User Manual for XL7 OCS MAN0974-01-EN HE-XW1E0 / HEXT391C100 HE-XW1E2 / HEXT391C112 HE-XW1E3 / HEXT391C113 HE-XW1E4 / HEXT391C114 HE-XW1E5 / HEXT391C115
XL7 User Manual PREFACE This manual explains how to use the XL7 OCS. Copyright© 2013 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.
XL7 User Manual LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the XL7 (HE-XW/HEXT391) OCS module manufactured by HE-APG is free from defects in material and workmanship under normal use and service.
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XL7 User Manual TABLE OF CONTENTS PREFACE ............................................................................................................................................2 For user manual updates, contact Technical Support:.............................................................................. 2 LIMITED WARRANTY AND LIMITATION OF LIABILITY ................................................................................ 3 ABOUT PROGRAMMING EXAMPLES ........................................
XL7 User Manual CHAPTER 5: SERIAL COMMUNICATIONS ........................................................................................... 24 5.1 Overview ........................................................................................................................................ 24 5.2 Port Descriptions............................................................................................................................ 24 5.3 Wiring and Dip Switches ......................................
XL7 User Manual CHAPTER 11: HIGH SPEED I/O (HSC / PWM) ..................................................................................... 44 11.1 Overview ...................................................................................................................................... 44 11.2 Glossary ........................................................................................................................................ 44 11.3 High Speed Counter (HSC) Functions ......................
XL7 User Manual 15.3.2 Communicating via On Board Ethernet Port ............................................................................ 84 15.5 Configuration ............................................................................................................................... 85 15.6 Digital Input / HSC Configuration ................................................................................................. 85 15.7 Digital Output / PWM Configuration ......................................
XL7 User Manual Visual map of major tasks and the key chapters to assist you FIRST STEP of ANY TASK: DATASHEET Each XL7 OCS unit is sent with a datasheet in the box. The datasheet (MAN0971-02-EN) is the first document to refer to for model-specific information related to XL7 OCS models such as pin-outs, jumper settings, and other key installation information. To obtain updates to datasheets, manuals and user documentation, visit a Horner website (US: http://www.heapg.com and Europe: http://www.horner-apg.
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XL7 User Manual CHAPTER 1: SAFETY / COMPLIANCE 1.1 Safety Warnings and Guidelines When found on the product, the following symbols specify: Warning: Consult user documentation. Warning: Electrical Shock Hazard. WARNING – EXPLOSION HAZARD – Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth) ground before making any other connections.
XL7 User Manual g. Make sure the unit is turned OFF before making connection to terminals. Make sure all circuits are de-energized before making connections. h. Before each use, inspect all cables for breaks or cracks in the insulation. Replace immediately if defective. 1.2 Grounding 1.3 Compliance Grounding is covered in various chapters within this manual. To check for compliance and updates, visit the Horner website (US: http://www.heapg.com or Europe: http://www.horner-apg.com.
XL7 User Manual CHAPTER 2: INTRODUCTION 2.1 Visual Overview of XL7 OCS Figure 2.1 – Overview of the XL7 2.1.1 Where to Find Information about the XL7 OCS a) Datasheet - The datasheet is the first document to refer to for key information related to specific XL7 OCS models. a. The datasheets for all XL7 OCS models are available on the Horner websites. b. Datasheets contain pin-outs, jumper settings and other model specific information.
XL7 User Manual 2.1.3 Manual Index Major topics of interest may be found in the Index towards the end of this manual. 2.1.4 Table of Figures Location of important drawing, illustrations (etc.) may be found in the Table of Figures. 2.2 Connectivity to the XL7 OCS The XL7 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 XL7 OCS.
XL7 User Manual - 2.4 On board Ethernet port (10/100Mbps) for Cscape programming and application defined communication, with Auto MDI/MDI-X. Required and Suggested Accessories The following list contains a sampling of required and suggested XL7 OCS accessories. Visit the Horner websites to view updates on new products and accessories. NOTE: The XL7 OCS is not shipped with a programming cable in the box. To obtain a programming cable, order HE500CBL300. Table 2.
