Specifications/Installation

MAN0971-06-EN

XL7 OCS Datasheet for

HE-XW1E0, HE-XW1E2, HE-XW1E3, HE-XW1E4, HE-XW1E5, HE-XW1E6
HEXT391C100, HEXT391C112, HEXT391C113, HEXT391C114,
HEXT391C115, HEXT391C116
1. Specifications
General Specifications Control & Logic Specifications
Standard Model -22 (Heater) Add-On
Up to 740mA @ Advanced Ladder Logic
Required Power
170mA @ 24VDC 24VDC Control Language Support Full IEC 1131-3 Languages
(Steady state)
(heater duty cycle) Tag-based Editor
Required Power Logic Program Size 1MB, maximum
7A for <1 ms @ 24 VDC
(Inrush) & Logic Scan Rate 0.013mS/K
Primary Power Range 10–30VDC 10-24VDC Online Programming Changes Supported in Advanced Ladder
Relative Humidity 5 to 95% Non-condensing Digital Inputs 2048
+/- 20 ppm maximum at 25 C Digital Outputs 2048
Clock Accuracy I/O Support
(+/- 1 Minutes per Month) Analog Inputs 512
Surrounding Air Temp -10C to +60C -40°C to +60°C Analog Outputs 512
Storage Temp -40C to +60C
50,000 (words) Retentive
Weight 2lb. (without I/O)
General Purpose Registers 16,384 (bits) Retentive
USA: http://www.heapg.com/Pages/TechSupport/ProductCert.html
UL / CE 16,384 (bits) Non-retentive
Europe: http://www.horner-apg.com/en/support/certification.aspx
Display Specifications Connectivity
Serial Ports 1 RS-232 & 1 RS-485 on first Modular Jack (MJ1/2)
Display Type 7” TFT Transmissive Color
1 RS-232 or 1 RS-485 on second Modular Jack (MJ3)
Resolution 800x480 USB mini-B USB 2.0 (480MHz) Programming & Data Access
Color 16-bit (65,535) USB A USB 2.0 (480MHz) for USB FLASH Drives (2TB)
Screen Memory 27 MB CAN 2x Remote I/O, Peer-to-Peer Comms, Cscape
2x 10/100 Mb (Auto-MDX), Modbus TCP C/S, HTTP,
User-Programmable Screens 1023 Ethernet
FTP, SMTP, Cscape, Ethernet IP
Backlight LED – 50,000 hour life Remote I/O SmartRail, SmartStix, SmartBlock, SmartMod
User Configurable within the scan time. Removable Memory MicroSD, support for 32GB max.
Screen Update Rate (perceived as instantaneous in many Application Updates, Datalogging, more
cases)
Input / Output Specifications
DC mA/V mA/V High-Speed Counters
Model DC In Relays HS In HS Out mA/V In
Out RTD/Tc Out Number of Counters 2
Model 2 12 6 4 4 Maximum Frequency 500 kHz each
Model 3 12 12 4 2 2 Accumulator Size 32-bits each
Model 4 24 16 4 2 2 Modes Supported
Model 5 12 12 4 2 2 2 Totalizer Quadrature
Frequency
There are 4 high-speed inputs of the total DC Inputs. There are 2 high-speed outputs of the total DC Pulse Measurement
Measurement
outputs. Model 2, 3 & 4 feature 12-bit Analog I/O. Model 5 features 14/16-bit Analog I/O. High-speed
2 Position Controlled Outputs
Outputs can be used for PWM and Pulse Train Outputs, currently limited to <65kHz.
1 ON/OFF Setpoint per Output

2. Dimensions & Panel Cutout

Cutout tolerance to meet NEMA standards

is ±0.005” (0.1mm). Max. Panel Thickness is 5mm.

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3. Additional Controller Options

Part Number Description

-10 (part number suffix) Add -10 to the part number for Thermistor Support for analog inputs 1 and 2 (AI1 & AI2)
Example: HE-XW1E3-10

-22 (part number suffix) Display Heater for lower temperatures (rated at -40°C)
Example: HE-XW1E3-22

Note: When using the -22 Heater Option in XL7 (in extreme low temps), the controller must reach 0°C for 8 hours once every six months.
This allows time for the internal battery to charge, as it will not charge under 0°C. If the internal battery dies, volatile data could be lost.

