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1. 0 2 1 SR13 16 Reserved oo o ny SR21 22 SD SIZE Security Data Table Size eSR23 LADDER LadderColeCRC O 6559 SR24 25 Reserved c o i eSR26 IO CRC lO Configuration Table CRC 0 65535 eSR27 NET Network Configuration Table CRC 0 65535 eSR28 SD Security Data Table CRC 0 65535 253 9 SR30 NET BAUD Network Baud Rate CsCAN 3 0 125 12250KB 2 500KB 3 1 SR31 NET MODE Network Mode O network not required i 2network 0 3 January 31 2014 Page 82 of 120 MANO964 01 EN CH 14 Table 14 2 SR Registers Register Description MinVal required 2 network optimized 3 network required and optimized SR32 LCD CONT LCD Display Contrast setting 0 255 SR33 FKEY MODE Function Key Mode 0 Momentary 1 Toggle 0 4 RS232 Serial Protocol Mode 5 O Firmware Update RISM 12 CsCAN 2 Generic une ERU RRON Ladder Controlled 3 Modbus RTU 4 Modbus ASCII SR35 36 SERIAL NUM ThisStatiors32 bitSeralNumer 0 271 9 SR37 MODEL NUM This Station s Binary Model Number 0 65535 9 SR39 CPLD REV BIOS Rev Number 100 000 255 9eSR40 FPGA REV FPGAlmageRevNumber 10 00 255 9 SSRM LCD COLS Vert calPixel Count SR42_ LCD ROWS Horizontal Pixel Cout 7 SR43 KEY
2. m 25 5 5 SiBIASING m NU UU E MN 25 January 31 2014 5 of 120 Table of Contents MANO964 01 EN 5 6 Cscape Programming via Serial POrt cccccccsssscccccsssseceeeceeeeeeeecsesseeeeseeeeseeeeseeaaseeeessaageeeeessaaess 26 5 7 Ladder Controlled Serial Communication 26 5 8 Downloadable Serial Communication Protocols ccccccssseeeceeeceeeeeeeeeeaeeeeeeeeeueaeeeeeesaeeeeeeeesaeees 26 CHAPTER 6 CAN COMMUNICATIONS annos an eu vue CE cu ooa Gus eve Cou o ean ore su saver v comuna vienes 27 2 ER 27 RODO TR T 27 MET LT 28 6 4 Programming 28 6 5 Ladder Controlled CAN Communication eeeeeeesssseesseseseeeee nennen nennen nnne 28 6 6 Using CAN for I O Expansion Network I O sssseeeeeeseeeeeeeneneennnn nnne 28 CHAPTER 7 ETHERNET 29 7 1 Ethernet Module Protocols and Features 29 Ethernet System hegqulremoehls ar a 29 7 97 EthernetModule SpeclilleatlOliS aed lobe a Un 29 TA Ethernet Module cohltiglalgliszss is resinae eie Sepia Por redi oe a LO e rue CO ete ico ee petites 29 CHAPTER
3. 1 by the firmware and never reset January 31 2014 Page 110 of 120 MANO964 01 EN CH 18 CHAPTER 18 MAINTENANCE 18 1 Firmware Updates The XL4 OCS products contain field updatable firmware to allow new features to be added to the product at a later time Firmware updates should only be performed when a new feature or correction is required Warning Firmware updates are only performed when the equipment being controlled by the XL4 OCS is in a safe non operational state Communication or hardware failures during the firmware update process can cause the controller to behave erratically resulting in injury or equipment damage Make sure the functions of the equipment work properly after a firmware update before returning the device to an operational mode Steps for updating the firmware 1 Loading new firmware will erase any program stored in the OCS for safety and compatibility reasons Please backup the application prior to doing a firmware update 2 Copy the supplied files onto a FAT32 formatted micro SD or USB based flash device 3 Insert the flash device into the XL4 making sure no other memory or drives are connected to the device 4 Press and hold the system menu for at least 6 seconds You will be presented with a firmware update menu 5 If you are just updating the firmware press the Update Firmware button If you are updating the bootloader firmware and FPGA press the Update Bootloader button On early v
4. The XL4 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 XL4 OCS to a location that minimizes shock and or vibration 3 6 7 Panel Layout Design and Clearance Checklist The following list provides highlights of panel layout design factors Meets the electrical code and applicable standards for proper grounding etc Meets the panel manufacturer s requirements for grounding etc 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 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 XL4 OCS Is there adequate ventilation Is the ambient temperature range maintained Are cooling or heating devices required Are noise suppression devices or isolation transformers required Is there adequate distance between the base of the XL4 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
5. Models HE XC100 HEXT251C100 have no installed I O or COM modules All other models have an I O module in Slot 1 and could have a user installed COM module in Slot 2 This chapter briefly describes the Modem COM module options For detailed information regarding these modules please refer to the individual documents provided with the modules January 31 2014 Page 35 of 120 CH 8 MANO964 01 EN 8 2 Modem COM Module XMC Option A Modem COM module can be installed to allow Cscape programming of an XL4 OCS over a dial up network In addition the application ladder program can take control of the modem for application specific modem communication The Modem COM module supports the standard AT command set and can connect to the dial up network at speeds up to 14 4 KBaud Connection speed is auto negotiated The Modem COM module connects to the dial up network phone line via a cable with a standard RJ11 modular plug To enable Cscape programming via a dial up network the Modem COM module should first be configured as the Default Programming Port using the XL4 OCS System Menu Doing this puts the Modem COM module in auto answer mode so Cscape can call the XL4 OCS via a remote modem To program the ladder application to communicate via the Modem COM module standard Cscape Serial and Modem function blocks can be used January 31 2014 Page 36 of 120 111037 MANO964 01 EN CH 10 CHAPTER 9 REMOVABLE MEDIA 9 1 Overview All XL4 OCS
6. This node s CAN Network ID was out of range at power up This node s Network ID is unique on the CAN network This node s Network ID is duplicated in another node Time and date have been set Time and date need to be set configuration matches the installed I O and COM modules configuration needs updating to match installed modules Backup battery operating properly Backup battery needs to be replaced The View I O Slots Sub Menu displays three System Settings all of which are not editable Internal to the XL4 OCS there is a CPU board and up to two installed modules Model XE100 has no installed I O or COM modules All other models have an I O module and can have a user installed COM module Depending on which module is installed and which I O module has been configured by Cscape one of the following six System Settings should appear for Slot 1 January 31 2014 Page 61 of 120 CH 12 MANO964 01 EN Slot 1 I O Empty No module installed or configured Slot 1 Unsupported Unsupported module installed Slot 1 I O Missing No I O module installed but an I O module is configured Slot 1 1 0 XExyy yy module installed but no I O module configured Slot 1 I O XExyy yy I O module installed but another I O module configured Slot 1 I O XExyy yy I O module installed and configured properly Depending on the COM module that is installed and the COM module that has been configured b
7. Y d T a T E ET ro be a ee e LE dot MB carat UAM Rip EIL F ey 6 474 crt XL4 I O Cover Removed sample I O board Once the back is removed the jumper selection can be changed The jumper settings are documented on each data sheet using a diagram such as Figure 9 4 below and a description of the jumper settings J1 Figure 10 4 Example Jumper Diagram To re install the cover place the I O cover back on the unit Place the screw back into the hole and turn the screw slowly counter clockwise until it clicks into the threads This prevents the screw from being cross threaded Now turn the screw clock wise until the cover is firmly secured Repeat this process for all four 4 screws January 31 2014 Page 42 of 120 MANO964 01 EN CH 10 10 3 Model and I O Overview Table 10 1 1 0 Model Overview Model s iu Relay Digital Analog Universal Analog XL4 Outputs Inputs Inputs Analog Inputs Outputs HE XC1E0 HEXT251C100 EO 131 HEXT251 C112 Y Y oo o s HEXT251 C113 Y Y o o HEXT251 C114 _ _ _ 251 115 Table 10 1 shows the different types of included with the various XL4 OCS models Specific specifications jumper settings and wiring diagrams can be found on the data sheets attached at the end of the manual Descriptions and
8. regulations Be sure to consult with the appropriate regulatory agencies before disposing batteries In addition do not re charge disassemble heat or incinerate lithium batteries Warning Do not make substitutions for the battery Be sure to only use the authorized part number to replace the battery The XL4 OCS uses a lithium ion battery available from Horner Below are the steps to replace the battery Make sure the user program and any data stored in retentive memory is backed up Disconnect all power from the XL4 OCS unit including I O power Remove the back cover Remove the I O board Remove the tape securing the battery and remove the battery Dispose of the old battery properly see the above warning on disposal regulations Install the new battery Install the I O board being careful to align the connector pins Place the back cover back on the unit 0 Apply power to the unit Check that the battery error is no longer reported If the unit still reports the error remove the battery immediately and contact Technical Support d m E EP January 31 2014 Page 112 of 120 MANO964 01 EN CH 19 CHAPTER 19 TROUBLESHOOTING TECHNICAL SUPPORT Chapter 18 provides commonly requested troubleshooting information and checklists for the following topics Connecting to the XL4 OCS controller Local controller and local I O CsCAN Network Removable media In the event that this information is not what you need plea
9. 1 2004 3 45 34 PM Filename Data M D csv Data0301 csv Filename Year Y Month M aa D_ h csv Year04 Month0O3 aa01_15 csv Filename Month_ M Day_ D h_ m_ s csv Month_03 Day_01 15 45 34 csv 9 10 System Registers used with RM SR175 Status This shows the current status of the RM interface SR176 Free Space This 32 bit register shows the free space on the RM card in bytes SR178 Card Capacity This 32 bit register shows the total card capacity in kilobytes Possible status values are shown in the table Table 8 2 RM Status Values _ 0 interface OK Card present but unknown format No card in slot Card swapped before operation was complete Unknown error Card present but not supported January 31 2014 Page 40 of 120 MANO964 01 EN CH 10 CHAPTER 10 GENERAL I O Note Each XL4 OCS unit is sent with a datasheet in the box The datasheet is the first document you need to refer to for model specific information related to XL4 OCS models such as pin outs jumper settings and other key installation information Visit our website to obtain datasheets user documentation and updates 10 1 Overview The XL4 OCS is a compact unit that contains high density very versatile I O Using the I O properly requires wiring to the proper terminals configuring jumpers inside the XL4 OCS unit and configuring Cscape properly This section will offer some tips and suggestions to configure the I O properly Fo
10. 15 2 Digital Input HSC Configuration Dialog January 31 2014 Page 95 of 120 CH 16 MANO964 01 EN The Active mode group box allows the user to select if inputs are active high Positive logic or active low Negative logic It is important that this setting match what the jumper settings are on the hardware The High Speed Counters group box contains all of the windows that are used for configuring the 4 available high speed counters on the XL4 OCS In configuring a counter the user needs to set the type mode and counts per rev The type drop down includes the following options A Disabled Frequency Measurement Period Measurement Totalize Pulse Width Measurment Quadrature 15 7 Digital Output PWM Configuration The following figure illustrates the Digital Output PWM Configuration dialog Digital HSC Input Configuration Digital inputs active mode Positive Logic Note This setting must match that of the jumpers C Negative Logic product HSC 1 0 Mapping Starting Digital ln x11601 8 8 Starting Digital Out 52016017 WE x 32 StattingAnalog n za 401 meem xg Starting Analog Dut zag401 seem x12 Counter Counter Totalizer Input Input2 Mode Up down Input 1 up input 2 down External Input 1 External Input 2 Disable Function Disabled gt Polarity High level Latch Function External Input H3 Polarity High level Pre
11. 3 1 Panel Mounting of an XL4 Series OCS suse nennen nnns nnn nnn nennen 17 Figure 3 2 XL4 OCS with Mounting CIiIpS eee ccccccccceeeeeeeeeeecaaeeeeeeeeeeeeeaeeeeeeeeeeeseeeseeeeeeeesaeegeeeeeeeesaaas 18 Figure 3 3 Orientation of XL4 OCS 18 Figure 3 4 Panel Cutout Tolerances 19 Figure 3 5 4 0 5 01 19 Figure 4 1 Two Point Ground Connection nennen nnne nnn 23 Figure 4 2 Power Connector Primary Power nnne nnn nnne nnn 24 Figure 4 3 Primary Power Port as Viewed Looking at the XL4 24 Figure 6 1 CAN1 ConnectoL ou uei Eust tube pecu e pled ees cde Las de aicut edad eee d su pesi ub voa Es tipa 27 Figure 62 CANT Port COlFPIeGCIOF ied 28 Figure 7 1 Configuration Dialog ssseeesssssssseeeeenneenennnnennnnnennn nnne nnns nsns naar nnn nnns nana 30 Figure 7 2 Ethernet Module Configuration 0 cccccccccccccceeseeeceeeeeeeaeee
12. 31 2014 Page 49 of 120 CH 11 MANO964 01 EN Width Low 1 us Counts In this sub mode the accumulator value will contain the number of 1 us counts the pulse is low L Width Low Figures 11 1 11 2 Pulse Width Measurements High amp Low 11 3 4 Period Measurement In period measurement mode the high speed input can measure the period of a pulse stream in one of two modes and provides a continuous indication of the last sampled value In this mode the Disable and Latch special functions are allowed Please see section 11 2 for a description of these functions Period Rising Edges 1 us Counts In this sub mode the period of the input signal is reported in one 1 us units The period measurement will start on the rising edge of the input FL __ Period from Rising Edge Period Falling Edges 1 us Counts In this sub mode the period of the input signal is reported in one 1 us units The period measurement will start on the falling edge of the input LL Period from Falling Edge Figures 11 3 11 4 Period Measurement Rising Edges amp Falling Edges 11 3 5 Quadrature Quadrature mode uses two HSC inputs any of the four HSC inputs can be assigned for this purpose Quadrature mode works much like the totalizer except the accumulator will automatically increment or decrement based on the rotation phase of the two inputs See the following example for more details Quadrature inputs are typically used for reporting
13. Click to continue Found New Hardware Wizard This wizard helps you install software for OCS USB COM Part m If your hardware came with an installation CD nr floppy disk insert it now What do want the wizard to da C Install fram a list or specific location Advanced Click Next to continue January 31 2014 Page 89 of 120 CH 16 MANO964 01 EN Hardware Installation The software you are installing for this hardware OLS USE COM Port has not passed Windows Logo testing to verify compatibility with Windows F me why this testing rs important Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that haz passed Windows Logo testing STOP Installation January 31 2014 Page 90 of 120 MANO964 01 EN CH 16 Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has finished installing the software for E OCS USB COM Part Click Finish to close the wizard Finish Cancel January 31 2014 Page 91 of 120 CH 16 MANO964 01 EN Now that the XL4 is plugged in go to Cscape Tools Application Settings Communications and choose the USB port in this example Com 3 Cscape untitled1 Edit Program Controller Deb
14. 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 including safety glasses and insulated gloves when making connections to power circuits f Ensure hands shoes and floor is dry before making any connection to a power line g Make sure the unit is turned OFF before making connection to terminals Make sure all circuits are de energized before making connections h Before each use inspect all cables for breaks or cracks in the insulation Replace immediately if defective January 31 2014 Page 11 of 120 CH 1 MANO964 01 EN 1 2 Grounding Grounding is covered in various chapters within this manual 1 3 CE Compliance To check for compliance and updates visit our website at http www heapg com or http www horner apg com January 31 2014 Page 12 of 120 MANO964 01 EN CH 2 CHAPTER 2 INTRODUCTION 2 1 Visual Overview of XL4 OCS Dip Switches microSD Memory Slot J4 O Terminal model 4 only Serial MJ1 2 USB 2 0A Ethernet J2 Terminal TY 0 9 2T Left Right DC Power In 10 30 amp CAN Port Frame Ground J3 Terminal model 4 amp 5 Bottom 2 1 1 Where to Find Information about the XL4 OCS a Datasheets The datasheets are the first documents you
15. Register 31 Version Register 32 Ethernet Module Configuration 29 Ethernet Module Protocol Configuration 33 Ethernet Module Protocols and Features 29 Ethernet Module Specifications 29 Ethernet System Requirements 29 Fail Safe System Overview 101 Fail Safe System Settings 102 Features 14 Firmware Updates 113 Frequency 50 53 55 56 57 58 98 Front Panel and USB Programming Connector 90 fusing 44 45 GENERAL I O 41 Overview 41 Glossary High Speed I O 49 Ground Specification 23 Grounding Locations of Information 12 Grounding Definition 23 High Speed Configure Inputs 50 Frequency 50 High Speed PWM Overview 49 High Speed Counting 49 HIGH SPEED I O 49 HSC 49 50 51 52 53 54 55 97 Cover Removal 41 IP Address 31 Jumpers Example 42 LIMITED WARRANTY 3 Load Clone 71 111 Maintenance 109 113 Make Clone 109 Manual Index 14 Mechanical installation 17 Micro SD Cards 37 Installing Removing 37 Micro SD System 38 MANO964 01 EN Table of Figures Minimum Clearance Requirements for Panel Box and Door 20 MJ Serial Port Connectors Photograph 25 Model I O Overview 42 Modem COM Module Option 36 Mounting Orientation 18 Mounting Requirements 17 Panel Door Mounting 17 Net Mask 31 OCS Reference Document Numbers 16 Orientation of XL6 OCS 18 Panel Box Clearances 20 Grounding 20 Noise 21 Orientation 21 Temperature 20 Panel Box Shock and Vibration 21 Panel Cut out 19 P
16. Service Request Modbus TCP Slave Ethermet IP FTP File Server CJ HTTP web Server Download the configuration in to Controller Connect LAN cable to the Controller in default LAN Port From Cscape go to Tools gt Editor Options gt Communication Port gt configure Select Ethernet and enter IP address which is configured in the file Select mode as XL Series mode from drop down list The controller should get connected to Cscape If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above January 31 2014 Page 94 of 120 MANO964 01 EN CH 16 15 5 Configuration An overview of configuration 1 2 3 4 5 6 7 8 Start the configuration by selecting the Controller I O Configure menu item If the XL4 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 XL4 OCS is not connected press the Config button to the right of the top of the unit This allows the base CPU to be selected Select either XL4 OCS Cscan from the type drop down box Once the type of XL4 OCS is selected the model drop down box will provide the XL4 OCS model numbers from which to choose from Once the XL4 OCS CPU is selected press OK to exit the dialog and configure the 1 0 that is present in the first slot The I O configure dialog S
