens a screen jump object is generally used This object may be visually represented as a button responding to touch or remain invisible and logically tied to an OCS register An optional system ICON may be configured for display along with the legend which aids in identifying the object as one that causes a screen change Page 59 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 11 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 1 Force Screen 1 1000 Screen 1 Input 2 Switch Screen 2 210002 Screen 2 Figure 11 4 Force and Switch Coils in Ladde
18. 4 Once the cloning is successful OCS gives a message as below Page 80 of 91 AUTOMATION GROUP PRELIMINARY ZX User Manual Clone Unit Cloning Status SUCCESS MAKE CLONE operation Ok Free 1880522551 Total 1004257280 E Hake E Clone 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 15 3 Load Clone This option loads the application all unit settings and register values from Removable media to the Battery backed RAM Regardless of AutoLoad settings and then resets the OCS for the settings to take effect User needs to perform the following to Load Clone 1 Select Clone Unit from main system menu of OCS as shown below Set Hetwork ID Set Hetwork Baud View Status View 012905 View 1 0 Slots View Protocols set Fkeys Set Serial Ports Set Time Date
19. Draw 620 1500 mA More Info gt gt Add Module 7 Several bases can be added with similar steps just ensure a unique address is used for each base Whenever another base is added the configuration will automatically update the initial I O registers depending on the base previously added Example if base 1 ended at 10016 and Q016 base 2 would start automatically at 910017 and 9610017 8 Ensure the ZX OCS has proper I P address entered on the Set Networks tab in the System Menu 9 2 Configuring Other I O using CSCAN CsCAN I O can also be configured to the two CAN port options that become available when using the single six port to two five port adapter as seen below wy 81069 20 To configure the CSCAN network 1 Go to Hardware I O or CAN2 depending on which port used 2 Click Add 3 Select CAN I O module from the available menus Example Smartblock HE579DIQ880 Page 42 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Add CsCAN Select Model SmartR ail SmartStis SmartBlack Other 790101880 a DEIN Relay HES SDI 881 8 OC Out HEBBS3D UM opt Helay 55H HEB SALM 300 AL EnengyPower Monitor 302 AL Energy Power Monitor 102 12pt DC In Relay 4 Analog In HES SSM 1 02 11 1zpt DIE Relay 1 Thermistor 3 m amp Analog In HES PSM 02 12 1zpt DIE In
20. Slot ZX452 top and ZX752 1152 bottom 36 Foue ThI Eam 57 Figure 11 2 Alpha numeric Keypad and ASCII Keypad 58 Figure 13 3 Typical Screen Jump 59 Figure 11 4 Force and Switch Coils in Ladder nnne nennen 60 Figure 133 A m M 61 RO VIC WEY a x 61 Figure 1 3 7 Hemovable Media ODIBGL siete aa qu tuo 62 Figure 13 8 Removable media 62 Figure 13 9 Example application segment for safe removal of removable media 63 Figure 16 1 Fail Safe System 72 Figure 16 2 Backup Heslore Dla ecu encre Heron cni cott un acuta E 73 Figure 73 Figure 16 4 Restore OCS inns iss assa
21. USB Flash drive rename one of the following files to syslinux cfg syslinux cfg zx452 upgrade 7 ZX452 syslinux cfg zx752 upgrade a 15 ZX752 syslinux cfg zx1152 to upgrade a 22 ZX1152 Plug the USB Flash drive into a powered up ZX Touch the upper right hand screen corner to slide out the control panel Press and hold the F5 key until the Boot Installer screen appears Press the Install Bootloader button and then press Yes When Operation Completed appears press OK Power cycle the ZX and wait for it to boot up Touch the upper right hand screen corner to slide out the control panel Press SYSTEM select View Status and press the Enter button Scroll down to see the versions numbers which should be Tom Oo AO Page 83 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Firmware Rev 14 02 BIOS Rev Depends on Model CAN Rev 0 05 InitRD Rev 1 01 OS Ver 3 1 4 01 Note Different firmware versions will reflect different values If any of the version numbers are incorrect verify the correct files were copied to the USB Flash drive and repeat steps c through k Page 84 of 91 HORNER AUTOMATION GROUP ZX User Manual CHAPTER 17 TROUBLESHOOTING TECHNICAL SUPPORT Chapter 17 provides commonly requested troubleshooting information and checklists for the following topics Connecting to the ZX OCS controller Local controller and local I O CsCAN Network Removable
22. application ladder program can use Rename and Delete Removable Media function blocks to rename and delete files 8 5 Using Removable Media to Load and Save Applications A special file type with a PGM extension is used to store ZX OCS application programs on MicroSD To load an application from Flash Drive to the ZX 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 Fl To save an application from the ZX to Flash storage open the Removable Media Manager in the System Saue Menu and press the Save 9 function key The application will be saved in a file called DEFAULT PGM in the MicroSD root directory NOTE Saving an application to Flash 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 flash drive which is plugged into the PC s compatible USB port by selecting the Export to Removable Media item on the Cscape File menu Page 37 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 8 6 Using Removable Media to View and Capture Screens The OCS File System uses bitmap files with the BMP extension to store XL6 e XL10 OCS graphic screen captures To view a captured OCS screen 1 Open the Removable Media Manager 2 Find an
23. bit is set to 1 by the firmware and never reset Page 82 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 16 MAINTENANCE 16 1 Screen Cleaning The screen and overlay on the ZX OCS should be cleaned with a damp soft cloth and dried appropriately The unit should be powered down for screen cleaning It is not recommended to use harsh chemicals or abrasives on the screen and overlay as they may cause damage to the unit 16 2 Firmware Updates Overvew The ZX controller firmware is updated by a bootloader using USB Flash drive not through the Cscape Firmware Update Wizard To update or change firmware 1 Save Firmware files to USB 2 Update the firmware through the controller s Firmware Update function Configuration 1 Visit www heapg com and click LOG IN an account is required to access firmware updates create one if necessary Go to Support Controller Firmware and download the most recent firmware set with the correct communication protocol OR Visit http www horner apg com en download ocs aspx and click the Firmware tab In and download the desired firmware an account is required to access firmware updates create one if necessary Note The following process will clear the application program Make sure to back up before updating firmware 2 Update firmware in a ZX by completing the following steps a Unzip all files from step 1 s downloaded zip file onto a USB Flash drive b Onthe
24. 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 5 5 is enabled Touch Calibration Screen Please touch extreme Top Right corner point Page 56 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 11 USER INTERFACE 11 4 Overview This chapter presents the user interface or operator view of the ZX and some of the model specific characteristics of the ZX 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 The following aspects are discussed e Displaying and entering data e Alarm log dialog e Alpha numeric data entry e HM dialog e Navigating around screens e Screen Saver e Beeper acknowledgement e Dimmer e Touch slip sensitivity 11 2 Displaying and entering Data Brew Kettle 2 T n n Back to Graphics Menu Door Closed Door Open g 5 e a a8 Figure 11 1 Example Screen Page 57 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Multiple objects are provided for displaying data such as virtual panel lights push buttons numeric value displays bar graphs meters graphs and animated bitmaps On the ZX these graphical objects through la
25. media In the event that this information is not enough please contact Technical Support at the locations indicated at the end of this chapter 17 1 Connecting to the ZX 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 If a number shows next to Local then communication is established to the local Local controller Cscape is unable to access the COM port of the PC This could mean that Cscape is configured for a COM port that is not present or that another program has control of the COM port Only one Cscape window can access a port at a time Subsequent instances of Cscape opened will indicate No Port l Cscape has accessed a PC COM port but is not communicating with the controller Local No Com i This typically occurs when the controller is not physically connected Local Port Local Unknown communication error Close Cscape power cycle the contro
26. of certain types of soft failures These soft failures include Battery power loss Battery Backed Register RAM or Application Flash corruption due to for example an excessive EMI event The Fail Safe System has the following capabilities Manually backup the current Battery Backed RAM Register Settings into Flash memory Manually restore Register Settings from the values previously backed up in Flash to Battery Backed RAM Detect corrupted Register Settings at power up and then automatically restore them from Flash Detect corrupted or empty application in Flash memory at power up and then automatically load the AUTOLOAD PGM application file from Removable Media Compact Flash or MicroSD 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 oafe 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 System Menu Enable AutoRun Enable Autoload ESC to exit Figure 16 1 Fail Safe System Menu 14 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 oystem Menu options 2 From Cscape create AUTOLOAD PGM for the application program using E
27. 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 file s type Change display to parent directory change display to child directory bmp jpeg display bitmap if compatible format load application if compatible model and version Page 62 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 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 media This prevents corruption to the file system if the removable media is removed during a file write sequence The g
