User Manual for XL4 OCS HE-XC1E0 / HEXT251C100 HE-XC1E2 / HEXT251C112 HE-XC1E3 / HEXT251C113 HE-XC1E4 / HEXT251C114 HE-XC1E5 / HEXT251C115 MAN0964-01-EN June 29, 2012 Page 1 of 122
PAGE 2 MAN0964-01-EN PREFACE 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.
MAN0964-01-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.
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MAN0964-01-EN Table of Contents TABLE OF CONTENTS PREFACE .................................................................................................................................................... 2 For user manual updates, contact Technical Support: ............................................................................. 2 LIMITED WARRANTY AND LIMITATION OF LIABILITY ........................................................................ 3 ABOUT PROGRAMMING EXAMPLES ..........
Table of Contents MAN0964-01-EN 5.6 Cscape Programming via Serial Port ............................................................................................ 26 5.7 Ladder-Controlled Serial Communication ..................................................................................... 26 5.8 Downloadable Serial Communication Protocols ........................................................................... 26 CHAPTER 6: CAN COMMUNICATIONS ..............................
MAN0964-01-EN Table of Contents 11.6 PWM Examples........................................................................................................................... 57 11.7 STP Examples ............................................................................................................................ 57 CHAPTER 12: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................... 59 12.1 System Menu - Overview .....................
Table of Contents MAN0964-01-EN 19.1.1 Connecting Troubleshooting Checklist (serial port – MJ1 Programming) ................. 116 19.1.2 Connecting Troubleshooting Checklist (USB Port - Mini B Programming) ................ 116 19.1.3 Connecting Troubleshooting Checklist (ETN port programming)............................... 116 19.2 Local Controller and Local I/O................................................................................................... 116 19.2.
MAN0964-01-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 website http://www.heapg.com to obtain updates to datasheets, manuals and user documentation.
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MAN0964-01-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. 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.
CH.1 1.2 MAN0964-01-EN 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.
MAN0964-01-EN CH.2 CHAPTER 2: INTRODUCTION 2.1 Visual Overview of XL4 OCS Top microSD Memory Slot Dip Switches J4 I/O Terminal (model 4 only) Serial MJ1/2 USB 2.0 A Ethernet USB 2.0 mini-B J1 I/O Terminal J2 I/O Terminal Left Right CAN Port DC Power In (10-30Vdc) & Frame Ground J3 I/O Terminal (model 4 & 5 only) Bottom 2.1.1 Where to Find Information about the XL4 OCS a.
CH.2 MAN0964-01-EN 2.1.2 Four main types of information are covered in the manual. a. b. c. d. 2.1.3 Safety and Installation guidelines / instructions (Mechanical and Electrical) Descriptions of hardware features (Serial ports, Removable Media, Communication Options, etc.) Configuration and Use of the XL4 OCS Maintenance and Support Manual Index Index Major topics of interest may be found in the Index towards the end of this manual. 2.1.
MAN0964-01-EN • • • • • • • • • 2.4 CH.2 Removable 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.
CH.2 2.5 MAN0964-01-EN 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.
MAN0964-01-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.
CH.3 3.3 MAN0964-01-EN 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: The orientation shown above provides for optimum readability of the screen and ease of use of the keypad. CAUTION: For DIN Rail mounting: To prevent the unit from slipping off the DIN Rail, do not install the unit on its sides as shown.
MAN0964-01-EN 3.4 CH.3 Panel Cut-Out 3.622 [92mm] 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 [92mm] 001XLE002 Figure 3.4 – Panel Cutout Tolerances 3.5 XL4 Dimensions Figure 3.
CH.3 3.6 MAN0964-01-EN Factors Affecting Panel Layout Design and Clearances Warning: It is important to follow the requirements of the panel manufacturer and to follow all applicable electrical codes and standards. The designer of a panel layout needs to assess the requirements of a particular 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.
MAN0964-01-EN 3.6.4 CH.3 Orientation When panel-mounted, there are no orientation restrictions on the XL4 OCS. 3.6.5 Noise Consider the impact on the panel layout design and clearance requirements if noise suppression devices are needed. Be sure to maintain an adequate distance between the XL4 OCS and noisy devices such as relays, motor starters, etc. For details on output protection, especially when using contactors, solenoids… see MAN0962-01EN. 3.6.
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MAN0964-01-EN CH.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.