17. The following sections describe each of the Sub Menus in detail Set Networks This sub menu allows setting for the CAN and Ethernet network to be viewed or changed CAN Ok Yes connected to a CAN network and functioning properly Not ready to communicate on CAN network CAN ID 1 to 253 This node s CSCAN Network ID must be unique on network CAN Baud 125 125 KBaud CAN network 250 250 KBaud CAN network 500 KB 500 KBaud CAN network 1 MB 1 MBaud CAN network MAC ID Displays the Ethernet MAC ID of the unit IP Displays the Ethernet IP address of the unit NetM Displays the Ethernet net mask of the unit GatWy Displays the Ethernet gateway of the unit Note The IP address Net Mask and Gateway can be changed from the system menu This is designed for commissioning or temporary field changes The actual parameters are defined in Cscape under the Ethernet configuration View Status Hodel Scan Rate mS Lcl Net Use All Net Use Ladder Size Config Size Graphics Size String Size Bitmap Size Text Tbl Size Font Tbl Size Protocol Size SHS File Size Firmware Rev The View Status Sub Menu displays up to 19 System Settings Only the Mode System Setting is editable Model XLiyz Model number of this XL4 OCS unit 1yz indicates the installed I O module 00 no I O module OCS Mode Idle XL4 OCS is in Idle mode DolO XL4 OCS is in Do I O mode Run XL4 OCS is in Run mode
18. aerias 97 15 9 Analog Output CohligBllatOEisss Ue d Lu rebote via LO Me eus insertion EP LOI e veter ode ei D 98 CHAPTER 1 5 FAIL SAFE SYSTEM iini ioi iat oo iuo opu EE omo censa base 99 uox EEG UI E 99 16 2 gt ER 100 1623 BACKUP Restore Dald DU ELE 100 s oW cR ERN 104 169 MU 106 CHAPTER 17 CLONE UNIT owe du cama vesc dtu 107 OVEM W e eae et 107 I WECIILIO 107 IS Load lont EU 109 CHAPTER 18 MAINTENANCE E Or ec auae oS e aae aded 111 18 1 Firmware Updates cccccccccccssssececcceeseeceeseaeseeeeeseeesseeeseseaaeceeesseaaeeeeeseaaeeeeesseaeeeeessaaeeeeeessagess 111 182 BACKUP Balen X E 111 18 2 1 Indications the battery needs 111 1822 Battery Replacement uiuat non univ eund sem 112 CHAPTER 19 TROUBLESHOOTING TECHNICAL SUPPORT 113 191 EO e oin eligen 113 January 31 2014 Page 7 of 120 Table of Contents M
19. applications of the different type of I O can be found below January 31 2014 Page 43 of 120 CH 10 MANO964 01 EN 10 4 Solid State Digital Outputs oolid state digital outputs are generally used to activate lamps low voltage solenoids relays and other low voltage and low current devices Note The digital outputs used on the XL4 OCS are sourcing outputs This means the output applies a positive voltage to the output pin when turned ON When turned off the output applies approximately zero volts with respect to the I O ground 10 30VDC Figure 10 5 Typical Output Wiring The digital outputs used in the XL4 OCS have electronic short circuit protection and current limiting While these electronic protections work in most applications some application may require external fusing on these outputs The digital outputs in the XL4 OCS are typically controlled via Q bits in the register mapping Some of the outputs are designed for high speed applications and can be used for PWM or frequency output applications Please see the data sheet and the chapter on High Speed 1 0 for additional information When the controller is stopped the operation of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state By default digital outputs turn off For more information on stop state see the Index to find pages referencing Cscape settin
20. eb CO os Qa Dh pu abusu a 54 Td 5 PWM functions register COR eta ui Det ea duc dba ds Det eda das ee COM ure is s bou 55 January 31 2014 Page 6 of 120 MANO964 01 EN Table of Contents TLO su s tiec Me ERU m 55 AME cao Ru RENT 56 CHAPTER 12 SYSTEM SETTINGS AND nnn nnns 57 12 4 System MEDUS OVEVIEW souscrit el Cu 57 12 2 System Menu Navigation and Editing nennen 58 12 9 Oy lemn Men GLANS ects in n RE ULM E 59 p MEE ocean eiie 2l E ET DES 70 CHAPTER 13 USER INTERFACE a dod m vie Gti oa 71 MENS 71 132 Displaying and enternng hea ee a wa weed ee 71 13 3 SAIphaspilliere KeyDpaQdaoiiecacuitav en ute cue o aad EUM a deca LO De wav ead ne Fue RO DUE 72 por SSCS I S UL Tt LEE 74 13 5 Ladder Based Screen Navigation a Wee eat eds e hs COP e de Pere e oe bas 74 12 6 Beeper Acknowledgetmiefib stie I ecc haxa chess eve e e Ob e dau piu edel be oria 75 aii Pe coe tee DE LEE e ceo ea LOO Ee a 75 DOE e
21. high voltage to any I O pin can cause high voltage to appear at other I O pins 230VAC OR 25VDC 230VAC OR 25VDC 230VAC OR 25VDC 230VAC OR 25VDC 230VAC 230VAC OR 25VDC 12 24VDC OV ON J1 001XLE015 Figure 10 6 Relay Fusing January 31 2014 Page 45 of 120 CH 10 MANO964 01 EN Protection for Inductive Loads Inductive loads can cause reverse currents when they shut off that can shorten the life of relay contacts Some protective measures need to be determined by an engineer Below you will find recommendations that will work for many applications If you have additional questions on protection from inductive load consult an application engineer or HEAPG Technical Support Details on devices that may protect outputs can be found in MANO0962 01 Output State on Controller Stop When the controller is stopped the operation of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state By default relay outputs turn off For more information on stop state see the Index for Cscape settings pages 10 6 Digital Inputs Note Refer to the datasheet for XL4 OCS model you are using for details on jumper settings Note The digital inputs on the XL4 OCS are designed for low voltage DC inputs The inputs are designed to support both positive and negative input modes The mode is set by a jumper sett
22. idle R run or D do I O shows next to Target number then communication is established to the target controller Target I R D Communication is not established to the target controller Check node ID of controller and 4 2 Target set Target to match Make sure local connection is established January 31 2014 Page 113 of 120 CH 19 MANO964 01 EN 19 1 1 Connecting Troubleshooting Checklist serial port MJ1 Programming d 2 3 Programming and debugging must use MJ1 or USB Mini B Port Controller must be powered up Ensure that the correct COM port is selected in Cscape Tools Editor Options Communications Port Ensure that a straight through non null modem serial cable is being used between PC and controller port MJ1 Check that a Loaded Protocol or ladder is not actively using MJ1 Taking the controller out of run mode from the System Menu on the controller will make MJ1 available to Cscape Make sure the COM port of the PC is functioning An RS 232 serial loopback and Microsoft HyperTerminal can determine positively if the COM port is working Or connect to an alternate device to determine if the port is working Successful communications with USB to serial adapters vary If in doubt Horner APG offers a USB to serial adapter Part number HE500USB600 XL4 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 pro
23. minutes seconds in 24 hour format Date 10 Jul 2008 Current date day month year Day Thursday Current day of week calculated from the Date setting Set Beeper ves Use 7 to adjust The Set Beeper Sub Menu displays one System Setting which is editable Beeper enable Yes default Enables beeper No Disables beeper does NOT affect ladder access Set Screen The Set Screen Sub Menu displays four System Settings all of which are editable January 31 2014 Page 64 of 120 MANO964 01 EN CH 12 Saver enable Timenut min Popup Status Update 5 Update time sets the maximum time used by graphics in the logic scan Saver enable Yes Enable screen saver No default Disable screen saver Timeout min 5 1200 Amount of time in minutes to expire with NO touch activity before activating screen saver black screen Popup Status Off default Disable popup status Warning Display popup status only if controller status changes to NOT Ok or NOT Run mode ON Display popup status on any controller status change Update Time mS 2 50 Maximum amount of time to allow for graphics update per scan Removable Media Media Directory SER8801 07 10 08 SCR8808 2 15209 07 10 08 SCR8803 29708 07 10 08 SCROGG4 29582 07 10 08 SCROO65 23263 67 10 68 SCR88086 14643 07 10 08 SCR8807 14976 07 10 08 SCR8BBS 15994 67 16 68 5 0009 17561 67 16 68 Free 511672320 To
24. models provide a Removable Media slot labeled Memory Card which supports standard Micro SD Flash memory cards Micro SD cards can be used to save and load applications to capture graphics screens and to log data for later retrieval Figure 9 1 Removable Micro SD Memory Card Slot 9 2 Micro SD Cards When the Micro SD card format was introduced it was originally called TransFlash Cards labeled either Micro SD or TransFlash with up to 32 GB of Flash memory are compatible with the XL4 OCS Memory slot larger sizes were not tested at time of publication The Memory slot is equipped with a push in push out connector and a Micro SD card can be safely inserted into the Memory slot whether the XL4 OCS power is On or Off To install a Micro SD card Align its 8 pin gold edge connector down facing the front of the XL4 OCS unit as shown in Figure 9 2 then carefully push it all the way into the Memory slot Ensure that it clicks into place To remove the Micro SD card Push down on the top of the card gently to release the spring The card pops up for removal lt Ce gt e a Figure 9 2 Installing Removable Memory Card January 31 2014 Page 37 of 120 CH 10 MANO964 01 EN 9 3 Micro SD File System The Micro SD Memory slot uses the PC compatible FAT32 File System This means that a PC with a Micro SD compatible card reader can read files that have been written by the XL4 OCS and can write files
25. provisions for the end equipment as is usual and customary in industrial applications as defined in any codes or standards which apply Note The programming examples shown in this manual are for illustrative purposes only Proper machine operation is the sole responsibility of the system integrator January 31 2014 Page 3 of 120 PAGE 4 964 01 INTENTIONALLY LEFT BLANK January 31 2014 Page 4 of 120 MANO964 01 EN Table of Contents TABLE OF CONTENTS PREFACE Hi oti pui fL it teagan an eee fecu b remi cuf Ue 2 For user manual updates contact Technical 2 LIMITED WARRANTY AND LIMITATION OF LIABILITY eeesseeeeeeeennnnnnnnnnnnn nnn 3 ABOUT PROGRAMMING EXAMPLES eeeeeeeesssseseeene nennen 3 2 PET 5 INTENTIONALLY 10 CHAPTER 1 SAFETY GOMPLTIANGE 2 cu Pe e euo p buc oon eue aiaiai 11 1 1 Safety Warnings and G ldellfies a a E 11 Grounding Met a 12 p Ezio TT TR 12 CHAPTER 2 INTRODUGTIQNJL eacus eto ou uuu cte o warten sare 13 2 4 Visual Overview Of XLA bna d
26. that can be read by the XL4 OCS However the XL4 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 characters Directories and sub directories can be nested up to 16 levels deep as long as each pathname string does not exceed 147 characters 9 4 Using the Removable Media Manager The Removable Media Manager is an interactive XL4 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 Micro SD card Load and save application programs View screen capture bitmaps 90o0o0p The Removable Media Manager can be accessed via the System Menu or by using Cscape to place a Removable Media Manager object on an application graphics screen Media Directory PI 7 0n70 SCR808801 JPG 14272 67 10 68 SCR80882 JPG 15209 07 10 08 SCR88683 JPG 29708 07 10 08 SCR0860 JPG 29582 07 10 08 SCR080605 JPG 23263 07 10 08 SCR0886 JPG 14643 67 10 68 SCR0807 JPG 14976 67 10 68 SCROO68 JPG 15994 67 10 68 SCROO69 JPG 17561 07 10 08 Free 511672320 Total 511959646 a AJ Y oea Bt S ee Figure 9 3 Removable Media Submenu 9 5 Using Removable Media to Log Data Using Read and Write Removable Media function blocks an application ladder program
27. 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 Setting that can be edited is highlighted lf desired the 4 and 7 keys can be used to select a different System Setting to be edited At this point either press ESC to exit the Sub Menu returning to the Main Menu or press Enter to edit the highlighted System Setting If Enter is pressed the System Setting s value will be highlighted indicating that it is ready to be modified When modifying a System Setting s value use either the arrow keys lt gt J 1 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 Ed ERE BBC In addition to edit a single numeric digit use the or key to select the digit and then either press a numeric key or use J or 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 January 31 2014 Page 58 of 120 MANO964 01 EN CH 12 12 3 System Menu Details
28. the XL4 and some of the model specific characteristics of the XL4 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 Displaying and entering data Alpha numeric data entry Navigating around screens Beeper acknowledgement Touch slip sensitivity Alarm log dialog dialog Screen Saver Dimmer 13 2 Displaying and entering Data Roller 2 A cem Running Hours 1274 S Cleaning Hours 34 Figure 13 1 Example Screen XL4 only January 31 2014 Page 71 of 120 CH 13 MANO964 01 EN Multiple objects are provided for displaying data such as virtual panel lights push buttons numeric value displays bar graphs meters graphs and animated bitmaps the XL4 these graphical objects through ladder manipulation of attribute bits can change color flash or change visibility to attract operator attention On objects that accept user input the input is provided by touching the object or alternately 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
29. the value of an encoder January 31 2014 Page 50 of 120 MANO964 01 EN CH 11 Two modes are available for quadrature that select whether the accumulator counts up or down when the phase of input 1 leads input 2 Check the encoder s documentation to determine the output form it uses or try both modes to determine if the encoder counts up when expected Er 1 leading lagging Figures 11 5 Quadrature Using the above waveforms and a HSC input configuration of Quadrature 1 leads 2 count up the accumulator will count up when 1 is rising and 2 is low 1 is high and 2 is rising 1 is falling and 2 is high and when 1 is low and 2 is falling This results in 4 counts per revolution So in order to determine the number of cycles the accumulator would have to be divided by 4 Marker reset operation is configured in the special operations and can be assigned to any of the 4 high speed iputs or can be assigned to be controlled by a Q bit in ladder Note the quadrature mode enables the Disable Latch Preload Clear and Marker special functions Please see section 11 2 for details 11 3 6 Register Match All counter modes support a register match function When the accumulator value matches the Match 1 or Match 2 value setup in AQ registers a high speed output with either turn on turn off or toggle based on settings in Cscape January 31 2014 Page 51 of 120 CH 11 MANO964 01 EN 11 4 Functions R
30. three wire leads and two ground rods Instructions are supplied for either a two point or three point ground test Figure 4 1 shows a two point ground connection test GROUND RESISTANCE METER GROUND DISCONNECTED CR SE FROM SERVICE SS SA METAL WATER PIPE OR OTHER GOOD GROUND Figure 4 1 Two Point Ground Connection Test January 31 2014 Page 23 of 120 4 MANO964 01 EN 4 4 Primary Power Port Table 4 1 Primary Power Port Pins Description Signal Input power supply ground Input power supply positive voltage Pin _ 10 30 VDC supply Power Connector Power Up Figure 4 2 Power Connector Primary Power Port Connect to Earth Ground Apply 10 30 VDC Screen lights up Torque rating 4 5 7 Lb In m 0 50 0 78 N m NONO PIN 1 PIN 2 PIN 3 Figure 4 3 Primary Power Port as Viewed Looking at the XL4 OCS January 31 2014 Page 24 of 120 111037 MANO964 01 EN CH 5 CHAPTER 5 SERIAL COMMUNICATIONS 5 1 Overview All XL4 OCS models provide two serial ports which are implemented with single 8 pin modular RJ45 connectors and are labeled MJ1 and MJ2 The MJ1 serial port is RS 232 while the MJ2 port is RS 485 MJ1 defaults to OCS programming by connecting it to the COM port of a PC running Cscape In addition both MJ1 and MJ2 can be used for application specific communication using a variety of standard data exchange protocols 5 2 Port
31. types of soft failures These soft failures include e Battery power loss e Battery Backed Register RAM or Application Flash corruption due to for example an excessive EMI event selecting Fail Safe System menu will open the following menu screen January 31 2014 Page 66 of 120 MANO964 01 EN CH 12 Backup Restore Data Enable AutoRun Enable AutoLoad ESC to exit oelecting Backup Restore Data displays the following screen in Backup Restore Data Clear Backup Backup Copies Battery Backed RAM contents on to the onboard FLASH memory of the OCS Restore Copies the backed up data from onboard FLASH to the battery backed RAM Clear Backup The backup data will be erased from the onboard FLASH Exit Goes back to previous menu Enable AutoRun displays the following options which can be selected Enable AutoRun Ho AUT IUHs Auto Enters RUN after AutoLoad or Battery Fail 31 2014 Page 67 of 120 CH 12 MANO964 01 EN Enable AutoRun NO OCS will be in IDLE mode after AutoLoad or Automatic Restore Yes OCS will be automatically placed into RUN mode after AutoLoad or Automatic Restore Enable AutoLoad displays the following options which can be selected Enable AutoLoad Ho AutoLoad from Removable Media s AUTOLOAD PGH File when triggered Enable AutoLoad No Does not load AUTOLOAD PGM automatically when applicatio
32. 0 no forces indicates no I O has been forced CH 16 MANO964 01 EN 15 3 Establishing Communications The preferred method of communicating between Cscape and an XL4 OCS is via USB port The XL4 OCS can communicate with Cscape using USB to USB USB to serial adapters serial port communications via MJ1 Port Ethernet with an Ethernet adapter board onboard Ethernet Port CAN CsCAN or modems For communications other than USB or the MJ1 port please refer to the manual which ships with the communications adapter hardware being used for programming To communicate with the XL4 via USB you will need the automated driver installer located on the Horner APG web site For XL4 use Cscape Ver 9 30 SP3 or newer Next connect a PC s Personal Computer running a Windows Microsoft operating system USB port via USB cable to the USB mini B port on the XL4 OCS Figure 15 1 USB Programming Connector The PC will detect a new device has been plugged into the USB port January 31 2014 Page 88 of 120 MANO964 01 EN CH 16 Found Hew Hardware Wizard Welcome to the Found New Hardware Wizard Windows will search for current and updated software by looking on your computer on the hardware installation or on the Windows Update Web site with your permission Read aur privacy policy Can Windows connect to Windows Update to search for software CO Yes this time only now and every time connect a device
33. 09 Figure 17 7 Clone Unit Menu after nnne nnne nnn nnn 110 Figure 17 8 Load Clone Confirm Screen cccccccccccccccceeceeeseeeeeeeeeeeeeeeeeeeeseaeaseeeeeeessaeeeeeeeeeesseaaaeeeeeseesaaas 110 No part of this publication may be reproduced without the prior agreement and written permission of Horner APG Inc Information in this document is subject to change without notice January 31 2014 Page 120 of 120
34. 16 CHAPTER 16 FAIL SAFE SYSTEM 16 1 Overview The Fail Safe System is a set of features that allow an application to continue running in the event of certain types of soft failures These soft failures include e Battery power loss e Battery Backed Register RAM or Application Flash corruption due to for example an excessive EMI event The Fail Safe System has the following capabilities e Manually backup the current Battery Backed RAM Register Settings into Flash memory e Manually restore Register Settings from the values previously backed up in Flash to Battery Backed RAM e Detect corrupted Register Settings at power up and then automatically restore them from Flash e Detect corrupted or empty application in Flash memory at power up and then automatically load the AUTOLOAD PGM application file from Removable Media Compact Flash or MicroSD e f an automatic Register Restore or Application Load occurs the OCS can automatically be placed in RUN mode The fail safe system can be accessed by going to the system menu of the controller A new menu Fail Safe System has been added at the end of the main system menu for this Selecting Fail Safe System menu will open the following menu screen Backup Restore Data Enable AutoRun Enable AutoLoad ESC to exit Figure 16 1 Fail Safe System Menu January 31 2014 Page 99 of 120 CH 16 MANO964 01 EN 16 2 Settings To use the fail safe feature the u