28. or both In the View Protocols Sub Menu the currently downloaded protocol if any and its version number are displayed for each of MJ1 MJ2 COM board and MJ3 Set Fkeys Mode System Menu Momentary o A Fkeys SYS Fn enable Yes lt gt ES Jte se EA ET S E The Set Fkeys Sub Menu displays two System Settings both of which may be edited Fkevs Momentary 1 5 bits go On amp Off as F1 F5 are pressed amp released y Toggle 1 5 bits toggle each time F1 F4 are pressed Yes Reset and all clear system functions enabled dus No Reset and all clear system functions disabled Page 49 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Set Serial Ports System Menu DF1t Port 1 Use 47 to adjust D Esc Enter E Je ea E s xg a The Set Serial Ports Sub Menu displays three System Settings all of which may be edited and one optional item For the Dflt Pgm Port System setting only MJ1 232 can be selected unless a Modem XMC COM module is installed Dflt Pam Port MJ1 232 MJ1 RS232 port is the default programming port 9 Modem Modem COM module is the default programming port No MJ2 RS485 bias resistors are not switched in ARE Sues EES Yes MJ2 RS485 bias resistors are switched in No R5485 bias resistors are not switched in RS485 Bias Yes MJ3 R5485 bias resistors are swit
29. orientation The ZX1152 and ZX752 also support standard VESA 75x75 or 100x100 mounting for wall or arm mounting The ZX452 supports the VESA 75x75 mounting pattern 4mm screws should be used and are typically supplied with the mount VESA Mount ZX1152 shown Page 17 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 3 3 2 ZX OCS Panel Mounting Orientation Figure 3 3 General Orientation of OCS NOTE There are no orientation restrictions on the ZX OCS However the above orientation provides for optimum readability of the screen and ease of use of the keypad 3 4 Panel Cut Out ZX1152 Panel Cutout The tolerance to meet NEMA standards is 11 81 0 005 0 1 mm Max panel thickness 5 mm 3 00m m e Refer to the User Manual MANO0883 for panel box information and a checklist of requirements 19 84 125 3 mm TYP RADIUS 504mm CORNERS WHEN REQUIRING DUST OR WATERTIGHT SEAL PERNEMA 4 4X 12 Page 18 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual ZX752 Panel Cutout I gt e The tolerance to meet NEMA standards is 10 75 0 005 0 1 mm 273 m m e Max panel thickness 5 mm Refer to the User Manual 883 for panel box information and a checklist of requirements 14 49 368mm ZX452 Panel Cutout 5 24 Thetolerance to meet NEMA standards is 133mm 0 005 0 1 mm panel thickness 5 Refer t
30. specifications of attached devices 4 Proper termination is required Use 121 ohm or 120 ohm resistors at each end of the network The resistors should placed across the CAN and CAN LO terminals 5 Measure the resistance between CAN and CAN LO If the network is properly wired and terminated there should be around 60 ohms 6 Check for duplicate node ID s 7 Keep proper wires together One twisted pair is for V and V and the other twisted pair is used for CAN and CAN LO 8 Make sure the baud rate is the same for all controllers on the network 9 Assure shields are connected at one end of each segment they are not continuous through the network 10 Do not exceed the maximum length determined by the baud rate and cable type 11 Total drop length for each drop should not exceed 6m 20 feet A drop may include more than one node The drop length adds to the overall network length 12 Network should be wired in straight line fashion not in a star pattern 13 In applications requiring multiple power supplies make sure the V of all supplies is connected together and to earth ground at one place only 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 17 4 Removable Media Basic Troubles
31. 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 6 Alarm Viewer The currently selected entry is indicated by a yellow highlight which can be moved up or down by touching the arrow buttons or by directly touching an entry 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 ACK RTN The operator can acknowledge an alarm by selecting it from the list and touching the ACK button The operator can also clear an alarm if that function is enabled in the alarm object If not enabled the Clear buttons are grayed and do not respond to touch Once view operations are complete simply touch the Esc button to remove the pop up alarm viewer Note that OCS registers 955 181 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 Page 61 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 11 9 Removable Media The removable media object is generally used to inform the operator on the current state of the
32. 6 Relay 2 Thermistor 2 Analog In HES SSM 102 13 1zpt DE In 6 Relay 3 Thermistor 1 ma Analog In HES 02 14 1zpt DC In bpt Relay 4 Thermistor In 105 12pt DC In 12pt DC Out 2 2 Univ Analog dich m Analog In zch m Analog Out HEBZSMISS ech may Analog In 4ch Analog Out dch m Analog Out HEB SDAL2U ech ma Analog Out 100 dch In HES SR TO 200 ach In 100 ich Thermocouple In HEB STHHM 200 ech Thermocouple In HEB SADLESU Tech m Thermistor Analog In mv Thermistor analog In Cancel 4 Press 5 Configure the following options in the Configure Digital Network I O window Field Description MEME purposes Select whether to utilize positive default or negative logic active mode Start digital In Starting register for the Digital Inputs on the Module Start digital out Starting register for the Digital Outputs on the Module Status register Status register for the module see below Update method Update on change of state Updates when the value of the input changes Update periodically Updates at a set interval 100 mSec 25 5 Sec Comm Timeout Maximum time the module will wait to indicate or act on communication before timing out Set between 400 mSec to 25 5 Sec Page 43 of 91 IM HORNER AUTOMATION GROUP P
33. 6 Using CAN for I O Expansion Network I O Connecting Network I O devices SmartStix SmartBlock or SmartRail to the ZX OCS CAN2 port allows the ZX OCS I O to be economically expanded and distributed A variety of modules are available for this purpose Page 31 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 7 ETHERNET COMMUNICATION 7 1 Ethernet Module Protocols and Features The following table describes the Ethernet Module Protocols and features supported by ZX Protocol Feature Protocol Feature Description CMP Ping EGD Peer SRTP Server CsCAN TCP Server Modbus TCP Slave Ethernet IP Server FTP Server HTTP Server HyperText Transfer Protocol Web Server Table 7 1 Ethernet Module Protocols amp Features 7 2 Ethernet System Requirements Full Ethernet functionality requires PC running Cscape Programming Software Version 9 3 SP6 or later for configuration ZX FTP amp HTTP protocols 7 3 Ethernet Module Specifications Speeds 10 BaseT Ethernet 10 Mbps 100 BaseTx High Speed Ethernet 100 Mbps Modes Auto Negotiation Connector Type Shielded RJ 45 us IU ded 5 or better UTP Port Auto MDI MDI X Auto Crossover Table 7 2 Ethernet Module Specifications 7 4 Ethernet Configuration Note The following configuration is required for all applications regardless of the protocols used Additional configuration procedures must be performed for each protocol
34. 600 ZX 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 controller s System Menu If there are difficulties connecting make sure that the default programming port is set correctly with the connection method being attempted Connecting Troubleshooting Checklist ETN port programming Programming and debugging must use MJ1 or Ethernet Port Controller must be powered up Ensure that correct IP address is given in the Ethernet field and correct Mode is selected in Cscape Tools Editor Options Communications Port Ensure that the Ethernet Cable is connected between the controller and the Ethernet Hub Make sure the Ethernet cable is functioning properly Local Controller and Local I O The system menu provides the following status indications that are useful for troubleshooting and system maintenance To view the system menu press the System key 17 2 1 self test results diagnostics RUN and OK status Network status and usage Average logic scan rate Application memory usage Loaded firmware versions Loaded protocols Removable media access Local 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 Check data sheets to in
35. 7 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual SMS File Size x Number of bytes in application SMS protocol configuration Self Test Ok All power on self tests passed Fault One or more power on self tests failed Bitmap Size x Number of bytes in application bitmaps View Diags System Menu Logic Error o p gt 2s Ea EAEI EJ N a Warren The View Diags Sub Menu displays up to 11 System Diagnostics none of which are editable The first two System Diagnostics are critical If either of these indicate a Fault condition the ZX OCS will not enter or remain in Run mode and the problem must be investigated and corrected LOGIC ENOT Ok All executed ladder instructions are legal for loaded firmware g Fault A ladder instruction not supported by firmware was found Ok Ladder program and 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 these indicate a warning condition the ZX OCS can still enter and remain in Run mode but the problem should be investigated and corrected Ok Application graphics objects loaded successfully User Graphics Fault Application graphics objects not loaded or load failed 0 Watchdog timer has not tripped since the last power up Number of times watchdog timer has tripped 0
36. CAN Networks Screen Mirror and CAN2 USB Port B Secondary functions RM etc Port 2 5485 Port 1 RS 232 USB Port A Ethernet Port1 Ethernet Primary datalogging Rec Cscape Programming Port2 Primary 1 0 screen capture program loading recipes IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 2 1 1 Where to Find Information about the ZX OCS a Datasheet The datasheet is the first document to refer to for key information related to specific ZX OCS models a datasheets for all ZX OCS models are available on the Horner websites b Datasheets contain pin outs and other model specific information b User Manual This manual provides general information that is common to ZX OCS models and can be downloaded from our web Visit the Horner website US http www heapg com or Europe http www horner apg com to obtain further user documentation and updates 2 1 2 Four main types of information are covered in this manual a Safety and Installation guidelines instructions Mechanical and Electrical b Descriptions of hardware features a Ports Removable Media Communication Options etc c Configuration and Use of the ZX OCS d Maintenance and Support 2 1 3 Manual Index Major topics of interest may be found in the Index towards the end of this manual 2 1 4 Table of Figures Location of important drawing illustrations etc may be found in the Table of Figures 2 2 C