XL7 User Manual CHAPTER 3: MECHANICAL INSTALLATION Note: The datasheet is the first document to refer to for model-specific information related to XL7 OCS models such as pin-outs, jumper settings, and other key installation information. Visit the Horner websites to obtain datasheets, user documentation, and updates. 3.1 Overview 3.2 Mounting Requirements 3.2.
XL7 User Manual 3.3 Mounting Orientation 3.3.1 XL7 OCS Mounting Clip Slots for mounting clips Figure 3.2 – XL7 OCS with Mounting Clips 3.3.2 XL7 OCS Mounting Orientation Figure 3.3 – Orientation of XL7 OCS NOTE: There are no orientation restrictions on the XL7 OCS. However, the above orientation provides for optimum readability of the screen and ease of use of the keypad.
XL7 User Manual 3.4 Panel Cut-Out For installations requiring NEMA 4X liquid and dust protection the panel cutout should be cut with a tolerance of ± 0.005” (0.1 mm). Figure 3.4 – Panel Cutout Tolerances 3.5 XL7 Dimensions Figure 3.
XL7 User Manual 3.6 Factors Affecting Panel Layout Design and Clearances Warning: It is important to follow the requirements of the panel manufacturer and to follow all applicable electrical codes and standards. The designer of a panel layout needs to assess the requirements of a particular 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.
XL7 User Manual 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 XL7 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.
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XL7 User Manual CHAPTER 4: ELECTRICAL INSTALLATION Note: The datasheet is the first document to refer to for model-specific information related to XL7 OCS models such as pin-outs, jumper settings, and other key installation information. Visit the Horner websites to obtain datasheets, user documentation, and updates. 4.1 Grounding Definition 4.2 Ground Specifications 4.
XL7 User Manual 4.4 Primary Power Port Table 4.1 – Primary Power Port Pins Signal Description Frame Ground PIN 1 2 0V Input power supply ground 3 +24V Input power supply positive voltage Power Connector -+ Power Up: Connect to Earth Ground. Apply 10 – 30 VDC. Screen lights up. Torque rating 4.5 - 7 Lb-In (0.50 – 0.78 N-m) 10-30 VDC supply - + Figure 4.2 – Power Connector (Primary Power Port) -+ PIN 1 PIN 2 PIN 3 Figure 4.
XL7 User Manual CHAPTER 5: SERIAL COMMUNICATIONS 5.1 Overview All XL7 OCS models provide two independent serial ports, on the first 8-pin modular RJ45 connector, which is labeled MJ1/MJ2. The MJ1 serial port is RS232 while the MJ2 port is RS485. By default, MJ1 can be connected to the COM port of a PC running Cscape, for OCS programming. In addition, both MJ1 and MJ2 can be used for application-specific communication, using a variety of standard data exchange protocols.
XL7 User Manual 5.4 RS485 Termination Proper RS485 termination minimizes signal reflections and improves reliability. Both the MJ2 and MJ3 serial ports allow an internal termination resistor to be placed across pins 1 and 2 by DIP Switch Setting. Only the two devices physically located at the endpoints of the RS485 network should be terminated. 5.5 RS485 Biasing RS485 biasing passively asserts a line-idle state when no device is actively transmitting, which is useful for multidrop RS485 networking.
XL7 User Manual CHAPTER 6: CAN COMMUNICATIONS Note: For additional CAN information, refer to the CAN Networks manual (MAN0799) on the Horner websites. 6.1 Overview All XL7 OCS models provide two CAN network ports, which are implemented with 5-pin connectors. The connectors are labeled CAN1 and CAN2. CAN1 CAN2 Figure 6.1 – CAN1 & CAN2 Connector Locations Like the MJ1 serial port, the CAN1 port can be used for XL7 OCS programming by connecting it to the CAN port of a PC running Cscape.
