to - Horner APG
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1. Enable AutoRun option to YES if the controller needs to be placed in RUN mode automatically after automatic restore of data or AutoLoad operation D a ae It is especially recommended to use this functionality in conjunction with the 22 heater option in extreme cold temperatures 10 Technical Support For assistance and manual updates contact Technical Support at the following locations North America Europe Toll Free 1 877 665 5666 353 21 4321 266 http www heapg com http www horner apg com E mail techsppt heapg com E mail tech support horner apg com Page 4 of 10 MW HORNER AUTOMATION GROUP 11 Built in I O Model 2 3 4 amp 5 Specifications Installation MANO971 06 EN All XL7 models except the HE XW1E0 feature built in I O The I O is mapped into OCS Register space in three separate areas Digital Analog I O High Speed Counter I O and High speed Output I O Digital Analog I O location is fixed starting at 1 but the High speed Counter and High speed Output references may be mapped to any open register location For more details on using the High Speed Counter and High Speed Outputs see the XL7 OCS User s Manual MANO0974 01 ag q Analoc A 7 Model r ah Hic ANGaTOQ E iraa JCIAL ai a f Acaress Digital Inputs 1 12 13 31 25 31 ESCP Alarm 32 Digital Outputs 1 12 1 16 _ 13 24 17 24 1 2 2 n a 1 12 11601 13 31 Q1601 32 A10401 AQ0401 l1 Com2. A1 A2 A3 A4 Default 001XLE026 Default JP2 Analog In A1 A4 Current Voltage 20 mA 10 V Gal o o D 5 Io o 001XLE027 OOTXLED25 Location of I O jumpers JP1 amp JP2 and wiring connectors J1 and J2 with back cover removed Note The Cscape Module Setup configuration must match the selected I O JP jumper settings Note When using JP2 A1 A4 each channel can be independently configured Black Relay Out Digital In Relay 6 COM _ Relay6NO Relay 5 COM Relay5NO Relay 4 COM _ Relay4NO Relay 3 COM Relay3NO Relay 2 COM Relay2NO Relay 1NO HSC4 IN12 _ HSC3 IN11 HSC2 IN10 OV ON J1 001XLE015 Relay Life Expectancy 40 2 S 30 BE 2 0 1 2 3 4 Contact Current A WARNING EXPOSURE TO SOME CHEMICALS MAY DEGRADE THE SEALING PROPERTIES OF MATERIALS USED IN THE Tyco relay PCJ Cover case amp base Mitsubishi engineering Plastics Corp 5010GN6 30 or 5010GN6 30 M8 PBT Sealing Material Kishimoto 4616 50K I part epoxy resin It is recommended to periodically inspect the relay for any degradation of properties and replace if degradation is found Page 5 of 10 HORNER Specifications Installation AUTOMATION GROUP MANO971 06 EN Model 3 amp 4 I O The XL7 model 3 HE XW1E8 features 12 DC Inputs 12 DC outputs and 2 Analog Inputs The XL7 model 4 HE XW1E4 increases the I O count up to 24 DC Inputs and 16 DC O
3. Commons per Module Input Voltage Range 0 VDC 24 VDC Output Type Half Bridge Absolute Max Voltage 35 VDC Max Absolute Max Voltage 30 VDC Max Input Impedance Output Protection Short Circuit amp Overvoltage Input Current Positive Logic Negative Logic sees Output Current per UPA Minimum On current 0 8 mA 1 6 mA 7 Total C t dri 2A total current all drivers UL vee i ax Total Current per driver Maximum Off current 0 3 mA 2 1 mA Q1 4 Q5 8 Q9 12 rated 6A UL pending Min On Input 8 VDC Max Output Supply Voltage 30 VDC Max Off Input 3 VDC Minimum Output Supply 10 VDC Voltage Max Voltage Drop at Rated 0 25 VDC ON to OFF Response Galvanic Isolation VO Indication Common pin level Freq XL4 7 EXL6 10 500KHz max XL4 7 EXL6 10 500KHz max 3 5mm Pluggable cage clamp Connector Type connector Output Characteristics Current Sourcing Pos logic Analog Inputs Number of Channels 6 Absolute max Input Voltage 0 5 12V dc 30Vdc T C RTD mV gt 2 MQ mA 150 1 5V Input Impedance Clamped 0 5 to V 11 MQ 0 20mA 4 20 mA dc Input Range 0 60mV 0 10V dc T C J K N T E R S B RTD PT100 PT1000 10 23VDC 14 17 Bits variable depending Galvanic Isolation None Nominal Resolution on input type PTE SS 1420 to 1000 C 184 to 1832 F 0 2 FS 17 TK 180 to 1372 202 to 2501 6 0 2 FSHIC Po TE TSS 130 to 400 C 202 to 752 F 0 2 FS 17 Po TC