37. Clone brings up the confirmation screen Upon confirmation the OCS will create two new files in the root directory of the Removable Media Drive as shown below Clone Unit Clone Unit Clone Files DAT 24570 07 14 09 12 11 Are You Sure Ok Cancel Free 1004257280 Total 1004257280 Free 18005208128 Total 1004257280 Load Hake Load Hake V A Clone Clone Esc Clone Clone Esc AUTOLOAD PGM Application file CLONE DAT File having all unit settings and register values from Battery Backed RAM Load Clone Selecting Clone Unit menu will open the following menu screen Select Load Clone Clone Unit 24570 97 14 09 12 11a Free 18805208128 Total 1004257280 Load Hake Clone Clone V Esc NOTE For security enabled files Load clone asks for password validation before loading the application Page 55 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 10 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 1 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
38. I Grounding is also for the safety of the user 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 less 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 GROUND RESISTANCE METER GROUND LL Od DISCONNECTED 6 FROM SERVICE X ry 0777777 p 1 GROUND ROD METAL WATER PIPE OR OTHER GOOD GROUND Figure 4 1 Two Point Ground Connection Test Page 26 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 4 4 Primary Power Port Table 4 1 Primary Power Port Pins Signa Description o Input power supply ground Input power supply positive voltage Power Connector Power Up Connect to Earth Ground Apply 10 30 VDC Screen lights up Torque rating 4 5 7 Lb In 0 50 0 78 N m 10 30 VDC su
39. ION 70 datasheet 8 Default Gateway 34 Devices to Connect to XL6 13 Dimensions 20 ELECTRICAL INSTALLATION 26 Ethernet 65 71 87 Ethernet Communication 32 Ethernet Module Default Gateway 34 IP Address 34 Net Mask 34 Status Register 34 Ethernet Module Configuration 32 Ethernet Module Protocols and Features 32 Ethernet Module Specifications 32 Ethernet System Requirements 32 Fail Safe System Overview 73 ZX User Manual Fail Safe System Settings 73 Features 14 Firmware Updates 84 Ground Specification 26 Grounding Locations of Information 10 Grounding Definition 26 IP Address 34 LIMITED WARRANTY 3 Load Clone 56 82 Maintenance 80 84 Make Clone 80 Manual Index 13 Mechanical installation 16 Micro SD System 36 Minimum Clearance Requirements for Panel Box and Door 23 Mounting Orientation 17 Mounting Requirements 16 Panel Door Mounting 16 Net Mask 34 OCS Reference Document Numbers 14 Orientation of ZX OCS 18 Panel Box Clearances 23 Grounding 23 Noise 23 Orientation 23 Temperature 23 Panel Box Shock and Vibration 23 Panel Cut out 18 Panel Cutout Tolerances 19 Panel Design Checklist 24 Panel Layout Clearances 23 Panel Mounting of an ZX Series OCS 16 Power Connector Primary Power Port 27 Primary Power Port 27 Primary Power Port As Viewed Looking at the ZX OCS 27 Primary Power Port Pins 27 PROGRAMMING EXAMPLES 3 References Useful documents 14 registers 65 Register
40. N and Ethernet network to be viewed or changed CAN Ok Yes CAN1 connected to a CAN network and functioning properly No Not ready to communicate CAN network CAN ID 1 to 253 This node s CSCAN Network ID must be unique on network CAN Baud 125 KB 125 KBaud CAN network 500 KB 500 KBaud CAN network 250 KB 250 KBaud CAN network 1 1 CAN network MAC ID NOTE The IP address Net Mask and Gateway can be changed from the system menu This is designed for commissioning or temporary field changes The actual parameters are defined in Cscape under the Ethernet configuration and are reverted to whenever the unit goes from idle to run mode View Status system Menu ma Ladder si Ese Enter Config Size ps s 7 8 9 29 _ The View Status Sub Menu displays up to 19 System Settings Only the OCS Mode System Setting is editable XW1yz Model number of this ZX OCS unit 1 2 indicates the installed I O module 00 I O module Idle ZX OCS is in Idle mode OCS Mode DolO ZX OCS is in Do I O mode Run ZX OCS is in Run mode 0 0 ZX OCS is not in Run mode 0 1 to 999 9 Average number of mS for each ladder scan OCS Net Use 0 0 to 100 0 CAN network bandwidth used by this ZX OCS node All Net Use Ladder Size Config Size Graphics Size String Size x Number of bytes application string table Page 4
41. PRELIMINARY MAN1018 01 EN HORNER AUTOMATION GROUP User Manual for ZX OCS HE ZX452 HE ZX752 HE ZX1152 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual PREFACE This manual explains how to use the ZX OCS Copyright 2014 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 15 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 Ethernet is a trademark of Xerox Corporation MicroSD and CompactFlash are registered trademarks of SanDisk Corporation For user manual updates contact Technical Support North America Europe Tel 1 877 655 5666 Tel 353 21 4321 266 Fax 317 639 4279 Fax 353 21 4321 826 Web http Awww hornerautomation com Web hitp www horner apg com Email techsppt hornerautomation com Email tech support horner apg com Page 2 of 91 IM HORNER AUTOMATION GROUP ZX User Manual LIMI
42. Proper machine operation is the sole responsibility of the system integrator Page 3 of 91 IM HORNER AUTOMATION GROUP ZX User Manual INTENTIONALLY LEFT BLANK Page 4 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual TABLE OF CONTENTS PREFACE 2 For user manual updates contact Technical 2 LIMITED WARRANTY AND LIMITATION OF LIABILITY eeeesseseeeeeennnnnnnnnnnnn nnn 3 ABOUT PROGRAMMING 3 TABLE CON npzgp 5 INTENTIONALLY LEFT BLANK id icum 9 CHAPTER 1 SAFETY COMPLIANCE 10 1 1 Safety Warnings and Guidelines enne nnne nnns nnn nnns 10 125 Cio nino luo ERR E 10 C eei e 11 CHAPTER 2 INTRODUCTION m 12 21 Visual Overview of ZX Eien 12 2 1 1 Where to Find Information about the ZX 13 2 1 2 Four main types of information are covered in this 13 Manal gt 13 2 1 4 IQS Em 13 2 2 Connectivity to the ZX OCS cccccccc
43. RELIMINARY ZX User Manual Configure Digital N Network Digital inputs active mode Network ID f Positive Logic Negative Logic LO Mapping Start Digital In EXE M ame IDIDinputStart FE Start Digital Out 2033 M ame DiGouputStart Gem status Register F105 DID 15tatus Input Update Method Update on Change of State f Update Periodically Time 0 mSec 100 to 25 5 Sec Timeout Comm Timeout A000 mSec 400 mS to 25 5 Maximum time 120 controller will wait to Indicate 7 act an communication timent Output Defaults Cancel Note The Start in and out registers for each module will be populated based the previous module entered After the initial module is configured subsequent modules will have Start registers auto populated based on the registers already in use If other registers 951 Q registers are desired or required they can be manually configured otherwise The values will all be dependent on the initial device being configured Page 44 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 6 Select output Defaults to modify the default state of outputs Default Output State Output state on controller STOP 2 3 4 7 5 2121212 a a a Legend 1 or 93 o Hoo Last state ea Other I O con
44. RNER AUTOMATION GROUP PRELIMINARY ZX User Manual Table 14 3 SR Registers Name Description 6 CS MODE tie Station Mode 0 4 1 Do I O 5 9586 SCAN RATE Average Scan Rate 10 1000 SR7 MIN RATE Minimum Scan Rate 10 1000 SR8 MAX RATE Maximum Scan Rate 10 1000 9589 10 EDIT BUF Data Field Edit Buffer J2 5 11 12 PERSIA adder Code Size 256K 95 13 16 Reserved SR17 18 SIZE I O Configuration Table Size 127K SR19 20 NET SIZE Network Configuration Table Size SR21 22 SD SIZE Security Data Table Size SR23 oe Ladder Code CRC 65535 raum 9eSR26 10 l OConfiguration Table 0 65535 9eSR27 NET Network Configuration Table 0 165535 9eSR28 SD SecurityDataTableCRC 0 165535 SR29 NET ID This Station s Primary Network ID CsCAN Network Baud Rate CSCAN NET_BAUD 0 125 1 250KB 2 500 3 1MB o i Network Mode 0 network not required SR31 NET MODE 1 network required 2 network optimized 3 3 network required and optimized SR32 LCD CONT LCD Display Contrast setting 0 255 95833 FKEY MODE Function Key Mode O Momentary 1 10 1 85232 Serial Protocol Mode SR34 SERIAL_PRO O Firmware Update RISM 1 CsCAN 4 T 2 Generic Ladder Controlled 3 Modbus
45. RNING 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 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 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 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 incl
46. SmartRail Base and I O Modules 1 Open the Hardware Configuration screen and click the LAN2 I O tab First add the base to the LAN2 configuration Then configure the I O modules attached 2 Click Add Base to bring up the Configure SmartRail 3 Configure the following options Field Description Nickname for the Module Base IP address for the Base Must be static and unique to the network Assign IP using Click to enable then enter MAC ID address that can be found on the Boot P to MAC ID base unit itself This allows for the base to receive a configuration message upon power cycle automatically Status Register Keeps track of status of the Base Unit See below for bit information and mapping Digital Inputs Start The first register the digital inputs will be mapped to Example 9610001 Digital Outputs Start The first register the digital outputs will be mapped to Example amp Q0001 Analog Inputs Start The first register the analog inputs associated with that base will be mapped to Example AI0001 Analog Outputs The first register the analog outputs associated with that base will be Start mapped to Example 90001 Page 40 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Configure SmartRai Base S3E E Base IP 192 168 254 123 Assign IP using BOOT P to Mac ID 00 0 91 04 8 Status Register 00101 M ame aseStatus Digital inputs Stat 210001
47. TED 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 postpaid 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 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 ZX OCS module to appropriately design the end system to appropriately integrate the ZX 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
48. TED WARRANTY AND LIMITATION OF LIABILITY Horner APG LLC HE APG warrants to the original purchaser that the ZX OCS module manufactured by HE APG 15 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 INCONNECTION WITH THE SALE OF THIS ZX OCS module THIS WARRANTY SHALL NOT APPLY TO THIS ZX 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 ZX OCS module IS ORIGINALLY INSTALLED THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNI
