The Zeben XLe is a compact all-in-one OCS (Operator Control Station) controller that integrates PLC logic, a graphical HMI, built-in I/O, and comprehensive networking capabilities into a single, cost-effective package. Housed in a 96x96x57mm enclosure, the XLe can be mounted either on a panel (using a standard 1/4 DIN cutout of 92x92mm) or on a DIN rail, offering flexibility for various control cabinet layouts. The front panel features a 128x64 monochrome graphic LCD with a blue LED backlight, ensuring excellent readability even in challenging lighting conditions. Configurable function keys allow operators to interact directly with the machine process, creating a complete and intuitive user interface.

At its core, the XLe is powered by a 32-bit ARM processor with DSP and FPU acceleration, delivering a logic scan rate of 0.7 milliseconds per kilobyte. The controller includes 16Mb of built-in storage and supports MicroSD™ cards up to 32GB for program storage, data logging, and screen captures. The XLe offers six unique built-in I/O configurations, all of which include four high-speed counters. Depending on the model, the I/O mix can include digital inputs/outputs, analog I/O (10-bit, 12-bit, or 14-bit), temperature measurement (thermocouple/RTD), and PWM outputs. For applications requiring more I/O than the built-in configuration, the XLe can be expanded using SmartStix™ and SmartMod™ remote I/O modules, which can be mounted up to 1.5 kilometers away. External I/O expansion is also possible via CAN or Ethernet serial connections.

Communication is a cornerstone of the XLe's design. The base unit includes two serial ports that support simultaneous protocols, including Modbus, enabling connection to a wide array of serial devices. An optional CAN port is available with CANopen support. For networking and remote access, the XLe can be equipped with an optional telecommunications module that adds Ethernet, GSM/GPRS modem, or PSTN modem capabilities. The controller also features USB, RS232, and RS485 connectivity, ensuring seamless integration with other systems and equipment.

All aspects of the XLe—including PLC logic, HMI design, I/O configuration, and networking—are programmed using the free Cscape™ software suite. Cscape™ is fully compliant with the IEC 61131-3 international standard, providing a familiar and powerful development environment. Advanced software features include comprehensive datalogging for later analysis, a real-time clock for scheduling time-based events, floating-point math for complex calculations, and multi-language support with custom fonts. The XLe also incorporates a Fail-Safe System that allows the application to continue running in the event of soft failures such as battery power loss or application flash corruption. A Clone Unit feature enables rapid duplication of the entire application program and unit settings to another XLe of the exact same model, simplifying machine commissioning and maintenance.

The XLe is an ideal control solution for a wide range of small to medium-sized applications, from standalone machine control to distributed systems. Its combination of integrated HMI, flexible I/O, robust communication options, and advanced software features makes it particularly well-suited for remote machine control, pump stations, packaging machinery, and process automation tasks where cost-effectiveness and reliability are paramount.

Technical Specifications