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HORNER EXL6 OCS User Manual

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User Manual for EXL6 OCS
MAN1032-10-EN_EXL6_UserManual
HE-EXL1E0 / HEXT371C100
HE-EXL1E2 / HEXT371C112
HE-EXL1E3 / HEXT371C113
HE-EXL1E4 / HEXT371C114
HE-EXL1E5 / HEXT371C115
HE- EXL1E6 / HEXT371C116

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  • Page 1 User Manual for EXL6 OCS MAN1032-10-EN_EXL6_UserManual HE-EXL1E0 / HEXT371C100 HE-EXL1E2 / HEXT371C112 HE-EXL1E3 / HEXT371C113 HE-EXL1E4 / HEXT371C114 HE-EXL1E5 / HEXT371C115 HE- EXL1E6 / HEXT371C116...

  • Page 2: Preface

    PREFACE This manual explains how to use the EXL6 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.

  • Page 3: Limited Warranty And Limitation Of Liability

    NEITHER ASSUMES, NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS EXL6 OCS module. THIS WARRANTY SHALL NOT APPLY TO THIS EXL6 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.

  • Page 4: Visual Map Of Chapters

    VISUAL MAP OF CHAPTERS FIRST STEP of ANY TASK: DATASHEET Each EXL6 OCS unit is sent with a datasheet in the box. The datasheets are the first document to refer to for model-specific information related to EXL6 OCS models for installation information.

  • Page 5: Table Of Contents

    Grounding ............................11 Compliance ............................ 11 CHAPTER 2: INTRODUCTION ........................ 12 Visual Overview of EXL6 ......................12 Connectivity to the EXL6 OCS ....................14 Features of EXL6 OCS ........................ 15 Required and Suggested Accessories ..................16 Useful Documents and References ..................16 Opening Cscape Help File ......................
  • Page 6 Touch Calibration Screen ..................... 48 CHAPTER 6: REGISTERS ........................49 Register Definitions ........................49 Useful %S and %SR registers ....................50 Register Map for EXL6 OCS I/O ....................58 Resource Limits .......................... 59 CHAPTER 7: CSCAPE CONFIGURATION ................... 60 Overview ............................60 Cscape Status Bar ........................
  • Page 7 MAN1032-10-EN_EXL6_UserManual 10.16 STP Examples ......................... 103 10.17 HSC I/O Filtering ........................104 CHAPTER 11: SERIAL COMMUNICATIONS ..................107 11.1 Overview ............................107 11.2 Port Descriptions ........................107 11.3 Wiring and Dip Switches ......................107 11.4 RS485 Termination ......................... 108 11.5 RS485 Biasing ...........................
  • Page 8 MAN1032-10-EN_EXL6_UserManual 16.3 Video Properties: Video Type .................... 144 16.4 Video Properties: Control ....................145 16.5 Configuring Display Properties ..................146 16.6 Video Object Performance ....................146 16.7 Web Cameras..........................146 CHAPTER 17: REMOVABLE MEDIA ....................147 17.1 Overview ............................147 17.2 Removable microSD Cards .....................
  • Page 9 Steps for updating the firmware: ..................176 22.2 Replacing Backup Battery ....................177 CHAPTER 23: TROUBLESHOOTING / TECHNICAL SUPPORT ............179 23.1 Connecting to the EXL6 OCS ....................179 23.2 Local Controller and Local I/O .................... 181 23.3 CsCAN Network ........................182 23.5...

  • Page 10: Chapter 1: Safety And Compliance

    MAN1032-10-EN_EXL6_UserManual CHAPTER 1: SAFETY AND COMPLIANCE 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.

  • Page 11: Grounding

    Before each use, inspect all cables for breaks or cracks in the insulation. Replace immediately if defective. Grounding Grounding is covered in various chapters within this manual. Compliance To check for compliance and updates, visit the Horner website: North America https://hornerautomation.com Europe http://www.hornerautomation.eu...

  • Page 12: Chapter 2: Introduction

    MAN1032-10-EN_EXL6_UserManual CHAPTER 2: INTRODUCTION Visual Overview of EXL6 Figure 2.1 – Overview of the EXL6 Use caution when connecting controllers to PCs via serial or USB. PCs, especially NOTE: laptops may use “floating power supplies” that are ungrounded. This could cause a damaging voltage potential between the laptop and controller.
  • Page 13 Datasheet - The datasheet is the first document to refer to for key information related to specific EXL6 OCS models. The datasheets for all EXL6 OCS models are available on the Horner websites. Datasheets contain pin-outs, jumper settings and other model specific information.