4. for maximum flexibility J1 Orange Positive Logic Digital Inputs p INS ING N8 orn Narn Tc 1 or RTD 1 or 100mV 1 Tc 1 or RTD 1 or 100mvV 1 Tc 2 or RTD 2 or 100mV 2 Tc 2 or RTD 2 or 100mV 2 Tange A a a Location of I O jumpers JP1 JP4 and wiring connectors J1 J4 with back cover removed 12 24VDC lt 001XLE007 0 10 V Analog In NC 0 10VDC 20 mA Analog Int 20mA a Output Power C NoConnect__ J2 Black Positive Logic Digital Outputs 001XLE008 4 20 mA Analog Out ie 0 10 V Analog Out Note Be sure to wire OV as shown for proper LOOP PWR 7 operation 10VDC Note Loop Power requirements are determined by the transmitter specification Jumper Setting Details JP1 Digital DC Inputs Positive Logic Negative Logic o mm mm Default JP2 amp JP3 ANALOG INPUT SETTING T C 100mV RTD PT100 JP2 JP3 JP2 JP3 onoono oono il oa HE IH EH T1 T2 TA 10V 20mA JP2 JP3 sail snl kk Boo MA1 V1 MA2 V2 Default JP4 ANALOG OUTPUT SETTING VOLTAGE OR CURRENT CURRENT VOLTAGE 20mA 10V co On a AQ2 AQ1 AQ2 AQ1 60008 0 Default Page 7 of 10 HORNER Specifications Installation AUTOMATION GROUP MANO971 06 EN Model 6 I O Hardware Specification Digital DC Inputs Digital DC Outputs Inputs per Module Outputs per Module Commons per Module
5. 4 4X or 12 Ke A z 7 468 189 7mm gt 8 27 210 06m 1 73 43 94 mm without I O Cutout tolerance to meet NEMA standards is 0 005 0 1mm Max Panel Thickness is 5mm Page 1 of 10 dy HORNER Specifications Installation AUTOMATION GROUP MANO971 06 EN 3 Additional Controller Options Part Number Description 10 part number suffix Add 10 to the part number for Thermistor Support for analog inputs 1 and 2 Al1 amp Al2 Example HE XW1E3 10 22 part number suffix Display Heater for lower temperatures rated at 40 C Example HE XW1E3 22 Note When using the 22 Heater Option in XL7 in extreme low temps the controller must reach 0 C for 8 hours once every six months This allows time for the internal battery to charge as it will not charge under 0 C If the internal battery dies volatile data could be lost 4 Installation Procedures 1 Carefully locate an appropriate place to mount the XL7 Be sure to leave enough room at the top of the unit for insertion and removal of the microSD card Also leave enough room at the bottom for the insertion and removal of USB FLASH drives 2 Carefully cut the host panel per the diagram on Page 1 creating a 189 7mm x 131 2mm 0 1mm opening into which the XL7 may be installed If the opening is too large water may leak into the enclosure potentially damaging the XL7 If the opening is too small the OCS may not fit through the hole without da
6. AZARD BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE NON HAZARDOUS 8 Common Cause of Analog Input Tranzorb Failure A common cause of Analog Input Tranzorb Failure on Analog Inputs Model 2 3 4 amp 5 If a 4 Digi Key 235 1074 ND or equiv 20mA circuit is initially wired with loop power but without a load the Analog input could see 24Vdc This is higher than the rating of the tranzorb This can be solved by NOT connecting loop power prior to load connection or by installing a low cost PTC in series between the load and Analog input NOTET Refers to Model 2 orange pg 5 Models 3 amp 4 J1 pg 6 and Model 5 20mA Analog In pg 7 9 Fail Safe Functionality All XL7 models have a built in fail safe feature that can back up program and register data to flash memory from battery backed RAM This way the controller will