4. Installation Procedures
1. Carefully locate an appropriate place to mount the XL7. Be sure to leave enough room at the top of the unit for insertion and removal of the
microSD card. Also leave enough room at the bottom for the insertion and removal of USB FLASH drives

2. Carefully cut the host panel per the diagram on Page 1, creating a 189.7mm x 131.2mm ±0.1mm opening into which the XL7 may be installed. If the
opening is too large, water may leak into the enclosure, potentially damaging the XL7. If the opening is too small, the OCS may not fit through the
hole without damage.

3. Remove all Removable Terminals from the XL7. Insert the XL7 through the panel cutout (from the front). The gasket needs to be between the host
panel and the XL7.

4. Install and tighten the four mounting clips (provided in the box) until the gasket forms a tight seal (max torque 7-10 lb-in. [0.8 – 1.13 Nm])

5. Reinstall the XL7 I/O Removable Terminal Blocks. Connect communications cables to the serial port, USB ports, Ethernet port, and CAN port as
required.

6. Ports & Connectors

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7. Safety

WARNING: Only qualified electrical personnel familiar with the construction Power input and output (I/O) wiring must be in accordance with Class I,
and operation of this equipment and the hazards involved should install, Division 2 wiring methods of the National Electric Code, NFPA 70 for
adjust, operate, or service this equipment. Read and understand this manual installations in the U.S., or as specified in Section 18-1J2 of the Canadian
and other applicable manuals in their entirety before proceeding. Failure to Electrical Code for installations within Canada and in accordance with the
observe this precaution could result in severe bodily injury or loss of life. authority having jurisdiction.
WARNING: To avoid the risk of electric shock or burns, always connect the This equipment is suitable for use in Class I, Division 2, Groups A, B, C, and
earth ground before making any other connections. D or Non-hazardous locations only.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is WARNING: EXPLOSION HAZARD – Do not disconnect equipment unless
strongly recommended to fuse all Power Sources connected to the OCS. Be power has been switched off or the area is known to be non-hazardous.
sure to locate fuses as close to the source as possible.
WARNING: EXPLOSION HAZARD – Substitution of components may impair
WARNING: Replace fuse with the same type and rating to provide protection suitability for Class 1, Division 2.
against risk of fire and shock hazards.
Digital outputs shall be supplied from the same source as the Operator
WARNING: In the event of repeated failure, do not replace the fuse again as Control Station.
a repeated failure indicates a defective condition that will not clear by
replacing the fuse. Jumpers on connector JP1 and others shall not be removed or replaced while
the circuit is live unless the area is known to be free of ignitable
WARNING: Battery may explode if mistreated. Do not recharge, concentrations of flammable gasses or vapors.
disassemble or dispose of in fire.
WARNING: EXPLOSION HAZARD – BATTERIES MUST ONLY BE
CHANGED IN AN AREA KNOWN TO BE NON-HAZARDOUS

8. Common Cause of Analog Input Tranzorb Failure

A common cause of Analog Input Tranzorb Failure on Analog Inputs Model 2, 3, 4 & 5: 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. This can be solved by NOT connecting
loop power prior to load connection, or by installing a low-cost PTC in series between the load
and Analog input.

NOTE†: Refers to Model 2 – orange (pg.5,) Models 3 & 4 – J1 (pg.6) and Model 5 – 20mA
Analog In (pg.7.)

9. Fail-Safe Functionality
All XL7 models have a built in fail-safe feature that can back up program and register data to flash memory from battery-backed RAM. This way, the controller
will retain data in the event of battery power loss or file corruption. The Backup / Restore functions are available from the system menu, and are described in
more detail in the full product manual (MAN0974).

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. 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.

It is especially recommended to use this functionality in conjunction with the -22 heater option in extreme cold temperatures.