49. and Topics 12 Where to Find Information 13 ZX Dimensions 20 ZX Manual PREFACE 2 ZX OCS Accessories 14 ZX OCS Dimensions 20 ZX OCS Mounting Clip 17 ZX OCS Mounting Orientation 18 Page 89 of 91 IM HORNER AUTOMATION GROUP ZX User Manual Index of Figures amp Tables Figure 2 1 Visual Overview Of the ZX 5 13 Figure 2 2 Visual Overview of Types of Devices that can be connected to ZX 13 Figure 2 2 Visual Overview of Types of Devices that can be connected to ZX 13 Figure 3 1 General Panel Mounting of AN 16 Figure 3 3 General Orientation of 18 Figure 4 1 Two Point Ground Connection 26 Figure 4 2 Power Connector Primary Power nnn nnne nnn rne 27 Figure 4 3 Primary Power Port as Viewed Looking at the ZX esses nnne nnne nnn nnn nnne 27 Figure 6 1 CAN1 amp CAN2 Connector Locations ZX452 Left and ZX752 1152 Right cesses 30 Figure 6 2 CAN1 Port Pins Single above when used with adapter Dual Below sss 31 Figure 7 1 Hardware Configuration Dialog above Figure 7 2 Ethernet Configuration below 33 Figure 8 1 Removable MicroSD Memory Card
50. artStix SmartBlock and SmartRail Modules The CAN2 port supports CSCAN CANopen J1939 and DeviceNet Master layer as a selectable option one only such that the ZX can run dual protocols CSCAN and an alternate simultaneously wv 81059 60210 Single CAN Connector left can be manually wired for Dual CAN networks and Dual CAN adapter right 6 2 Port Description The ZX OCS CAN ports implement the ISO 11898 2 physical layer and the CAN 2 0A data link layer standards Also since the CAN ports are powered by an internal isolated power supply external CAN power is not required The single six pin port on the unit can be easily split and set up for dual ports by adding the dual port adapter that comes with the ZX unit The Dual Port Adapter splits the connection so that both utilize the standard CAN wiring The multiple CAN protocol configurations allows for flexibility in control and communications using a wide variety of I O and auxiliary devices in a network See below for CAN port details Page 30 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 6 3 CAN Port Wiring 1 amp 2 Port Pins Signal Description v Use the CAN Connector when using CsCAN or other network 3 SHLD 0 50 0 78 N m Figure 6 2 Port Pins Single above when used with adapter Dual Below CAN 1 Pin Assignments Pin Si
51. ason 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 System Menu enable AutoRun eeeeeelAUTLONeeeees Auto Enters RUN after Autoload or Battery Fail Figure 16 9 AutoRun Menu Page 78 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 15 CLONE UNIT 15 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 for details in using RM It can then be used to clone a different OCS exact same model The ZX uses Flash drive A to both clone and copy to additional units This feature can be used for Replacing an OCS by another unit of the same model Duplicating or clone units without a PC 15 2 Clone User needs to perform the following to Clone 1 The Clone Unit can be accessed by going to the System Menu of the OCS A new menu Clone Unit has been added at the end of the main system menu as shown below Set Netvork ID set Hetunrk Baud Uiew S
52. ault setting 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 Must be entered prior to programming 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 5 Configure the Ethernet setting in the System menu entering appropriate I P address for the controller System Menu CAN1 Ok 9 ID 253 gt CAN1 Baud 125 KB N 101 09 03 1 91 5 1 IP1 192 168 254 128 255 255 255 0 0 0 0 0 NetM1 GatW1 x 102 99 03 1 91 5 2 IP2 192 168 254 128 NetM2 255 255 255 0 GatW2 0 0 0 0 Page 34 of 91 HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Table 7 3 Ethernet Status Word Register Format High Byte Low Byte Cow Byte teo o Re te ue 1P Status Bit s Status Indication dem Values 0 HERO EO Tre Ful Bust Rx Receive State T Active Connections
53. be selected System Menu Enable AutoRun Auto Enters RUN after AutoLoad or Battery Fail N gt ca a ca ca Cea a Enable AutoLoad AutoLoad from Removable Media s AUTOLOAD PGM file when triggered Co A Dabah ES No Does not load AUTOLOAD PGM automatically when application program is absent or corrupted Yes Loads AUTOLOAD PGM file automatically from RM when application program is absent or corrupted Enable AutoLoad 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 when Replacing an OCS by another unit of the same model Duplicating or clone units without a PC Page 54 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Clone Selecting Clone Unit menu will open the following menu screen Clone Unit COMM CON COPY OF DOCUMENT DRAWINGS F IRMWARE OPC LITE PRESS PROTOCOL RELEASE USB TO S 02 Free Kbytes 1510496 Total Kbytes 2028256 tie um V A Note Free Total displays number of free and total bytes in Removable Media Selecting Make
54. cescessecccsccceeeeeesscceeeceesccsseeeeesnesencensccsseneeesccsseeeeesccseeeeessccens 13 TGS roc pose paces OE os 13 255888 eee 14 2 4 Required and Suggested Accessories 14 2 5 Useful Documents and 5 14 CHAPTER 3 MECHANICAL INSTALLATION 16 M 16 3 2 Mounting Requirements 16 3 2 1 Mounting Procedures Installed Panel 16 3 3 1 ZX OCS Mounting Clip Slot Locations 17 3 3 2 ZX OCS Panel Mounting Orientation eeesseseseseseeeeeeeenneenene nnne nnne 18 220 1 207207 18 35 20 3 6 1 Clearance Adequate Space 23 23 3 6 3 Temperature nnne 23 36 4 EO dcc 23 S0 23 3 6 6 X Shock and Vibration 23 3 6 7 Panel Layout Design and Clearance Checklist esses 24 CHAPTER 4 ELECTRICAL INSTALLATION ee 26 Grounding
55. ch has the ability to display a screen If the bit is SET the screen is displayed Single bit input registers Typically an external switch is connected to the registers Single bit flags used to give the programmer direct access to any front keys appearing on a unit Retentive single bit registers Single bit output registers Typically these bits are connected to an actuator indicator light or other physical outputs l Digital Input K Key Bit M Retentive Bit Q Digital Output R General Purpose Register 905 System Bit SR System Register T Temporary Bit Retentive 16 bit registers Single bit bit coils predefined for system use 16 bit registers predefined for system use Non retentive single bit registers 2 2 Useful S and SR registers Table 14 2 Common S Register Definitions Register Description joo 1 ndicate First Scan 9052 Network is 90593 10mS timebase 9094 100mS timebase 95 1 second timebase 96 I O is OK oS 7 Always ON Always OFF Pause n Load soon 90510 Pause n load done S 11 I O being forced Table 14 3 SR Registers Register Description MinVal SR1 USER SCR Current User Screen Number 1023 9058 9059 SR2 ALRM_SCR _ Current Alarm Screen Number 0 1023 SR3 SYS_SCR Current System Screen Number 0 0 14 SR4 SELF TEST Bit Mapped Self Test Result 0 65535 64 91 HO
56. ched in Set Time Date System Menu RUN Al Friday lt gt WEE AR RON Ese Enter Bn 0 gt m The Set Time Date Sub Menu displays three System Settings Time and Date may be edited and Day is automatically calculated from the Date setting Note that Time and Date are split into three fields each all of which may be edited Use lt or to select a field and then use Y or f to edit the field Page 50 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Set Beeper System Menu OK RUN po X Use 47 to adjust E RJ EXE JEN EA JE E I n NN N A c c g The Set Beeper Sub Menu displays one System Setting which may be edited Yes default Enables beeper ZOPET CIEE No Disables beeper does NOT affect ladder access Set Screen The Set Screen Sub Menu displays four System Settings all of which may be edited System Menu Ao el Update Time mS V Update time sets Esc Enter the maximum time used by graphics in the logic scan Bala BEI Li Yes Enable screen saver 5 1200 Amount of time in minutes to expire with NO touch activity before activating screen saver black screen 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 a
57. cters Directories and sub directories can be nested up to 16 levels deep as long as each pathname string does not exceed 147 characters Page 36 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 8 3 Using the Removable Media Manager The Removable Media Manager is an interactive ZX OCS screen that performs the following functions Display number of total and free K bytes Browse file and directory lists Delete files and directories Format a Removable Media Load and save application programs View screen capture bitmaps The Removable Media Manager can be accessed the System Menu or using Cscape to Removable Media Manager object on an application graphics screen Media Directory JPG 26267 5 01 JPG 14272 07 10 08 5 80002 JPG 15209 67 16 68 SCR8803 JPG 29708 67 16 68 SCROGG4 JPG 29582 07 10 08 SCRO0805 JPG 23263 07 10 08 80006 JPG 14643 07 10 08 80007 JPG 14976 07 10 08 SCROGOG8 JPG 15994 07 10 08 SCRO889 JPG 17561 07 10 08 Free 511672326 Total 511959646 A V Del For Save 4 Del 11 mat Pgm Esc Figure 8 2 Removable Media Submenu 8 4 Using Removable Media to Log Data Using Read and Write Removable Media function blocks an application ladder program can read and write ZX OCS register data in the form of comma delimited files with a CSV extension These files are compatible with standard database and spreadsheet PC programs In addition an
58. d highlight the desired BMP file and then press Enter El To capture an OCS screen 1 Turn On the assigned Screen Capture Control Register in Cscape Graphic Editor a Open Edit View Screens b Select Config Screen Capture from the top dropdown menu c Assign Control Register optional for a button press or a system key and define file name as below here the screenshot will be processed on F5 key press screen Capture iquratior Control Register optional Register k5 Name KEY uem Note The file will be stored on the SD Card with the appropriate file name Use Table 8 1below for more details on the filename system 8 7 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 A or nothing OR USB A Flash Drive when filename is prefixed with B Action Description Read RM csv This function allows reading of a comma separated value file from the Micro SD interface into the controller register space Write RM csv This function allows writing of comma separated value file to the Micro SD interface from the con
59. dder 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 changing an OCS register i e Function key registers Objects that allow input generally have a raised 3D appearance An 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 aloha 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 lt lt lt lt lt lt lt in a numeric field the value is too small to display or is below the minimum for an editable field 11 3 Alpha numeric keypad To allow entry of a specific number or text seve