retain data in the event of battery power loss or file corruption The Backup Restore functions are available from the system menu and are described in more detail in the full product manual MANO974 To use the fail safe feature the user needs to do the following Backup the current Battery Backed RAM Register contents in On Board Flash memory using System Menu options From Cscape create AUTOLOAD PGM for the application program using Export to Removable Media Place the Removable Media with AUTOLOAD PGM in the device Set the Enable AutoLoad option in the device to YES Set the
7. C HORNER Specifications Installation AUTOMATION GROUP MANO971 06 EN XL7 OCS Datasheet for HE XW1E0 HE XW1E2 HE XW1E3 HE XW1E4 HE XW1E5 HE XW1E6 HEXT391C100 HEXT391C112 HEXT391C113 HEXT391C114 HEXT391C115 HEXT391C116 1 Specifications General Specifications Control amp Logic Specifications Standard Model 22 Heater Add On Required Power Up to 740mA Advanced Ladder Logic 170mA 24VDC 24VDC Control Language Support Full IEC 1131 3 Languages Steady state heater duty cycle Tag based Editor Required Power Logic Program Size 1MB maximum Inrush PEGE AS a ue amp Logic Scan Rate 0 013mS K Primary Power Range 10 30VDC 10 24VDC Online Programming Changes Supported in Advanced Ladder Relative Humidity 5 to 95 Non condensing Digital Inputs 2048 20 ppm maximum at 25 C Digital Outputs 2048 Clock Accurac 1 Minutes per Month po Eon Analog Inputs Surrounding Air Temp 10 C to 60 C 40 C to 60 C Analog Outputs Storage Tem 40 C to 60 C 2lb th t 1 0 peated py teeta ee Toe 7 ee er vr General Purpose Registers 16 384 bits Retentive i i UL CE ttp WWW eapg com ages ec upport roductCert hntm 16 384 bits Non retentive Europe http www horner apg com en support certification aspx Display Specifications Connectivity Display Type 7 TFT Transmissive Color Serial Ports 1 RS 232 amp 1 RS 485 on first Modular Jack MJ1 2 pay Yp 1 RS 232 or 1 RS 485 on secon
8. CRIPTION WE v CAN Ground Black 1 Ground ____FrameGround 2 E ShieldGround None 3 DC Input Power Supply Voltage 4 CNH CAN Data High White IN OUT _ V NC NoConnect Red MJ1 2 Independent Serial Ports sot vee Port MJ1 RS 232 w Full Handshaking Two multiplexed Serial Ports on One Modular Jack 8posn MJ2 RS 485 Half Duplex V a VU1 PINS MIZ PINS I oS lt 5 5V 60ma OUT 4 TX RSs485 OUT 3 Tx RS485 OUT iN OUT 2 RX RS485 IN T e ov SV 60mA OUT a RX TX RX TX IN OUT 2 RX RS485 IN DIP Switches FUNCTION DEFAULT 1 MJ3RS485 Termination ON Terminated OFF E ON Half OFF Full 4 MJ2RS485 Termination ON Terminated Page 3 of 10 C HORNER Specifications Installation AUTOMATION GROUP MANO971 06 EN 7 Safety WARNING Only qualified electrical personnel familiar with the construction Power input and output I O wiring must be in accordance with Class and operation of this equipment and the hazards involved should install Division 2 wiring methods of the National Electric Code NFPA 70 for adjust operate or service this equipment Read and understand this manual installations in the U S or as specified in Section 18 1J2 of the Canadian and other applicable manuals in their entirety before proceeding Failure to Electrical Code for installations within Canada and in accordance wit
