• XL6/XL6M/XL6e (HE-XL/ HEXT350/ HEXT351) OCS


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Horner APG, LLC Technical Support North America Tel User Manual for
XL6/XL6M/XL6e
(HE-XL/ HEXT350/ HEXT351) OCS
HE-XL100 / HE-XL1M0 / HEXT350C100 / HEXT280C100
HE-XL102 / HE-XL1M2 / HEXT350C112 / HEXT280C112
HE-XL103 / HE-XL1M3 / HEXT350C113 / HEXT280C113
HE-XL104 / HE-XL1M4 / HEXT350C114 / HEXT280C114
HE-XL105 / HE-XL1M5 / HEXT350C115 / HEXT280C115
HE-XL1E0 / HEXT351C100
HE-XL1E2 / HEXT351C112
HE-XL1E3 / HEXT351C113
HE-XL1E4 / HEXT351C114
HE-XL1E5 / HEXT351C115
MAN0883-05-EN
MAN0883-05-EN Preface
PREFACE
This manual explains how to use the XL6/XL6e (HE-XL/HEXT350/HEXT351) OCS Modules.
Copyright (C) 2008 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights
reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language or computer language, in any form by any means, electronic,
mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written
permission of Horner APG, Inc.
All software described in this document or media is also copyrighted material subject to the terms and
conditions of the Horner Software License Agreement.
Information in this document is subject to change without notice and does not represent a commitment on
the part of Horner APG.
Cscape, SmartStack, SmartStix and CsCAN are trademarks of Horner APG.
Ethernet is a trademark of Xerox Corporation.
Micro SD and CompactFlash are registered trademarks of SanDisk Corporation.
For user manual updates, contact Technical Support:
North America:
Tel: (+) (317) 916-4274
Fax: (+) (317) 639-4279
Web: www.heapg.com
Email: [email protected]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Web: www.horner-apg.com
Email: [email protected]
March 4, 2010 Page 3 of 135 #1037
MAN0883-05-EN Limited Warranty and Liability
LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the XL6/XL6e (HE-XL/HEXT350/HEXT351)
OCS module manufactured by HE-APG is free from defects in material and workmanship under normal use and
service. The obligation of HE-APG under this warranty shall be limited to the repair or exchange of any part or parts
which may prove defective under normal use and service within two (2) years from the date of manufacture or
eighteen (18) months from the date of installation by the original purchaser whichever occurs first, such defect to be
disclosed to the satisfaction of HE-APG after examination by HE-APG of the allegedly defective part or parts. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR
LIABILITIES AND HE-APG NEITHER ASSUMES, NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR
HE-APG, ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS XL6/XL6e OCS module. THIS
WARRANTY SHALL NOT APPLY TO THIS XL6/XL6e OCS module OR ANY PART THEREOF WHICH HAS BEEN
SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. HE-APG MAKES NO WARRANTY
WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE-APG. THE TERM
"ORIGINAL PURCHASER", AS USED IN THIS WARRANTY, SHALL BE DEEMED TO MEAN THAT PERSON FOR
WHOM THE XL6/XL6e (HE-XL/HEXT350/HEXT351) OCS module IS ORIGINALLY INSTALLED. THIS WARRANTY
SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES.
In no event, whether as a result of breach of contract, warranty, tort (including negligence) or otherwise, shall HE-
APG or its suppliers be liable of any special, consequential, incidental or penal damages including, but not limited to,
loss of profit or revenues, loss of use of the products or any associated equipment, damage to associated equipment,
cost of capital, cost of substitute products, facilities, services or replacement power, down time costs, or claims of
original purchaser's customers for such damages.
To obtain warranty service, return the product to your distributor with a description of the problem, proof of
purchase, post paid, insured and in a suitable package.
ABOUT PROGRAMMING EXAMPLES
Any example programs and program segments in this manual or provided on accompanying diskettes are included
solely for illustrative purposes. Due to the many variables and requirements associated with any particular
installation, Horner APG cannot assume responsibility or liability for actual use based on the examples and diagrams.
It is the sole responsibility of the system designer utilizing the XL6/XL6e OCS module to appropriately design the
end system, to appropriately integrate the XL6/XL6e OCS module and to make safety provisions for the end
equipment as is usual and customary in industrial applications as defined in any codes or standards which apply.