10. Technical Support

For assistance and manual updates, contact Technical Support at the following locations:

North America Europe

Toll Free: 1-877-665-5666 (+) 353-21-4321-266
http://www.heapg.com http://www.horner-apg.com
E-mail: [email protected] E-mail: [email protected]

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11. Built-in I/O (Model 2, 3, 4 & 5)

All XL7 models (except the HE-XW1E0) feature built-in I/O. The I/O is mapped into OCS Register space, in three separate areas – Digital/Analog I/O, High-
Speed Counter I/O, and High-speed Output I/O. Digital/Analog I/O location is fixed starting at 1, but the High-speed Counter and High-speed Output
references may be mapped to any open register location. For more details on using the High-Speed Counter and High-Speed Outputs, see the XL7 OCS
User’s Manual (MAN0974-01).

Model 2 – I/O
The XL7 model 2 (HE-XW1E2) features 12 DC Inputs, 6 Relay outputs, and 4 Analog Inputs. The DC Inputs are 12/24Vdc compatible, and can be jumpered
for Positive Logic (sinking), or Negative Logic (sourcing). Two of the inputs (H1-H2) can be used for high-speed functions up to 500kHz. The 12-bit Analog
Inputs can be jumpered for voltage (0-10V) or current (4-20mA) on a channel by channel basis. The Relay outputs are isolated, supporting AC and DC
voltages, with output currents of up to 3A/relay, 5A total.

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Model 3 & 4 – I/O

The XL7 model 3 (HE-XW1E3) features 12 DC Inputs, 12 DC outputs, and 2 Analog Inputs. The XL7 model 4 (HE-XW1E4) increases the I/O count up to 24
DC Inputs, and 16 DC Outputs and 2 Analog Inputs. The DC Inputs are 12/24Vdc compatible, and can be jumpered for Positive Logic (sinking), or Negative
Logic (sourcing). Two of the inputs (H1-H2) can be used for high-speed functions up to 500 kHz. The 12-bit Analog Inputs can be jumpered for voltage (0-
10V) or current (4-20mA) on a channel by channel basis. The 12/24VDC Outputs feature Electronic Short Circuit protection, and support currents up to 0.5A
per point, and 4A total. Two of the DC Outputs can be used for high speed functions (PWM or PTO). The output frequency is limited by the switching
capability of the output drivers (about 10kHz), although an optional accessory (HE-XHSQ) can be added to provide parallel output drivers supporting
frequencies up to 200kHz.

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Model 5 – I/O
The XL7 model 5 (HE-XW1E5) features 12 DC Inputs, 12 DC outputs, with high performance, highly configurable Analog Inputs (2) and Analog Outputs (2). ,
The DC Inputs are 12/24Vdc compatible, and can be jumpered for Positive Logic (sinking), or Negative Logic (sourcing). Two of the inputs (H1-H2) can be
used for high-speed functions up to 500kHz. The 12/24VDC Outputs feature Electronic Short Circuit protection, and support currents up to 0.5A per point, and
4A total. Two of the DC Outputs can be used for high speed functions (PWM or PTO). The output frequency is limited by the switching capability of the output
drivers (about 10kHz), although an optional accessory (HE-XHSQ) can be added to provide parallel output drivers supporting frequencies up to 200kHz.

The two high resolution Analog Inputs can be configured for 4-20mA, 0-10V, or 0-100mV at 14-bit resolution. They also can be configured for 16-bit
temperature measurement – supporting Thermocouples or RTDs with 0.05°C resolution. The Analog Outputs are sourcing, and can be configured for 4-20mA
or 0-10V at 14-bit resolution. Each Analog Input or Output channel can be configured independently for maximum flexibility.

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Model 6 – I/O Hardware Specification