60. device with indications which the Cscape program is exchanging data Note The Local unit and Target unit can be the e Modelz the actual Target Controller matches the same unit or they can be separate units configured Controller Model and Network The following are status indicators e Model Not the actual Target Controller does not match the configured Controller Model and Network R Running D Do l o Model there may have been a change since the 1 Idle last time the Target Controller was compared to the Cscape is not communicating with the remote unit configured Controller Model and Network no forces indicates no I O has been forced Figure 15 1 Cscape Status Bar Page 69 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 13 3 Establishing Communications The preferred method of communicating between Cscape and an ZX OCS is via CAN or Ethernet port The ZX OCS can communicate with Cscape using USB to serial adapters serial port communications via MJ1 Port Ethernet or CAN CsCAN For ZX use Cscape Ver 9 30 SP6 or newer 13 3 1 Communicating via MJ1 Serial Port otart by configuring Cscape to use 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 ZX If communications are successful the target indicator should show the mode of the controlle
61. dified If a directory name is highlighted pressing Enter will switch to that directory showing its files and sub directories In a sub directory highlighting dot dot and pressing Enter will move up one directory Fail Safe System The Fail Safe System is a set of features that allow an application to continue running in the event of certain types of soft failures These soft failures include Page 52 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 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 System Menu Backup Restore Data e o A Enable AutoRun Enable AutoLoad Si ESC to exit Esc Enter n AN ES 1 121 2121 sj EN ES oelecting Backup Restore Data displays the following screen in Backup Restore Data Restore A Clear Backup Tl Copies Battery Backed RAM contents on to the onboard FLASH memory of the OCS Copies the backed up data from onboard FLASH to the battery backed RAM Clear Backup The backup data will be erased from the onboard FLASH Exit Goes back to previous menu Page 53 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Enable AutoRun displays the following options which can
62. em and to consider the following design factors 3 6 1 Clearance Adequate Space Install devices to allow sufficient clearance to open and close the panel door Table 3 1 Minimum Clearance Requirements for Panel Box and Door Minimum Distance between of device and sides of cabinet 2 Inches 50 80mm Minimum Distance between 1 5 inches 38 10mm base of device and wiring ducts If more than one device installed in panel box or on door Minimum Distance between 4 inches between bases of each device 101 60mm bases of each device When door is closed Minimum distance between device and closed door Be sure to allow enough depth for the OCS 2 inches 50 80mm 3 6 2 Grounding Warning Be sure to meet the ground requirements of the manufacturer and also meet applicable electrical codes and standards Panel box The panel box must be properly connected to earth ground to provide a good common ground reference Panel door Tie a low impedance ground strap between the panel box and the panel door to ensure that they have the same ground reference 3 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 adeq
63. ernately for each digit ASCII Object When editing an ASCII value an ASCII keypad is displayed as shown figure 13 2 The ASCII keypad has 3 modes numeric symbols and alpha In Alpha mode the Caps Lock button may be pressed to access capital letters When you first enter this editor typing a character will overwite the entire old string and start a new entry You may press the back space arrow to delete the previous character Pressing Enter will save the entry pressing ESC will cancel the edit and return the string to the previous value 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 11 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
64. figuration methods exist the previous chapter only gives examples of some of the communication and options that can be used with the ZX Other protocols or communications options are available but are out of the scope of this section Page 45 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual CHAPTER 10 SYSTEM SETTINGS AND ADJUSTMENTS 10 1 System Menu Overview The ZX has built in System Menu which lets the user view System Settings and makes adjustments To start the System Menu press the SYSTEM key or set SR3 to 1 which will display the Main Menu Then use the 4 and Up Arrow or Down Arrow keys to select Main Menu item and press Enter Return Arrow to display the item s Sub Menu System Menu Set Networks SEK A ean View Status lt Set Fkeys Mode Esc Enter Set Serial Ports Set Time Date Removable Media Fail Safe System Clone Unit Press ESC to exit Figure 10 1 System Menu ZX Screenshot 10 2 System Menu Navigation and Editing As mentioned above the System Menu is started by pressing the System key on softkey menu bar press top right corner of screen to display on the ZX Next press ESC to exit the System Menu or use 4 and to select an item and press Enter to display the item s Sub Menu A Sub Menu generally shows a list of System Settings and their values After opening a Sub Menu if any of its System Settings are editable the first System Set
65. gnal Signal Description Direction 1 1 V CAN 1 Ground _ Blue en White CAN 2 Pin Assignments Pin Signal Signal Description Direction Black 5 2 2 Data Low In Out Elli MEE BUM Lis Las White Single port dual CAN Connector Use the CAN Connector when using CsCAN or other CAN network Torque rating 4 5 7 Lb In 0 50 0 78 N m 6 4 Cscape Programming via CAN The port supports CSCAN Programming Protocol If a PC has CAN interface installed via PCI card or USB and the PC CAN port is connected to the ZX OCS CAN 1 port Cscape can access the ZX OCS for programming and monitoring In addition the ZX OCS supports single point programming of all ZX OCS and other OCS RCS devices that are connected to the port network If the PC COM port is connected to the ZX OCS MJ1 serial port the ZX OCS can act as a pass through gateway allowing Cscape to access all ZX OCS and OCS RCS devices that are attached to the CAN1 port network 6 5 Ladder Controlled CAN Communication Using Put and Get Network Words function blocks the CAN 1 port can exchange digital and analog global data with other ZX OCS or OCS RCS devices nodes attached to the CAN1 port network In addition Put and Get Network Heartbeat function blocks allow nodes on the CAN 1 port network to regularly announce their presence and to detect the presence or absence of other nodes on the network 6
66. hooting Description Action ZX OCS does not read media card The media card should be formatted with the ZX OCS Make sure the project file is saved as a pgm file and not a file In addition to file must be pgm the file s I O configuration must match the ZX configuration for it to download ZX OCS will not download project file Table 19 2 Removable Media Troubleshooting 17 5 Technical Support Contacts For manual updates and assistance contact Technical Support at the following locations North America Europe Tel 1 877 665 5666 Tel 353 21 4321 266 Fax 317 639 4279 Fax 4353 21 4321826 www heapg com www horner apg com Email techsppt hornerautomation com Email tech support hornerapg com Page 87 of 91 IM HORNER AUTOMATION GROUP Main Index Accessories 14 AutoLoad 77 AutoRun 79 Backup Restore 73 Battery backed RAM 55 80 CAN Comm Cscape Programming 31 Expansion Network I O 31 Ladder Controlled 31 Overview 30 Ports 30 CAN Communications 30 11 Clone Unit 55 80 CLONE DAT 56 81 28 29 31 48 49 51 65 86 87 86 87 Communicating 1 Serial Port 71 Communication options 32 Communications Port 87 Compliance CE 11 Csape Program Via Serial Port 29 Cscape 14 28 29 30 31 37 49 50 61 68 70 71 86 87 Configuration Procedures 72 Establishing Communications 71 Overview 70 Status Bar 70 CSCAPE CONFIGURAT
67. inimum Net Usage of this unit SR192 NT TX MAX Maximum Net Usage of this unit For additional information on system bits and registers refer to the on line help found in Cscape 12 3 Resource Limits Table 14 5 Resource Limits Resource Value 16000 49999 Model dependent 5 or 7 2048 2048 Value CsCAN Ping EGD SRTP Modbus Ethernet TCP Master Downloadable protocol amp Slave Ethernet IP FTP or HTTP 10 100 MBd CsCAN 125 kBd 250 kBd 500 kBd or 1 MBd Serial Ports 1 RS232 1 RS485 Ports IDs Per CSCAN 64 w o repeat 253 w 3 repeaters Memory Data Fields Per User 1023 Screen Ladder Code 1024 kB Page 67 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual NOTES Page 68 of 91 HORNER AUTOMATION GROUP ZX User Manual CHAPTER 13 CSCAPE CONFIGURATION 13 1 Overview ZX OCS hardware is programmed with a Windows based PC application called Cscape This application can be used to program configure monitor and debug all aspects of the ZX OCS unit Please see the on line help provided with Cscape for additional details 13 2 Cscape Status Bar When the ZX OCS 15 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 ZX OCS and the Cscape program Components of the Cscape S
68. ion The application will be loaded from the Removable media only after getting the correct password SR164 6 can set to enable AutoLoad feature System Menu Autoload AutoLoad fron Removable Media s AUTOLOAD PGM File when triggered Figure 16 7 AutoLoad Menu Page 76 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual The OCS follows the following sequence in execution of AutoLoad 4 Power up OCS gt v Application Program absent Or Application Program corrupted NO AutoLoad Enabled OCS put in IDLE mode NO UTOLOAD PGM present iri gt the RM of the device failure YES AutoLoad initiated NO AutoRun Enabled OCS put in IDLE Mode YES OCS put in RUN Mode Page 77 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Figure 16 8 Flow Chart for AutoLoad 14 5 AutoRun This system menu option when enabled YES allows the user to automatically place the OCS into RUN mode after the AutoLoad operation or automatic Restore Data operation When the AutoRun setting is disabled NO the OCS remains in the IDLE mode after a Restore Data or AutoLoad operation SR164 5 can be set by putting the system into RUN mode automatically once an AutoLoad has been performed or an Automatic Restore has occurred If for any re
69. le 19 1 Cscape Target amp Local Numbers nnns nna nnns nans 102 Table 19 2 Removable Media 105 Page 91 of 91