35. 20 GTXT SIZE Graphics Text TableSize 8 128K SR121 122 SIZE Graphics Font Table Size 8 256K eSR125 GOBJ CRC Graphics Object Table CRC 0 65535 eSR126 GSTR Graphics String Table CRC 0 65535 eSR127 GBMP Graphics Bitmap Table CRC 0 65535 eSR128 GTXT CRC Graphics Text Table CRC 0 65535 __ 5 129 CRC __ Graphics Font Table CRC O 65535 eSR130 PROT CRC Protocol Tabe CRC O 65535 SR131 SR164 3 Read bit indicating Auto Restore of Register Data January 31 2014 Page 83 of 120 CH 14 MANO964 01 EN Table 14 2 SR Registers Register Description Min Val Max Val _ has been performed Fail Safe eee Read bit indicating Backup of Register Data has been performed Fail Safe SR1645 Enable AUTORUN Fail Safe CC SR1646 Enable AUTOLOAD Fail Safe SR164 7 Backpt ggebit SR1648 CT Clear Backup trigger bit SR1649 MAKE CLONE trigger bit SR164 10 LOAD CLONE trigger bit Status indicating Make Clone Fail This bit goes eulos high when Make Create clone fails o SR164 12 Status indicating Load Clone Fail This bit goes high when Load clone fails 25 165 174 SR175 Current Removable Media interface
36. 33 434 434 PWM 2 PWM2Frequeny Run stepper 2 EXP E 438 Run Count BM count Stepper 2 AQ439 440 440 Deceleration Count Deceleration Count Stepper2 2 Start Move Bit Stepper 1 02 Start Move Bit Stepper 2 8 Stepper 1 1 L nen one Stepper _ Stepper 2 620 Ermor Stepperr2 2 Q30 and Q31 for model 2 using HSQ or HSQ 5 necessary to start move 11 7 PWM Examples Example 1 Duty Cycle Frequency T 96 D 10 kH o get a 50 Duty Cycle 10 kHz Set AQ421 422 16 000 Set AQ423 424 10 000 waveform on PWM1 Example 2 Duty Cycle Frequency Set AQ421 422 16 000 To get a 50 Duty Cycle on PW1 and Baa Set AQ423 424 1 000 0 90 Duty Cycle on PWM2 1 kHz Set AQ431 432 28 800 f 433 434 1 waveform duty cycle 32000 0 9 Set AQ433 43 000 Example 3 Duty Cycle Frequency To turn PWM 1 output ON all the time Set AQ421 422 32 000 Set AQ423 424 Any Value Example 4 Duty Cycle Frequency T PWM 1 FF all th n ii output OFF all the Set AQ421 422 0 Set AQ423 424 Any Value January 31 2014 Page 55 of 120 CH 11 MANO964 01 EN 11 8 STP Examples Example 1 Start Frequency Frequency Accel Count Run Count Decel Count 10 000 000 Set AQ421 Set AQ422 Set AQ423 4 Set AQ425 6 Set AQ427 8 steps control 2500 Hz 5000 Hz 1 000 000 Steps 8 000 000 Steps 1 0000 000 Steps seq
37. 50 User Screen Ladder Code 1024 kB January 31 2014 Page 85 of 120 CH 14 MANO964 01 EN NOTES January 31 2014 Page 86 of 120 MANO964 01 EN CH 16 CHAPTER 15 CSCAPE CONFIGURATION 15 1 Overview XL4 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 XL4 OCS unit Please see the on line help provided with Cscape for additional details 15 2 Cscape Status Bar When the XL4 OCS is connected to a PC using Cscape software a Status Bar appears at the bottom of the screen The Cscape Status Bar can be used to determine if communications have been established between the XL4 OCS and the Cscape program Components of the Cscape Status Bar are explained below Message Line The contents of these messages stored in the Target Controller Equal Indicator indicates whether the current program in Cscape is equal to the program are context e f Equal the program in Cscape is the same as the program stored in the Target Controller sensitive The e f Not Equal the program in Cscape is not the same as the program stored in the Target Message line can Controller be empty f Unknown there may have been a change since the last time the program in Cscape was compared to the Target Controller Current User indicates who is logged for security purposes File Modified Indicator indicates that the fi
38. 7 2 January 31 2014 Page 30 of 120 111037 MANO964 01 EN CH 7 Module Configuration Register Usage Default Settings Register Direction IP Address 182 168 254 128 Read Only Use CAN ID for last Octet MetMask 255 255 255 0 9 Geer l 0 0 0 0 gm Status MEE Read Ony Version PO dem Read Ony Enhanced Configuration Frotocol Support z PUN Configure Selected Protocol SATF Slave 90 30 Service Request Modbus TCP Slave EthemetzlP FTF File Server LJ HTTP web Server Cancel Figure 7 2 Ethernet Module Configuration 4 Configure the Ethernet Module parameters as follows IP Address Enter the static IP Address for the Ethernet Module being configured Note IP Addresses are entered as four numbers each ranging from 0 to 255 These four numbers are called octets and they are always separated by decimal points Net Mask Enter the Net Mask Sometimes called Subnet Mask being used by all nodes on the local network Typical local networks use Class C IP Addresses in which case the low octet rightmost number is used to uniquely identify each node on the local network In this case the default Net Mask value of 255 255 255 0 should be used Gateway Enter the 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 communica
39. 79 of 120 MANO964 01 EN CH 14 January 31 2014 Page 80 of 120 MANO964 01 EN CH 14 CHAPTER 14 REGISTERS 14 1 Register Definitions When programming the XL4 OCS data is stored in memory that is segmented into different types This memory in the controller is referred to as registers Different groups of registers are defined as either bits or words 16 bits Multiple registers can usually be used to handle larger storage requirements For example 16 single bit registers can be used to store a Word or two 16 bit registers can be used to store a 32 bit value Below is a list of the type of registers found in the XL4 OCS 1 Analog Input 16 bit input registers used to gather analog input data such as voltages temperatures and speed settings coming from an attached device AQ Analog Output 16 bit output registers used to send analog information such a voltages levels or speed settings to an attached device AIG Global Analog Input Specially defined 16 bit input registers that come from the network AQG Global Analog Output Specially defined 16 bit output registers that go to the network D Display Bit These are digital flags used to control the displaying of screens on a unit which has the ability to display a screen If the bit is SET the screen is displayed l Digital Input oingle bit input registers Typically an external switch is connected to the registers IG Global Digital Input opecially defined single b
40. 8 COMMUNICATION OP TIONS idiot dist etc aui roe uos 35 Gall 2 4 CE cm 35 8 2 COM Module AMC Option ee tit duse eto pea a 36 CHAPTER 9 REMOVABLE MEDIA tirade ver bae oe 37 20 cmt 37 9 2 JMICIO S tbe a ct Lp MEM ELA ES LEE RM 37 9 95 iMICIO SD File amp M ER 38 9 4 Using the Removable Media Managel cccccsssseccccccssseceeeceeseeceescaeeeeeesesaeeeeesesaaeeeeeessaeeeeeessaaaes 38 9 5 Using Removable Media to Log 38 9 6 Using Removable Media to Load and Save 39 9 7 Using Removable Media to View and Capture 39 9 8 Removable Media RM Function Blocks in Cscape 39 9 9 Filenames used with the Removable Media RM Function Blocks 40 9 10 System Registers used with RM sucus donee ots vett te Pen et ete d SO d eiue etes 40 CHAPTER 10 GENERAL obeunda n euo oan oc ttum au cu ede su ea 41 TUS eee Nem MEM I ad RM 41 10 2 Removing the XL4 OCS Cove senes ana cc nana aane essa
41. ANO964 01 EN 19 1 1 Connecting Troubleshooting Checklist serial port MJ1 Programming 114 19 1 2 Connecting Troubleshooting Checklist USB Port Mini B Programming 114 19 1 3 Connecting Troubleshooting Checklist ETN port programming 114 19 2 1 and eite donde i tede dioe baiser eis 114 19 2 1 Local I O Troubleshooting Checklist seseeeeeesseeeeneeeenen 115 19 3 Oe METEO MN 115 19 3 1 CsCAN Network Troubleshooting Checklist eeeeeeeeeesseeeeeeeeeee 115 194 Removable Medid D 116 19 4 4 Basic Troubleshooting ssseesssssssssssseeeeeenneeennne nennen nennen nnn nnns 116 19 5 Technical Support Contacts ssssseissssseessiseseeeen nennen nennen nnn nnns hannis naar 116 117 Table OLF HE 120 January 31 2014 Page 8 of 120 MANO964 01 EN Visual Map Visual Map of major tasks and the key chapters to assist you FIRST STEP of ANY TASK DATASHEET Each XL4 OCS unit is sent with a datasheet in the box The datasheet is the first document you need to refer to for model specific information related to XL4 OCS models such as pin outs jumper settings and other key installation information Visit our web
42. Descriptions The MJ1 serial port contains a RS 232 interface with RTS CTS handshaking The MJ2 serial port contains half duplex RS 485 interface with no handshaking The MJ2 RS 485 interface provides switchable termination and bias resistors internally 5 3 Wiring and Dip Switches MJ1 2 Serial Ports DIP Switches MJ1 RS 232 w Full Handshaking MJ2 RS 485 Half Duplex Two Serial Ports on One Modular Jack 8posn MJ2 Pins 6 ov ov Ground Function Default ms jor OFF 3 j 2 RTT IN OUT 1 RK TXT 5 4 RS 485 Termination Proper RS 485 termination minimizes reflections and improves reliability The 485 serial port allows an internal RS 485 termination resistor to be placed across pins 1 and 2 by DIP owitch Setting Only the two devices physically located at the endpoints of the RS 485 network should be terminated 5 5 RS 485 Biasing RS 485 biasing passively asserts a line idle state when no device is actively transmitting which is useful for multi drop RS 485 networking January 31 2014 Page 25 of 120 CH 5 MANO964 01 EN The 485 serial ports allow internal RS 485 bias resistors to be switched in pulling pin 1 up to 3 3V and pulling pin 2 down to ground The Set Serial Ports item in the System Menu can be used to enable RS 485 biasing Also an application graphics screen that writes to SR164 can do the same thing Setting SR164 1 e
43. Disable A special function to prevent the counter from running esee A sensor or transducer for converting rotary motion or position to a series of electronic oulses Frequency The number of times an electromagnetic signal repeats an identical cycle in a unit of Input time usually one second A special function that uses a digital logic circuit to store one or more bits A latch has a data input a clock input and an output When the clock input is active data on the input is latched or stored and transferred to the output register either immediately or when the clock input goes inactive The output retains its value until the clock goes active again Clear Latch strobe Input into the OCS that indicates a particular position Typically an encoder has a Marker z marker output that represents a specific point in the rotation A Polarity pull down box is associated with each function and indicates the manner in Pelei which the trigger happens e g High level Low Level Falling Edge Rising Edge Preload A special function used to trigger loading of a value into a register upon an event Not load used with Frequency or Period Measurement A high speed device that expresses the phase relationship between two periodic Quadrature quantities of the same period when the phase difference between them is one fourth of a period A coupler in which the two output signals are 90 out of phase Totalizer A counter that sums the t
44. File System uses bitmap files with the BMP extension or JPEG files with the JPG extension to store XL4 OCS graphic screen captures To view a captured XL4 OCS screen use the Removable Media Manager to find and highlight the desired BMP or JPG file and then press Enter To capture an XL4 OCS screen turning On the assigned Screen Capture Control Register will capture the current XL4 OCS graphics screen and write it to the Micro SD card using the assigned Screen Capture Filename Before capturing an XL4 OCS screen Cscape must first be used to assign a Screen Capture Control Register and Filename in the application To do this first open the Graphics Editor by selecting the View Edit Screens item on the Cscape Screens menu Next select the Screen Capture item of the Graphics Editor Config menu and then enter a Control Register and Filename 9 8 Removable Media RM Function Blocks in Cscape Note For detailed information regarding RM function blocks and parameters refer to the help file in Cscape Software Refer USB Flash Media support for RM Functions for USB flash drive access details The following RM functional blocks are available in Cscape Software These function blocks will reference Micro SD when filename is prefixed with nothing OR USB A Flash Drive when filename is prefixed with B a Read RM csv This function allows reading of a comma separated value file from the Micro SD interface into the controll
45. G THE TERM ORIGINAL PURCHASER AS USED IN THIS WARRANTY SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM THE XL4 OCS module IS ORIGINALLY INSTALLED THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES In no event whether as a result of breach of contract warranty tort including negligence or otherwise shall HE APG or its suppliers be liable of any special consequential incidental penal damages including but not limited to loss of profit or revenues loss of use of the products or any associated equipment damage to associated equipment cost of capital cost of substitute products facilities services or replacement power down time costs or claims of original purchaser s customers for such damages To obtain warranty service return the product to your distributor with a description of the problem proof of purchase post paid insured and in a suitable package ABOUT PROGRAMMING EXAMPLES Any example programs and program segments in this manual or provided on accompanying diskettes are included solely for illustrative purposes Due to the many variables and requirements associated with any particular installation Horner 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 XL4 OCS module to appropriately design the end system to appropriately integrate the XL4 OCS module and to make safety
46. HORNER AUTOMATION GROUP User Manual for XLA OCS HE XC1E0 HEXT251C100 HE XC1E2 HEXT251C112 HE XC1E3 HEXT251C113 HE XC1E4 HEXT251C114 HE XC1E5 HEXT251C115 DOCS BARAA lt 964 01 31 2014 1 of 120 PAGE 2 964 01 This manual explains how to use the XL4 OCS Copyright C 2012 Horner APG LLC 59 South State Avenue Indianapolis Indiana 46201 All rights reserved No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form by any means electronic mechanical magnetic optical chemical manual or otherwise without the prior agreement and written permission of Horner APG Inc All software described in this document or media is also copyrighted material subject to the terms and conditions of the Horner Software License Agreement Information in this document is subject to change without notice and does not represent a commitment on the part of Horner APG Cscape SmartStack SmartStix SmartRail and CsCAN are trademarks of Horner APG Ethernet is a trademark of Xerox Corporation Micro SD and CompactFlash are registered trademarks of SanDisk Corporation For user manual updates contact Technical Support North America Tel 817 916 4274 Fax 817 639 4279 Web www heapg com Email techsppt heapg com Eur
47. ING 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 WARNING The USB parts are for operational maintenance only Do not leave permanently connected unless area is known to be non hazardous WARNING EXPLOSION HAZARD BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE NON HAZARDOUS WARNING Battery May Explode Mistreated Do Not Recharge Disassemble or Dispose Of In Fire WARNING Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life a All applicable codes and standards need to be followed in the installation of this product b For I O wiring discrete use the following wire type or equivalent Belden 9918 18 AWG or larger Adhere to the following safety precautions whenever any type of connection is made to the module Connect the green safety earth ground first before making any other connections a b When connecting to electric circuits or pulse initiating equipment open their related breakers
48. LM 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 SR181 and SR182 are available for ladder use which indicate presence of unacknowledged or acknowledged alarm respectively The screen designer may implement these registers to switch screens or activate the beeper to attract the operator s attention January 31 2014 Page 76 of 120 MANO964 01 EN CH 13 13 9 Removable Media The removable media object is generally used to inform the operator on the current state of the removable media device and allow access to its file structure The removable media object is displayed as a button that changes colors to indicate the current state of the removable media device The following indicates the device states and the default colors associated with these states e Highest Red Device Error Yellow Device Full threshold adjustable e Lowest Green Device OK Figure 13 5 Removable Media Object To view and perform file operations the operator must access the removable viewer This is accomplished by either touching an enabled removable media object or through the system menu When a
49. LOAD PGM file for security enabled files 4 Once the cloning is successful OCS gives a message as below January 31 2014 Page 108 of 120 MANO964 01 EN CH 17 Clone Unit Cloning Status SUCCESS MAKE CLONE operation Ok Free 1004224512 Total 1004257280 Load Hake Clone Clone Esc Figure 17 5 Cloning Status Make Create clone can also be triggered by setting SR164 9 bit to 1 from Ladder program or graphics Once the operation is completed this bit is made zero by the firmware When Make clone operation is triggered by this SR bit it does not ask the user for confirmation for making clone The success failure of the operation is also not notified on screen to the user In case of failure of Make Clone operation SR164 11 bit is set to 1 by the firmware and never reset NOTE Backup of registers in flash memory is not performed by Clone Feature If user desires Backup should be done as explained in Chapter 16 Fail Safe System 17 3 Load Clone This option loads the application all unit settings and register values from Removable media to the Battery backed RAM Regardless of AutoLoad settings and then resets the OCS for the settings to take effect User needs to perform the following to Load Clone 1 Select Clone Unit from main system menu of OCS as shown below Set Hetunrk ID Set Hetwork Baud Uiew Status View Diags Uiew I O 51015 Uiew Protocols set Fkeys Set Serial
50. NO964 01 EN CH 10 The analog inputs have a digital filter that can be used to filter electrical noise that may be unavoidable in some installations The downside to digital filtering is the inputs will respond more slowly to sudden changes in the actual input 10 8 X Universal Analog Inputs Note See the data sheet for the XL4 OCS model you are using for jumper settings and see the appropriate pages in this manual see Index for details on how to use Cscape to configure the digital filtering The universal analog inputs provide a high resolution very flexible interface for a variety of analog inputs These inputs include voltage current thermocouple RTD and millivolt Each channel can be configured separately using jumpers and configuration settings in Cscape Like the standard analog inputs these inputs have a digital filter that can be used to filter electrical noise that may be unavoidable in some installations The downside to digital filtering is the inputs will respond more slowly to sudden changes in the actual input 10 9 Analog Outputs Note Refer to the datasheet for XL4 OCS model you are using for details on jumper settings The analog outputs on XL4 OCS devices provide high resolution voltage or current outputs The voltage or current selection is controlled with jumpers and configuration settings in Cscape Note that each channel can be separately configured for voltage or current mode When the controller is stopped the op