9. E S 130 to 780 C 202 to 1436 F 0 2 FS 1 C Po TENS 180 to 1300 202 to 2372 F 0 2 FS 1 Po TERS 20 to 1768 C 68 to 3214 4 F 0 2 FS 3 C Po TE BSF 100 to 1820 C 212 to 3308 F 0 2 FS 3 C Po BT 100 1000 200 to 850 C 328 to 1562 F 0 15 FS pf ROMA ROMA OFS OM OM Cd 0 15 FS OV OV 0 15 FS Analog Outputs Number of Channels Minimum Current load 5000 0 10Vdc l None Output Ranges 0 20mA 4 20mA de Galvanic Isolation Nominal Resolution 12 Bits Conversion Speed Min all channels once per scan One update per ladder scan Max Error at 25 C Additional Error for 0 20mA 0 1 of full scale aie excluding zero 0 10 V 0 1 of full scale aaa other than 20mA 0 0126 C see I O information below for detail regarding HSC and PWM Page 8 of 10 dy HORNER Specifications Installation AUTOMATION GROUP MANO971 06 EN Model 6 I O Connection Details For ease of operability the high density terminals are divided into more manageable pairs of connectors J1A J1B J2A J2B J3A J3B To ensure proper installation connector symbols must match as seen below J J1 Orange Signal Name eTA I 12 13 14 15 I6 I7 18 VIN8S O H1 H2 H3 HSC3 V IN11 aE HSC4 VINI2 YE Common _ STN Univ Alt pint SEE Univ Alt pin2 SI Univ Alt pins SIS No Connection IN Univ Al2 pint A2B Univ Al 2 pin 2 A2C Univ Al 2 pin 3 N C No Connection J3 Oran
10. analogue inputs return data types as follows 0 2mA 4 20mA 0 32000 i O _0 10V 0 60mV_ 0 32000 So O T C RTD Temperature in C or C or F may be selected in the I O config F to 1 decimal place section XXX Y The value is an integer the user should divide by 10 5 4 5 Status Register Register Description Firmware version R4 pss bis se C Calibration Scan rate of the 106 board average in units of 100uS Scan rate of the 106 board max in units of 100uS Channel Status Channel 2 Channel 1 eS Open RTD Out of Shorted Open T C Open RTD Out of Shorted Open T C Limits RTD Limits RTD Channel So Channel Status Channel 4 Channel 3 eS i 7 Je JS J2 S1 k Open RTD Out of Shorted Open T C Open RTD Out of Shorted Open T C Limits RTD Limits RTD s Sree 4 a Sms Granel Sta Staus Chan sanes 6 Channel 5 m RTD Lor of E Te T C aT RTD Soop of noted ane T C Limits RTD Limits RTD R10 14 Reserved S O R10 14 0 14 Reserved Note For the purposes of the example the block is shown starting at R1 but it can be set to anywhere in the R memory map Page 10 of 10
11. d Modular Jack MJ3 800x480 USB mini B USB 2 0 480MHz Programming amp Data Access 16 bit 65 535 USB A USB 2 0 480MHz for USB FLASH Drives 2TB 27 MB 2x Remote I O Peer to Peer Comms Cscape 2x 10 100 Mb Auto MDX Modbus TCP C S HTTP User Programmable Screens 1023 ETP SMTP Cscape Ethernet IP Backlight LED 50 000 hour life Remote I O SmartRail SmartStix SmartBlock SmartMod User Configurable within the scan time Removable Memory MicroSD support for 32GB max Screen Update Rate perceived as instantaneous in many Application Updates Datalogging more cases Input Output Specifications DC mA V mA V High Speed Counters Model2 12 a J Maximum Frequency 500OkHzeach Model3 12 n 4 2 2 Accumulatorsize _32 bitseach Model4 24 165 4 2 2 Modessupported Model5 142 12 J a 2 2 2 Totalizer Quadrature Frequenc There are 4 high speed inputs of the total DC Inputs There are 2 high speed outputs of the total DC Pulse Measurement eo outputs Model 2 3 amp 4 feature 12 bit Analog I O Model 5 features 14 16 bit Analog I O High speed Outputs can be used for PWM and Pulse Train Outputs currently limited to lt 65kHz PO T AON PARA EPU 1 ON OFF Setpoint per Output 2 Dimensions amp Panel Cutout E N R 125 3 mm TYP A A Radius corners when a a requiring dust or water tight 5 66 143 76 mm A seal per NEMA
12. ge Signal Name eTA gt NIC A3A A3B A3C N C A4A A4B AAC N C a d A5 A Transmitter A5B A5C N C 12 24VDC Black gt Green Signal Name V3 V OUT 3 V2 V OUT 2 V1 V OUT 1 mA4 mA Out 4 mA Out 3 mA Out 2 mA Out 1 LOAD OUT 1 PWM1 LOAD OUT 2 PWM2 TOAD OUT 3 TOAD OUT 4 TOAD OUT 5 om OUT 6 OUT 7 OUT 8 OUT 9 OUT 10 OUT 11 OUT 12 V External ommon Page 9 of 10 Note Both mA amp V outputs are active for each output channel however only the configured output type is calibrated maximum 4 channels simultaneously LOAD HORNER Specifications Installation AUTOMATION GROUP MANO971 06 EN Note Both