  • Page 14: Connectivity To The Exl6 Ocs

    Sensors Indicators Alarms Cscape Encoders OPC Server Pumps Ethernet I/P Relays Modbus TCP Devices Solenoids Flash Drive Cscape Figure 2.2 – Visual Overview of Types of Devices that can be connected to EXL6 OCS March 12, 2020 14 | 191...

  • Page 15: Features Of Exl6 Ocs

    Features of EXL6 OCS The EXL6 OCS are all-in-one industrial control devices. They combine control, user interface, I/O and networking into a single, integrated package. Unique features of the EXL6 OCS include: Bright, 65,536 color graphical touch sensing LCD display in all models of EXL6.

  • Page 16: Required And Suggested Accessories

    MAN1032-10-EN_EXL6_UserManual Required and Suggested Accessories Please visit the Horner Control Accessories website for communication, programming, and I/O accessories. North America http://hornerautomation.com/product-category/home/control-accessories/ Europe http://horner-apg.com/en/products.aspx Useful Documents and References Visit the Horner website to obtain user documentation, supplemental documents, certificates, and other documentation.

  • Page 17: Chapter 3: Mechanical Installation

    MECHANICAL INSTALLATION NOTE: The datasheet is the first document to refer to for model-specific information related to EXL6 OCS models such as pin-outs, jumper settings, and other key installation information. Visit the Horner websites to obtain datasheets, user documentation, and updates.

  • Page 18: Mounting Orientation

    3. Pass the unit through the panel. 4. Insert each of the ten (10) mounting clips into the slots in the EXL6 OCS case. One clip should be installed on each corner. Lightly tighten each screw so the clip is held in place.

  • Page 19: Panel Cut-Out

    3.3.2 EXL6 OCS Mounting Orientation Figure 3.3 – Orientation of EXL6 OCS NOTE: There are no orientation restrictions on the EXL6 OCS. However, the above orientation provides for optimum readability of the screen and ease of use of the keypad.

  • Page 20: Exl6 Dimensions

    MAN1032-10-EN_EXL6_UserManual EXL6 Dimensions Figure 3.5 – EXL6 OCS Dimensions March 12, 2020 20 | 191...

  • Page 21: Factors Affecting Panel Layout Design And Clearances

    3.6.4 Orientation When panel-mounted, there are no orientation restrictions on the EXL6 OCS. March 12, 2020 21 | 191...
  • Page 22 MAN0962. 3.6.6 Shock and Vibration The EXL6 OCS has been designed to operate in typical industrial environments that may inflict some shock and vibration on the unit. For applications that may inflict excessive shock and vibration please use proper dampening techniques or relocate the EXL6 OCS to a location that minimizes shock and/or vibration.

  • Page 23: Chapter 4: Electrical Installation

    CHAPTER 4: ELECTRICAL INSTALLATION NOTE: The datasheets are the first documents to refer to for model-specific information related to EXL6 OCS models for key installation information. Visit the Horner websites to obtain datasheets, user documentation, and updates. North America https://hornerautomation.com Europe http://www.hornerautomation.eu...

  • Page 24: How To Test For Good Ground

    MAN1032-10-EN_EXL6_UserManual How to Test for Good Ground In order to test ground resistance, a Ground Resistance Tester must be used. A typical Ground Resistance Meter Kit contains a meter, two or three wire leads, and two ground rods. Instructions are supplied for either a two-point or three-point ground test. GROUND RESISTANCE METER GROUND DISCONNECTED...

  • Page 25: Primary Power Port

    MAN1032-10-EN_EXL6_UserManual Primary Power Port Table 4.1 – Primary Power Port Pins Signal Description Frame Ground Input power supply ground +24V Input power supply positive voltage 10-30VDC supply Figure 4.2 – Power Connector (Primary Power Port) D/C INPUT / FRAME Solid/Standard Wire: 12-24 awg (2.5 - 0.2mm). Strip Length: 0.28”...

  • Page 26: Chapter 5: System Settings And Adjustments

    MAN1032-10-EN_EXL6_UserManual CHAPTER 5: SYSTEM SETTINGS AND ADJUSTMENTS System Menu - Overview The EXL6 has a built-in System Menu, which lets the user view System Settings and make adjustments. To start the System Menu, press the SYSTEM key (or set %SR3 to 1), which will display the Main Menu.