51. Ports Set Time Date set Beeper Set Screen Removable Hedia Fail Safe System Clone Unit Figure 17 6 System Menu January 31 2014 Page 109 of 120 CH 17 MANO964 01 EN 2 Selecting Clone Unit menu will open the following menu screen Select Load Clone Clone Unit eich I uz 11 DRT 24570 07 14 09 12 11a Free 1805208128 Total 1004257280 Load Hake Clone Clone V Esc Figure 17 7 Clone Unit Menu after Cloning 3 User needs to confirm Load Clone as shown below Clone Unit Load Clone Files Are You Sure Ok Cancel Free 1805208128 Total 1004257280 Load Hake 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 bit is set to
52. S will not enter or remain in Run mode and the problem must be investigated and corrected Logic Error Ok Allexecuted ladder instructions are legal for loaded firmware Fault A ladder instruction not supported by firmware was found January 31 2014 Page 60 of 120 MANO964 01 EN User Program Ok Fault CH 12 Ladder program and configuration loaded successfully Ladder program or configuration not loaded or load failed The last nine System Diagnostics are informational If any of them indicate a Warning condition the XL4 OCS can still enter and remain in Run mode but the problem should be investigated and corrected User Graphics W Dog Trips Net Errors Network State Network ID Dup Net ID Clock Error I O System Battery View I O Slots Slot 1 1 0 Empty Slot 2 1 0 Empty Slot 3 I 0 ETN300 Ok Fault 0 X 0 X Ok Warning Ok Warning Ok Warning Ok Warning Ok Warning Ok Warning Application graphics objects loaded successfully Application graphics objects not loaded or load failed Watchdog timer has not tripped since the last power up Number of times watchdog timer has tripped No CAN network bus off errors have occurred Number of CAN network bus off errors that have occurred At least one other node was found on the CAN network No other nodes were found on the CAN network This node s CAN Network ID is in the range 1 to 253
53. Scan Rate mS 0 0 XL4 OCS is not in Run mode 0 1 to 999 9 Average number of mS for each ladder scan January 31 2014 Page 59 of 120 CH 12 MANO964 01 EN OCS Net Use 0 0 100 0 CAN network bandwidth 96 used by this XL4 OCS node All Net Use 90 0 0 to 100 0 CAN network bandwidth 96 used by all nodes Ladder Size x Number of bytes in application ladder program Config Size x Number of bytes in application I O configuration Graphics Size x Number of bytes in application graphic screens String Size x Number of bytes in application string table Bitmap Size Number of bytes in application bitmaps Text Size x Number of bytes in application text tables Font Size x Number of bytes in application font tables Protocol Size x Number of bytes in application downloaded protocols SMS File Size x Number of bytes in application SMS protocol configuration Firmware Rev xx yy Current firmware version OS Ver a b cd yz Current Operating System version FPGA Rev x y Current FPGA version High Speed IO Sub System InitRD Rev x yZ Bootloader version Self Test Ok All power on self tests passed Fault One or more power on self tests failed View Diags Logic Error User Program I 0 System Battery The View Diags Sub Menu displays up to 11 System Diagnostics none of which are editable The first two System Diagnostics are critical If any of them indicate a Fault condition the XL4 OC
54. Sets the frequency for the last cycle during the acceleration phase the consistent Run Frequency frequency during the run phase and the frequency of the first cycle during the pulses per second deceleration mode The Run Frequency must be greater than 0 and must not exceed 5000Hz standard 400 000Hz HE XHSQ or 1 0 MHz HE XHSQ 5 Sets the number of cycles to occur within the acceleration phase The frequency of the cycles within this mode will vary linearly between the specified Start and Run frequency The Accel count must not equal 1 or an error is generated oetting this value to zero disables this phase Acceleration Count Sets the number of cycles to occur within the run phase The frequency of the Run Count cycles within this mode is constant at the specified Run frequency The Run count may be any value Setting this value to zero disables this phase Sets the number of cycles to occur within the deceleration phase The frequency of the cycles within this phase will vary linearly between the specified Run and otop frequency The Decel count must not equal 1 or an error is generated oetting this value to zero disables this phase Deceleration Count The stepper provides two Boolean registers to provide stepper status A high indication on this register indicates the stepper sequence can be started i e not currently busy and also when the move is completed A high indication on this register indicates that one of the ana
55. TP amp HTTP protocols 7 3 Ethernet Module Specifications opeeds 10 BaseT Ethernet 10 Mbps 100 BaseTx Fast Ethernet 100 Mbps Half or Full Duplex Auto Negotiation Both 10 100 Mbps and Half Full Duplex ShielledRJ 45 0 Connector Type Shielded RJ 45 Cable Type 5 or better UTP Recommended Auto MDI MDI X Auto Crossover 7 4 Ethernet Module Configuration Note The following configuration is required for all applications regardless of the protocols used Additional configuration procedures must be performed for each protocol used To configure the Ethernet Module use Cscape Programming Software to perform the following steps 1 On the main Cscape screen select the Controller menu and its I O Configure sub menu to open the I O Configuration dialog Figure 7 1 2 If configuring a different OCS Model than the one shown in the I O Configuration dialog click on the topmost Config button select the desired OCS Model and then click OK January 31 2014 Page 29 of 120 CH 7 MANO964 01 EN Hardware Configuration CPU 1 0 CsCAN 1 0 Ethemet 1 0 Configuration ED HEXExx2 Config Empty m Contig Ethernet 300 Ethernet Config Cancel Figure 7 1 I O Configuration Dialog 3 Click the Config button to the right of the Ethernet Module and then select the Module Setup tab revealing the Ethernet Module Configuration dialog as shown in figure
56. TYPE KeypadTyppg 5 44 RTC SEC Real Time Clock Second 0 59 9 SSRas RICMIN jRea Time ClokMinte 0 59 95846 HOUR ReakTime ClockHou 0 23 eSRa8 RTC MON Real Time ClockMonth 1 12 SR50 RTC DAY Real Time Clock Day t Sunday 7 SR51 NET CNT NetwokErmorCout O0 65535 96SRB2 WDOG CNT Watchdog TrippedErorCount 0 65535 96SR53 54 BAD LADDER Bad Ladder Code Error Index 0 65534 9eSR55 F SELF TEST Filtered Bit Mapped Self Test Result 0 65535 SR56 LAST KEY Key Code of Last Key Press or Release 0 255 LCD Backlight Dimmer Register iind 0 0 On 25 25 On 100 255 100 On idi 9eSR58 USER LEDS User LED Control Status 0 65535 SR59 60 Reserved C t ooo 9eSR e3 SS BASE j SmarStaecklOBaseSelecter 0 7 SR64_ SS STATUS SmartStackl OBaseStatus 0 2 9eSR65 76 SS INFO 1 SmartStack Module 1 Information Structure eSR77 88 SS INFO 2 SmartStack Module 2 Information Structure SR89 100 55 INFO 3 SmartStack Module 3 Information Structure SR101 112 SS INFO 4 SmartStack Module 4 Information Structure SR113 114 GOBJ SIZE Graphics Object Table Size BLK SR115 116 GSTR SIZE Graphics String TableSize 8 128K SR119 1
57. Usage General January 31 2014 Page 32 of 120 111037 MANO964 01 EN CH 7 For the Status and Version registers if configured the Direction settings are always Read Only The Use CAN ID for last Octet checkbox does not affect Net Mask Gateway Status or Version configuration Ethernet Module Protocol Configuration The Protocol Support area contains a list of all the protocols supported by the platform being configured To activate a protocol check its checkbox For protocols that require additional configuration click on a listed protocol to select it and then click the Configure Selected Protocol button This will open a new dialog with configuration options for the selected protocol For detailed information on individual protocol configuration refer latest version of ETN 300 Manual SUPO0740 January 31 2014 Page 33 of 120 1037 CH 7 MANO964 01 EN NOTES January 31 2014 Page 34 of 120 111037 MANO964 01 EN CH 8 CHAPTER 8 COMMUNICATION OPTIONS 8 1 Overview To supplement the built in MJ1 and MJ2 serial ports additional communication options are available This is accomplished by installing a COM module internal to the XL4 OCS controller 8 1 1 Previous OCS controllers shared a serial port with the communication options The XL4 has a separate serial port which allows using both MJ1 MJ2 and the communication options simultaneously Internal to the XL4 OCS there is a CPU board and up to two installed modules
58. adder 75 FOUET S Alani OD 76 Figure 13 4 Alarim iod oboe p un eco suba vee salad m decode toe estera cures Ge mp v ceu ftum toan 76 Figure 13 5 Removable Media 77 Figure 13 6 Removable media VIGWOL orco e Queue tito 77 Figure 13 7 Example application segment for safe removal of removable media 78 Figure 15 1 USB Programming Connector sss nnne nnns nn nar n nnn nsns n na ann nnns nnn 88 Figure 15 2 Digital Input HSC Configuration Dialog seeeeeessssssseeeseeeeeeeennnnn nennen 95 Figure 15 3 Digital Output PWM Configuration Dialog seeeeeessesseeeeerneeneennn menn 96 Figure 15 4 Analog Input Configuration Dialog seeessssssessssseeeeennneeennen nennen 97 Figure 15 5 Analog Output Configuration Dialog cccccccccccccccceeeeeeeeeeeeeeeeeeaeeeeeeeeeeeseeeeeeseeeeessaaeeeeeeeeeeseaas 98 Figure 16 1 Fail Safe System Menu e rerit See bo Rex Re pese vL eee deen 99 Figure 16 2 Backup Restore Data ccccccccccccseeeeeceeeeeeceeeeeeseeeeeseeueeeseaseeeseaeeeeseue
59. anel Cutout Tolerances 19 Panel Design Checklist 21 Panel Layout Clearances 20 Panel Mounting of an XL6 Series OCS 17 Power Connector Primary Power Port 24 Primary Power Port 24 Primary Power Port As Viewed Looking at the XL6 OCS 24 Primary Power Port Pins 24 PROGRAMMING EXAMPLES 3 Pulse 50 51 pulse mode 50 51 pulse stream 50 51 Pulse Width Modulation 49 54 PWM 15 44 49 54 56 57 97 98 99 Examples 57 Frequency Formula 55 Registers 56 Quadrature 50 51 52 98 References Useful documents 16 register mapping 41 44 registers 83 905 SR 84 Definitions 83 I O 87 Resource Limits 87 Relay Outputs 44 REMOVABLE MEDIA 37 Load Save Applications 39 Log Data 38 Overview 37 Save Applications XL6 39 View Capture 39 Removable Media Manager 38 Removable Media Manager Submenu 38 Removable Media XL6 67 January 31 2014 Page 118 of 120 Removable Memory Card Slot Photograph 37 RS 485 Biasing 25 RS 485 Termination 25 safety compliance 11 Safety Warnings Guidelines 1 1 Serial Comm Cscape Programming 26 Downloadable Protocols 26 Ladder Controlled 26 Overview 25 Ports 25 Wiring 25 SERIAL COMMUNICATIONS 25 Set Network ID 61 95 96 Solid State Digital Outputs 44 sourcing 44 46 stepper 49 55 56 stop state 44 46 Sub Menus 59 System Menu 59 Details 61 72 Navigate Edit 60 System Menu XL6 Screenshot 60 SYSTEM SETTINGS AND ADJUSTMENTS 59 Sytem Men
60. ators Alarms Encoders Pumps Relays Flash Drive Solenoids Cscape Figure 2 3 Visual Overview of Types of Devices that can be connected to XL4 OCS C Cscape USB OPC Server Modbus TCP Devices 2 3 Features of XL4 OCS The XL4 OCS are all in one industrial control devices They combine control user interface I O and networking into a single integrated package Unique features of the XL4 OCS include Bright 65536 color graphical touch sensing LCD display in all models of XL4 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 January 31 2014 Page 14 of 120 111037 MANO964 01 EN CH 2 Hemovable media for 32 gigabytes of storage of programs data logging or screen captures CsCAN networking port for communication with remote I O other controllers or PCs High speed USB port for communication with PCs and programming of controller Configurable serial protocols for communication to drives PLCs or other serial peripherals Full featured built in I O including high resolution analog thermocouple RTD high speed counters PWM outputs and relays depending upon the XL4 OCS model used Advanced high speed I O capabilities e Cscape programming software that allows all aspects of the XL4 OCS to be programmed and confi
61. aver 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 XL4 Any additional touch activity is also ignored by the XL4 for approximately one second thereafter It is possible for the application to temporarily disable the screen saver by generating a positive transition to SR57 16 coil only at a rate faster than the screen saver timeout value This may be desired while waiting for alarm acknowledgement January 31 2014 Page 78 of 120 MANO964 01 EN CH 13 13 11 Screen Brightness The XL4 provides a feature that allows screen dimming for night operation To enable this feature the application must access and control system register SR57 Display Backlight Brightness Screen brightness is continuously variable by driving SR57 through the range of 100 full bright to O full off It is left to the screen designer on if and how to present a Screen Brightness control to the user Note that backlight life may be shorted when screen is dimmed or screen brightness is varied on a repetitive basis INTENTIONALLY LEFT BLANK January 31 2014 Page
62. cables for all X products including a USB to serial adapter in a travel case HE CPK Cscape on a reusable usb flash drive Programming cables for all X products including a USB to serial adapter in a travel case January 31 2014 Page 15 of 120 111037 CH 2 MANO964 01 EN 2 5 Useful Documents and References The following information serves as a general listing of Horner controller products and other references of interest with their corresponding manual numbers Visit our website to obtain user documentation and updates Table 2 2 OCS Reference Document numbers Note This list is not intended for users to determine which products are appropriate for their application controller products differ in the features that they support If assistance is required refer to Technical Support Controllers Manual Number HE XExxx XLe and XLt MANO878 XL4 MANO883 January 31 2014 Page 16 of 120 111037 MANO964 01 EN CH 3 CHAPTER 3 MECHANICAL INSTALLATION Note The datasheet is the first document you need to refer to for model specific information related to XL4 OCS models such as pin outs jumper settings and other key installation information Visit our website to obtain datasheets user documentation and updates 3 1 Overview 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 reco
63. can read and write XL4 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 application ladder program can use Rename and Delete Removable Media function blocks to rename and delete files January 31 2014 Page 38 of 120 MANO964 01 EN CH 10 9 6 Using Removable Media to Load and Save Applications A special file type with a PGM extension is used to store XL4 OCS application programs on Micro SD To load an application from Micro SD to the XL4 OCS use the Removable Media Manager open the Removable Media Manager in the System Menu to find and highlight the desired PGM file and then press the Enter key To save an application from the XL4 to Micro SD open the Removable Media Manager in the System Save Menu and press the Save 29 function key The application will be saved in a file called DEFAULT PGM in the Micro SD root directory Note Saving an application to Micro SD can only be done from the Removable Media System Menu and is not available on a Removable Media Manager object that was placed on an application graphics screen by Cscape Cscape can also save an application directly to a Micro SD card which is plugged into the PC s Micro SD compatible card reader by selecting the Export to Removable Media item on the Cscape File menu 9 7 Using Removable Media to View and Capture Screens The XL4 OCS
64. ccessed 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 SCREENO1 BHP 153654 81 13 96 1 13 SEREEH26 BHP 153654 61 13 96 1 8p Free 992247808 Total 992739328 A V Del For Save 4 Del 11 Esc Figure 13 6 Removable media viewer The currently selected entry is indicated by a yellow highlight which can be moved up or down by touching the arrow 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 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 January 31 2014 Page 77 of 120 CH 13 MANO964 01 EN 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 lt Enter button if enabled performs certain operations based on the selected file s type change display to parent directory lt DIR gt change display to child d
65. control through ladder manipulation of an attribute bit 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 slide 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 in a numeric field the value is too small to display or is below the minimum for an editable field 13 3 A Alpha numeric keypad To allow entry of a specific number or text several of the input objects invoke a pop up alpha numeric keypad when the object is touched An example of the alpha numeric keypad invoked from a numeric input object is shown in Figure 13 2 Once invoked the operator may touch the 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 va
66. d not exceed 6m 20 feet A drop may include more than one node The drop length adds to the overall network length Network should be wired in straight line fashion not in a star pattern In applications requiring multiple power supplies make sure the V of all supplies is connected together and to earth ground at one place only January 31 2014 Page 115 of 120 CH 19 MANO964 01 EN 14 In some electrically noisy environments it may be necessary to add repeaters to the network Repeaters can be used to add additional nodes and or distance to the network and protect the signal against noisy environments The Horner APG repeater is part HE200CGM 100 19 4 Removable Media 19 4 1 Basic Troubleshooting XL4 OCS does not read media card ee card should be formatted with the XL4 Make sure the project file is saved as a pgm file and not a csp file XL4 OCS will not download project file In addition to file must be pgm the file s I O configuration must match the XL4 configuration for it to download 19 5 Technical Support Contacts For manual updates and assistance contact Technical Support at the following locations North America Tel 817 916 4274 Fax 317 639 4279 www heapg com Email techsppt heapg com Europe Tel 353 21 4321 266 Fax 4353 21 4321826 www horner apg com Email tech support hornerapg com January 31 2014 Page 116 of 120 MANO964 01 EN Index Q bits 44 Access
67. d only or Read Write If the register is Read only the Default IP Address becomes the unit s IP Address and is loaded into the assigned register where it can be read by the application Note In this case the low octet of the IP Address can be replaced with the units CAN Network ID by checking the Use CAN ID for last Octet checkbox If the register is Read Write the application should write an IP Address to the assigned register and this value will then be the units IP Address In this case the Default IP Address is used only if communication is lost during an I O configuration download otherwise the Default IP Address is ignored The system menu of the XL4 allows temporarily changing the IP address net mask and gateway This is useful for initially communicating with the XL4 for commission or making changes in the field The Cscape configuration gets priority after a power cycle or transition to RUN Ethernet Module Register Usage Enhanced Configuration To perform Enhanced Configuration first check the Enhanced Configuration checkbox In this case IP Address Net Mask Gateway Status and Version can all be optionally assigned to OCS registers By default the register edit boxes are empty indicating that no registers are assigned As with the IP Address register described in the Standard Configuration section above Net Mask and Gateway register Directions can be set to Read Only or Read Write Ethernet Module Register