CH.4 4.4 MAN0964-01-EN Primary Power Port Table 4.1 – Primary Power Port Pins Pin 1 Signal Description Frame Ground 2 0V Input power supply ground 3 +24V Input power supply positive voltage -+ 10-30 VDC supply - + Power Connector Figure 4.2 – Power Connector (Primary Power Port) -+ Power Up: Connect to Earth Ground. Apply 10 – 30 VDC. Screen lights up. Torque rating 4.5 - 7 Lb-In (0.50 – 0.78 N-m) PIN 1 PIN 2 PIN 3 Figure 4.
MAN0964-01-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.
CH.5 MAN0964-01-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 RS485 biasing. Also, an application graphics screen that writes to %SR164 can do the same thing. Setting %SR164.1 enables MJ1 biasing and setting %SR164.2 enables MJ2 biasing. If biasing is used, it should be enabled in only one of the devices attached to the RS-485 network. 5.
MAN0964-01-EN CH.6 CHAPTER 6: CAN COMMUNICATIONS Note: For additional CAN information, refer to the CAN Networks manual (MAN0799) 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 CAN1. Figure 6.1 – CAN1 Connector Like the MJ1 serial port, the CAN1 port can be used for XL4 OCS programming by connecting it to the CAN port of a PC running Cscape.
CH.6 6.3 MAN0964-01-EN CAN1 Port Wiring CAN Network & Power Port Pin Assignments CAN Connector Pin Signal Signal Description Direction Use the CAN Connector when using CsCAN or other CAN network. 1 V- CAN and Device Ground - Black − In/Out Torque rating 4.5 – 7 Lb-In (0.50 – 0.78 N-m) 2 CN_L CAN Data Low - Blue 3 SHLD Shield Ground - None − 4 CN_H CAN Data High - White In/Out 5 V+ Positive DC Voltage Input (10-30VDC) - Red − Figure 6.2 – CAN1 Port Connector 6.
MAN0964-01-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 Ping EGD (Peer) SRTP Server CsCAN TCP Server Modbus TCP Slave Ethernet / IP Server FTP Server HTTP Server 7.
CH.7 MAN0964-01-EN 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 7.
MAN0964-01-EN CH.7 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.
CH.7 MAN0964-01-EN Bit 16 Bit 15 Bit 14 Table 7.
MAN0964-01-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.
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MAN0964-01-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.
CH.8 MAN0964-01-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.
MAN0964-01-EN CH.10 CHAPTER 9: REMOVABLE MEDIA 9.1 Overview All XL4 OCS 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.
CH.10 9.3 MAN0964-01-EN 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 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.
MAN0964-01-EN 9.6 CH.10 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.
CH.10 MAN0964-01-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.
MAN0964-01-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.
CH.10 MAN0964-01-EN Figure 10.3 – 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. J4 JP1 J1 J2 JP3 J3 001XLE005-R1 Figure 10.4 – Example Jumper Diagram To re-install the cover, place the I/O cover back on the unit.
MAN0964-01-EN CH.10 Outputs HE-XC1E0 / HEXT251C100 HE-XC1E2 / HEXT251C112 HE-XC1E3 / HEXT251C113 HE-XC1E4 / HEXT251C114 HE-XC1E5 / HEXT251C115 Table 10.1 shows the different types of I/O 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 applications of the different type of I/O can be found below.
CH.10 10.4 MAN0964-01-EN Solid-State Digital Outputs Solid-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.
MAN0964-01-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.
CH.10 MAN0964-01-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 MAN0962-01.
MAN0964-01-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 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.
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MAN0964-01-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.
CH.11 11.3 MAN0964-01-EN 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.
MAN0964-01-EN CH.11 Width High 1 µs Counts – In this sub-mode the accumulator value will contain the number of 1 µs counts the pulse is high. Width High Width Low 1 µs Counts - In this sub-mode the accumulator value will contain the number of 1 µs counts the pulse is low. Width 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.
CH.11 MAN0964-01-EN Two modes are available for quadrature that select whether the accumulator counts up or down when the phase of input 1 leads input 2. Check your encoder’s documentation to determine the output form it uses or try both modes to determine if the encoder counts up when expected.
MAN0964-01-EN 11.3 CH.11 HSC 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.
CH.11 11.4 MAN0964-01-EN High Speed Output Functions On units that support the PWM, two dedicated outputs are available that can be configured for one of four modes of operation. Those modes are Normal, PWM, HSC Match and Stepper. 11.4.1 Normal When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives that respective output. 11.4.2 PWM When either Q1 or Q2 is configured for PWM, the PWM function drives that respective output.