  • Page 27: System Menu - Navigation And Editing

    MAN1032-10-EN_EXL6_UserManual System Menu – Navigation and Editing As mentioned above, the System Menu is started by pressing the System key on the EXL6. Next press ESC to exit the System Menu or use  and  to select an item and press Enter to display the item’s Sub-Menu.
  • Page 28 MAN1032-10-EN_EXL6_UserManual Sub-Menus Sub-Menus CAN Ok? CAN ID: CAN Baud: 125KB Fkeys: Momentary SYS-Fn enable: MAC ID: 00:E0:C4:04:C7:35 ( Use ↑↓ to adjust ) 192.168.254.128 NetM: 255.255.255.0 GatW1 0.0.0.0 EXL6 System Menu Map Dflt Pgm Port MJ1-232 MJ2 RS485 Bias Model: EXL1E6 MJ3 RS485 Bias Mode:...

  • Page 29: System Menu - Details

    MAN1032-10-EN_EXL6_UserManual 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. Yes= CAN connected to a CAN network and functioning properly CAN Ok? No= Not ready to communicate on CAN network CAN ID...

  • Page 30: View Status

    0.1 to 999.9= Average number of mS for each ladder scan OCS Net Use % 0.0 to 100.0 = CAN network bandwidth % used by this EXL6 OCS node All Net Use % 0.0 to 100.0 = CAN network bandwidth % used by all nodes...

  • Page 31: View Diags

    The View Diags Sub-Menu displays up to 11 System Diagnostics, none of which are editable. The first two System Diagnostics are critical. If either of these indicate a Fault condition, the EXL6 OCS will not enter or remain in Run mode, and the problem must be investigated and corrected.

  • Page 32: View Battery Status

    MAN1032-10-EN_EXL6_UserManual View Battery Status The View Battery Status displays the following information. Waiting The charging system is waiting for voltages and temperatures to stabilize. Battery Charging The battery is charging. Battery Full Shows at the end of a charge cycle. Remains in this state until the battery is steadily discharging.

  • Page 33: View I/O Slots

    The View I/O Slots Sub-Menu displays three System Settings, none of which may be edited. Internal to the EXL6 OCS, there is a CPU board, and up to two installed modules. Model 0 has no installed I/O or COM modules. All other models have an I/O module and can have a user- installed COM module.

  • Page 34: View Protocols

    Protocols, both the MJ1/MJ2 (Port 1) and MJ3 (Port 2) serial ports support downloadable protocols. To assign a downloadable protocol to an EXL6 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).

  • Page 35: Set Fkeys Mode

    MAN1032-10-EN_EXL6_UserManual Set Fkeys Mode The Set Fkeys Sub-Menu displays two System Settings, both of which may be edited. Momentary= %K1-5 bits go On & Off as F1-F5 are pressed & released Fkeys Toggle= %K1-5 bits toggle each time F1-F4 are pressed SYS_Fn Yes = Reset and all clear system functions enabled enable...

  • Page 36: Set Serial Ports

    MAN1032-10-EN_EXL6_UserManual 5.10 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. MJ1-232= MJ1 RS232 port is the default programming port Dflt Pgm Port Modem= Modem COM module is the default programming port...

  • Page 37: Set Time/Date

    MAN1032-10-EN_EXL6_UserManual 5.11 Set Time/Date The following instructions are to set and display the real-time clock in the controller. More details can be found in the Help File in Cscape. Table 5.1 Clock and Time Setting Terms Coordinated Universal Time Abbreviated to UTC, Coordinated Universal Time is the (UTC) primary time standard by which the world regulates clocks and time.
  • Page 38 MAN1032-10-EN_EXL6_UserManual To Set Time Zone: The Time Zone setting is an hourly offset from UTC time. If using the Time Zone setting, set it first, then set the local time. UTC time will be automatically set based on the time zone and local time settings. If using NTP: NTP utilizes UTC time, therefore when using NTP, the appropriate hourly offset from UTC time must entered into the time zone setting.

  • Page 39: Set Beeper

    MAN1032-10-EN_EXL6_UserManual 5.12 Set Beeper The Set Beeper Sub-Menu displays one System Setting, which may be edited. (default) = Enables beeper Beeper enable (does NOT affect ladder access) No = Disables beeper March 12, 2020 39 | 191...