68. e V Esc Load Clone January 31 2014 Page 69 of 120 CH 12 MANO964 01 EN Selecting Clone Unit menu will open the following menu screen Select Load Clone Clone Unit DAT 24570 07 15 09 12 11a Free 1004208128 Total 1004257280 Load Hake Clone Clone V Esc NOTE For security enabled files Load clone asks for password validation before loading the application 12 4 Touch screen calibration The touch screen is calibrated at the factory and rarely needs modification However if actual touch locations do not appear to correspond with responding objects on the display field adjustment is available To access the field adjustable touch screen calibration dialog press and hold both the SYS and F1 key for longer than 2 seconds and a dialog similar to figure 9 2 should appear Thereafter use a plastic tip stylus and follow the dialog instructions Note that special system keys may be locked out from user access If the SYS F1 combination does NOT respond verify that the system menu s Set Fkeys sub menu s parameter SYS Fn is enabled Touch Calibration Screen Touch crosshair with stylus calculated touch point will appear and will auto align with crosshair Repeat until touch point and crosshairs no longer need alignment to match January 31 2014 Page 70 of 120 MANO996 01 EN CH 13 CHAPTER 13 USER INTERFACE 13 1 Overview This chapter presents the user interface or operator view of
69. e 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 January 31 2014 Page 74 of 120 MANO964 01 EN CH 13 Input 1 Force Screen 1 T1 Screen 1 Input 2 Switch Screen 2 Screen 2 Figure 13 4 Force and Switch Coils in Ladder Programming There is also a system register that can be used to for control based screen navigation SR1 can be read to determine the current screen or written to change the current screen Refer to the on line help in Cscape for more information on control based screen navigation 13 6 Beeper Acknowledgement The XL4 contains an internal beeper that provides an audible acknowledgment when an operator touches a graphic object that accepts touch input When the graphic object is enabled a short 5ms tone is emitted When the graphic object is disabled a longer 100ms tone is emitted to enounce that graphical object is not currently accepting the touch input If beep acknowledgement is not desi
70. ed Output functions two dedicated outputs are available that can be configured for one of four modes of operation Those modes are Normal PWM HSC Match and otepper 11 5 1 Normal When either Q1 or Q2 is configured for Normal operation the digital output registers Q1 and Q2 drives that respective output 11 5 2 PWM When either Q1 or Q2 is configured for PWM the PWM function drives that respective output Both PWM channels may be individually enabled and can have independent frequency and duty cycles The PWMs require two parameters AQs to be set for operation These parameters may be set at run time Duty Cycle The Duty Cycle is a 32 bit value from 0 to 32 000 indicating the relative duty cycle of the output For example a value of 8000 would indicate a 2596 duty cycle a value of 16 000 would indicate a 5096 duty cycle O turns the output off 32 000 turns the output on Jil Duty Cycle Frequency The Frequency is a 32 bit value indicating the output frequency in Hertz One over the frequency is the period LJ mE Period Figures 11 6 amp 11 7 PWM two parameters Duty Cycle amp Frequency At controller power up or during a download the PWM output is maintained at zero until both the Frequency and the Duty cycle are loaded with non zero values When the controller is placed in stop mode the state of the PWM outputs is dependent on the PWM State on Controller Stop configuration This configuration all
71. ee 75 1597 TREMOVEDIC Medd I LE 77 DONI MES ia TE M 78 OCS IACI S SS ter m 79 CHAPTER 14 PE GS oct aeu ela uuu vr natn sou eL adele aula 81 VAST Register Sc ee sett heck abc oan da tani 81 142 JUsetulveo and FediSlelS ui eoe itera ae eH s ir Eoo eve peut eI ee evade OU eoe piv a eee 82 14 9 Regeer Map TOF SEAT OCS dues Le eye mie pue 85 m MM eB LIMS T TM 85 CHAPTER 15 CSCAPE CONFIGURATION 35 a2 isosusG oue suero eecat uS ou ei eu aU 87 ISSEEG I em 87 15 2 Cscabe lallus ede le inh ota ua ote Mete tous 87 15 9 sEStablishing COMMUNICATIONS o 88 15 3 1 Communicating via MJ1 Serial 93 15 3 2 Communicating via On Board Ethernet Port 94 159 ee Eo au dU e suut oue Mns 95 156 Digital Input HOO OCobllg l aliQli 95 15 7 Digital Output ven ies os obtu 96 15 9 Analog InpatGohitgltrallolils uem i e euet eda cur Wt eve bou ada eu LOO e eno DU e
72. eeeeeeeeeseeeeeeeeeeesseaseeeeeeeesssaaeaeeeeeeeesaaas 31 Figure 9 1 Removable Micro SD Memory Card 5 1 1 37 Figure 9 2 Installing Removable Memory Catd ccccccscecccecseeeeeeeeeeeeeeeeeseeeeeeeesaeeeeeeeseeeeeeessaeeeeeesaaeeeeeeeas 37 Table 8 1 Filename Special SyYMbOIS 40 RhMStatis Values bows 40 Figure 10 1 Removing the COVGE necati tes Ecos Bae eiae 41 Figure 10 4 Example Jumper Diagram nnn n 42 Figure 10 5 Typical Output WINO 5 1i deseo edu deste dios do quur Deoa 44 Figure 10 7 Positive and Negative nennen 46 Figure 12 1 System 57 Figure 13 1 Example Screen XL4 only ssssssessssssssssseeeeneneennnnnnnnn nennen nenne 71 Figure 13 2 Alpha numeric Keypad and ASCII Keypad 13 Figure 13 3 Typical Screen Jump Object 14 74 Figure 13 4 Force and Switch Coils in L
73. eessaueeeseueeeeseneesssaneeesaesees 100 Figure 16 3 Backup Heglslers oi e EI e I pe HR eR c Pee 101 Figure 16 4 Restore OCS Data ssssssssssssssssssesenen enne nnnnnnna nnn nne sssnna ann n nissan naa gans n 101 Figure 16 5 Clear Backup EU quen se pu Uster eis te 102 Figure 16 6 Flow Chart for Automatic Restore sssssssssssssssseeeeeneen nennen nnne nnne nnn nnns 103 Figure 16 7 AutoLoad MOTndu d dicte oM diu d issue edel ee 104 Figure 16 8 Flow Chart for AutoLoad sssesssessssssssssseeeeeennen nennen nnne nnn nnn nnn nnns 105 Figure 10 9 RE ETE E T 106 em EE cu eT P 107 Figure 17 2 Clone Unit Menu before Cloning sssssssssssssssseeseennen nnne nennen nnn nnne nnn 107 Figure 17 3 Clone Unit Confirm 108 Figure 17 4 Clone Unit Files oe Ue din ote as ma Oen e uit c bn tm deo hdd aut eaaa uuo 108 Figure 17 5 Cloning Slalus eo t repu I D Ur E i as 109 Figure 17 0 System M V 1
74. egister The register assignments for the high speed I O can be moved via a setting in Cscape The values shown are the DEFAULT values and may not match the same starting point as the values shown below Table 11 2 HSC Functions Register Map Register Frequency Pulse Totalize Quad Accumulator Counter 1 Latch Value Counter 1 Accumulator Counter 2 Latch Value Counter 2 9 amp 4040102 Match1 Counter 1 Match2 Counter 1 9 amp 0401402 5 1 2 Match1 Counter 2 Match2 Counter 2 Latch Counter 1 Clear Counter 1 Disable Counter 1 Output Reset Counter 1 Preload Disable Counter 1 Latch Disable Counter 1 Disable Marker C1 Latch Marker C1 Preload Marker C1 Clear Marker C1 Reserved Latch Counter 2 Clear Counter 2 Disable Counter 2 Output Reset Counter 2 Preload Disable Counter 2 Latch Disable Counter 2 Disable Marker C2 Latch Marker C2 Preload Marker C2 Clear Marker C2 Overflow Flag Counter 1 Underflow Flag Counter 1 High Speed Out 1 Reserved Overflow Flag Counter 2 Underflow Flag Counter 2 High Speed Out 2 Reserved January 31 2014 Page 52 of 120 MANO964 01 EN CH 11 11 5 High Speed Output Functions On units that support High Spe
75. ely time events This increments the accumulator when the input is enabled Note that two inputs can be assigned Either input can cause the counter to increment The second input can also be disabled Count Down This decrements the accumulator when the input is enabled Note that two inputs can be assigned Either input can cause the counter to decrement The second input can also be disabled Up Down In this mode input 1 assigned to any of the four inputs increments the Input 1 Up Input 2 counter while input 2 also assigned to any of the 4 inputs decrements the Down counter Clk Dir This mode uses input 1 as a clock signal to increment or decrement the Input 1 Clk Input 2 counter and then uses input 2 to decide the direction Input 2 disabled Dir increments the counter while input 2 enabled decrements the counter NOTE the totalize mode enables the Disable Latch Preload and Clear special functions Please see section 11 2 for details 11 3 3 Pulse Width Measurement In pulse width measurement mode the high speed input can measure the width of a pulse stream in one of two modes and provides a continuous indication of the last sampled value In this mode the Disable and Latch special functions are allowed Please see section 11 2 for a description of these functions Width High 1 us Counts In this sub mode the accumulator value will contain the number of 1 us counts the pulse is high Width High 010 January
76. er register space b Write RM csv This function allows writing of a comma separated value file to the Micro SD interface from the controller register space January 31 2014 Page 39 of 120 CH 10 MANO964 01 EN c Rename RM csv This function allows renaming a file on the RM card The data in the file is not changed d Delete RM csv This function allows deleting a file on the RM card e Copy RM csv This function allows copying a file on the RM card The data in the file is not changed 9 9 Filenames used with the Removable Media RM Function Blocks The RM function blocks support the flash with a DOS Windows standard FAT 16 file system All names must be limited to the 8 3 format where the filename contains eight characters a period then a three character extension The entire filename including any path must be less than or equal to 147 characters When creating filenames and directories it is sometimes desirable to include parts of the current date or time There are six special symbols that can be entered into a filename that are replaced by the OCS with current time and date information Table 8 1 Filename Special Symbols Symbol _ X Example 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
77. eration of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined value By default analog outputs are set to a value of zero For more information on Stop State refer to the appropriate pages see Index for the configuration chapter for Cscape settings January 31 2014 Page 47 of 120 MANO964 01 EN CH 11 CHAPTER11 HIGH SPEED I O HSC PWM 11 1 Overview In addition to the compliment of simple analog and digital I O several of the XL4 OCS I O modules support High Speed Counting HSC I O functions and may also support Pulse Width Modulation PWM Output functions non relay modules The HSC functions include internal timing frequency totalizing pulse width period and quadrature measurement The PWM functions include traditional PWM with variable rate and duty cycle and a stepper limited functionality with variable acceleration and deceleration rates To determine function availability refer to the associated model s Specification Installation sheet Digital DC Input Output sections This chapter describes the operation of these high level I O functions For configuration details of these functions see Cscape Configuration 11 2 Glossary 1 Register used to accumulate or store up sum or count of many items or events A special function to zero out the value in a specific register Not used with Frequency or Period Measurement
78. ersions of firmware this can take several minutes This will take about 15 seconds on newer firmware 18 2 Backup Battery The XL4 has a more advanced battery system t uses a rechargeable lithium battery The battery powers the real time clock when power is removed To store registers the battery continues to powetr the OCS for less than a second after external power is removed n this time the registers and other retentive data is saved to internal flash memory This battery will need about 8 hours of charging to last approximately 2 years when powered off Note for the registers to be retentive the battery only need to be charged and present at power down Under normal conditions the battery in the XL4 OCS should last 7 years Higher operating temperatures or variations in batteries may reduce this time 18 2 1 Indications the battery needs replacing The XL4 OCS indicates the battery is low failed or missing in a variety of ways At power up an error message is displayed indicating the low or missing battery The user program can monitor the battery using SR55 13 This bit will turn on if the battery is low or missing The system menu also contains battery status message under the diagnostics sub menu see the chapter on System Settings and Adjustments January 31 2014 Page 111 of 120 CH 18 MANO964 01 EN 18 2 2 Battery Replacement Warning Disposal of lithium batteries must be done in accordance with federal state and local
79. etween device and closed door 2 inches 50 80mm Be sure to allow enough depth for the OCS 3 6 2 Grounding Warning Be sure to meet the ground requirements of the panel manufacturer and also meet applicable electrical codes and standards Panel box The panel box needs to be properly connected to earth ground to provide a good common ground reference Panel door Tie a low impedance ground strap between the panel box and the panel door to ensure that they have the same ground reference 3 6 8 Temperature Ventilation Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient temperature range Consider the impact on the design of the panel layout if operating at the extreme ends of the ambient temperature range For example if it is determined that a cooling device is required allow adequate space and clearances for the device in the panel box or on the panel door January 31 2014 Page 20 of 120 111037 MANO964 01 EN CH 3 3 6 4 Orientation When panel mounted there are no orientation restrictions on the XL4 OCS 3 0 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 XL4 OCS and noisy devices such as relays motor starters etc For details on output protection especially when using contactors solenoids see MAN0962 01 EN 3 6 6 Shock and Vibration
80. fe System Date 28 Jun 2009 Protocol Size Clone Unit Day Thursday SMS File Size Firmware Rev Press ESC to Exit Use LT to adjust BIOS Rev each field FPGA Rev Self Test CO OO N p NO Saver enable Yes Timeout min 15 Logic Error User Program User Graphics W Dog Trips Net Errors Network State Network ID Dup Net ID Clock Error I O System Battery Slot 1 I O Empty Slot 2 I O Empty Slot 3 I O ETN300 January 31 2014 Backup Restore Data Enable AutoRun Enable AutoLoad ESC to exit Beeper Enable Yes Use VT to adjust Figure 12 1 System Menu Page 57 of 120 Popup Status Off Update Time m3 5 Update time sets the maximum time used by graphics in the logic scan Media Directory Media Card Not Present Clone Unit Directory Empty CH 12 MANO964 01 EN Set Hetwork ID Set Hetwork Baud View Status View Diags View 1 0 Slots 7 and i keys Uiew Protocols set Fkeys Set Serial Ports Set Time Date ESC key set Beeper Set Screen Removable Fail Safe System Enter key Clone Unit Figure 12 2 System Menu XL4 Screenshot 12 2 System Menu Navigation and Editing As mentioned above the System Menu is started by pressing the System key on the XL4 Next press ESC to exit the System Menu or use and 7 to select an item and press Enter
81. gramming 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 19 1 2 Connecting Troubleshooting Checklist USB Port Mini B Programming Programming and debugging must use Mini B USB Port or MJ1 2 Controller must be powered up 3 Ensure that the correct COM port is selected in Cscape Tools Editor Options Communications Port 4 Be sure that the USB cable is connected between the PC and controller and check the Windows Device Manager to find out if the USB driver is properly installed and which port it set itself up on 5 Make sure the USB port of the PC is functioning and or connect to an alternate device to determine if the port is working 6 XL4 OCS units without Ethernet must use the Mini B USB Port or MJ1 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 19 1 3 Connecting Troubleshooting Checklist ETN port programming 1 Programming and debugging must use MJ1 or Ethernet Port 2 Controller must be powered up 3 Ensure that correct IP address is given in the Ethernet field and correct Mode is selected in Cscape Tools Editor Op
82. gs The digital outputs feature an output fault bit 90 82 will turn on if any of the outputs experience a short circuit over current or the output driver overheats 10 5 Relay Outputs Relay outputs are designed to switch loads that typically have high voltage or current requirements or require isolation that relays provide Note The design of the XL4 OCS does not require external coil power for the relays to function The relays will activate anytime the XL4 OCS is powered There are several factors that should be considered when using relays January 31 2014 Page 44 of 120 MANO964 01 EN CH 10 Relay Life Relays are mechanical devices that have a long but limited life Typically switching more current limits the life of relays Please check the data sheets at the end of this manual for expected relay life Current Temperature De Rating Products containing relays often have total current limits based on the ambient temperature of the application Please see the product data sheet for current temperature de rating information for relays Fusing External fusing is generally required to protect the relays devices and wiring from shorts or overloads arning To protect the module and associated wiring from load faults use external 5 A fuse s as shown Fuses of lower current or fusing for the entire system need to be in place to assure the maximum current rating of the unit is not exceeded arning Connecting
83. gured from one integrated application e Optional communication add on modules On board Ethernet port 10 100Mbps for Cscape programming and application defined communication with Auto MDI MDI X 2 4 Required and Suggested Accessories The following list contains a sampling of required and suggested XL4 OCS accessories Visit our website to view updates on new products and accessories Note The XL4 OCS is not shipped with a programming cable in the box To obtain a programming cable order HE500CBL300 Table 2 1 XL4 OCS Accessories Part E HE XMC 14 4 k Telephone modem option kit field installable Kit includes all parts necessary for internal installation within the XL4 OCS case including a deeper plastic back cover adapted for modem operation HE MC1 Removable Media card compatible with XL4 OCS Card capacity is 2 GB or larger HE MR1 Media Card Reader for HE MC1 Portable device allows HE MC1 to be plugged into the USB port of personal computers as a portable hard drive HE X24 AS Power supply 100 240VAC or 140 340VDC Switching supply that outputs 1 5 A 3A HE X24 AS AL at 24 VDC Mounts on Standard DIN rail Designed for X Family products HE X24 AL Power supply 100 240 VAC or 140 340 VDC Switching supply that outputs 1 5 A 3A HE X24 AS AL at 24VDC Mounts on Standard DIN rail Designed for X Family products HECSP Cscape Software Package on a reusable USB flash drive with symbol library HE XCK Programming