mA amp V outputs are active for each output channel however only Model 6 l OExample Universal Input Wiring Schematic the configured output type is calibrated maximum 4 channels simultaneously 0 10 V Analog In Thermocouple In 4 20 mA Analog Out 100mV l 20mA l 4 _ I 100mV 20 mA Analog In 20mA 0 10 V Analog Out LOOP PWR O 10VDC L _ I D Loop Power requirements are determined by the transmitter specification Power supply should be isolated Notes Configuration The data registers are as follows Digital Inputs Digital Outputs Analogue Inputs Analogue Outputs l1 12 Q1 12 PAI 1 4 AI33 38 AQI 12 5 4 4 Data values The
13. h the observe this precaution could result in severe bodily injury or loss of life authority having jurisdiction WARNING To avoid the risk of electric shock or burns always connect the This equipment is suitable for use in Class Division 2 Groups A B C and earth ground before making any other connections D or Non hazardous locations only WARNING To reduce the risk of fire electrical shock or physical injury it is WARNING EXPLOSION HAZARD Do not disconnect equipment unless strongly recommended to fuse all Power Sources connected to the OCS Be power has been switched off or the area is known to be non hazardous f h ible SAE NES eee Ome e Poses WARNING EXPLOSION HAZARD Substitution of components may impair WARNING Replace fuse with the same type and rating to provide protection suitability for Class 1 Division 2 against risk of fire and shock hazards l g Digital outputs shall be supplied from the same source as the Operator WARNING In the event of repeated failure do not replace the fuse again as Control Station a repeated failure indicates a defective condition that will not clear by replacing the fuse Jumpers on connector JP1 and others shall not be removed or replaced while the circuit is live unless the area is known to be free of ignitable WARNING Battery may explode if mistreated Do not recharge concentrations of flammable gasses or vapors disassemble or dispose of in fire WARNING EXPLOSION H
14. ing JP3 A1 A2 each channel _OUT1 PWM1_ can be independently configured J4 Orange Positive Logic Digital Out Note Model 3 uses J1 amp and J2 only LE Model 4 uses J1 J2 J3 amp J4 Page 6 of 10 MW HORNER AUTOMATION GROUP Model 5 I O The XL7 model 5 HE XW1E5 features 12 DC Inputs 12 DC outputs with high performance highly configurable Analog Inputs 2 and Analog Outputs 2 The DC Inputs are 12 24Vdc compatible and can be jumpered for Positive Logic sinking or Negative Logic sourcing Two of the inputs H1 H2 can be used for high speed functions up to 500kHz The 12 24VDC Outputs feature Electronic Short Circuit protection and support currents up to 0 5A per point and 4A total Two of the DC Outputs can be used for high speed functions PWM or PTO The output frequency is limited by the switching capability of the output drivers about 10kHz although an optional accessory HE XHSQ can be added to provide parallel output drivers supporting frequencies up to 200KHz The two high resolution Analog Inputs can be configured for 4 20mA 0 10V or 0 100mV at 14 bit resolution They also can be configured for 16 bit temperature measurement supporting Thermocouples or RTDs with 0 05 C resolution The Analog Outputs are sourcing and can be configured for 4 20mA Specifications Installation MANO971 06 EN or 0 10V at 14 bit resolution Each Analog Input or Output channel can be configured independently