MAN0964-01-EN CH.11 Note for standard I/O modules (1E3, 1E4 and 1E5 models) that the nominal output driver turn-on-time delay (to reach 50% output) is 25 microseconds. Therefore, this limitation should be considered when determining both the minimum pulse width and the duty cycle accuracy of the application. Special high speed output options will be available. 11.4.
CH.11 MAN0964-01-EN Error A high indication on this register indicates that one of the analog parameters specified above is invalid or the stepper action was aborted before the operation was complete. This register is cleared on the next start command if the error was corrected. The stepper requires one discrete register to control the stepper action. Setting this register starts the stepper cycle. This register must remain set to complete the entire cycle.
MAN0964-01-EN 11.6 CH.11 PWM Examples Example 1 To get a 50% Duty Cycle @ 10 kHz waveform on PWM1: Set %AQ421-422 = 16,000 (duty cycle) Set %AQ423-424 = 10,000 (frequency Example 2 To get a 50% Duty Cycle on PW1 and 90 % Duty Cycle on PWM2 @ 1 kHz waveform: Set %AQ421-422 = 16,000 (duty cycle) Set %AQ423-424 = 1,000 (frequency Set %AQ431-432 = 28,800 (duty cycle (32000 * 0.
CH.11 MAN0964-01-EN Set %AQ1 = 500 (Hz) Set %AQ2 = 1000 (Hz) Set %AQ3-4 = 2000000 (Steps) Set %AQ5-6 = 2000000 (Steps) Set %AQ7-8 = 1000000 (Steps) {Start Frequency} {Run Frequency} {Accel Count} {Run Count} {Decel Count} Example 3 6,000,000 steps control sequence The following example starts at 50 Hz and ramps up to 250 Hz during the first 150,000 steps. Then, it runs at 250 Hz for the next 5,500,000 steps. Finally during the last 350,000 steps it slows to a stop.
MAN0964-01-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 ↓ 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.
CH.12 MAN0964-01-EN F ↑ and ↓ keys ESC key Enter key 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 ↑ to select an item and press Enter to display the item’s Sub-Menu. A Sub-Menu generally shows a list of System Settings and their values.
MAN0964-01-EN 12.3 CH.12 System Menu – Details 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.
CH.12 MAN0964-01-EN OCS Net Use %: 0.0 to 100.0 = CAN network bandwidth % used by this XL4 OCS node All Net Use %: 0.0 to 100.
MAN0964-01-EN User Program: CH.12 Ok Fault = Ladder program and I/O configuration loaded successfully = Ladder program or I/O configuration not loaded or load failed The last nine System Diagnostics are informational. If any of them indicate a Warning condition, the XL4 OCS can still enter and remain in Run mode, but the problem should be investigated and corrected.
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MAN0964-01-EN CH.12 Port 2: Protocol name Protocol version = (None Loaded) or name of the protocol assigned to MJ2 = Blank or version of the protocol assigned to MJ2 Set Fkeys Mode The Set Fkeys Sub-Menu displays two System Settings, both of which are editable.
CH.12 MAN0964-01-EN Set Time/Date 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 → to select a field and then use ↓ or ↑ to edit the field.
MAN0964-01-EN Saver enable: CH.12 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.
CH.12 MAN0964-01-EN The Removable Media Sub-Menu displays the Removable Media Manager.
MAN0964-01-EN CH.12 Selecting Backup/Restore Data displays the following screen in: Backup Restore Clear Backup Exit = Copies Battery Backed RAM contents on to the onboard FLASH memory of the OCS. = Copies the backed up data from onboard FLASH to the battery backed RAM. = The backup data will be erased from the onboard FLASH. = Goes back to previous menu.
CH.12 MAN0964-01-EN Enable AutoRun No Yes = OCS will be in IDLE mode after AutoLoad or Automatic Restore. = 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 No Yes = Does not load AUTOLOAD.PGM automatically when application program is absent or corrupted. = Loads AUTOLOAD.PGM file automatically from RM when application program is absent or corrupted.
MAN0964-01-EN CH.12 Note: Free/Total – displays number of free and total bytes in Removable Media. Selecting Make Clone brings up the screen below for the user: After confirmation, the OCS will create two new files in the root directory of the Removable Media Drive as shown below: AUTOLOAD.PGM CLONE.
CH.12 MAN0964-01-EN Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”. NOTE: For security enabled files, Load clone asks for password validation before loading the application. 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.
MAN0996-01-EN CH.13 CHAPTER 13: USER INTERFACE 13.1 Overview This chapter presents the user interface (or operator view) of 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: • • • • • • • • • 13.