  • Page 40: Set Screen

    MAN1032-10-EN_EXL6_UserManual 5.13 Set Screen The Set Screen Sub-Menu displays four System Settings, all of which may be edited. Yes = Enable screen saver Saver Enable (default) = Disable screen saver 5 - 1200 = Amount of time in minutes to expire with NO touch Timeout (min) activity before activating screen saver (black screen) (default)

  • Page 41: Removable Media

    MAN1032-10-EN_EXL6_UserManual 5.14 Removable Media The Removable Media Sub-Menu displays the Removable Media Manager. Having selected Removable Media from the Main Menu, one of four Sub-Menu screens will appear: Media Directory No Card = No microSD card has been installed in the Memory slot Media Directory Initializing = microSD card is installed, but it is still initializing...

  • Page 42: Fail - Safe System

    MAN1032-10-EN_EXL6_UserManual 5.15 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. These "soft" failures include: • Battery power loss • Battery-Backed Register RAM or Application Flash corruption due to, for example, an excessive EMI event.

  • Page 43: Autorun

    MAN1032-10-EN_EXL6_UserManual 5.16 AutoRun “Enable AutoRun” displays the following options which can be selected: No = OCS will be in IDLE mode after AutoLoad or Automatic Restore. Enable AutoRun Yes = OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore. March 12, 2020 43 | 191...

  • Page 44: Autoload

    MAN1032-10-EN_EXL6_UserManual 5.17 AutoLoad “Enable AutoLoad” displays the following options which can be selected: No = Does not load AUTOLOAD.PGM automatically when application program is absent or corrupted. Enable AutoLoad Yes = Loads AUTOLOAD.PGM file automatically from RM when application program is absent or corrupted. March 12, 2020 44 | 191...

  • Page 45: Clone Overview

    MAN1032-10-EN_EXL6_UserManual 5.18 Clone 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 10, for details on using RM). It can then be used to clone a different OCS (exact same model).

  • Page 46: Load Clone

    MAN1032-10-EN_EXL6_UserManual 5.19 Load Clone Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”. NOTE: For security enabled files, Load clone asks for password validation before loading the application. March 12, 2020 46 | 191...

  • Page 47: License Details

    MAN1032-10-EN_EXL6_UserManual 5.20 License Details License details page displays the information about the WebMI license. The information can also be viewed from Cscape using the following %SR registers: %SR209.3 WebMI server status %SR209.4 WebMI user logged in status %SR209.8 to SR209.16 Number of Users %SR218 Number of Webpages...

  • Page 48: Touch Calibration Screen

    MAN1032-10-EN_EXL6_UserManual 5.21 Touch Calibration Screen 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 the far upper right corner of the touchscreen to bring out the function keys, then press and hold the SYSTEM key for longer than five (5) seconds and a menu with several advanced functions will appear.

  • Page 49: Chapter 6: Registers

    REGISTERS Register Definitions When programming the EXL6 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.

  • Page 50: Useful %S And %Sr Registers

    MAN1032-10-EN_EXL6_UserManual Useful %S and %SR registers Table 6.2 – Common %S Register Definitions Register Name Description FST_SCN Indicate First Scan NET_OK Network is OK T_10MS 10mS timebase T_100MS 100mS timebase T_1SEC 1 second timebase IO_OK I/O is OK ALW_ON Always ON ALW_OFF Always OFF PAUSING_SCN...
  • Page 51 MAN1032-10-EN_EXL6_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values %SR4.3 Self-Test Results – Ladder Error Read Only Read Only %SR4.4 Self-Test Results – RAM Error Read Only Read Only %SR4.5 Self-Test Results –...
  • Page 52 MAN1032-10-EN_EXL6_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values LCD Display Contrast setting %SR32 0 to 255 Read Only Read/Write *Excludes RCC Units Function Key Toggle Mode 0= Momentary Read/Write %SR33 0 to 1...
  • Page 53 MAN1032-10-EN_EXL6_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values F10 = 10 F11= 11 F12 = 12 Enter = 13 +/ - = 14 . (dot) = 15 0 = 16 1 = 17 2 = 18...
  • Page 54 MAN1032-10-EN_EXL6_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values WebMI License Details – Number of %SR101.8- users Read Only Read Only 101.16 *XLEe, XLTe, X2, X4, & X7 only %SR102-107 Reserved WebMI License Details –...
  • Page 55 MAN1032-10-EN_EXL6_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values Enable AUTOLOAD – Sets “Enable %SR164.6 EN_AUTO_LD Read / Write Read / Write AutoLoad” to “Yes” or “Not” Start Backup trigger bit – Setting TRUE %SR164.7 STRT_BCKUP Read / Write...
  • Page 56 MAN1032-10-EN_EXL6_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values NOTE: See %SR57.16 %SR186 Screen Saver Time in minutes (delay) 5 to 1200 Read Only Read Only %SR187 NET_USE Network Usage (Avg) 0 to 1000 Read Only...
  • Page 57 MAN1032-10-EN_EXL6_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Default I/O Min-Max Register Description (Read/Write) (Read/Write) Name Values %SR206- Reserved WebMI Server Status. Bit 3 is ON if %SR209.3 Read Only Read Only server running. WebMI User Logged in Status. Bit 4 is %SR209.4 Read Only Read Only...