Note: The programming examples shown in this manual are for illustrative purposes only.
Proper machine operation is the sole responsibility of the system integrator.
March 4, 2010 Page 4 of 135 #1037
MAN0883-05-EN Table of Contents
TABLE OF CONTENTS
PREFACE ..................................................................................................................................................... 3
LIMITED WARRANTY AND LIMITATION OF LIABILITY........................................................................... 4
VISUAL MAP OF MAJOR TASKS AND THE KEY CHAPTERS TO ASSIST YOU ................................... 9
CHAPTER 1: SAFETY / COMPLIANCE ................................................................................................... 11
1.1 Safety Warnings and Guidelines .................................................................................................. 11
1.2 Grounding ..................................................................................................................................... 12
1.3 CE Compliance............................................................................................................................. 12
CHAPTER 2: INTRODUCTION ................................................................................................................. 13
2.1 Visual Overview of XL6/XL6e OCS .............................................................................................. 13
2.1.1 Where to Find Information about the XL6/XL6e OCS........................................................... 14
2.1.2 Four main types of information are covered in the manual................................................... 14
2.1.3 Manual Index ......................................................................................................................... 14
2.1.4 Table of Figures .................................................................................................................... 14
2.2 Connectivity to the XL6/XL6e OCS .............................................................................................. 15
2.3 Features of XL6/XL6M/XL6e OCS ............................................................................................... 15
2.4 Required and Suggested Accessories .........................................................................................16
2.5 Useful Documents and References.............................................................................................. 16
CHAPTER 3: MECHANICAL INSTALLATION......................................................................................... 17
3.1 Overview....................................................................................................................................... 17
3.2 Mounting Requirements ............................................................................................................... 17
3.2.1 Mounting Procedures (Installed in a Panel Door) ................................................................. 17
3.3 Mounting Orientation .................................................................................................................... 18
3.3.1 XL6/XL6e OCS Mounting Clip..................................................................................... 18
3.3.2 XL6/XL6e OCS Mounting Orientation ................................................................................... 18
3.4 Panel Cut-Out ............................................................................................................................... 19
3.5 XL6/XL6M/XL6e Dimensions........................................................................................................ 19
3.6 Factors Affecting Panel Layout Design and Clearances .............................................................. 20
3.6.1 Clearance / Adequate Space ................................................................................................ 20
3.6.2 Grounding.............................................................................................................................. 20
3.6.3 Temperature / Ventilation ......................................................................................................20
3.6.4 Orientation ............................................................................................................................. 21
3.6.5 Noise ..................................................................................................................................... 21
3.6.6 Shock and Vibration .............................................................................................................. 21
3.6.7 Panel Layout Design and Clearance Checklist ..................................................................... 21
CHAPTER 4: ELECTRICAL INSTALLATION .......................................................................................... 23
4.1 Grounding Definition ..................................................................................................................... 23
4.2 Ground Specifications .................................................................................................................. 23
4.3 How to Test for Good Ground ...................................................................................................... 23
4.4 Primary Power Port....................................................................................................................... 24
CHAPTER 5: SERIAL COMMUNICATIONS ............................................................................................ 25
5.1 Overview....................................................................................................................................... 25
5.2 Port Descriptions .......................................................................................................................... 25
5.3 Wiring............................................................................................................................................ 25
5.4 RS-485 Termination...................................................................................................................... 27
5.5 RS-485 Biasing............................................................................................................................. 27
5.6 Cscape Programming via Serial Port ........................................................................................... 27
5.7 Ladder-Controlled Serial Communication .................................................................................... 27
5.8 Downloadable Serial Communication Protocols .......................................................................... 27
March 4, 2010 Page 5 of 135 #1037
Table of Contents MAN0883-05-EN
CHAPTER 6: CAN COMMUNICATIONS................................................................................................. 29
6.1 Overview....................................................................................................................................... 29
6.2 Port Description ............................................................................................................................ 29
6.3 CAN (NET1) Port Wiring............................................................................................................... 30
6.4 Cscape Programming via CAN..................................................................................................... 30
6.5 Ladder-Controlled CAN Communication ...................................................................................... 30
6.6 Using CAN for I/O Expansion (Network I/O) ................................................................................ 30