84. ha numeric keypad services several different graphical objects certain keys on the alpha numeric keypad may be disabled grayed when the keypad is invoked for certain objects The following describes the alpha numeric keypad variation based on object Numeric Object When editing a numeric value the or the key are disabled grayed if the object is NOT configured for floating point value or a signed value Password Object When editing a password value the arrow keys and the keys are disabled Additionally overwrite mode is disabled When entering digits the pop up keypad hides the value by displaying alternately for each digit ASCII Object When editing an ASCII value 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 capitol 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 January 31 2014 Page 73 of 120 CH 13 MANO964 01 EN W
85. he CAN port of a PC running Cscape The port also allows the XL4 OCS to exchange global data with other OCS RCS controllers and to access remote Network I O devices SmartStix Smart Blocks and Smart Rail Modules 6 2 Port Description The XL4 OCS CAN port implements the ISO 11898 2 physical layer and the CAN 2 0A data link layer standards Also since the CAN1 port is powered by an internal isolated power supply external CAN power is not required January 31 2014 Page 27 of 120 CH 6 MANO964 01 EN 6 3 CAN 1 Port Wiring CAN Network amp Power Port Pin Assignments CAN Connector Pin Signal Signal Description Direction AN D Use the CAN Connector V pne Black when using CsCAN or other CAN network Toquero S loan SHLD Shield Ground None BEEN CAN Data High White In Out V Positive DC Voltage Input 10 30VDC Red Figure 6 2 CAN1 Port Connector 2 CAN Data Low Blue In Out 3 SHD 6 4 Cscape Programming via CAN The port supports CSCAN Programming Protocol If a PC has a CAN interface installed via PCI card or USB and the PC CAN port is connected to the XL4 OCS port Cscape can access the XL4 OCS for programming and monitoring In addition the XL4 OCS supports single point programming of all XL4 OCS and other OCS RCS devices that are connected to CAN network If the PC COM port is connected to the XL4 OCS MJ1 serial port the XL4 OCS can act as pass thr
86. hen editing a Time Date Table Object all the keys except the Up Down Left and Right arrow keys are grayed and disabled The specific field i e hour or minutes is selected using the Left and Right arrows The value in the selected field is changed by pressing either the Up or Down arrow 13 4 Screen Navigation To allow the operator to change screens a screen jump object is generally used This object may be visually represented as a 3 D button responding to touch or remain invisible and logically tied to an OCS register An optional system ICON may be configured for display along with the legend which aids in identifying the object as one that causes a screen change shown below in figure 13 3 Reactor Temper ature Reactor Trend Seconds 121 Figure 13 3 Typical Screen Jump Object XL4 ocreen 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 13 5 Ladder Based Screen Navigation Ladder logic can use several techniques to control screen navigation Coils can be tied to D registers to make them screen coils Thes
87. ign and Clearance 20 3 6 Clearance Adequate eect aad 20 3 6 2 Ciro Melee tL 20 3 6 3 Temperat re7 20 904 EO iege ETT 21 365 intu MR VC 21 3 6 6 Shock ANG VIDESUOFP a OC 21 3 6 7 Panel Layout Design and Clearance Checklist sse 21 CHAPTER 4 ELECTRICAL INSTALLATION Ere uui aod a eee eve cusa pues ecu des 23 AT Grounding 9 i e 23 42 KGYOUNG SDSCIICATIONS me MR O eee 23 4 3 HOWTO TeSl for Good Ground sxc cesta nd ts beni sex oneal ered teh ecient ues 23 AA Primary Pwer POM 24 CHAPTER 5 SERIAL COMMUNICATIONS 25 JMBEO 7 17 lta 25 52 SOR DeSUS ka ted 25 9 9 ana DID SWIDICIGS paene dete mnt EAR Edu aaa Rc cute leat ct tz road tete et O 25 SA 460 FERMI RE
88. ing and a configuration parameter in Cscape All the inputs on the unit must be configured to the same mode Positive Logic vs Negative Logic Wiring The XL SERIES OCS can be wired for Positive Logic inputs or Negative Logic inputs Mu ES 12 24VDC 001 XLE036 Positive Logic In Negative Logic In Figure 10 7 Positive and Negative Inputs In positive logic mode a positive voltage applied to the input will turn the input The internal design of this mode is basically a resistor from the input to I O ground This mode is sometimes called sourcing In negative logic mode connecting the input to the I O ground or zero volts will turn the input on The internal design of this mode is basically a resistor from the input to the positive I O voltage usually 12 or 24 volts This mode is sometime called sinking oome of the digital inputs may support high speed input functional such as counting or frequency measurement 10 7 Analog Inputs Note See the data sheet for the XL4 OCS model you are using for jumper settings and see the appropriate page in this manual see Index for details on how to use Cscape to configure the digital filtering The analog inputs on the XL4 OCS allow voltage or current measurement from a variety of devices The voltage or current mode is set though jumpers on the unit and settings in Cscape Each channel can be separately configured for voltage or current mode January 31 2014 Page 46 of 120 MA
89. ing our website for the address to obtain documentation and updates Network status node ID errors and baud rate in the controller system menu are all in reference to the CsCAN network These indications can provide performance feedback on the CsCAN network and can also be used to aid in troubleshooting 10 11 12 13 19 3 1 CsCAN Network Troubleshooting Checklist Use the proper Belden wire type or equivalent for the network as specified in 799 The XL4 OCS does not provide 24VDC to the network An external voltage source must be used for other devices such as SmartStix I O Check voltage at both ends of the network to insure that voltage meets specifications of attached devices Proper termination is required Use 121 ohm or 120 ohm resistors at each end of the network The resistors should be placed across the CAN and CAN LO terminals Measure the resistance between CAN and LO f the network is properly wired and terminated there should be around 60 ohms Check for duplicate node ID s Keep proper wires together One twisted pair is for V and V and the other twisted pair is used for CAN and CAN LO Make sure the baud rate is the same for all controllers on the network Assure shields are connected at one end of each segment they are not continuous through the network Do not exceed the maximum length determined by the baud rate and cable type Total drop length for each drop shoul
90. irectory bmp jpeg display bitmap if compatible format pgm load application if compatible model and version Alternately the enter button can be configured to simply load the ASCII representation of the file path including the file name to a group of OCS registers That pathname can then be used by ladder for Opening and manipulating that file Once view operations are complete simply touch the Esc button to remove the pop up removable media viewer If the removable media is used in an application the removable media device requires changing by the operator and the application is attempting to write to the removable media when it is removed the screen designer should create objects that allow the operator to temporally halt access to the removable media This prevents corruption to the file system if the removable media is removed during a file write sequence The graphic objects should set OCS register SR174 1 when requesting the card be removed and provide an indicator based on OCS register SR174 2 which indicates that it is safe to remove the removable media Halt Activity Safe for Removal Figure 13 7 Example application segment for safe removal of removable media 13 10 Screen Saver The XL4 screen backlight life is typically 5 years when in continuous use If the application does not require interaction with the XL4 for long periods of time the backlight life can be extended by using the screen s
91. is section presents a typical configuration thereby providing an introductory description on what the operator should expect January 31 2014 Page 75 of 120 CH 13 MANO964 01 EN 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 e Highest Red Unacknowledged Alarms Exist Yellow Acknowledged Alarms Exist Lowest Green No Alarms Exist fa ES Figure 13 3 Alarm Object To view acknowledge and or clear alarms the operator must access the alarm viewer This is accomplished by touching an enabled alarm object When accessed the alarm viewer is displayed as pop up alarm viewer dialog similar to that shown in Figure 13 6 Figure 13 4 Alarm Viewer 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 The current state of the displayed alarm is indicated by its color and optionally by an abbreviated indicator after the date time stamp A
92. it inputs that come from the network K Key Bit oingle bit flags used to give the programmer direct access to any front panel keys appearing on a unit M Retentive Bit Retentive single bit registers Q Digital Output Single bit output registers Typically these bits are connected to an actuator indicator light or other physical outputs QG Global Digital Output Specially defined single bit outputs that go to the network R General Purpose Register Retentive 16 bit registers January 31 2014 Page 81 of 120 CH 14 MANO964 01 EN S System Bit oingle bit bit coils predefined for system use SR System Register 16 bit registers predefined for system use T Temporary Bit Non retentive single bit registers 14 2 Useful 96S and SR registers Table 14 1 Common S Register Definitions Description Indicate First Scan Table 14 2 SR Registers Register Description MinVal Max Val eSR2 ALRM SCR Current Alarm Screen Number 0 non 0 1023 9eSR3 575 SCR Current System Screen Number O none 0 14 SR4 SELF TEST BitMappedSelfTestResut 0 65535 9eSRo CS MODE Control Station Mode 0 Idle 1 Do VO 2 Run 0 2 SR6 SCAN RATE Average ScanRate 10 1000 SR7 MIN RATE MinimumScanRate 10 1000 SR8 MAX RATE MaximumScanRate 10 1000 9eSR9 10 EDIT BUF DataFieldEditBuffer
93. ka aaa c sana asa kDa sanas 41 10 3 Model and VO OVelVIGW e e d e bae oes e et e a E 43 104 Solid State Digital OPUS a a eet e n M el dta bad eid 44 10 5 Relay OUIDUIS c in ni esee D n Erica ete be e ue Ioco voles e edens 44 106 Nec 46 PVG MAUS centies cot sah oa a oa fasst WN QU 46 109 Umversal Analog t aides td Pe lanes de oaa didnt i aUas o rd cec 47 109 EP 47 CHAPTER11 HIGH SPEED I O HSC __ aa aaa aaia a 48 bel dM MEE 48 11 3 High Speed Counter HSC Error Bookmark not defined IgE 2 CINE dnte tr RP 49 eer EE 49 113 3 Pulse Width Ue ne 49 11 32 e o nc Le Dei e 50 11 2 5 Quadrature 2 cadet iad Miles tates count Telecine 50 11 9 HSC Functions Register Map e noD E bata ad o ei eae edo es tete 52 1124 Highspeed Output FUDclODS aui ce o no Ete e ay o aid ote tenute 53 AAA 53 IESU m 53 11 44 Sepper T Uri lIOLi ne eae Oulu
94. le in the selected window has been modified but has not been saved User NONE HE XExx1 CsCAN Model Local 1 Target 2 R no forces MOD Controller Model Network Model Confirmation Communications Status indicates the current status of the pass through Connector Controller Model indicates the controller model for which the program in Cscape is configured e Network indicates the type of network that the program in Cscape expects to use e g CSCAN Model Confirmation provides the following e indications Modelz the actual Target Controller matches the configured Controller Model and Network Model Not the actual Target Controller does not last time the Target Controller was compared to the Local xx indicates the Network ID of the OCS to which the Cscape program is physically connected through its serial port It can serve as a pass through device to other nodes on the network Target yy R indicates the Network ID of the device with which the Cscape program is exchanging data Note The Local unit and Target unit can be the same unit or they can be separate units The following are status indicators Cscape is not communicating with the remote unit match the configured Controller Model and Network R Running D Do l o e Model there may have been a change since the Idle January 31 2014 configured Controller Model and Network Page 87 of 12
95. load Function 5 Polarity High level Clear Function Polarity High level Marker gt Polarity Match Disable Cancel Figure 15 3 Digital Output PWM Configuration Dialog January 31 2014 Page 96 of 120 MANO964 01 EN CH 16 The Q1 and Q2 group boxes allow the user to specify the operation of the multi function outputs The PWM State On Controller Stop group box contains items that allow the user to specify how the PWM outputs behave when the controller is stopped These items can either hold their value or default to some value when the controller is stopped Note that the PWM outputs are set to the OFF state at power up and during program download and remain in that state until the unit is placed in RUN The Output State On Controller Stop group box contains items to allow the user to specify how the remaining digital outputs behave when the controller is stopped These items can either hold their value or default to some value when the controller is stopped 15 8 Analog Input Configuration The following figure illustrates the Analog Input Configuration dialog Analog Input Configuration X Channel 1 0 10 Channel 2 O10 Channel 3 Channel 4 hd Filter Constant Figure 15 4 Analog Input Configuration Dialog The Channel x drop down windows allow the user to specify the mode for each analog input to operate The Channel x drop dow
96. log parameters Ready Done specified above is invalid or the stepper action was aborted before the operation was complete This register is cleared on the next start command if the error was corrected The stepper requires one discrete register to control the stepper action Setting this register starts the stepper cycle This register must remain set to complete the entire cycle Clearing this register before the cycle is complete aborts the step sequence and sets the error bit NOTE Setting the PLC mode to stop while the stepper is in operation causes the stepper output to immediately drop to zero and the current stepper count to be lost January 31 2014 Page 54 of 120 MANO964 01 EN CH 11 NOTE The stepper output level may cause damage or be incompatible with some motor drive inputs Consult drive documentation to determine if output level and type is compatible 11 6 High Speed Output Functions Register Map The register assignments for the high speed I O can be moved via a setting in Cscape The values shown are the DEFAULT values and may not match the same starting point as the values shown below Table 11 3 PWM Functions Register Map Regster AQ421 422 PWM 1 Duty Cycle 32 bit Start Frequency Stepper 1 AQ423 424 PWM 1 Frequency Run Hedge stepper 1 o 428 Run Count Sepp 1 1 96A0429 430 430 Deceleration Count Deceleration Count Stepper 1 1 AQ4
97. lue 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 January 31 2014 Page 72 of 120 MANO964 01 EN CH 13 Figure 13 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 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 alp
98. ly once an AutoLoad has been performed or an Automatic Restore has occurred If for any reason the AutoLoad Run Loading the AUTOLOAD PGM automatically and OCS put in RUN mode sequence does not succeed a pop up message box saying AUTO LOAD RUN SEQUENCE FAILED will be displayed It will also show the reason for its failure On acknowledging this message box the AutoLoad Run sequence will be terminated controller will return to the first user screen and will be placed in IDLE mode Enable AutoRun Ho IDHSsssxx Auto Enters RUH after fiutaL aad ar Battery Fail Figure 16 9 AutoRun Menu January 31 2014 Page 106 of 120 MANO964 01 EN CH 17 CHAPTER 17 CLONE UNIT 17 1 Overview Clone Unit feature allows the user to clone the OCS of the exact same model This feature clones application program and unit settings stored in Battery backed RAM of an OCS into the RM refer Removable Media Chapter 9 for details in using RM It can then be used to clone a different OCS exact same model This feature can be used for e Replacing an OCS by another unit of the same model e Duplicating or clone units without a PC 17 2 Clone User needs to perform the following to Clone 1 The Clone Unit can be accessed by going to the System Menu of the OCS A new menu Clone Unit has been added at the end of the main system menu as shown below Set Network ID View Protocols set Fkey
99. mmendations for the proper mechanical installation of the unit 3 2 Mounting Requirements 3 2 1 Mounting Procedures Installed in a Panel Door 001XLE055 Figure 3 1 Panel Mounting of an XL4 Series OCS Once the panel design has been completed using the criteria and suggestions in the following sections use the following steps to panel mount the XL4 OCS 1 Remove all connectors from the XL4 OCS unit 2 Make sure the gasket is installed on the XL4 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 the each of the four 4 mounting clips into the slots in the XL4 OCS case One clip should be installed on each corner Lightly tignten each screw so the clip is held in place 5 Tighten the screws on the clips such that the gasket is compressed against the panel Recommended torque is 4 ft Ib 5 4 N m January 31 2014 Page 17 of 120 CH 3 MANO964 01 EN 3 3 Mounting Orientation 3 3 1 XL4 OCS Mounting Clip Slot for Clip DIN Rail Clip Figure 3 2 XL4 OCS with Mounting Clips 3 3 2 XL4 OCS Mounting Orientation 001XLE056 NOTE For panel or DIN rail mounting CAUTION For DIN Rail mounting The orientation shown above provides for To prevent the unit from slipping off the DIN Hail do optimum readability of the screen and not install the unit on its sides as shown Be sure the ease of u
100. n program is absent or corrupted Yes Loads AUTOLOAD PGM file automatically from RM when application program is absent or corrupted Clone Unit Clone Unit feature allows the user to clone the OCS of the exact same model This feature clones application program and unit settings stored in Battery backed RAM of an OCS into the RM refer Removable Media Chapter 9 for details on using RM It can then be used to clone a different OCS exact same model This feature can be used for e Replacing an OCS by another unit of the same model e Duplicating or clone units without a PC Clone Selecting Clone Unit menu will open the following menu screen January 31 2014 Page 68 of 120 MANO964 01 EN CH 12 Clone Unit Directory Empty Free 1004257280 Total 1004257280 Load Hake Clone Clone ESC Note Free Total displays number of free and total bytes in Removable Media Selecting Make Clone brings up the screen below for the user Clone Unit Hake Clone Files Are You Sure Ok Cancel Free 18057572880 Total 1004257280 Load Hake Clone Clone ESC After confirmation the OCS will create two new files in the root directory of the Removable Media Drive as shown below AUTOLOAD PGM Application file CLONE DAT File having all unit settings and register values from Battery Backed RAM Clone Unit DAT 24570 07 15 09 12 11a Free 1004208128 Total 1004257280 Load Hake Clone Clon
101. n will be automatically initiated if a backup has been previously created and on power up the Battery Backed RAM registers fail their check The following process will be followed for restoring data e The controller will be placed in IDLE mode Data will be copied from onboard FLASH to OCS Battery Backed RAM e e The controller will reset e The controller will be put in RUN mode if the AutoRun setting is Yes else it will remain in IDLE mode Backup Restore Data Restore Register Data Are You Sure This will cause System Resett Figure 16 4 Restore OCS Data 2R164 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 January 31 2014 Page 101 of 120 CH 16 MANO964 01 EN Restoring of data can be manually performed by selecting RESTORE option from the Backup Restore Data menu This will cause the controller to reset Clear Backup Data When initiated the backup data will be erased from the onboard Flash and no backup will exist 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 January 31 2014 Page 102 of 120 MANO964 01 EN CH 16 The OCS follows the following sequence in execution of Automatic Restore 4 OCS Power Cycle 2 Battery Backed RAM Regis