XL7 User Manual 6.4 Cscape Programming via CAN The CAN1 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 XL7 OCS CAN1 port, Cscape can access the XL7 OCS for programming and monitoring. In addition, the XL7 OCS supports single-point-programming of all XL7 OCS and other OCS/RCS devices that are connected to the CAN1 port network.
XL7 User Manual CHAPTER 7: ETHERNET COMMUNICATION 7.1 Ethernet Module Protocols and Features The following table describes the Ethernet Module Protocols and features supported by XL7.
XL7 User Manual Figure 7.1 – I/O Configuration Dialog 3. Click the Config button to the right of LAN1 for LAN 1 or LAN2 for LAN2, revealing the Ethernet Module Configuration dialog as shown in figure 7.2 Figure 7.
XL7 User Manual 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.
XL7 User Manual Configuration – The configuration for the IP Address, Net Mask, or the Gateway will be assigned using the value in the Default Settings in this window. Register – The configuration for the IP Address, Net Mask, or the Gateway will be assigned using the values in the registers assigned. 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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XL7 User Manual CHAPTER 8: COMMUNICATION OPTIONS 8.1 Overview To supplement the built-in MJ1, MJ2 and MJ3 serial ports, additional communication options are available. This is accomplished by installing a COM module in the XL7 OCS controller. Previous OCS controllers shared a serial port with the communication options. The XL7 has a separate serial port which allows using MJ1, MJ2, MJ3 and the communication options simultaneously.
XL7 User Manual CHAPTER 9: REMOVABLE MEDIA 9.1 Overview All XL7 OCS models provide a Removable Media slot, labeled Memory Card, which supports standard MicroSD Flash memory cards. MicroSD cards can be used to save and load applications, to capture graphics screens and to log data for later retrieval. Figure 9.1 – Removable MicroSD Memory Card Slot 9.2 MicroSD Cards When the MicroSD card format was introduced, it was originally called TransFlash.
XL7 User Manual 9.4 Using the Removable Media Manager The Removable Media Manager is an interactive XL7 OCS screen that performs the following functions: a. b. c. d. e. f.
XL7 User Manual Cscape can also save an application directly to a MicroSD card, which is plugged into the PC’s MicroSD 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 XL7 OCS File System uses bitmap files with the .BMP extension or JPEG files with the .JPG extension to store XL7 OCS graphic screen captures.
XL7 User Manual Table 9.1 – Filename Special Symbols Description Substitutes the current 2 digit year Substitutes the current month with a 2 digit code Substitutes the current day Substitutes the current hour in 24 hour format Substitutes the current minute Substitutes the current second Symbol $Y $M $D $h $m $s Example 2004 = 04 March = 03 nd 22 = 22 4 pm = 16 45 = 45 34 = 34 Note that all the symbols start with the dollar sign ($) character.
XL7 User Manual CHAPTER 10: GENERAL I/O Note: Each XL7 OCS unit is sent with a datasheet in the box. The datasheet is the first document to refer to for model-specific information related to XL7 OCS models such as pin-outs, jumper settings, and other key installation information. Visit the Horner websites to obtain datasheets, user documentation, and updates. 10.1 Overview 10.2 Removing the XL7 OCS I/O Cover The XL7 OCS is a compact unit that contains high density, very versatile I/O.
XL7 User Manual Figure 10.2 – XL7 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 10.3 – Example Jumper Diagram To re-install the cover, place the I/O cover back on the unit.
XL7 User Manual 10.3 Model and I/O Overview XL7 Models HE-XW1E0 / HEXT391C100 HE-XW1E2 / HEXT391C112 HE-XW1E3 / HEXT391C113 HE-XW1E4 / HEXT391C114 HE-XW1E5 / HEXT391C115 DC In DC Out Table 10.1 – I/O and Model Overview Relays HS In HS Out mA/V In 12 6 4 mA/V RTD/Tc mA/V Out 2 2 4 12 12 4 2 2 24 16 4 2 2 12 12 4 2 Table 10.1 shows the different types of I/O included with the various XL7 OCS models.