CHAPTER 7: ETHERNET COMMUNICATION (XL6E ONLY) ................................................................. 31
7.1 Ethernet Module Protocols and Features..................................................................................... 31
7.2 Ethernet System Requirements.................................................................................................... 31
7.3 Ethernet Module Specifications .................................................................................................... 31
7.4 Ethernet Module Configuration..................................................................................................... 31
CHAPTER 8: COMMUNICATION OPTIONS............................................................................................ 37
8.1 Overview....................................................................................................................................... 37
8.2 Ethernet COM Module (XEC) Option ........................................................................................... 37
8.3 Modem COM Module (XMC) Option ............................................................................................38
CHAPTER 9: REMOVABLE MEDIA......................................................................................................... 39
9.1 Overview....................................................................................................................................... 39
9.2 Micro SD Cards ............................................................................................................................ 39
9.3 Micro SD File System ................................................................................................................... 40
9.4 Using the Removable Media Manager ......................................................................................... 40
9.5 Using Removable Media to Log Data........................................................................................... 40
9.6 Using Removable Media to Load and Save Applications ............................................................ 41
9.7 Using Removable Media to View and Capture Screens .............................................................. 41
9.8 Removable Media (RM) Function Blocks in Cscape .................................................................... 41
9.9 Filenames used with the Removable Media (RM) Function Blocks ............................................. 42
9.10 System Registers used with RM ...............................................................................................42
CHAPTER 10: GENERAL I/O ................................................................................................................... 43
10.1 Overview ................................................................................................................................... 43
10.2 Removing the XL6/XL6e OCS I/O Cover.................................................................................. 43
10.3 Model and I/O Overview ........................................................................................................... 45
10.4 Solid-State Digital Outputs........................................................................................................ 46
10.5 Relay Outputs ........................................................................................................................... 46
10.6 Digital Inputs ............................................................................................................................. 48
10.7 Analog Inputs ............................................................................................................................ 48
10.8 Universal Analog Inputs ............................................................................................................ 49
10.9 Analog Outputs ......................................................................................................................... 49
CHAPTER11: HIGH SPEED I/O (HSC / PWM)......................................................................................... 51
11.1 Overview ................................................................................................................................... 51
11.2 High Speed Counter (HSC) Functions......................................................................................51
11.2.1 Frequency.............................................................................................................................. 51
11.2.2 Totalize .................................................................................................................................. 51
11.2.3 Pulse...................................................................................................................................... 52
11.2.4 Quadrature ............................................................................................................................ 53
11.3 HSC Functions Register Map ................................................................................................... 56
11.4 Pulse Width Modulation (PWM) Functions ............................................................................... 56
11.4.1 Normal ................................................................................................................................... 56
11.4.2 PWM...................................................................................................................................... 56
11.4.3 HSC (High Speed Counter)................................................................................................... 58
11.4.4 Stepper Function ................................................................................................................... 58
11.5 PWM functions register map.....................................................................................................59
11.6 PWM Examples......................................................................................................................... 59
11.7 STP Examples .......................................................................................................................... 60
March 4, 2010 Page 6 of 135 #1037
MAN0883-05-EN Table of Contents
CHAPTER 12: SYSTEM SETTINGS AND ADJUSTMENTS.................................................................... 61
12.1 System Menu - Overview.......................................................................................................... 61
12.2 System Menu – Navigation and Editing.................................................................................... 62
12.3 System Menu – Details ............................................................................................................. 63
12.4 Touch screen calibration........................................................................................................... 74
CHAPTER 13: USER INTERFACE............................................................................................................ 75
13.1 Overview ................................................................................................................................... 75
13.2 Displaying and entering Data.................................................................................................... 75
13.3 Alpha-numeric keypad .............................................................................................................. 76
13.4 Screen Navigation..................................................................................................................... 78