70. lename Month_ M Day_ D h_ m_ s csv Month_03 Day_01 15 45 34 csv 8 9 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 No card in slot Unknown error 5 Unknownerror SSS O Page 39 of 91 HORNER AUTOMATION GROUP ZX User Manual CHAPTER 9 REMOTE I O CONFIGURATION The ZX family controllers are easy to set up with remote I O to suit any application needs For the most compact economical and flexible control the SmartRail line of devices are recommended SmartRail systems consists of a base with a specific type of communications ethernet ModBus TCP or Ethernet or CSCAN that have configurable customizable modular I O modules attached With this system any I O needs can be met and easily expanded in the future by adding additional modules to a base or additional bases to a network The following section covers a quick setup to show the flexibility and control the SmartRail I O system offers using Ethernet communications CSCAN configuration is similar only different base configuration is required 9 1 Configuration of ETX200 Ethernet
71. ller and reopen with a blank project Check Local If idle R run or D do shows next to Target number then communication is M een i to the target Target 1 R D Communication is not established to the target controller Check node ID of controller Target daten and set Target to match Make sure local connection is established Table 19 1 Cscape Target amp Local Numbers Page 85 of 91 17 1 1 1 2 3 4 17 1 3 17 2 HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Connecting Troubleshooting Checklist serial port MJ1 Programming 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 Cscape Make sure the COM port of the PC is functioning An RS232 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 HE500USB
72. mmunicating MJ1 Serial Port nennen nnn nnn nnns nnns 70 13 3 2 Communicating Ethernet 70 13 4 OMA EMEN 71 CHAPTER 14 FAIL SAFE SYSTEM 2 72 222490 7 7 ae 72 SOUS E a a 72 14 3 Backup Restore Des Aun etes 72 iL ES 76 OOEO OO O O O UOeOO0u u OUuOeOe Oe O 78 CHAPTER 155 CLONE UNIT a s Ort Cue 79 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 15 1 N ONY oor nate nada E 79 15 2 CIONO episod ates cee etm tee ese odie 79 15 3 NS eee 81 CHAPTER 16 MAINTENANCE iiic casas ic cessas _ 83 16 1 Firmware Updates 83 CHAPTER 17 TROUBLESHOOTING TECHNICAL SUPPORT
73. ny controller status change Update Time mS 2 50 Maximum amount of time to allow for graphics update per scan Timeout min Popup Status Page 51 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Removable Media Media Directory COMM CON COPY OF DOCUMENT DRAWINGS F IRMWARE OPC LITE PRESS PA PROTOCOL RELEASE USB 5 vy ay zy ey ey et 02 Kbytes 1516848 Total Kbytes 2028256 Del For Save The Removable Media Sub Menu displays the Removable Media Manager Having selected Removable Media from the Main Menu one of four Sub Menu screens will appear T V Media Directory No Card No MicroSD card has been installed in the Memory slot Media Directory Initializing MicroSD card is installed but it is still initializing DET MicroSD card is installed and initialized but contains no files Hedia Directory MicroSD card is installed and initialized and it contains files 009 JPG 680001 JPG SCROO02 JPG SCR0003 JPG SCROO0A JPG 29582 07 SCROOOS JPG 23263 07 10 SCROO06 JPG 14643 07 10 08 SCROOO7 JPG 15976 07 10 08 SCROO08 JPG 15994 07 10 08 SCROO09 JPG 17561 07 10 08 12 Free 511672320 Total Shows size of highlighted shows lt DIR gt if directory is highlighted Shows the date file or directory was created or last modified Shows the time file or directory was created or last mo
74. o the User Manual 883 for panel box information and a checklist of requirements ZO 125 3 mm TYP RADIUS CORNERS WHEN 191mm REQUIRING DUST OR WATERTIGHT SEAL PERNEMA 4 4X 12 Figure 3 4 Panel Cutout Tolerances Page 19 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 3 5 ZX Dimensions 109 0 109 0 95 0 95 0 65 0 60 8 8 3 0 20 8 6 0 109 0 109 0 Figure 3 5 ZX452 OCS Dimensions Page 20 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 200 200 152 152 e qu qu o 14 8 14 8 Figure 3 6 ZX752 OCS Dimensions Page 21 of 91 9c 6 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 267 267 239 239 01 N a 5 A 252 252 145 214 5 80 18 625 162 5 425 142 5 1 0 1 0 D 0 _ ll LJ FR a 798 798 2186 218 6 229 8 2298 6 267 267 Figure 3 7 ZX1152 OCS Dimensions Page 22 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 3 6 Factors Affecting Panel Layout Design and Clearances Warning It is important to follow the requirements of the panel manufacturer and to follow all applicable electrical codes and standards The designer of a panel layout needs to assess the requirements of a particular syst
75. onnectivity to the ZX OCS The ZX OCS has excellent capabilities for connecting to a variety of devices The diagram below shows some examples of devices that can be used with the ZX OCS Other OCS Devices Other OCS Devices Smart Stix I O Serial Drives PLCs OPC Server Bar Code Readers Printers ZX OCS SCADA OPC Servers Serial I O Ethernet Remote I O Cscape OPC Server Modbus TCP Devices Flash Drive ETX200 300 Base Data logging Figure 2 2 Visual Overview of Types of Devices that can be connected to ZX OCS Page 13 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 2 3 Features of ZX OCS The ZX OCS models are industrial control devices They combine control user interface and networking into a single integrated package Unique features of the ZX OCS include Bright 65 536 color graphical touch sensing LCD display in all models of ZX Display of complex graphical objects including trends gauges meters and animations Very high performance graphic processing Advanced control capabilities including floating point multiple auto tuning PID loops and string handling capabilities Removable media USB drive for 32GB of storage of programs data logging or screen captures CsCAN networking port for communication with remote other controllers or PCs Configurable serial protocols for communication to drives PLCs or other serial peripherals Cscape programming softwa
76. 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 It is left to the screen designer on how to present a Screen Brightness control to the user if required NOTE the backlight life may be shorted when screen is dimmed or screen brightness is varied on a repetitive basis Page 63 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual CHAPTER 12 REGISTERS 12 1 Register Definitions When programming the ZX 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 Table 14 1 Types of Registers found the ZX OCS 16 bit input registers used to gather analog input data such as voltages CA Ana Caput temperatures and speed settings coming from an attached device 16 bit output registers used to send analog information such a voltages XU levels or speed settings to an attached device These are digital flags used to control the displaying of screens on a unit D Display Bit whi
77. ort Resident Protocols ICMP Ping EGD Ethernet Global Data Configure Selected Protocol SRTP Slave 90 30 Service Request Modbus TCP Slave Ethernet TP FTP File Server HTTP Web Server ASCH Over TCP IP Downloadable Protocols ETN2 1 Mane Network Devices Scan List ETN2 2 Network Devices Scan List Cancel 33 of 91 AUTOMATION GROUP PRELIMINARY ZX User Manual 4 Configure the Ethernet Module parameters as follows IP Address Net Mask Gateway Status Register See Table 7 1 Version Register Enter the static IP Address for the Ethernet Module being configured Note 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 Must be unused on network 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 Enter the IP Address of a Gateway Server on the local network that allows for communication outside of the local network To prevent the Ethernet Module from communicating outside the local network set the Default Gateway IP Address to 0 0 0 0 the def
78. pply Figure 4 2 Power Connector Primary Power Port PIN 1 PIN 2 PIN 3 Figure 4 3 Primary Power Port as Viewed Looking at the ZX OCS Page 27 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 5 SERIAL COMMUNICATIONS 5 1 Overview All ZX OCS models provide independent serial ports The ZX452 model uses one RS232 and one RS485 port and ZX752 and ZX1152 models come with an additional RS232 port The MJ1 serial port is RS232 while the MJ2 port is RS485 By default MJ1 can be connected to the COM port of a PC running Cscape for OCS programming In addition both MJ1 and MJ2 can be used for application specific communication using a variety of standard data exchange protocols The second 8 pin modular RJ45 connector which is labeled MJ3 provides a multiplexed serial port which can be configured for either RS232 or RS485 MJ3 can be optionally set for OCS programming via the System Menu for connection to the COM port of a PC running Cscape 5 2 Port Descriptions The MJ1 serial port contains an RS232 interface with RTS CTS handshaking MJ2 serial port contains a half duplex RS485 interface with no handshaking The MJ3 serial port can be configured as either RS232 or RS485 The MJ2 and MJ3 RS485 interfaces provide switchable termination and bias resistors internally which can be enabled disabled with DIP switches 5 3 Serial Port Pin Assignments Serial Port 1 amp 3 Pin Assignments RS 232 Signal
79. r Programming There is also a system register that can be used to for control based screen navigation SR1 can be read to determine the current screen or written to change the current screen Refer to the on line help in Cscape for more information on control based screen navigation 11 6 Acknowledgement The ZX contains internal beeper that provides audible acknowledgment when operator touches a graphic object that accepts touch input When the graphic object is enabled a short 5ms tone 15 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 11 7 Touch Slip Sensitivity Touch 5 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 5 sensitivity allows for a slight s ip of the finger on the graphical object before the ZX assumes touch has been released equates to approximately a quarter inch of movement with a stylus In some applications such as jog buttons where the operator is pushing a button for a period of time the amount of s ip while holding a button pressed may exceed the default sensitivity To increase the amount of tolerable slip and p