XL7 User Manual 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 settings. The digital outputs feature an output fault bit. %I32 will turn on if any of the outputs experience a short circuit, over-current or the output driver overheats. 10.
XL7 User Manual 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. If you have 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.
XL7 User Manual 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. 10.7.1 Common cause of analog input tranzorb failure, Models 2,3 & 4 If a 4-20mA circuit is initially wired with loop power but without a load, the analog input could see 24Vdc. This is higher than the rating of the tranzorb.
XL7 User Manual CHAPTER 11: HIGH SPEED I/O (HSC / PWM) 11.1 Overview In addition to the compliment of simple analog and digital I/O, several of the XL7 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.
XL7 User Manual 11.3 High Speed Counter (HSC) Functions The XL7 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.
XL7 User Manual 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 Figures 11.1-11.2 - Pulse Width Measurements, High & Low 11.3.
XL7 User Manual 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 the value of an encoder.
XL7 User Manual Register %AI401-402 %AI403-404 AI405-406 %AI11-12 Frequency Table 11.
XL7 User Manual 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 runtime.
XL7 User Manual 11.5.3 HSC Output (High Speed Counter Match) When either Q1 or Q2 is configured for HSC Output operation, HSC1 or HSC2 turns on, off or toggles 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 XL7 supports two stepper functions, one on each high speed output. The Stepper requires five parameters (%AQs) to be set for operation.
XL7 User Manual 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. 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 PWM Functions Register Map The register assignments for the high speed I/O can be moved via a setting in Cscape.
XL7 User Manual 11.8 STP Examples Example 1 10,000,000 steps control sequence Start Frequency Run Frequency Accel Count Run Count Decel Count Set %AQ1 = 2500 (Hz) Set %AQ2 = 5000 (Hz) Set %AQ3-4 = 1,000,000 (Steps) Set %AQ5-6 = 8,000,000 (Steps) Set %AQ7-8 = 1,0000,000 (Steps) 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.
XL7 User Manual CHAPTER 12: SYSTEM SETTINGS AND ADJUSTMENTS 12.1 System Menu - Overview The XL7 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. Figure 12.1 – System Menu (XL7) Screenshot 12.
XL7 User Manual 12.3 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.
XL7 User Manual Text Tbl Size Font Tbl Size Protocol Size SMS File Size Firmware Rev OS Ver FPGA Rev InitRD Rev Self-Test x = Number of bytes in application text tables x = Number of bytes in application font tables x = Number of bytes in application downloaded protocols x = Number of bytes in application SMS protocol configuration xx.yy = Current firmware version a.b.cd.yz = Current Operating System version x.y = Current FPGA version (High Speed IO Sub System) x.
XL7 User Manual I/O System Battery Warning = Time and date need to be set Ok = I/O configuration matches the installed I/O and COM modules Warning = I/O configuration needs updating to match installed modules Ok = Backup battery operating properly Warning = Backup battery needs to be replaced View I/O Slots The View I/O Slots Sub-Menu displays three System Settings, none of which may be edited. Internal to the XL7 OCS, there is a CPU board, and up to two installed modules.
XL7 User Manual View Protocols The View Protocols Sub-Menu displays two System Settings, neither of which may be edited. As mentioned in 0, both the MJ1/MJ2 (Port 1) and MJ3 (Port 2) serial ports support downloadable protocols. To assign a downloadable protocol to an XL7 OCS serial port, select the Protocol Config item in Cscape’s Program menu and then set up a protocol for Port 1 or Port 2 (or both).
XL7 User Manual Set Serial Ports The Set Serial Ports Sub-Menu displays three System Settings, all of which may be edited, and one optional item. For the Dflt Pgm Port System setting, only MJ1-232 can be selected, unless a Modem (XMC) COM module is installed.
XL7 User Manual Set Beeper The Set Beeper Sub-Menu displays one System Setting, which may be edited. 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 may be edited.