13.5 Ladder Based Screen Navigation ............................................................................................. 79
13.6 Beeper Acknowledgement ........................................................................................................79
13.7 Touch (Slip) Sensitivity ............................................................................................................. 79
13.8 Alarms ....................................................................................................................................... 80
13.9 Removable Media ..................................................................................................................... 81
13.10 Screen Saver ............................................................................................................................ 83
13.11 Screen Brightness..................................................................................................................... 83
CHAPTER 14: REGISTERS....................................................................................................................... 85
14.1 Register Definitions ................................................................................................................... 85
14.2 Useful %S and %SR registers .................................................................................................. 86
14.3 Register Map for XL6/XL6e OCS I/O ........................................................................................ 88
14.4 Resource Limits ........................................................................................................................ 89
CHAPTER 15: CSCAPE CONFIGURATION ............................................................................................ 91
15.1 Overview ................................................................................................................................... 91
15.2 Cscape Status Bar .................................................................................................................... 91
15.3 Establishing Communications................................................................................................... 92
15.3.1 Communicating via MJ1 Serial Port........................................................................................ 105
15.3.2 Communicating via On Board Ethernet Port (For XL6e Only)................................................ 106
15.4 Models supported.................................................................................................................... 106
15.5 Configuration........................................................................................................................... 107
15.6 Digital Input / HSC Configuration ............................................................................................107
15.7 Digital Output / PWM Configuration ........................................................................................ 109
15.8 Analog Input Configuration ..................................................................................................... 110
15.9 Analog Output Configuration................................................................................................... 111
CHAPTER 1 6: FAIL – SAFE SYSTEM ................................................................................................... 113
16.1 Overview................................................................................................................................... 113
16.2 Settings ................................................................................................................................... 114
16.3 Backup / Restore Data............................................................................................................ 114
16.4 AutoLoad................................................................................................................................. 118
16.5 AutoRun .................................................................................................................................. 120
CHAPTER 17: CLONE UNIT................................................................................................................... 121
17.1 Overview ................................................................................................................................. 121
17.2 Clone....................................................................................................................................... 121
17.3 Load Clone.............................................................................................................................. 123
CHAPTER 18: MAINTENANCE.............................................................................................................. 125
18.1 Firmware Updates................................................................................................................... 125
18.2 Backup Battery........................................................................................................................ 125
18.2.1 Indications the battery needs replacing...............................................................................125
18.2.2 Battery Replacement...........................................................................................................126
March 4, 2010 Page 7 of 135 #1037
Table of Contents MAN0883-05-EN
CHAPTER 19: TROUBLESHOOTING / TECHNICAL SUPPORT .......................................................... 127
19.1 Connecting to the XL6/XL6e OCS ..........................................................................................127
19.1.1 Connecting Troubleshooting Checklist (serial port – MJ1 Programming)........................... 128
19.1.2 Connecting Troubleshooting Checklist (USB Port - Mini B Programming) ......................... 128
19.1.3 Connecting Troubleshooting Checklist (ETN port programming) [For XL6e only].............. 128
19.2 Local Controller and Local I/O ................................................................................................128
19.2.1 Local I/O Troubleshooting Checklist....................................................................................129
19.3 CsCAN Network ...................................................................................................................... 129
19.3.1 CsCAN Network Troubleshooting Checklist........................................................................129
19.4 Removable Media ................................................................................................................... 130
19.4.1 Basic Troubleshooting......................................................................................................... 130
19.5 Technical Support Contacts....................................................................................................130
Index ..................................................................................................................................................... 131
Table of Figures................................................................................................................................... 134
March 4, 2010 Page 8 of 135 #1037
MAN0883-05-EN Visual Map
Visual Map of major tasks and the key chapters to assist you
FIRST STEP of ANY TASK: DATASHEET
Each XL6/XL6e OCS unit is sent with a datasheet in the box. The datasheet is the first document
you need to refer to for model-specific information related to XL6/XL6e OCS models such as
pin-outs, jumper settings, and other key installation information. Visit our website
http://www.heapg.com to obtain updates to datasheets, manuals and user documentation.