102. n windows are enabled disabled according to which model is being configured All of the models have the following modes available 0 10V 0 20mA 4 20mA On model 005 channels 3 and 4 also have the following modes available 100mV PT100 DIN RTD 1 20 C Type J Thermocouple 1 20 C Type K Thermocouple 1 20 C January 31 2014 Page 97 of 120 CH 16 MANO964 01 EN Type N Thermocouple 1 20 C Type T Thermocouple 1 20 C Type E Thermocouple 1 20 C Type R Thermocouple 1 20 C Type S Thermocouple 1 20 C Type B Thermocouple 1 20 C The Filter Constant provides filtering to all channels 15 9 Analog Output Configuration The following figure illustrates the Analog Output Configuration dialog 4nalog Output Configuration X Output Mode 010v 010v Output value on STOP 1 Gata 0 v Hold Last Value 2 Goto 0 v Hold Last Value Cancel Figure 15 5 Analog Output Configuration Dialog The Output value on Stop group box contains items that allow the user to specify how the analog output channels behave when the controller is stopped The outputs can either hold their value or default to a value when the controller is stopped The Output Mode group box allows the user to select the operating modes for each of the analog outputs The modes include the following 0 101 0 20 4 20mA 31 2014 Page 98 of 120 MANO964 01 EN CH
103. nables MJ1 biasing and setting SR164 2 enables 2 biasing If biasing is used it should be enabled in only one of the devices attached to the RS 485 network 5 6 Cscape Programming via Serial Port The XL4 OCS MJ1 serial port supports CSCAN Programming Protocol If a PC COM port is connected to the XL4 OCS MJ1 serial port Cscape can access the XL4 OCS for programming and monitoring Programming can also be done via the CAN port USB port or Ethernet 5 7 Ladder Controlled Serial Communication Using Serial Communication function blocks both MJ1 and MJ2 support Generic Modbus Master and Modbus Slave Protocols In addition external modems can be connected and accessed using Init Dial and Answer Modem function blocks 5 8 Downloadable Serial Communication Protocols Both MJ1 and MJ2 also support downloadable protocols such as Allen Bradley DF1 CSCAN Master GE Fanuc SNP and Modbus Master Note Refer download section of our website for the list of latest supported protocols January 31 2014 Page 26 of 120 111037 MANO964 01 EN CH 6 CHAPTER 6 CAN COMMUNICATIONS Note For additional CAN information refer to the CAN Networks manual 799 on our website 6 1 Overview All XL4 OCS models provide a CAN networking port which is implemented with a 5 pin connector The connector is labeled Figure 6 1 CAN1 Connector Like the MJ1 serial port the CAN1 port can be used for XL4 OCS programming by connecting it to t
104. need to be considered January 31 2014 Page 21 of 120 1037 CH 3 MANO964 01 EN NOTES January 31 2014 Page 22 of 120 1037 MANO964 01 EN 4 CHAPTER 4 ELECTRICAL INSTALLATION Note The datasheet is the first document you need to refer to for model specific information related to XL4 OCS models such as pin outs jumper settings and other key installation information Visit our website to obtain datasheets user documentation and updates 4 1 Grounding 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 RFI 4 2 Ground Specifications Ideally a ground resistance measurement from equipment to earth ground is 0 ohms In reality it typically is higher The U S National Electrical Code NEC states the resistance to ground shall not exceed twenty five 25 ohms Horner APG recommends ess than fifteen 15 ohms resistance from our equipment to ground Resistance greater than twenty five 25 ohms can cause undesirable or harmful interference to the device 4 3 How to Test for Good Ground In order to test ground resistance a Ground Resistance Tester must be used A typical Ground Resistance Meter Kit contains a meter two or
105. need to refer to for key information related to specific XL4 OCS models The datasheets for all XL4 OCS models are available on our website Datasheets contain pin outs jumper settings and other model specific information b User Manual This manual provides general information that is common to XL4 OCS models and can be downloaded from our web Visit our website at http www heapg com to obtain user documentation and updates January 31 2014 Page 13 of 120 CH 2 MANO964 01 EN 2 1 2 Four main types of information are covered in the manual a oafety and Installation guidelines instructions Mechanical and Electrical b Descriptions of hardware features Serial ports Removable Media Communication Options etc C Configuration and Use of the XL4 OCS d Maintenance and Support 2 1 3 Manual Index Index Major topics of interest may be found in the Index towards the end of this manual 2 1 4 Table of Figures Table of Figures Location of important drawing illustrations etc may be found in the Table of Figures 2 2 Connectivity to the XL4 OCS The XL4 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 XL4 OCS XL4 OCS Other OCS Devices Serial Drives PLCs Bar Code Readers Other OCS Devices Smart Stix I O RCX116 I O Base kt OPC Server Printers SCADA OPC Servers Serial I O Sensors Indic
106. o MJ2 Set Fkeys Mode Momentary 595 enable Yes Use 1T to adjust The Set Fkeys Sub Menu displays two System Settings both of which are editable Fkeys Momentary 1 4 bits go On amp Off as F1 F4 are pressed amp released Toggle 1 4 bits toggle each time F1 F4 are pressed SYS Fn enable Yes Reset and all clear system functions enabled No Reset and all clear system functions disabled Set Serial Ports Ast mes 1 232 HJ2 5485 Bias Ho Use 1t to adjust The Set Serial Ports Sub Menu displays three System Settings all of which are editable and one optional item For the Dflt Pgm Port System setting only MJ1 232 can be selected unless a Modem XMC COM module is installed Dfit Pgm Port MJ1 232 MJ1 RS232 port is the default programming port Modem Modem COM module is the default programming port MJ2 RS485 Bias MJ2 RS485 bias resistors not switched in Yes MJ2 RS485 bias resistors are switched in January 31 2014 Page 63 of 120 CH 12 MANO964 01 EN Set Time Date 16 06 59 Date 10 Jul 2008 Day Thursday Use 41 to adjust each field The Set Time Date Sub Menu displays three System Settings Time and Date are editable and Day is automatically calculated from the Date setting Note that Time and Date are split into three editable fields each Use or gt to select a field and then use or to edit the field Time 16 09 49 Current time hours
107. onfigured January 31 2014 Page 93 of 120 CH 16 MANO964 01 EN To check or change the ID on the XLe XLt press the UP and DOWN keys on the XLe XLt simultaneously to enter the system menu The first item in the menu is Set Network ID Pressing Enter allows you to view or modify the ID of the unit To change the Target ID of Cscape use the Controller Set Target Network ID dialog 15 3 2 Communicating via On Board Ethernet Port From Cscape go to Controller gt Configure and do auto configuration for the connected controller Click on Config of Ethernet amp go to Module Setup You can temporarily set the IP address Net Mask and Gateway of the controller 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 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 Module Configuration 170 Map Module Setup Register Usage Default Settings Register Direction IP Address 192 168 5 175 F100 Read Only Use CAN ID for last Octet Net Mask 255 255 255 0 em Enhanced Configuration Gateway 6 0 0 0 Status 200 Read Only Version Es 300 deem Read Only Protocol Support Configure Selected Protocol SATP Slave 30 30
108. ope Tel 353 21 4321 266 Fax 353 21 4321 826 Web www horner apg com Email tech support hornerapg com January 31 2014 Page 2 of 120 MANO964 01 EN Limited Warranty and Liability LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner APG LLC HE APG warrants to the original purchaser that the XL4 HE XC HEXT251 OCS module manufactured by HE APG is free from defects in material and workmanship under normal use and service The obligation of HE APG under this warranty shall be limited to the repair or exchange of any part or parts which may prove defective under normal use and service within two 2 years from the date of manufacture or eighteen 18 months from the date of installation by the original purchaser whichever occurs first such defect to be disclosed to the satisfaction of HE APG after examination by HE APG of the allegedly defective part or parts THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE APG NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE APG ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS XL4 OCS module THIS WARRANTY SHALL NOT APPLY TO THIS XL4 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 AP
109. ories 15 accumulator 50 51 52 Analog Inputs 46 Analog Outputs 47 AutoLoad 106 AutoRun 108 Backup Restore 102 Battery Backup 113 Replacement 114 Warnings 114 When to Replace 113 Battery backed RAM 70 109 CAN Comm Cscape Programming 28 I O Expansion Network I O 28 Ladder Controlled 28 Overview 27 Ports 27 Wiring 28 CAN Communications 27 CE 12 Clone Unit 70 109 CLONE DAT 71 110 COM 25 26 28 35 36 63 64 65 84 115 116 COM port 94 115 116 Communicating via MJ1 Serial Port 95 Communication options 29 35 Modem COM Module XMC 36 Overview 35 Communications Port 94 116 Compliance CE 12 Count 54 55 57 58 Csape Program Via Serial Port 26 Cscape 2 15 25 26 27 28 36 38 39 41 44 46 47 49 63 64 77 86 89 90 95 115 116 117 Analog In Configuration 99 Analog Out Configuration 100 Configuration Procedures 97 Digita In HSC Configuration 97 Digital Out PWM Configuration 98 Establishing Communications 90 Overview 89 Status Bar 89 CSCAPE CONFIGURATION 89 datasheet 9 41 46 47 Default Gateway 31 Device Manager 116 Devices to Connect to XL6 14 January 31 2014 Page 117 of 120 CH 19 Digital Inputs 46 Dimensions 19 Duty Cycle 56 57 Duty Cycle Examples 57 ELECTRICAL INSTALLATION 23 Ethernet 84 90 116 Ethernet Communication 29 Ethernet Module Default Gateway 31 IP Address 31 Net Mask 31 Status
110. otal number of cycles applied to its input Table 11 1 Glossary of High Speed Terms January 31 2014 Page 48 of 120 MANO964 01 EN CH 11 11 3 High Speed Counter HSC Functions The XL4 supports two very high speed configurable counters There are four dedicated inputs that can be configures to a number of different options Each of the two counters can run in one of five modes Those modes are Totalizer Frequency Counter Pulse Width Measurement Period Measurement and Quadrature measurement For some modes more than one HSC input may be consumed The measurement values are provided to ladder in a 95 register see mapping below 11 3 1 Frequency In frequency mode the frequency of the input signal is written to the accumulator in terms of Hertz cycles second When using frequency mode four update selections are provided which specify the width of the sample window Note that selecting a shorter sample window provides a quicker measurement faster response but lowers the frequency accuracy resolution and increases the minimum frequency measurement limit In this mode the Disable and Latch special functions are allowed Please see section 11 2 for a description of these functions 11 3 2 Totalize In totalize mode the accumulator is simply incremented or decremented each time the input transitions in a specific direction The totalizer supports the following modes ate The special functions can be used to accurat
111. ough gateway allowing Cscape to access XL4 OCS and OCS RCS devices that are attached to the CAN network 6 5 Ladder Controlled CAN Communication Using Put and Get Network Words function blocks the NET1 port can exchange digital and analog global data with other XL4 OCS or OCS RCS devices nodes attached to the CAN network In addition Put and Get Network Heartbeat function blocks allow nodes on the CAN network to regularly announce their presence and to detect the presence or absence of other nodes on the network 6 6 Using CAN for I O Expansion Network I O Connecting Network I O devices SmartStix SmartBlocks or SmartRails to the XL4 OCS CAN1 port allows the XL4 OCS I O to be economically expanded and distributed A variety of modules are available for this purpose January 31 2014 Page 28 of 120 111037 MANO964 01 EN CH 7 CHAPTER 7 ETHERNET COMMUNICATION 7 1 Ethernet Module Protocols and Features The following table describes the Ethernet Module Protocols and features supported by XL4 Protocol Feature Protocol Feature Description ICMP Pina Internet Control Message Protocol EGD Peer GE Fanuc Ethernet Global Data SRTP Server GE Fanuc Service Request Transfer Protocol Modbus over Ethernet 7 2 Ethernet System Requirements Full Ethernet functionality requires 1 running Cscape Programming Software Version 9 3 SP3 or later for configuration 2 XL4 controller with onboard Ethernet port F
112. ows for either hold last state or specific frequency and duty cycle counts opecifying zero for either the period or duty causes the PWM output to remain low during stop mode NOTE for standard I O models 1E3 1E4 and 1E5 models the maximum recommended PWM frequency is 5000Hz due to the limitations of built in output circuitry The HE XHSQ generates 24V pulse outputs with a recommended max of 400 000Hz The HE XHSQ 5 generates 5V pulse outputs with a recommended max of 1 0MHz The addon HSQ and HSQ 5 module can be added to the 1E2 unit for HSC function January 31 2014 Page 53 of 120 CH 11 MANO964 01 EN 11 5 3 High Speed Counter Match When either Q1 or Q2 is configured for HSC Output operation their output state is based on a comparison between the counter accumulator and match registers See details above in the high speed input section 11 5 4 Stepper Function The XL4 supports two stepper functions one on each high speed output The Stepper requires five parameters AQs to be set for operation These parameters may be set at run time but are latched when the stepper is commanded to start oets the frequency for the first cycle during the acceleration phase and the Start Frequency frequency of the last cycle during the deceleration phase When an acceleration pulses per second or deceleration count is specified the Start Frequency must be greater than 0 and must not exceed the run frequency or an error is generated
113. pecifically the Module Setup tab provides 4 buttons to configure all of the I O Go through each area of I O and configure it Once done configuring the I O OK out of configuration dialogs Configuring the XL4 OCS I O has four main portions that are covered in this chapter For additional information on I O refer the chapters covering General I O or High Speed I O in this manual The four areas of configuration are 15 6 Digital in HSC Digital out PWM Analog in Analog out Digital Input HSC Configuration The following figure illustrates the Digital Input HSC Configuration dialog Digital 7 HSC Input Configuration Digital inputs active mode Positive Logic Note This setting must x match that of the jumpers f Negative Logic the product HSC 140 Mapping Starting Digital In 21 601 que 8 Starting Digital Out x01 601 8 32 Starting Analog In 51401 g8 Starting Analog Out 40 seem x12 Counter Counter Type Input Input2 Mode Up down Input 1 input 2 down External Input 1 External Input 2 Disable Function Disabled x SESE gt Polarity High level v Latch Function Extemal Input 3 MM gt Polarity High level Preload Function aderflow interrupt 6 gt Polarity High level v Clear Function Disabled MM gt Polarity High level Marker Polarity Match Disable Cancel Figure
114. r the register mapping of the I O refer to the Index at the end of this manual for the pages referencing register mapping 10 2 Removing the XL4 OCS I O Cover Some 1 configurations require jumper settings to be changed inside the XL4 OCS unit Examples of these settings are setting positive or negative logic on digital inputs or setting current or voltage on analog inputs Each XL4 OCS I O jumper is set to a factory default Refer to the data sheet for your XL4 OCS model to find the default setting to determine if a jumper change is necessary for your application To remove the I O cover of the XL4 OCS remove the four 4 Phillips screws from the I O back It may help to place the XL4 OCS unit face down on a clean work surface Once the four screws are removed the I O cover can be lifted straight off Figure 10 1 Removing the I O Cover January 31 2014 Page 41 of 120 CH 10 B I XEM TT 33 BCE EMER ays d 4 L3 CO 871 14 c TIT i P 1 12 27 3 H HEN eu tiag ip as 2 al 19 E 32333333 ing t ta 026 Figure 10 3 irt MANO964 01 EN _Popwanze R2F 3 d m os C Por mitt peni 2a ATAT yan 1 M T gR d
115. red the beeper function can be disabled from the system menu 13 7 Touch Slip Sensitivity Touch s ip sensitivity is preset to meet most applications however adjustment is available to reduce the sensitivity for touch release That is once a graphical object button is touched and held by a finger the default touch slip sensitivity allows for a slight slip of the finger on the graphical object before the XL4 assumes touch been released equates to approximately a quarter inch of movement with a stylus In some applications such as jog buttons where the operator is pushing a button for a period of time the amount of s ip while holding a button pressed may exceed the default sensitivity To increase the amount of tolerable s ip and prevent false releases of the button the XL4 allows adjustment of the allowable s ide up to 5x the default value To enable the touch slip sensitivity first an OCS data register must be allocated through the Graphics editor Configuration menu for Display Settings Once a Touch Sensitivity register is assigned that register may be modified range 1 Low to 5 High to the desired slide amount a value outside the valid range is entered in the touch sensitivity register it is ignored and the last valid value is used 13 8 Alarms Alarm presentation to the operator is highly configurable and beyond the scope of this document to describe fully For more information refer to the graphics editor help file Th
116. roller is not communicating you may need to set the target ID of the controller in Cscape or on the unit The Target ID allows directing communications to a particular unit when multiple units are connected via a CSCAN network Units without CSCAN network ports respond to any network ID and do not require the ID to be configured To check or change the ID on the XL4 OCS press the system menu key a The first item in the menu is Set Networks Pressing Enter allows you to view or modify the ID of the unit Set Network ID Set Network Baud View OCS Status View OCS Diags View 1 0 Slots View Protocols Set Fkeys Mode Set Serial Ports Set Time Date Set Beeper Set Screen Removable Media Press ESC to exit 15 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 XL4 If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above If the controller is not communicating you may need to set the target ID of the controller in Cscape or on the unit The Target ID allows directing communications to a particular unit when multiple units are connected via a CSCAN network Units without CSCAN network ports respond to any network ID and do not require the ID to be c