XL7 User Manual Removable Media The Removable Media Sub-Menu displays the Removable Media Manager.
XL7 User Manual If a directory name is highlighted, pressing Enter will switch to that directory showing its files and subdirectories. In a sub-directory, highlighting “..” (dot dot) and pressing Enter will move up one directory. Fail – Safe System The Fail-Safe System is a set of features that allow an application to continue running in the event of certain types of "soft" failures.
XL7 User Manual “Enable AutoRun” displays the following options which can be selected: Enable AutoRun No = OCS will be in IDLE mode after AutoLoad or Automatic Restore. Yes = OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore. “Enable AutoLoad” displays the following options which can be selected: Enable AutoLoad No = Does not load AUTOLOAD.PGM automatically when application program is absent or corrupted. Yes = Loads AUTOLOAD.
XL7 User Manual Clone Selecting “Clone Unit” menu will open the following menu screen: Note: Free/Total – displays number of free and total bytes in Removable Media. Selecting Make Clone brings up the confirmation screen. Upon confirmation, the OCS will create two new files in the root directory of the Removable Media Drive as shown below: AUTOLOAD.PGM CLONE.
XL7 User Manual 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.
XL7 User Manual CHAPTER 13: USER INTERFACE 13.1 Overview This chapter presents the user interface (or operator view) of the XL7 and some of the model specific characteristics of the XL7 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.
XL7 User Manual 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, alpha-numeric entry objects invoke a pop-up alpha-numeric keypad for additional user input. The alpha-numeric keypad is discussed below.
XL7 User Manual NOTE: Each numeric entry object has a configured minimum and maximum value. If the operator enters a value outside of the configured range, the new value is ignored when Enter is pressed and the current object value is NOT changed. Since the alpha-numeric keypad services several different graphical objects, certain keys on the alphanumeric keypad may be disabled (grayed) when the keypad is invoked for certain objects.
XL7 User Manual 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. These coils have two modes, switch and alarm. If the ladder program energizes an alarm display coil, the screen associated with this coil is displayed and overrides the normal user screens. This is designed to show alarm conditions or to display other ladder-detected events.
XL7 User Manual amount of tolerable slip and prevent false releases of the button, the XL7 allows adjustment of the allowable slide up to 5x the default value. To enable the touch (slip) sensitivity, first an OCS data register must be allocated through the Graphics editor Configuration menu for Display Settings. Once a Touch Sensitivity register is assigned, that register may be modified [range = 1(Low) to 5 (High)] to the desired slide amount.
XL7 User Manual The current state of the displayed alarm is indicated by its color and optionally by an abbreviated indicator after the date/time stamp (ALM, ACK, RTN). The operator can acknowledge an alarm by selecting it from the list and touching the ACK button. The operator can also clear an alarm if that function is enabled in the alarm object. If not enabled, the Clear buttons are grayed and do not respond to touch.
XL7 User Manual 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.
XL7 User Manual 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 XL7. Any additional touch activity is also ignored by the XL7 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.
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XL7 User Manual CHAPTER 14: REGISTERS 14.1 Register Definitions When programming the XL7 OCS, data is stored in memory that is segmented into different types. This memory in the controller is referred to as registers. Different groups of registers are defined as either bits or words (16 bits). Multiple registers can usually be used to handle larger storage requirements. For example 16 single bit registers can be used to store a Word or two 16 bit registers can be used to store a 32-bit value. Table 14.
XL7 User Manual Table 14.
XL7 User Manual Table 14.3 – %SR Registers Register %SR64 %SR65-76 %SR77-88 %SR89-100 %SR101-112 %SR113-114 %SR115-116 %SR117-118 %SR119-120 %SR121-122 %SR123-124 %SR125 %SR126 %SR127 %SR128 %SR129 %SR130 %SR131-163 %SR164.3 %SR164.4 %SR164.5 %SR164.6 %SR164.7 %SR164.8 %SR164.9 %SR164.10 %SR164.11 %SR164.