80. r Target yy R as shown in the status section above If the controller is not communicating it may be required to set the target ID of the controller in Cscape or on the unit The Target ID allows directing communications to a particular unit when multiple units are connected 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 ZX press the System Button to enter the system menu The first item in the menu is Set Network ID Pressing Enter allows the ID of the unit to be viewed or modified To change the Target ID of Cscape use the Controller Set Target Network ID dialog 13 3 2 Communicating Ethernet Port The following is an overview of the information found in Chapter 7 From Cscape go to Controller l O Configure and do auto configuration for the connected controller Click on Config of Ethernet amp go to Module Setup The IP address Net Mask and Gateway of the controller may be temporarily set from the system menu under the Set Networks menu item Once running or power cycled the configuration will come from the Cscape configuration stored in the unit Must set Status Register 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 shot for the same as follows Download the configuration in to Controller Connect LAN cable to
81. ral 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 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 o 00000 123 X 155 P emer hello lt ESTEE HZ 1 2 3 4 5 6 7 8 9 01
82. raphic 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 Halt RM Activity Safe for Removal Figure 13 9 Example application segment for safe removal of removable media 11 10 Screen Saver The ZX screen backlight life is typically 5 years when in continuous use If the application does not require interaction with the ZX 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 ZX Any additional touch activity is also ignored by the ZX for approximately one second thereafter lt is possible for the application to temporarily disable the screen saver by generating a positive transition to SR57 16 coil only at a rate faster than the screen saver timeout value This may be desired while waiting for alarm acknowledgement 11 41 Screen Brightness The ZX provides a feature that allows screen dimming for night
83. re that allows all aspects of the ZX OCS to be programmed and configured from one integrated application Onboard Ethernet port 10 100Mbps for Cscape programming and application defined communication with Auto MDI MDI X 2 4 Touch Screen Interface and Function Keys The ZX unit uses digital on screen soft keys for function keys streamlining the appearance of the unit The function key menu can be configured to toggle on and off screen or to automatically go off screen after a specific delay To access the function keys press the top right corner of the touch screen display The menu button can be found here as well More details on configuring the function key tray will be covered in later chapters 2 4 Required and Suggested Accessories The following list contains a sampling of required and suggested ZX OCS accessories Visit the Horner websites to view updates on new products and accessories NOTE The ZX OCS is not shipped with a programming cable in the box Table 2 1 ZX OCS Accessories Part Number HE X24 AL 72W Power supply 100 240 VAC or 140 340 VDC Switching supply that outputs 3 A HE X24 AS AL at 24VDC HE CSP Cscape Software Package on a reusable USB flash drive with symbol library SmartRail I O The Smartrail Series I O is recommended for the ZX 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 cor
84. 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 Figure 13 7 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 Media Directory 236584 13 96 1 SCREEHO1 1536554 61 13 96 1 13 SCREEN 153655 61 13 96 1 8p Free 992257808 Total 992739328 I A V on I nat Fam ese Figure 13 8 Removable media viewer The currently selected entry is indicated by a yellow highlight which can be moved up or down by touching the arrow buttons or by directly touching an entry If more entries exist than can fit on the page a scroll bar is displayed on the right side that also indicates the current relative position File
85. responding manual numbers Visit the Horner websites 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 Manual Description Manual Number User Manual for XLe XLt OCS models Page 14 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Other Useful References Manual Number CAN Networks Spark Quenchers for Arc and Noise Suppression output protection Page 15 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 3 MECHANICAL INSTALLATION Note The datasheet is the first document to refer to for model specific information related to ZX OCS models such as pin outs jumper settings and other key installation information Visit the Horner websites to obtain datasheets user documentation and updates 3 1 Overview The mechanical installation greatly affects the operation safety and appearance of the system Information is provided to mechanically install the unit such as cut out sizes mounting procedures and other recommendations for the proper mechanical installation of the unit 3 2 Mounting Requirements 3 2 1 Mounting Procedures Installed in a Panel Door EN Figure 3 1 General Panel Mounting of OCS
86. revent false releases of the button the ZX 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 Page 60 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual register may be modified range 1 Low to 5 High to the desired slide amount If a value outside the valid range 15 entered in the touch sensitivity register it is ignored and the last valid value 15 used 11 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 ba ES Figure 13 5 Alarm Object To view acknowledge and or clear alarms the operator must access the alarm viewer This is accomplished by
87. rial Communication Using Serial Communication function blocks serial ports support Generic Modbus Master and Modbus olave Protocols In addition external modems can be connected and accessed using Init Dial and Answer Modem function blocks 5 8 Downloadable Serial Communication Protocols Serial ports on the ZX also support downloadable protocols such as Allen Bradley DF1 CsCAN Master GE Fanuc SNP and Modbus Master NOTE Refer to the Download section of the Horner websites for the list of latest supported protocols Page 29 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 6 CAN COMMUNICATIONS Note For additional CAN information refer to the CAN Networks manual 799 on the Horner websites 6 1 Overview All ZX OCS models provide Dual CAN ports which are implemented through a single six pin connector for flexibility and compact controls This grants the option for either single or dual connectors to be used The port has and CAN2 connections labeled separately CAN1 and CAN2 Port CAN1 and Port O O9 b Figure 6 1 CAN1 amp CAN2 Connector Locations ZX452 Left and ZX752 1152 Right Like the serial ports the port can be used for ZX OCS programming by connecting it to the CAN port of a PC running Cscape The 1 port allows the ZX OCS to exchange global data with other OCS RCS controllers Both CAN1 and CAN2 support accessing of remote network I O devices Sm
88. ring data The controller will be placed in IDLE mode Data will be copied from onboard FLASH to OCS Battery Backed RAM controller will reset controller will be put in RUN mode if the AutoRun setting is Yes else it will remain in IDLE mode Page 73 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 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 when a new backup is created Restoring of data can be manually performed by selecting RESTORE option from the Backup Restore Data menu This will cause the controller to reset Clear Backup Data When initiated the backup data will be erased from the onboard Flash and no backup will exist SR164 4 and SR164 3 is reset to 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 The OCS follows the following sequence in execution of Automatic Restore Page 74 of 91 IM HORNER AUTOMATION GROUP 6 OCS Power Cycle b Battery Backed RAM Registers check failed Backup PRELIMINARY ZX User Manual NO exists YES Controller placed in IDLE mode v v Applica
89. s 905 SR 65 Definitions 65 Resource Limits 68 Removable Media Page 88 of 91 IM HORNER AUTOMATION GROUP Load Save Applications 37 Log Data 37 Overview 36 Save Applications XL6 37 View Capture 38 REMOVABLE MEDIA 36 Removable Media Manager 37 Removable Media Manager Submenu 37 Removable Media ZX 53 Removable Memory Card Slot Photograph 36 RS 485 Biasing 28 safety compliance 10 Safety Warnings Guidelines 10 Serial Comm Cscape Programming 29 Downloadable Protocols 29 Ladder Controlled 29 Overview 28 Ports 28 SERIAL COMMUNICATIONS 28 Set Network ID 47 71 Sub Menus 46 System Menu Details 47 57 Navigate Edit 46 System Menu XL6 Screenshot 46 SYSTEM SETTINGS AND ADJUSTMENTS 46 Sytem Menu Overview 46 Table of Contents 5 target ID 71 Target ID 71 ZX User Manual target indicator 71 Technical Support 2 14 86 88 Contacts 38 Testing for Good Ground 26 Troubleshooting Common problems 86 Connecting Checklist 87 CsCAN Checklist 88 CsCAN Network 88 Removable Media 88 troubleshooting technical support 86 Troubleshooting Checklist serial port MJ1 Programming 87 Troubleshooting Checklist Ethernet port Programming 87 Two Point Ground Connection Test 26 Types of Devices that can be connected to ZX 13 USB 31 71 87 User Interface Ladder Based Navigation 61 Screen Navigation 60 Using Removable Media to View and Capture Screens 38 Visual Overview of ZX
90. sure proper wiring Insure that hardware jumpers and software configuration for I O match Check data sheets for voltage and current limits 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 WARNING Setting outputs ON in Do I O mode can result in injury or cause machinery to engage in an unsafe manner depending on the application and the environment Page 86 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 17 3 CsCAN Network For complete information on setting up CSCAN network refer to CAN Networks manual 799 by visiting the Horner websites 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 17 3 1 CsCAN Network Troubleshooting Checklist 1 Use the proper Belden wire type or equivalent for the network as specified in 799 2 The ZX OCS does not provide 24VDC to the network An external voltage source must be used for other devices such as SmartStix I O 3 Check voltage at both ends of the network to insure that voltage meets
91. tatus Uiew Diags Uiew 1 0 Slots Uiew Protocols Fkeys Mode Serial Ports Time Date Beeper Screen Removable 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 1004257280 Total 1004257280 Load Hake Clone Clone ESC Figure 17 2 Clone Unit Menu before Cloning Free Total displays number of free and total bytes in Removable Media 3 Make Create Clone option enables user to duplicate Clone application file all unit settings and all register values from Battery Backed RAM Page 79 of 91 HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 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 E Hake E Clone 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 DAT 24570 07 14 09 12 114 Free 1004208128 Total 1004257280 diane cone V A Esc Figure 17 4 Clone Unit Files NOTE Make Create clone operation automatically includes the security AUTOLOAD PGM file for security enabled files