QUICK START INSTALLATION PROGRAMMING TROUBLESHOOTING
Safety / Compliance Safety / Compliance Safety / Compliance Safety / Compliance
page 11 page 11 page 9 page 11
Introduction Introduction Introduction Introduction
page 13 page 13 page 11 page 13
Mechanical Installation Serial Communications Maintenance
page 17 Page 25 page 125
Electrical Installation CAN Communications Troubleshooting
page 23 page 29 page 127
Ethernet (XL6e only)
Page 31
Communication Options
page 37
Removable Media
page 39
High Speed I/O
page 51
System Settings
page 61
User Interface
page 75
Registers
page 85
Cscape Configuration
page 91
Fail- Safe System
Page 113
Clone Unit
Page 121
March 4, 2010 Page 9 of 135 #1037
Visual Map MAN0883-05-EN
NOTES
March 4, 2010 Page 10 of 135 #1037
MAN0883-05-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.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly recommended to fuse
the voltage measurement inputs. Be sure to locate fuses as close to the source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk of fire and shock
hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated failure indicates a
defective condition that will not clear by replacing the fuse.
WARNING – EXPLOSION HAZARD – Substitution of components may impair suitability for Class I, Division
2
WARNING - The USB parts are for operational maintenance only. Do not leave permanently connected
unless area is known to be non-hazardous
WARNING – EXPLOSION HAZARD - BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE
NON-HAZARDOUS
WARNING - Battery May Explode If Mistreated. Do Not Recharge, Disassemble or Dispose Of In Fire
WARNING: Only qualified electrical personnel familiar with the construction and operation of this equipment
and the hazards involved should install, adjust, operate, or service this equipment. Read and understand
this manual and other applicable manuals in their entirety before proceeding. Failure to observe this
precaution could result in severe bodily injury or loss of life.
a. All applicable codes and standards need to be followed in the installation of this product.
b. For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG or
larger.
Adhere to the following safety precautions whenever any type of connection is made to the module.
a. Connect the green safety (earth) ground first before making any other connections.
b. When connecting to electric circuits or pulse-initiating equipment, open their related breakers. Do
not make connections to live power lines.
c. Make connections to the module first; then connect to the circuit to be monitored.
d. Route power wires in a safe manner in accordance with good practice and local codes.
e. Wear proper personal protective equipment including safety glasses and insulated gloves when
making connections to power circuits.
f. Ensure hands, shoes, and floor is dry before making any connection to a power line.
g. Make sure the unit is turned OFF before making connection to terminals. Make sure all circuits
are de-energized before making connections.
h. Before each use, inspect all cables for breaks or cracks in the insulation. Replace immediately if
defective.
March 4, 2010 Page 11 of 135 #1037
CH.1 MAN0883-05-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/Pages/TechSupport/ProductCert.html
March 4, 2010 Page 12 of 135 #1037
MAN0883-05-EN CH.2
CHAPTER 2: INTRODUCTION
2.1 Visual Overview of XL6/XL6e OCS
Figure 2.1 – Visual Overview of XL6/XL6e type OCS - Side and Rear Views
March 4, 2010 Page 13 of 135 #1037
CH.2 MAN0883-05-EN
Figure 2.2 – Front View of XL6/XL6M/XL6e type OCS
2.1.1 Where to Find Information about the XL6/XL6e OCS
a. Datasheets - The datasheets are the first documents you need to refer to
for key information related to specific XL6/XL6e OCS models. (A datasheet is
provided in the box with your unit.)
The datasheets for all XL6/XL6e OCS models are available on our website.
Datasheets contain pin-outs, jumper settings and other model specific
information.
b. User Manual -This manual provides general information that is common to
XL6/XL6e OCS models and can be downloaded from our web. Visit our website
at http://www.heapg.com to obtain user documentation and updates.
2.1.2 Four main types of information are covered in the manual.
a. Safety 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 XL6/XL6e 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
March 4, 2010 Page 14 of 135 #1037
MAN0883-05-EN CH.2
Table of Figures
Location of important drawing, illustrations (etc) may be found in the Table of Figures .
2.2 Connectivity to the XL6/XL6e OCS
The XL6/XL6e OCS has excellent capabilities for connecting to a variety of devices. The diagram below
shows some examples of devices that can be used with the XL6/XL6e OCS.
Other OCS Devices Other OCS Devices
Smart Stix I/O CAN Serial Drives
RCS116 I/O Base PLCs
OPC Server Bar Code Readers
Printers
XL6 / XL6e SCADA
OCS OPC Servers


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