XL7 User Manual 14.3 Register Map for XL7 OCS I/O Fixed Address %I1 %Q1 %AI1 %AQ1 14.4 Table 14.
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XL7 User Manual CHAPTER 15: CSCAPE CONFIGURATION 15.1 Overview 15.2 Cscape Status Bar XL7 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 XL7 OCS unit. Please see the on-line help provided with Cscape for additional details. When the XL7 OCS is connected to a PC using Cscape software a Status Bar appears at the bottom of the screen.
XL7 User Manual 15.3 Establishing Communications The preferred method of communicating between Cscape and an XL7 OCS is via USB port. The XL7 OCS can communicate with Cscape using USB to USB, USB to serial adapters, serial port communications via MJ1 Port, Ethernet, 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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XL7 User Manual Now that the XL7 is plugged in, go to Cscape, Tools, Application Settings, Communications and choose the USB port (in this example Com 3).
XL7 User Manual If communication is established, the target indicator will 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, ensure the target ID is set correctly. If not, 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.
XL7 User Manual To check or change the ID on the XL7, press the System Button to enter the system menu. The first item in the menu is Set Network ID. Pressing Enter allows the ID of the unit to be viewed or modified. To change the Target ID of Cscape use the Controller | Set Target Network ID dialog. 15.3.2 Communicating via On Board Ethernet Port From Cscape go to Controller -> I/O Configure and do auto configuration for the connected controller, Click on Config of Ethernet & go to Module Setup.
XL7 User Manual 15.4 Configuration An overview of configuration: 1. Start the configuration by selecting the Controller | I/O Configure menu item. 2. If the XL7 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 XL7 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 XL7 OCS Cscan from the type drop down box. 5.
XL7 User Manual 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 XL7 OCS. In configuring a counter, the user needs to set the type, mode, and counts per rev.
XL7 User Manual 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. 15.7 Analog Input Configuration The following figure illustrates the Analog Input Configuration dialog. Figure 15.
XL7 User Manual 15.8 Analog Output Configuration The following figure illustrates the Analog Output Configuration dialog. Figure 15.6 – 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.
XL7 User Manual 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. The Fail-Safe System has the following capabilities: - Manually backup the current Battery-Backed RAM Register Settings into Flash memory.
XL7 User Manual 5. Set the ‘Enable AutoRun’ option to YES if the controller needs to be placed in RUN mode automatically after automatic restore of data or AutoLoad operation. 16.3 Backup / Restore Data Selecting this option brings up a screen having four operations: - Backup OCS Data. - Restore OCS Data. - Clear Backup Data. - Exit Figure 16.
XL7 User Manual Restore OCS Data: When initiated, this will allow the user to manually copy the backed up data from the onboard FLASH to the Battery-Backed RAM. A restore operation will be automatically initiated if a backup has been previously created and on power-up the Battery-Backed RAM registers fail their check. The following process will be followed for restoring data: - The controller will be placed in IDLE mode.
XL7 User Manual 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.
XL7 User Manual 16.4 AutoLoad This system menu option allows the user to specify whether the OCS automatically loads the application AUTOLOAD.PGM located in Removable Media. When the AutoLoad 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.
XL7 User Manual 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.
XL7 User Manual 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 automatically, once an AutoLoad has been performed or an Automatic Restore has occurred.
XL7 User Manual 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.
XL7 User Manual 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.
XL7 User Manual 4. Once the cloning is successful, OCS gives a message as below: 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.
XL7 User Manual 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.
XL7 User Manual CHAPTER 18: MAINTENANCE 18.1 Firmware Updates The XL7 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 should only be performed when the equipment being controlled by the XL7 OCS is in a safe, non-operational state.
XL7 User Manual 18.2.2 Battery Replacement Warning: Lithium Batteries may explode or catch fire if mistreated Do not recharge, disassemble, heat above 100⁰C (212⁰F) 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.