  • Page 58: Register Map For Exl6 Ocs I/O

    MAN1032-10-EN_EXL6_UserManual Register Map for EXL6 OCS I/O Table 6.4 – I/O Register Map Description Registers EXL6 with EXL6 with EXL6 with EXL6 with EXL6 with EXL6 with no I/O 102 I/O 103 I/O 104 I/O 105 I/O 106 I/O %I1-%I12...

  • Page 59: Resource Limits

    MAN1032-10-EN_EXL6_UserManual Table 6.5 – PWM Function Registers Map Register Stepper %AQ1 HSC1 Start Frequency PWM1 Duty Cycle (32-bit) %AQ2 Preset Value Run Frequency %AQ3 HSC2 Accel Count PWM2 Duty Cycle (32-bit) %AQ4 Preset Value (32-bit) %AQ5 PWM Prescale Run Count %AQ6 (32-bit) (32-bit)

  • Page 60: Chapter 7: Cscape Configuration

    Please see the on-line help provided with Cscape for additional details. Cscape Status Bar When the EXL6 OCS is connected to a PC using Cscape software, a Status Bar appears at the bottom of the screen. The Cscape Status Bar can be used to determine if communications have been established between the EXL6 OCS and the Cscape program.

  • Page 61: Establishing Communications

    MAN1032-10-EN_EXL6_UserManual Establishing Communications The EXL6 OCS can communicate with Cscape using USB to USB, USB to serial adapters, serial port communications via MJ1 Port and MJ3 Port, Ethernet (with an Ethernet adapter board), onboard Ethernet Port, CAN (CsCAN), or modems.
  • Page 62 MAN1032-10-EN_EXL6_UserManual The PC will detect a new device has been plugged into the USB port. Now that the EXL6 is plugged in, go to Cscape → Controller → Connection Wizard. If you are just opening Cscape, Connection Wizard usually opens by default. Select USB and click Next >>.
  • Page 63 MAN1032-10-EN_EXL6_UserManual If the Connection Wizard dialog does not open, go to the Cscape menu Controller → Connection Wizard, choose your connection method. If you’re connecting for the first time, we suggest connecting via USB. Figure 7.3– Cscape Connection Wizard Screenshots If Controller USB COM Port is not present in the dropdown list, the Windows operating system has not yet recognized the OCS as an installed device.
  • Page 64 MAN1032-10-EN_EXL6_UserManual An alternate way to select the COM setting is to go to Cscape → Tools → Application Settings →Communication → Configure and choose connection method in Add Target. Figure 7.4 – Cscape: Alternative Connection Method Screenshot Figure 7.5 – Add Target Screenshot in Cscape NOTE: The following fields, Target Name, Connection Medium, Connected Device, and Connection Settings, need to be filled for communication configuration if Cscape Connection Wizard was not used.
  • Page 65 NOTE: Cscape will do necessary initialization for the selected internal modem. Select this option to communicate over USB. Now Horner devices and Horner USB to serial converters are recognized and can be specifically selected.
  • Page 66 Units without CsCAN network ports respond to any network ID and do not require the ID to be configured. To check or change the ID on the EXL6 OCS, press the System Menu key. The first item in the menu is Set Networks. Pressing Enter allows the ID of the unit to be viewed or modified.
  • Page 67 MAN1032-10-EN_EXL6_UserManual 7.3.1 Communicating via MJ1 Serial Port and MJ3 Port Start by configuring Cscape to use the correct communications port. This can be done using the Tools → Options → Communication Port dialog in Cscape. Next, connect the PC’s serial port to the port labeled MJ1 on the EXL6. If using MJ3, then the Default Programming port needs to be set in the controller System Menu.
  • Page 68 MAN1032-10-EN_EXL6_UserManual 7.3.2 Communicating via On Board Ethernet Port From Cscape go to Controller → Hardware Configure and do auto configuration for the connected controller, Click on Config of Ethernet →Module Setup. The IP address, Net Mask, and Gateway of the controller may be temporarily set from the System Menu under the Set Networks menu item.