117. s Mode Set Serial Ports Set Time Date set Beeper Set Screen zi Removable Hedia Fail Safe System Clone Unit SPC Network Baud View Status View Diags View Slots Vv Figure 17 1 System Menu 2 Selecting Clone Unit menu will open the following menu screen Clone Unit Directory Empty Free 18054257288 Total 1004257280 Load Hake Clone Clone ESC Figure 17 2 Clone Unit Menu before Cloning January 31 2014 Page 107 of 120 CH 17 MANO964 01 EN Note Free Total displays number of free and total bytes in Removable Media 3 Make Create Clone option enables user to duplicate Clone application file all unit settings and all register values from Battery Backed RAM Selecting Make Clone brings up the screen below for the user Clone Unit Hake Clone Files Are You Sure Ok Cancel Free 1004257280 Total 1004257280 Load Hake Clone Clone Esc Figure 17 3 Clone Unit Confirm Screen After confirmation the OCS will create two new files in the root directory of the Removable Media Drive as shown below AUTOLOAD PGM Application file CLONE DAT File having all unit settings and register values from Battery Backed RAM Clone Unit 2120 09 12 11 DAT 24570 07 15 09 12 11a Free 1805208128 Total 1004257280 Load Hake Clone Clone V Esc Figure 17 4 Clone Unit Files NOTE Make Create clone operation automatically includes the security in AUTO
118. se contact Technical Support at the locations indicated at the end of this chapter 19 1 Connecting to the XL4 OCS Cscape connects to the local controller automatically when the serial connection is made The status bar below shows an example of a successful connection This status bar is located in the bottom right hand corner of the Cscape window Local 253 Target 25318 Forces In general the Target number should match the Local number The exception to this is when the controller is being used as a pass through unit where other controllers on a CSCAN network could be accessed through the local controller Determine connection status by examining feedback next to Local amp Target in the status bar of Cscape Local If a number shows next to Local then communication is established to the local controller Cscape is unable to access the COM port of the PC This could mean that Cscape is configured for a COM port that is not present or that another program has control of the Local No Port COM port Only one Cscape window can access a port at a time Subsequent instances of Cscape opened will indicate No Port Cscape has accessed a PC COM port but is not communicating with the controller This Local No Com typically occurs when the controller is not physically connected Unknown communication error Close Cscape power cycle the controller and reopen Local Cscape with a blank project Check Local If
119. se of the keypad DIN Rail is in the horizontal position Figure 3 3 Orientation of XL4 OCS January 31 2014 Page 18 of 120 111037 MANO964 01 EN CH 3 3 4 Panel Cut Out For installations requiring NEMA4X liquid and dust protection the panel cutout should be cut with a tolerance of 0 005 0 1 mm 3 622 22mm 3 622 92mm 001XLE002 Figure 3 4 Panel Cutout Tolerances 3 5 XL4 Dimensions 3 780 96 0 mm 3 780 96 0 mm OOLXLEOOS Figure 3 5 XL4 OCS Dimensions January 31 2014 Page 19 of 120 1037 CH 3 MANO964 01 EN 3 6 Factors Affecting Panel Layout Design and Clearances Warning Itis important to follow the requirements of the panel manufacturer and to follow all applicable electrical codes and standards The designer of a panel layout needs to assess the requirements of a particular system and to consider the following design factors 3 6 1 Clearance Adequate Space Install devices to allow sufficient clearance to open and close the panel door Table 3 1 Minimum Clearance Requirements for Panel Box and Door Minimum Distance between base of device and 2 inches 50 80mm sides of cabinet Minimum Distance between base of device and 1 5 inches 38 10mm wiring ducts If more than one device installed in panel box or on Ances beween o eaae Minimum Distance between bases of each device EH HOO When door is closed Minimum distance b
120. ser 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 Export to Removable Media Place the Removable Media with AUTOLOAD PQGM in the device Set the Enable AutoLoad option in the device to YES Set the Enable AutoRun option to YES if the controller needs to be placed in RUN mode automatically after automatic restore of data or AutoLoad operation i ci 16 3 Backup Restore Data selecting this option brings up a screen having four operations e Backup OCS Data e Restore OCS Data e Clear Backup Data e Exit Backup Restore Data Clear Backup Figure 16 2 Backup Restore Data Backup OCS Data When initiated this will allow the user to manually copy Battery Backed RAM contents on to the onboard FLASH memory of the OCS This will have the effect of backing up all the registers and controller settings Network ID etc that would otherwise be lost due to a battery failure SR164 4 is set to 1 when backup operation is performed January 31 2014 Page 100 of 120 MANO964 01 EN CH 16 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 operatio
121. site http www heapg com to obtain updates to datasheets manuals and user documentation QUICK START INSTALLATION PROGRAMMING TROUBLESHOOTING page 11 page 11 page 11 page 11 oage 13 page 13 page 13 page 13 page 17 Page 25 page 113 page 23 oage 27 page 115 Page 29 Communication page ka Se Media page Se High I O page Settings Bloc diii e 59 Mo Interface Eb NH e 73 BE NEN e 83 Bn um Configuration 89 Fail Safe pow S pow S e 101 Clone Unit Page 109 January 31 2014 Page 9 of 120 MANO964 01 EN INTENTIONALLY LEFT BLANK January 31 2014 Page 10 of 120 MANO964 01 EN CH 1 CHAPTER 1 SAFETY COMPLIANCE 1 1 Safety Warnings and Guidelines When found on the product the following symbols specify Warning Consult user documentation A 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 WARN
122. status poo 6 o SR176 177 Removable Indicates free space on the Removable Media card _a Media in K bytes SR178 179 Removable Indicates the total card capacity in K bytes 2 Media SR180 5 SR181 ALM UNACK Unacknowledged Alarm high bit indicates what group SR182 ALM ACT Active Alarm high bit indicates what group 5 188 Minimum Net Usage of all units on the network o SR189 NET MAX Maximum Net Usage of all units on the CAN network SR190 NT TX AVG Average Net Usage of this unit SR191 NT TX MIN Minimum Net Usage of this unit 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 January 31 2014 Page 84 of 120 MANO964 01 EN CH 14 14 3 Register Map for XL4 OCS I O Fixed Digital Analog XL4 Model Address I O Function 2 3 4 5 zen 13 31 13 31 ESCP Alarm 32 Digital Outputs D AAH _ 1 Reserved areas maintain backward compatibility with other XL Series OCS models 14 4 Resource Limits Table 14 4 Resource Limits CsCAN Ping EGD SRTP Modbus TCP Master Downloadable protocol amp Slave Ethernet IP FTP or HTTP 10 MBd 100 MBd 125 kBd 250 kBd 500 kBd or CsCAN 1 MBd Serial Ports 1 RS 232 1 RS 485 Ports IDs Per CSCAN 64 w o repeat 253 w 3 repeaters Data Fields Per
123. tal 511959646 a AJ Y pea BRE e January 31 2014 Page 65 of 120 CH 12 MANO964 01 EN The Removable Media Sub Menu displays the Removable Media Manager After selecting Removable Media from the Main Menu one of four Sub Menu screens will appear No Micro SD card has been installed in the Memory slot No Card Micro SD card is installed but it is still initializing Initializing Micro SD card is installed and initialized but contains no files Dir Empty Micro SD card is installed and initialized and it contains files Hedia Directory W 810 08 12 f 07 10 08 07 10 08 SCR0O003 JPG 29708 07 10 5 000 JPG 29582 07 10 08 12 SCROOOS JPG 23263 07 10 08 12 SCROOOG JPG 15643 07 10 08 12 SCROOO7 JPG 14976 07 10 08 12 SCROO008 JPG 15994 07 10 08 12 SCRO0O009 JPG 17561 07 10 08 Free 511672320 Total 511959040 Scrollbar Shows size of highlighted file or 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 modified 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
124. ters check failed Backup NO exists YES y Controller placed in Application IDLE mode Program erased Y Data copied from Onboard FLASH to OCS Battery backed RAM Controller Resets NO v AutoRun E OCS put in IDLE Enabled Mode YES v OCS put in RUN Mode Figure 16 6 Flow Chart for Automatic Restore January 31 2014 Page 103 of 120 CH 16 MANO964 01 EN 16 4 A 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 setting is enabled set to YES it can either be manually initiated or automatically initiated at power up The automatic initiation will happen only in the following two cases e When there is no application program in the OCS and a valid AUTOLOAD PGM is available in the removable media of the device When the program residing in onboard memory is corrupted and a valid AUTOLOAD PGM is available in the removable media of the device AutoLoad can be manually initiated when the SYS F3 key is pressed OCS can be in any of the following mode Idle Run DOIO This also requires a valid AUTOLOAD PGM to be present in the removable media of the device When the AutoLoad setting is not enabled set to NO OCS will be in IDLE mode and the application is not loaded If
125. the AUTOLOAD PGM is security enabled the user will be prompted to enter the password before loading the application The application will be loaded from the Removable media only after getting the correct password SR164 6 can be set to enable AutoLoad feature Enable AutoLoad Ho AutoLoad from Removable Hedia s AUTOLOAD PGH File when triggered Figure 16 7 AutoLoad Menu January 31 2014 Page 104 of 120 MANO964 01 EN lt q Power up OCS y The OCS follows the following sequence in execution of AutoLoad Application Program absent or Application Program corrupted AutoRun NO AutoLoad Enabled OCS put in IDLE mode NO UTOLOAD PGM present iri 1 none the RM of the device failure YES AutoLoad initiated NO Y Enabled YES 5 put in RUN Mode January 31 2014 gt OCS put in IDLE Mode Figure 16 8 Flow Chart for AutoLoad Page 105 of 120 CH 16 CH 16 MANO964 01 EN 16 5 AutoRun This system menu option when enabled YES allows the user to automatically place the OCS into RUN mode after the AutoLoad operation or automatic 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 automatical
126. ti xeu stand 13 2 1 1 Where to Find Information about the XL4 OCS sssssssssseseeeeeennenenennnnnn nnns 13 2 1 2 Four main types of information are covered in the 14 Tc MP HA 14 21 45 Tabledi FoU E m m m T 14 22 JQOonnecuvity tothe OG uestis D es VEDO UD 14 23 Features KEA OCS e 14 2 4 Required and Suggested 15 2 5 Useful Documents and References 16 CHAPTER 3 MECHANICAL INSTALLATION 17 SENEC ui 17 X2 Mounting Hedull Gmellls sus ker das oca iO eu dedu c cua ee leat ct tz raa watt cav ad 17 3 2 1 Mounting Procedures Installed in a Panel Door 17 SEEN Mouming RO inicie mtn 18 SIL AL4LOCS Mounting iius E eames cele 18 3 3 2 XL4 OCS Mounting Orientation nennen nnn rns nan nnns 18 234 uberius c a 19 30 READING ASIONS c 19 3 6 Factors Affecting Panel Layout Des
127. ting outside the local network set the Default Gateway IP Address to 0 0 0 0 the default setting Status Register Enter an OCS Register reference such as R100 to indicate which 16 bit OCS register will have the Ethernet Status word written to it Table 7 1 shows how this register value is formatted and explains the meaning of each bit in the Status Word January 31 2014 Page 31 of 120 1037 CH 7 MANO964 01 EN Table 7 1 Ethernet Status Word Register Format High Byte Low Byte Bit Bit Bit Bit E 16 12 8 7 o o ou spa o Rx Te tink TCP Connections Status Bit s Status Indication EH D m Values 0 Always 1 100 MHz TCP Connections Total Number of Active TCP Connections m CsCAN SRTP Modbus EIP FTP HTTP Version Register Enter an OCS Register reference such as R101 to indicate which 16 bit OCS register will have the Ethernet Firmware Version written to it The value stored in the Version Register is Ethernet Firmware Version 100 For example for Ethernet Firmware Version 4 30 the Version register will contain 430 Ethernet Module Register Usage Standard Configuration To perform Standard Configuration simply leave the Enhanced Configuration checkbox unchecked In this case Net Mask and Gateway cannot be assigned to OCS registers while IP Address Status and Version must be assigned to OCS registers Note that the assigned IP Address register s Direction can set to Rea
128. tion hardware on the XL4 can generate any frequency that can be evenly divided into 10Mhz 10 000 000 Hz under the maximum recommended frequencies for each model This results in a very smooth operation at lower frequencies with a progressively choppier operation at higher frequencies as the units reach their maximum recommended frequency January 31 2014 Page 56 of 120 MANO964 01 EN CH 12 CHAPTER 12 SYSTEM SETTINGS AND ADJUSTMENTS 12 1 System Menu Overview The XL4 has a 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 a Main Menu item and press Enter Return Arrow to display the item s Sub Menu Sub Menus Sub Menus CAN Port 1 CAN ID None Loaded CAN Baud Port 2 MAC ID None Loaded 00 00 00 00 00 00 IP 192 168 0 1 NetM 0 0 0 0 GatWy 0 0 0 0 Fkeys Momentary Sys Fn enable Yes Main Menu Use 4T to adjust Set Networks Model XLXxxx View Status Dflt Pgm Port MJIlI 232 OCS Mode Idle View Diags MJ2 RS485 Bias No Scan Rate mS 0 0 View I O Slots Use Vt to adjust All Net Use s View Protocols Ladder Size Set Fkeys Mode Config Size Set Serial Ports Graphics Sz Set Time Date String Size Set Beeper Bitmap Size Set Screen Text IDL Size Removable Media Time 10 21 36 Font Tbl Size Fail Sa
129. tions Communications Port 4 Ensure that the Ethernet Cable is connected between the controller and the Ethernet Hub 5 Make sure the Ethernet cable is functioning properly 19 2 Local Controller and Local I O The system menu provides the following status indications that are useful for troubleshooting and system maintenance oelf test results diagnostics RUN and OK status Network status and usage Average logic scan rate Application memory usage Loaded firmware versions January 31 2014 Page 114 of 120 MANO964 01 EN CH 19 e Loaded protocols e Removable media access To view the system menu press the System key 19 2 1 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 3 Check data sheets to insure proper wiring 4 Insure that hardware jumpers and software configuration for match 5 Check data sheets for voltage and current limits 6 Take ladder out of the picture From Cscape set controller to Do I O mode In this mode inputs can be monitored and outputs set from a data watch window in Cscape without interference from the ladder program Some l O problems are only a result of a mistake the ladder program 19 3 CsCAN Network For complete information on setting up a CSCAN network refer to CAN Networks manual 799 by visit
130. u Overview 59 Table of Contents 5 target ID 95 96 target indicator 95 96 Technical Support 2 16 46 114 115 118 Contacts 118 Testing for Good Ground 23 Totalize 50 Troubleshooting Common problems 115 Connecting Checklist 116 CsCAN Checklist 117 CsCAN Network 117 Local Controller I O 116 Local I O Checklist 117 Removable Media 118 troubleshooting technical support 115 Troubleshooting Checklist serial port MJ1 Programming 116 Troubleshooting Checklist USB Port Mini B Programming 116 Troubleshooting Checklist Ethernet port Programming For XL6e only 116 Two Point Ground Connection Test 23 Types of Devices that can be connected to XL6 14 Universal Analog Inputs 47 USB 15 28 90 116 USER INTERFACE 73 Ladder Based Navigation 76 Table of Figures MANO964 01 EN Screen Navigation 76 XL6 Manual PREFACE 2 Using Removable Media to View and Capture XL6 OCS Accessories 15 ocreens 39 XL6 OCS Dimensions 19 Visual Overview of XL6 and Topics 13 XL6 OCS Mounting Clip 18 Where to Find Information 13 XL6 OCS Mounting Orientation 18 XL6 Dimensions 19 XL6 OCS with Mounting Clips 18 XL6 I O Cover Photograph 42 XMC 36 XL6 I O Cover Removed sample I O board Photograph 42 January 31 2014 Page 119 of 120 MANO964 01 EN Table of Figures Table of Figures Figure 2 3 Visual Overview of Types of Devices that can be connected to XL4 OCS 14 Figure
131. uence When the start bit is energized the example starts at 2 5 kHz and ramps up to 5 kHz during the first 1 000 000 steps Then it runs at 5 kHz for the next 8 000 000 steps Finally during the last 1 000 000 steps it slows to a stop Example 2 Start Frequency Run Frequency Accel Count Run Count Decel Count 5 000 000 steps control sequence When the start bit is energized the example starts at 0 5 KHz and ramps up to 1 kHz during the first 2 000 000 steps Then it runs at 1 kHz for the next 2 000 000 steps Finally during the last 1 000 000 Steps it slows to a stop Example 3 Start Frequency Run Frequency Accel Count Run Count Decel Count ended Set AQ421 Set AQ422 Set AQ423 4 Set AQ425 6 Set AQ427 8 50 Hz 250 Hz 150 000 Steps 5 500 000 Steps 350 000 Steps Set AQ421 Set AQ422 Set AQ423 4 Set AQ425 6 Set AQ427 8 500 Hz 1000 Hz 2 000 000 Steps 2 000 000 Steps 1 000 000 Steps steps control sequence When the start bit is energized the following example starts at 50 Hz and ramps up to 250 Hz during the first 150 000 steps Then it runs at 250 Hz for the next 5 500 000 steps During the last 350 000 steps it slows to a stop Note Prior to the start of a move the Ready Done bit for that channel must be ON 9611617 or 9611619 for channel 1 and 2 respectfully The Ready Done bit will turn OFF during the move and then back ON once the move is completed Note The pulse genera
132. ug Tools ess ee ET E E pomm Screens View Window Help earch Network Inn Security amp Project Navigator StpCalc El eem untitled1 1 Unknown Mod Strip Chart 2 Hardware Configuratior Update SmartStack Module E E Control T amp T Logic Modules R2 Main Loop Mod main m Subroutine Mod SetPoints E I O Names Data Logging Recipes t Graphics md Networking View Data List Project Navigator 3C K LUE E egister i Editor Options Application Settings String Operations Target Target Name 1 Connection Medium C Com Port C Ethernet 76 240 2 113 Buil in ETN Ethernet Mode C Canlnterface C Installed Modem Phone Number 123456 OCS USB Port 20 Connected Device Connected Device C Target Node ID 1 zi Connection Settings Maximum Baud Rate 3600 Timeout 3000 ms Cancel January 31 2014 Page 92 of 120 MANO964 01 EN CH 16 If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above in this chapter section Cscape Status Bar User NONE XL6 Cscan Model Unknown Local253 Target 253 R no forces _ If the cont
133. y Cscape one of the following six System Settings appears for Slot 2 Slot 2 I O Empty No COM module installed or configured Slot 2 Unsupported Unsupported COM module installed Slot 2 I O Missing No COM module installed but a COM module is configured Slot 2 1 0 XzC 2 COM module installed but no COM module configured Slot 2 I O XzC 2 COM module installed but another COM module configured Slot 2 I O XzC 2 COM module installed and configured properly Slot 3 I O ETN300 ETN300 has been configured through Cscape View Protocols Port 1 None Loaded Part 2 None Loaded The View Protocols Sub Menu displays two System Settings neither of which are editable As mentioned in 0 both the MJ1 Port 1 and MJ2 Port 2 serial ports support downloadable protocols To assign a downloadable protocol to an XL4 OCS serial port select the Protocol Config item in Cscape s Program menu and then setup a protocol for Port 1 or Port 2 or both In the View Protocols Sub Menu the currently downloaded protocol if any and its version number are displayed for both Port 1 and Port 2 Port 1 Protocol name None Loaded or name of the protocol assigned to MJ1 Protocol version Blank or version of the protocol assigned to MJ1 January 31 2014 Page 62 of 120 MANO964 01 EN CH 12 Port 2 Protocol name None Loaded or name of the protocol assigned to MJ2 Protocol version Blank or version of the protocol assigned t

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