XL7 User Manual CHAPTER 19: TROUBLESHOOTING / TECHNICAL SUPPORT Chapter 19 provides commonly requested troubleshooting information and checklists for the following topics. - Connecting to the XL7 OCS controller Local controller and local I/O CsCAN Network Removable media In the event that this information is not enough, please contact Technical Support at the locations indicated at the end of this chapter. 19.
XL7 User Manual 19.1.1 1. 2. 3. 4. 5. 6. 7. 8. Connecting Troubleshooting Checklist (serial port – MJ1 Programming) Programming and debugging must use MJ1 or USB Mini B Port. Controller must be powered up. Ensure that the correct COM port is selected in Cscape. Tools/Editor Options/Communications Port. Ensure that a straight through (non-null modem) serial cable is being used between PC and controller port MJ1. Check that a Loaded Protocol or ladder is not actively using MJ1.
XL7 User Manual - Average logic scan rate Application memory usage Loaded firmware versions 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.
XL7 User Manual 11. Total drop length for each drop should not exceed 6m (20 feet). A drop may include more than one node. The drop length adds to the overall network length. 12. Network should be wired in "straight line" fashion, not in a "star" pattern. 13. In applications requiring multiple power supplies, make sure the V- of all supplies is connected together and to earth ground at one place only. 14. In some electrically noisy environments it may be necessary to add repeaters to the network.
XL7 User Manual Main Index %Q bits, 40 %S & %SR, 74 Accessories, 15 Accumulator, 44-46 Alarms, 69 Alpha-numeric keypad, 66 Analog Inputs, 42 Analog Input Tranzorb Failure, 43 Analog Outputs, 43 AutoLoad, 93 AutoRun, 95 Backup / Restore, 90 Backup OCS data, 90 Battery, 100 Backup, 100 Replacement, 101 Warnings, 101 When to Replace, 100 Battery-backed RAM, 61, 96, 98 Beeper Acknowledgement, 68 CAN1, 26, 27, 54 CAN2, 26, 27 CAN Communications, 26 Cscape Programming, 27 I/O Expansion (Network I/O), 27 Ladde
XL7 User Manual Model / I/O Overview, 40 Overview, 38 Relay Outputs, 40 Removing the I/O Cover, 38 Solid-State Digital Outputs, 40 Universal Analog Inputs, 43 Glossary, High Speed I/O, 44 Grounding, 12, 19 Definition, 22 Specification, 22 Testing for Good Ground, 22 High Speed / PWM, 44 High Speed Counting, 45 High Speed I/O, 44 HSC, 44, 45, 47, 85 I/O Cover Removal, 38 IP Address, 30 Jumpers, 38, 42, 43 Limited Warranty, 3 Load Clone, 63, 98 Maintenance, 100 Make Clone, 63, 97 Mechanical Installation, 16 M
XL7 User Manual Sub-Menus, 54 System Menu, 53 Clone Unit, 62 Fail-Safe System, 61 Load Clone, 63 Removeable Media, 60 Set Beeper, 59 Set Date/Time, 58 Set Fkeys Mode, 57 Set Networks, 54 Set Screen, 59 Set Serial Ports, 58 View Diags, 55 View I/O Slots, 56 View Protocols, 57 View Status, 54 System Settings and Adjustments, 53 Overview, 53 Details, 54 Navigate / Edit, 53 Table of Contents, 5 Target ID, 83 Target Indicator, 83 Technical Support, 2, 15, 42, 101, 102, 105 Contacts, 2, 107 Testing for Good Gro
XL7 User Manual Index of Figures & Tables Figure 2.1 – Visual Overview of the XL7 OCS .................................................................................................................................. 14 Figure 2.2 – Visual Overview of Types of Devices that can be connected to XL7 OCS.................................................................... 14 Figure 3.1 – Panel Mounting of an XL7 Series OCS .........................................................................................
XL7 User Manual Figure 17.1 – System Menu ............................................................................................................................................................ 96 Figure 17.2 – Clone Unit Menu Before Cloning .............................................................................................................................. 96 Figure 17.3 – Clone Unit Confirm Screen ...............................................................................................