92. tatus Bar are explained below Message Line Equal Indicator indicates whether the current program in Cscape is equal to the program The contents of stored in the Target Controller these messages e f Equal the program in Cscape is the same as the program stored in the Target Controller are context e f Not Equal the program in Cscape is not the same as the program stored in the Target sensitive The Controller Message line can e f Unknown there may have been a change since the last time the program in Cscape was be empty compared to the Target Controller Current User File Modified Indicator indicates that indicates who is m the file in the selected window has for security purposes been modified but has not been saved User HE XExx1 CsCAN Equal Local 1 Target 2 R no MOD Model forces 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 program in Cscape is configured e Local xx indicates the Network ID of the OCS to which the Cscape program is physically connected through its e Network indicates the type of network that the program serial port It can serve as a pass through device to other in Cscape expects to use e g CSCAN nodes on the network e Model Confirmation provides the following e Target yy R indicates the Network ID of the
93. 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 Page 70 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 13 4 Configuration An overview of configuration 1 Start the configuration by selecting the Controller Configure menu item 2 fthe ZX 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 ZX 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 4 Select either ZX OCS Cscan from the type drop down box 5 Once the type of ZX OCS is selected the model drop down box will provide the ZX OCS model numbers from which to choose from 6 Once the ZX OCS CPU is selected press OK to exit the dialog and configure the I O that is present in the first slot Page 71 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual CHAPTER 14 FAIL SAFE SYSTEM 14 1 Overview The Fail Safe System is a set of features that allow an application to continue running in the event
94. the panel door be easily opened and closed Is 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 ZX OCS Is there adequate ventilation 15 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 ZX 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 Page 24 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual NOTES Page 25 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 4 ELECTRICAL INSTALLATION Note The datasheet is the first document to refer to for model specific information related to ZX OCS models such as pin outs and other key installation information Visit the Horner websites to obtain datasheets user documentation and updates 4 1 Grounding Definition 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 RF
95. ting that can be edited is highlighted If desired the 4 and 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 Setting s value use either the arrow keys lt gt J 7 EE or the numeric keys or the appropriate touch screen icons to select a new value The arrow keys are used to edit System Settings that have just a few possible values Each time the arrow key is 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 3123 Enter In addition to edit a single numeric digit use the lt or key to select the digit and then either press a numeric key or use or f 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 Page 46 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 10 3 System Menu Details The following sections describe each of the Sub Menus in detail Set Networks This sub menu allows setting for the CA
96. tion Program erased Data copied from Onboard FLASH to OCS Battery backed RAM Controller Resets NO AutoRun v Enabled YES v 5 put in RUN Mode OCS put in IDLE Mode Figure 16 6 Flow Chart for Automatic Restore Page 75 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 14 4 AutoLoad This system menu option allows the user to specify whether the OCS automatically loads the application AUTOLOAD PGM located in Removable Media When the AutoLoad seiting 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 e When the program residing in onboard memory is corrupted and a valid AUTOLOAD PGM is available in the removable media of the device AutoLoad can be manually initiated when the SYS F3 key is pressed OCS can be in any of the following mode Idle Run DOIO This also requires 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 applicat
97. troller register space Rename RM csv oak allows renaming a file on the RM card The data in the file is not Delete RM csv This function allows deleting a file on the RM card Copy RM csv This function allows copying a file on the RM card The data in the file is not changed Page 38 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 8 8 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 Table 8 1 Filename Special Symbols Description ______ 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 Year04 Month03 aa01_15 csv Fi
98. uate space and clearances for the device in the panel box or on the panel door 3 6 4 Orientation When panel mounted there are no orientation restrictions on the ZX 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 ZX OCS and noisy devices such as relays motor starters etc For details on output protection especially when using contactors solenoids see MANO962 01 EN 3 6 6 Shock and Vibration The ZX 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 ZX OCS to a location that minimizes shock and or vibration Page 23 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 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 Meets the panel manufacturer s requirements for grounding etc Is the panel box properly connected to earth ground Is the panel door properly grounded Has the appropriate procedure been followed to properly ground the devices in the panel box and on the panel door Are minimum clearance requirements met Can
99. uding safety glasses and insulated gloves when making connections to power circuits Ensure hands shoes and floors are dry before making any connection to a power line g Make sure the unit is turned OFF before making connection to terminals 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 1 2 Grounding Grounding is covered in various chapters within this manual Page 10 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 1 3 Compliance To check for compliance and updates visit the Horner website US http www heapg com or Europe http Awww horner apg com Page 11 of 91 IM HORNER AUTOMATION GROUP ZX User Manual CHAPTER 2 INTRODUCTION 2 1 Visual Overview of ZX Models Figure 2 1 Overview of the ZX ZX1152 752 ZX452 Bottom Ethernet Ethernet Port1 Rec C i Port 3 RS 232 Port2 RS485 E Primary Audio Inputs and Outputs for future Firmware Release 0 O USB Port B DC Power Input CAN Networking Port Dual Port Port 1 RS 232 VGA Output 10 30VDC Supports Ps unique CAN Networks Screen Mirror iip and RM etc USB Port A Primary datalogging screen capture program loading recipes DC Power Input 10 30VDC CAN Networking Port Dual Port VGA Output Supports two unique
100. uptriggerbit 9581649 CLONE trigger bit p SR164 10 LOAD CLONE trigger bit Eo E Status indicating Make Clone Fail This bit goes high when Create clone fails 95816412 Status indicating Load Clone Fail This goes high when Load clone fails Page 66 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Table 14 3 SR Registers Register Description Max SR165 174 Reserved SR175 oe Current Removable Media interface status o je SR176 Removable Indicates free space on the Removable Media o 177 Media card in K bytes SR178 Removable 31 Indicates the total card capacity in K bytes o e n e SR180 E Unacknowledged Alarm high bit indicates SR181 ALM UNACK what group SR182 ALM_ACT Active Alarm high bit indicates what group SR183 SYS_BEEP system Beep Enable O disabled 1 enabled SR184 USER BEEP Software configurable OZOFF 1 ON S screen Saver Enabled O disabled SR185 SCR_SAVER 1 enabled SR186 SCR_SA_TM Screen Saver Time in minutes delay 8187 NET USE doin Net Usage of all units on the CAN SR188 NET MIN Net Usage of all units on the CAN NENNEN SR189 MAX Net Usage of all units on the CAN JE _ SR190 NT TX Average Net Usage of this unit SR191 NT TX MIN M
101. used To configure the Ethernet communications use Cscape Programming Software to perform the following steps 1 On the Cscape screen select the Controller gt Hardware Configuration Figure 7 1 2 Ensure the correct controller Series Device and Model 3 Click Config to the right of LAN 1 or LAN2 whichever is preferred for Programming to open the Ethernet Configuration screen Figure 7 2 Page 32 of 91 HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual Controller Local 1 0 CsCAN CAN2 CsCAN LAN1 1 0 LAN2 E e e Device Type 152 Display 1080 by 1920 LCD Network Ports Keypad Type Touch 7 F keys Config Program Memory 1024 Bytes CAN CsCAN Config Network CsCAN ETN3 M Config Advanced Ladder Functions Contig Supports Analog Data 2 ETN300 Config Real Time Clock Support Supports Retentive Data Serial Ports Contig Figure 7 1 Hardware Configuration Dialog above Figure 7 2 Ethernet Configuration below Register Usage Default Settings Register Get settings from IP Address 192 168 254 128 M ame GRBIT Configuration Use ID for last Octet NetMask 255 255 255 0 Configuration Gateway 0 0 0 0 M ame 55 Configuration Status Mame EthemetStatusReg Version Mama Protocol Supp
102. xport to Removable Media 3 Place the Removable Media with AUTOLOAD PGM in the device 4 Set the Enable AutoLoad option in the device to YES 5 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 14 3 Backup Restore Data selecting this option brings up a screen having four operations Backup OCS Data Restore OCS Data Clear Backup Data Exit Page 72 of 91 IM HORNER AUTOMATION GROUP PRELIMINARY ZX User Manual 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 5 164 4 is set to 1 when backup operation is performed Backup Restore Data Backup Register Data Overwrite Backup Figure 16 3 Backup 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 resto

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