CH.13 MAN0964-01-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. On 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).
MAN0964-01-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.
CH.13 MAN0964-01-EN When editing a Time/Date Table Object, all the keys except the Up, Down, Left and Right arrow keys are grayed and disabled. The specific field (i.e. hour or minutes) is selected using the Left and Right arrows. The value in the selected field is changed by pressing either the Up or Down arrow. 13.4 Screen Navigation To allow the operator to change screens, a screen jump object is generally used.
MAN0964-01-EN CH.13 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.
CH.13 MAN0964-01-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.
MAN0964-01-EN 13.9 CH.13 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.
CH.13 MAN0964-01-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 (Enter) button (if enabled) performs certain operations based on the selected file’s type: ..
MAN0964-01-EN 13.11 CH.13 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 0 (full off). It is left to the screen designer on if and how to present a Screen Brightness control to the user.
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MAN0964-01-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.
CH.14 MAN0964-01-EN %S System Bit Single-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 %S and %SR registers Register %S1 %S2 %S3 %S4 %S5 %S6 %S7 %S8 %S9 %S10 %S11 %S12 %S13 %S16 Table 14.
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CH.14 Register MAN0964-01-EN Name %SR164.4 %SR164.5 %SR164.6 %SR164.7 %SR164.8 %SR164.9 %SR164.10 %SR164.11 %SR164.12 %SR165-174 %SR180 Reserved Removable Media Removable Media Removable Media Reserved %SR181 ALM_UNACK %SR182 %SR183 %SR184 %SR185 %SR186 %SR187 ALM_ACT SYS_BEEP USER_BEEP SCR_SAVER SCR_SA_TM NET_USE %SR188 NET_MIN %SR189 NET_MAX %SR190 %SR191 %SR192 NT_TX_AVG NT_TX_MIN NT_TX_MAX %SR175 %SR176-177 %SR178-179 Table 14.
MAN0964-01-EN CH.14 14.3 Register Map for XL4 OCS I/O Fixed Address Digital/Analog I/O Function 3 4 5 1-12 1-12 1-24 1-12 Reserved 13-32 13-31 25-31 ESCP Alarm n/a 32 32 Digital Outputs 1-6 1-12 1-16 Reserved 7-24 13-24 17-24 Analog Inputs 1-4 1-2 1-2 Reserved 5-12 3-12 3-12 Reserved n/a 1-8 1-8 Analog Outputs n/a n/a n/a Reserved areas maintain backward compatibility with other XL Series OCS models 13-31 32 1-12 13-24 1-2 3-12 1-8 9-10 Digital Inputs %I1 %Q1 %AI1 %AQ1 14.
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MAN0964-01-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.
CH.16 15.3 MAN0964-01-EN 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.
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CH.16 MAN0964-01-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).
MAN0964-01-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. 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.
CH.16 MAN0964-01-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.
MAN0964-01-EN 15.5 CH.16 Configuration An overview of configuration: (1) Start the configuration by selecting the Controller | I/O Configure menu item. (2) 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. (3) 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. (4) Select either XL4 OCS Cscan from the type drop down box.
CH.16 MAN0964-01-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.
MAN0964-01-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.
CH.16 MAN0964-01-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. Figure 15.
MAN0964-01-EN CH.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: • • Battery power loss Battery-Backed Register RAM or Application Flash corruption due to, for example, an excessive EMI event.
CH.16 16.2 MAN0964-01-EN Settings To use the fail – safe feature, the user needs to do the following: 1. Backup the current Battery-Backed RAM Register contents in On-Board Flash memory using System Menu options. 2. From Cscape, create AUTOLOAD.PGM for the application program using ‘Export to Removable Media’. 3. Place the Removable Media with AUTOLOAD.PGM in the device. 4. Set the ‘Enable AutoLoad’ option in the device to YES. 5.
MAN0964-01-EN CH.16 Figure 16.3 – Backup Registers Restore OCS Data: When initiated, this will allow the user to manually copy the backed up data from the onboard FLASH to the Battery-Backed RAM. A restore operation will be automatically initiated if a backup has been previously created and on powerup the Battery-Backed RAM registers fail their check. The following process will be followed for restoring data: • The controller will be placed in IDLE mode.
CH.16 MAN0964-01-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. Figure 16.5 – Clear Backup Data Exit: Goes back to the previous screen.