  • Page 69: Configuration

    2. If the EXL6 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 EXL6 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.
  • Page 70 MAN1032-10-EN_EXL6_UserManual To access the I/O Setup Screen, select Config from the Hardware Configuration →Local I/O dialog. Then select the Module Setup tab, see screenshot below. March 12, 2020 70 | 191...

  • Page 71: Digital / Hsc Input Configuration

    The High-Speed Counters group box contains all of the windows that are used for configuring the four (4) available high-speed counters on the EXL6 OCS. In configuring a counter, the user needs to set the type, mode, and counts per rev.

  • Page 72: Digital / Pwm Output Configuration

    MAN1032-10-EN_EXL6_UserManual Digital / PWM Output Configuration The following figure illustrates the Digital → PWM Output Configuration dialog. Figure 7.8 – Digital / PWM Output Configuration Dialog The Q1 and Q2 group boxes allow the user to specify the operation of the multi-function outputs. The PWM State On Controller Stop group box contains items that allow the user to specify how the PWM outputs behave when the controller is stopped.

  • Page 73: Analog Input Configuration

    MAN1032-10-EN_EXL6_UserManual Analog Input Configuration The following figure illustrates the Analog Input Configuration dialog. Figure 7.9 – Analog Input Configuration Dialog The Channel x drop down windows allow the user to specify the mode for each analog input to operate. The Channel x drop down windows are enabled/disabled according to which model is being configured.

  • Page 74: Analog Output Configuration

    MAN1032-10-EN_EXL6_UserManual Analog Output Configuration The following figure illustrates the Analog Output Configuration dialog. Figure 7.10 – 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.

  • Page 75: Chapter 8: General I/O

    To remove the I/O cover of the EXL6 OCS, remove the four (4) Phillips screws from the I/O back. It may help to place the EXL6 OCS unit face down on a clean work surface. Once the four screws are removed the I/O cover can be lifted straight off.
  • Page 76 MAN1032-10-EN_EXL6_UserManual Figure 8.1 – Removing the I/O Cover Figure 8.2 – EXL6 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 8.3 below and a description of the jumper settings.

  • Page 77: Model And I/O Overview

    HE- EXV1E6 / HEXT505C116 Table 8.1 shows the different types of I/O included with the various EXL6 OCS models. Specific specifications, jumper settings and wiring diagrams can be found on the data sheets. Descriptions and applications of the different type of I/O can be found below.

  • Page 78: Solid-State Digital Outputs

    While these electronic protections work in most applications, some application may require external fusing on these outputs. The digital outputs in the EXL6 OCS are typically controlled via %Q bits in the register mapping. Some of the outputs are designed for high-speed applications and can be used for PWM or frequency output applications.

  • Page 79: Relay Outputs

    NOTE: The design of the EXL6 OCS does not require external coil power for the relays to function. The relays will activate anytime the EXL6 OCS is powered. There are several factors that should be considered when using relays: Relay Life –...

  • Page 80: Digital Inputs

    NOTE: Refer to the datasheet for EXL6 OCS model being used for details on jumper settings. NOTE: The digital inputs on the EXL6 OCS are designed for low voltage DC inputs. The inputs are designed to support both positive and negative input modes. The mode is set by a jumper setting and a configuration parameter in Cscape.

  • Page 81: Analog Inputs

    MAN1032-10-EN_EXL6_UserManual Analog Inputs NOTE: See the data sheet for the EXL6 OCS model being used for jumper settings. Refer to the Cscape Configuration chapter for more details. The analog inputs on the EXL6 OCS allow voltage or current measurement from a variety of devices.

  • Page 82: Universal Analog Inputs Model 6 Universal Analog Inputs

    Universal Analog Inputs Model 6 Universal Analog Inputs The Universal Analog Inputs on the Model 6 IO board are unique from other Horner X-series input/output cards in that they are configurable through the module configuration instead of having to change jumper settings in order to setup the input type. To configure the Universal Analog input type: 1) Select Analog In to access the Analog Input Configuration menu.