Digital DC Inputs Digital DC Outputs

Inputs per Module 12 Outputs per Module 12
Commons per Module 1 Commons per Module 1
Input Voltage Range 0 VDC - 24 VDC Output Type Half-Bridge
Absolute Max. Voltage 35 VDC Max. Absolute Max. Voltage 30 VDC Max.
Input Impedance 10 k Output Protection Short Circuit & Overvoltage
Max. Output Current per 0.5 A
Input Current Positive Logic Negative Logic point
Minimum ‘On’ current 0.8 mA -1.6 mA
Max. Total Current per driver 2A total current (all drivers) UL-
Maximum ‘Off’ current. 0.3 mA -2.1 mA
(Q1-4, Q5-8, Q9-12). rated, 6A UL pending
Min ‘On’ Input 8 VDC Max. Output Supply Voltage 30 VDC
Minimum Output Supply 10 VDC
Max ‘Off’ Input 3 VDC
Voltage
Max. Voltage Drop at Rated 0.25 VDC
OFF to ON Response 1 ms
Current
ON to OFF Response 1 ms Min. Load None
Galvanic Isolation None. I/O Indication None
Positive and Negative based on Galvanic Isolation None
Logic Polarity
Common pin level.
I/O Indication None. OFF to ON Response 150nS
High Speed Counter Inputs* 4 - DIN 8-12 ON to OFF Response 150nS
High Speed Counter Max XLE/T/6/10 (10KHz max) PWM Out* XLE/T/6/10 (65KHz max)
Freq* XL4/7 EXL6/10 (500KHz max) XL4/7 EXL6/10 (500KHz max)
3.5mm Pluggable cage clamp
Connector Type Output Characteristics Current Sourcing (Pos logic)
connector
Analog Inputs
Number of Channels 6 Absolute max Input Voltage -0.5 -12V dc. (+/-30Vdc)
0–20mA, 4-20 mA dc. T/C / RTD / mV > 2 MΩ
Input Impedance
0-60mV, 0-10V dc. mA: 15 Ω + 1.5 V
Input Range (Clamped @ -0.5 to
T/C - J, K, N, T, E, R, S, B V: 1.1 MΩ
10.23VDC).
RTD - PT100, PT1000
14 - 17 Bits (variable depending Galvanic Isolation None
Nominal Resolution
on input type)
Sensor Range and Accuracy Input Type Range Accuracy
TC J -120 to 1000°C / -184 to 1832°F ± 0.2% FS ± 1°C
TC K -130 to 1372°C / -202 to 2501.6°F ± 0.2% FS ± 1°C
TC T -130 to 400°C / -202 to 752°F ± 0.2% FS ± 1°C
TC E -130 to 780°C / -202 to 1436°F ± 0.2% FS ± 1°C
TC N -130 to 1300°C / -202 to 2372°F ± 0.2% FS ± 1°C
TC R, S 20 to 1768°C / 68 to 3214.4°F ± 0.2% FS ± 3°C
TC B 100 to 1820°C / 212 to 3308°F ± 0.2% FS ± 3°C
PT100/1000 -200 to 850°C / -328 to 1562°F ± 0.15% FS
0-20mA 0-20mA ± 0.15% FS
0-60mV 0-60mV ± 0.15% FS
0-10V 0-10V ± 0.15% FS
Conversion Speed Minimum all channels converted in approx. 150mS. Analogue Outputs
Analog Outputs
Number of Channels 4 Minimum Current load 500Ω
0 – 10Vdc. None
Output Ranges Galvanic Isolation
0 – 20mA, 4-20mA dc
Nominal Resolution 12 Bits Conversion Speed Min all channels once per
scan.
Response Time One update per ladder scan.
Max. Error at 25C Additional Error for
0-20 mA 0.1% of full scale.
(excluding zero) temperatures other than 20mA 0.0126%/°C.
0-10 V 0.1% of full scale
25C
*see I/O information below for detail regarding HSC and PWM

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Model 6 - I/O Connection Details

For ease of operability, the high density
terminals are divided into more
manageable pairs of connectors
(J1A + J1B, J2A + J2B, J3A + J3B)

To ensure proper installation, connector

symbols must match as seen below:

J1 J3
(Orange/ Signal Name (Orange/ Signal Name
Green) Green)
I1 V IN1 N/C No Connection
I2 V IN2 A3A Univ. AI 3 pin 1
I3 V IN3 A3B Univ. AI 3 pin 2
I4 V IN4 A3C Univ. AI 3 pin 3
I5 V IN5 Univ. N/C No Connection
J1A I6 V IN6 AI A4A Univ. AI 4 pin 1
I7 V IN7 A4B Univ. AI 4 pin 2
I8 V IN8 A4C Univ. AI 4 pin 3
H1 HSC1 / V IN9 N/C No Connection
H2 HSC2 / V IN10 A5A Univ. AI 5 pin 1
H3 HSC3 / V IN11 A5B Univ. AI 5 pin 2
H4 HSC4 / V IN12 A5C Univ. AI 5 pin 3
0V Common Univ. N/C No Connection
A1A Univ. AI 1 pin 1 AI A6A Univ. AI 6 pin 1
A1B Univ. AI 1 pin 2 A6B Univ. AI 6 pin 2
A1C Univ. AI 1 pin 3 A6C Univ. AI 6 pin 3
J1B N/C No Connection 0V Common
A2A Univ. AI 2 pin 1 V4 V OUT4*
A2B Univ. AI 2 pin 2
A2C Univ. AI 2 pin 3
N/C No Connection