MAN0964-01-EN CH.16 The OCS follows the following sequence in execution of Automatic Restore: OCS Power Cycle Battery Backed RAM Registers check failed NO Backup exists? YES Controller placed in IDLE mode Application Program erased Data copied from Onboard FLASH to OCS Battery backed RAM Controller Resets NO AutoRun Enabled? OCS put in IDLE Mode YES OCS put in RUN Mode Figure 16.
CH.16 16.4 MAN0964-01-EN 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: • When there is no application program in the OCS and a valid AUTOLOAD.PGM is available in the removable media of the device.
MAN0964-01-EN CH.16 The OCS follows the following sequence in execution of AutoLoad: Power up OCS Application Program absent or Application Program corrupted NO AutoLoad Enabled? OCS put in IDLE mode YES AUTOLOAD.PGM present in the RM of the device ? NO AutoLoad run sequence failed (with reasons for failure) YES AutoLoad initiated. NO AutoRun Enabled? OCS put in IDLE Mode YES OCS put in RUN Mode Figure 16.
CH.16 16.5 MAN0964-01-EN AutoRun This system menu option, when enabled (YES), allows the user to automatically place the OCS into RUN mode after the AutoLoad operation or automatic Restore Data operation. When the AutoRun setting is disabled (NO), the OCS remains in the IDLE mode after a Restore Data or AutoLoad operation. %SR164.5 can be set by putting the system into RUN mode automatically, once an AutoLoad has been performed or an Automatic Restore has occurred.
MAN0964-01-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: • • 17.2 Replacing an OCS by another unit of the same model. Duplicating or “clone” units without a PC.
CH.17 MAN0964-01-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: 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 CLONE.
MAN0964-01-EN CH.17 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.
CH.17 MAN0964-01-EN 2. Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”. Figure 17.7 – Clone Unit Menu after Cloning 3. User needs to confirm Load Clone as shown below: 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.
MAN0964-01-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.
CH.18 MAN0964-01-EN 18.2.2 Battery Replacement Warning: Lithium Batteries may explode or catch fire if mistreated Do not recharge, disassemble, heat above 100 deg.C (212 deg.F) incinerate, or puncture. Warning: Disposal of lithium batteries must be done in accordance with federal, state, and local regulations. Be sure to consult with the appropriate regulatory agencies before disposing batteries. In addition, do not re-charge, disassemble, heat or incinerate lithium batteries.
MAN0964-01-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, please contact Technical Support at the locations indicated at the end of this chapter. 19.
CH.19 MAN0964-01-EN 19.1.1 Connecting Troubleshooting Checklist (serial port – MJ1 Programming) 1. Programming and debugging must use MJ1 or USB Mini B Port. 2. Controller must be powered up. 3. Ensure that the correct COM port is selected in Cscape. Tools/Editor Options/Communications Port. 4. Ensure that a straight through (non null modem) serial cable is being used between PC and controller port MJ1. 5. Check that a Loaded Protocol or ladder is not actively using MJ1.
MAN0964-01-EN • • CH.19 Loaded protocols Removable media access To view the system menu, press the System key. 19.2.1 Local I/O Troubleshooting Checklist 1. Verify the controller is in RUN mode. 2. 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 I/O match. 5. Check data sheets for voltage and current limits. 6.
CH.19 MAN0964-01-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 # HE200CGM100. 19.4 Removable Media 19.4.1 Basic Troubleshooting Description XL4 OCS does not read media card. XL4 OCS will not download project file. 19.5 Action The media card should be formatted with the XL4 OCS.
MAN0964-01-EN CH.19 Index %Q bits, 44 Accessories, 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.
MAN0964-01-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 Panel Cutout Tolerances, 19 Panel Design Che
Table of Figures MAN0964-01-EN Screen Navigation, 76 Using Removable Media to View and Capture Screens, 39 Visual Overview of XL6 and Topics, 13 Where to Find Information, 13 XL6 Dimensions, 19 XL6 I/O Cover Photograph, 42 XL6 I/O Cover Removed (sample I/O board) Photograph, 42 June 29, 2012 Page 121 of 122 XL6 Manual PREFACE, 2 XL6 OCS Accessories, 15 XL6 OCS Dimensions, 19 XL6 OCS Mounting Clip, 18 XL6 OCS Mounting Orientation, 18 XL6 OCS with Mounting Clips, 18 XMC, 36
MAN0964-01-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 3.1 – Panel Mounting of an XL4 Series OCS ................................................................................................ 17 Figure 3.2 – XL4 OCS with Mounting Clips .............................................................................................................. 18 Figure 3.