15. mage 3 Remove all Removable Terminals from the XL7 Insert the XL7 through the panel cutout from the front The gasket needs to be between the host panel and the XL7 4 Install and tighten the four mounting clips provided in the box until the gasket forms a tight seal max torque 7 10 Ib in 0 8 1 13 Nm J 5 Reinstall the XL7 I O Removable Terminal Blocks Connect communications cables to the serial port USB ports Ethernet port and CAN port as required 6 Ports amp Connectors MJ1 RS 232 MicroSD MJ2 duplex RS 485 Data Storage IE K USB mini B d lt Programming ere a K RS 232 485 4 ilt in gt Serial Port q awe lt s l Pe CAN2 CAN1 a 3g CAN 1 0 amp CAN I O amp a S Fieldbus Port ons POWER 10 30V DC In 7 Audio ine iT FTL ET ee C Audio Out Speakers Audio In Microphone USB 2 0 A Flash Drives Future firmware update required Page 2 of 10 ty HORNER Specifications Installation AUTOMATION GROUP MANO971 06 EN DC Input Frame Sen Torque rating 4 5 7 Lb In T ee S ti Di a a 0 50 0 78 N m wo terminators Per Conductor Torque rating 4 5 Lb In 0 50 N m SHLD and V pins are not internally connected to XL7 DC is internally connected to 1 0 V but is isolated from CAN V A Class 2 power supply must be used CAN1 CAN Port Pin Sia BONE Rr Ea OPIN SIGNAL DESCRIPTION DIRECTION PIN SIGNAL DES
16. mand Bits Accumulator 1 amp 2 Preload amp Match Values n a AI1 be re mapped by user 32 32 1 3 12 3 1 na 18 18 Analog Outputs __ na ma nma Reserved areas maintain backward compatibility with other XL Series OCS models AAQ1 Model 2 I O n 5peed Counte y Func on Starting Address locations for l Q Al amp AQ may f Srasd Ai MGi ovVveecrc UL FUL nction Status Bits n a AQ421 PWM or Pulse Train 1 20 Parameters Starting Address locations for l amp AQ may be remapped by user Q1 Q2 are part of the Fixed I O Map In High Speed Output mode they can be used to initiate a Stepper PTO Move 2 9 Adar 11617 1 12 The XL7 model 2 HE XW1E2 features 12 DC Inputs 6 Relay outputs and 4 Analog Inputs The DC Inputs are 12 24Vdc compatible and can be jumpered for Positive Logic sinking or Negative Logic sourcing Two of the inputs H1 H2 can be used for high speed functions up to 500kHz The 12 bit Analog Inputs can be jumpered for voltage 0 10V or current 4 20mA on a channel by channel basis The Relay outputs are isolated supporting AC and DC voltages with output currents of up to 3A relay 5A total Oranget Digital In Analog In ory Nie waline J OO m OO mn Omn B f mns T INe rs Le 0 10VDC 001XLE017 Model 2 Jumper Setting Details JP1 Digital DC In HSC Positive Negative Logic Logic m
17. utputs and 2 Analog Inputs The DC Inputs are 12 24Vdc compatible and can be jumpered for Positive Logic sinking or Negative Logic sourcing Two of the inputs H1 H2 can be used for high speed functions up to 500 kHz The 12 bit Analog Inputs can be jumpered for voltage 0 10V or current 4 20mA on a channel by channel basis The 12 24VDC Outputs feature Electronic Short Circuit protection and support currents up to 0 5A per point and 4A total Two of the DC Outputs can be used for high speed functions PWM or PTO The output frequency is limited by the switching capability of the output drivers about 10kHz although an optional accessory HE XHSQ can be added to provide parallel output drivers supporting frequencies up to 200kHz J1 Orange Positive Logict B l Digital amp Analog In J3 Orange Positive Logic Digital In IN13 IN14 IN15 IN16 IN17 IN18 IN19 IN20 O IN21 IN22 IN23 O N24 O Common N5 N6 o N8 J2 Black Positive Logic Digital Out Jumper Setting Details JP1 Digital DC Inputs Positive Logic Negative Logic C Default JP3 Analog Inputs 10VDC HR 20mA F A1 1 B 2 AT 1a Bl J3 conaemosar A2 3 4 A2 3 0 oj Location of I O jumpers JP1 amp JP3 and ial wiring connectors Note The Cscape Module Setup configuration J1 J2 J3 amp J4 with back must match the selected I O JP jumper i cover removed settings OUT2 PWM2 Note When us
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