(Black/
Green) Signal Name V3
0-10V Out
+ -
V2 LOAD
V3 V OUT 3* 0-10V Out
+ LOAD -
V1
V2 V OUT 2* 0-20mA Out
mA4
+ -
LOAD
V1 V OUT 1* 0-20mA Out
+ LOAD -
mA4 mA Out 4* mA3
2A mA3 mA Out 3* mA2
mA2 mA Out 2* mA1
mA1 mA Out 1* Q1 LOAD

Q1 OUT 1 / PWM1 Q2 LOAD

Q2 OUT 2 / PWM2 Q3 LOAD

Q3 OUT 3 Q4 LOAD

Q4 OUT 4 Q5 LOAD

Q5 OUT 5 Q6 LOAD

Q6 OUT 6 Q7 LOAD

Q7 OUT 7 Q8 LOAD
2B Q8 OUT 8 Q9 LOAD

Q9 OUT 9
Q10 LOAD

Q10 OUT 10
Q11 LOAD

Q11 OUT 11
Q12 LOAD

Q12 OUT 12
V+
V+ V External+
0V Common 0V
Note * Both mA & V outputs are active for each output channel, however, only the
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configured output type is calibrated (maximum 4 channels simultaneously).
 Specifications/Installation
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Note * Both mA & V outputs are active for each output channel, however, only
Model 6 - I/OExample Universal Input Wiring Schematic the configured output type is calibrated (maximum 4 channels simultaneously).

0 – 10 V Analog In mV In Thermocouple In
4 - 20 mA Analog Out
NC A1A
100mV- A1A 20mA
A1B A1A
100mV+ A1B MA1
0-10VDC A1B
A1C
A1C
NC A1C 0V

20 mA Analog In RTD In

20mA A1A
A1A 0 -10 V Analog Out
LOOP PWR 10VDC
A1B
A1B V1

A1C
NC A1C
0V
Notes:
Loop Power requirements are determined by the transmitter specification.
Power supply should be isolated.

Configuration
The data registers are as follows:

Digital Inputs Digital Outputs Analogue Inputs Analogue Outputs

%I1-12 %Q1-12 %AI1-4, %AI33-38 %AQ9-12

5.4.4 Data values:

The analogue inputs return data types as follows:

Input Mode Data format Comment

0-2mA, 4-20mA 0-32000
0-10V, 0-60mV 0-32000
T/C, RTD Temperature in °C or °C or °F may be selected in the I/O config
°F to 1 decimal place section.
xxx.y The value is an integer, the user should divide
by 10.

5.4.5 Status Register

Register Description
%R1 Bit-wise status register enable – R1.1 – R1.9 enable for registers R2 to R9
%R2 Firmware version
%R3 Watchdog count – cleared on power-up.
%R4 Status bits - 16…4 3 2 1
Reserved Normal Config Calibration
%R5 Scan rate of the 106 board (average) in units of 100µS.
%R6 Scan rate of the 106 board (max) in units of 100µS.
%R7 Channel Status Channel 2 Channel 1
8 7 6 5 4 3 2 1
Open RTD Out of Shorted Open T/C Open RTD Out of Shorted Open T/C
Limits RTD Limits RTD
%R8 Channel Status Channel 4 Channel 3
8 7 6 5 4 3 2 1
Open RTD Out of Shorted Open T/C Open RTD Out of Shorted Open T/C
Limits RTD Limits RTD
%R9 Channel Status Channel 6 Channel 5
8 7 6 5 4 3 2 1
Open RTD Out of Shorted Open T/C Open RTD Out of Shorted Open T/C
Limits RTD Limits RTD
%R10-14 Reserved

Note: For the purposes of the example, the block is shown starting at %R1, but it can be set to anywhere in the %R memory map.
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