  • Page 83: Analog Outputs

    Analog Inputs as seen in the reference image below 8.10 Analog Outputs NOTE: Refer to the datasheet for EXL6 OCS model being used for details on jumper settings. The analog outputs on EXL6 OCS devices provide high resolution voltage or current outputs.

  • Page 84: Chapter 10: High Speed I/O

    10.1 Overview In addition to the compliment of simple analog and digital I/O, several of the EXL6 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.

  • Page 85: Glossary

    MAN1032-10-EN_EXL6_UserManual 10.2 Glossary Table 10.1 – Glossary of High Speed I/O Terms Register used to accumulate or store up a sum or count of many items or Accumulator events. A special function to zero out the value in a specific register. (Not used with Clear Frequency or Period Measurement.) Disable...

  • Page 86: High Speed Counter (Hsc) Functions

    MAN1032-10-EN_EXL6_UserManual 10.3 High Speed Counter (HSC) Functions The EXL6 supports two very high speed, configurable counters. There are four dedicated inputs that can be configured 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.
  • Page 87 MAN1032-10-EN_EXL6_UserManual Rising Edge Signal Falling Edge Signal NOTE: Counter triggers off the rising edge of the signal. Three different options are available to reset the current count. They are: • Configured reset value Counts per When configuring the Totalize function, a value may be specified under the column.

  • Page 88: Pulse Width Measurement

    MAN1032-10-EN_EXL6_UserManual 10.6 Pulse Width Measurement In Pulse Width Measurement mode, the high-speed input can measure the width of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode the Disable and Latch special functions are allowed. Refer to the HSC Glossary more details.

  • Page 89: Period Measurement

    MAN1032-10-EN_EXL6_UserManual 10.7 Period Measurement In period measurement mode, the high-speed input can measure the period of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode the Disable and Latch special functions are allowed. Refer to the HSC Glossary for more details.

  • Page 90: Quadrature

    MAN1032-10-EN_EXL6_UserManual 10.8 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.

  • Page 91: Register Match

    MAN1032-10-EN_EXL6_UserManual 10.9 Register Match Totalizer & Quadrature counter modes support a register match function. When the accumulator value matches either the Match 1 or Match 2 value configured in the corresponding %AQ registers, a high-speed output can Turn On, Turn Off, or Toggle. An internal %I register mirrors the output state whether the high-speed output is configured or not.

  • Page 92: Hsc Functions

    MAN1032-10-EN_EXL6_UserManual 10.10 HSC Functions The high-speed input on the EXL6 contains many optional tasks, all of which can be disabled, or set to an internal pre-assigned register (Assigned %Q) or to one of the external High-speed inputs (External Input #1, 2, 3 or 4). Also, they can be set as an “overflow interrupt” or “underflow interrupt”...

  • Page 93: Status Bits

    MAN1032-10-EN_EXL6_UserManual 10.11 Status Bits There are three status bits (%I registers for each high-speed counter): Overflow Flag: This status bit turns high when the Accumulator “overflows”, it moves from 4,294,967,295 (-1 if Signed) to 0, this bit can be reset with the “Output Reset Bit”, see table 11.4 Underflow Flag: This status bit turns high when the Accumulator “underflows”, it moves from 0 to 4,294,967,295 (-1 if Signed), this bit can also be reset with the “Output Reset Bit”.

  • Page 94: Hsc Functions Register Map

    MAN1032-10-EN_EXL6_UserManual 10.12 HSC Functions Register Map The register assignments for the high speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below.
  • Page 95 MAN1032-10-EN_EXL6_UserManual NOTE: Four Count Mode requires FPGA update. Table 10.4 – HSC Functions Register Map for 4 HSC Configuration Register Frequency Pulse Totalize %AI401-402 Accumulator - Counter 1 %AI403-404 Latch Value – Counter 1 %AI405-406 Accumulator – Counter 2 %AI407-408 Latch Value –...
  • Page 96 MAN1032-10-EN_EXL6_UserManual %Q1650 Preload – Counter 4 %Q1651 Clear – Counter 4 %Q1652 Disable – Counter 4 %Q1653 Direction – C4 %Q1654 Output Reset – Counter 4 %Q1655 Preload Disable – Counter 4 %Q1656 Latch Disable – Counter 4 %Q1657-1664 Reserved %I1601 Overflow Flag –...

  • Page 97: High Speed Output Functions

    MAN1032-10-EN_EXL6_UserManual 10.13 High Speed Output Functions On units that support High Speed Output functions, two dedicated outputs are available that can be configured for one of four modes of operation. Those modes are Normal, PWM, HSC Match and Stepper. 10.13.1 Normal When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives that respective output.
  • Page 98 MAN1032-10-EN_EXL6_UserManual At controller power-up or during a download, the PWM output is maintained at zero until both the Frequency and the Duty cycle are loaded with non-zero values. When the controller is placed in stop mode, the state of the PWM outputs is dependent on the PWM State on Controller Stop configuration.
  • Page 99 MAN1032-10-EN_EXL6_UserManual 10.13.4 High Speed Counter Match When either Q1 or Q2 is configured for HSC Output operation, their output state is based on a comparison between the counter accumulator and match registers. Refer to the Functions section for more details. 10.13.5 Stepper Function The EXL6 supports two stepper functions, one on each high-speed output when in two counter mode.
  • Page 100 MAN1032-10-EN_EXL6_UserManual The stepper provides two Boolean registers to provide stepper status: A high indication on this register indicates the stepper sequence can Ready/Done be started (i.e. not currently busy) and also when the move is completed. A high indication on this register indicates that one of the analog parameters specified above is invalid or the stepper action was Error aborted before the operation was complete.

  • Page 101: High-Speed Output Functions Register Map

    MAN1032-10-EN_EXL6_UserManual 10.14 High-Speed Output Functions Register Map The register assignments for the high speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below.

  • Page 102: Pwm Examples

    MAN1032-10-EN_EXL6_UserManual 10.15 PWM Examples Example 1 Duty Cycle Frequency To get a 50% Duty Cycle @ Set %AQ421-422 = 16,000 Set %AQ423-424 = 10,000 10kHz waveform on PWM1: Example 2 Duty Cycle Frequency Set %AQ421-422 = 16,000 To get a 50% Duty Cycle on Set %AQ423-424 = 1,000 PW1 and 90 % Duty Cycle on Set %AQ431-432 = 28,800...

  • Page 103: Stp Examples

    MAN1032-10-EN_EXL6_UserManual 10.16 STP Examples Example 1 Start Accel Count Run Count Decel Count Frequency Frequency 10,000,000 Set %AQ423- Set %AQ425- Set %AQ427-8 steps Set %AQ421 Set %AQ422 4 = 1,000,000 6 = 8,000,000 = 1,0000,000 control = 2500Hz = 5000Hz (Steps) (Steps) (Steps)

  • Page 104: Hsc I/O Filtering

    MAN1032-10-EN_EXL6_UserManual 10.17 HSC I/O Filtering This feature is used to enable digital Filter for HSC Inputs. Selecting Digital In/HSC configuration opens up the following dialog where in HSC I/O Filtering is available. Input signal is filtered based on the filter frequency and Number of samples selected. User has to select Filter Frequency and Number of samples based on the frequency of the Input signal.
  • Page 105 MAN1032-10-EN_EXL6_UserManual The state (high or low) of the high-speed input is sampled with every rising input edge of the filter frequency. The rising edges of the filter frequency are totaled in a sample counter, and when that total equals the number of samples configured, the sample counter is reset. If the high-speed input state did not change by the time of the sample counter reset, that state, high or low, is passed on to the high-speed accumulator.
  • Page 106 MAN1032-10-EN_EXL6_UserManual Figure 3: Input signal before filtering Figure 4: Input signal after filtering This delay will be 4μs. March 12, 2020 106 | 191...

  • Page 107: Chapter 11: Serial Communications

    11.1 Overview All EXL6 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.

  • Page 108: Rs485 Termination

    MAN1032-10-EN_EXL6_UserManual Figure11.1 – Wiring & Dip Switches 11.4 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.

  • Page 109: Cscape Programming Via Serial Port

    The EXL6 OCS MJ1 and MJ3 serial ports support CsCAN Programming Protocol. If a PC COM port is connected to the EXL6 OCS MJ1 or MJ3 serial port, Cscape can access the EXL6 OCS for programming and monitoring. Programming can also be done via the CAN port, USB A port, or Ethernet.

  • Page 110: Chapter 12: Can Communications

    J1939, and DeviceNet Master (layer 3 as a selectable option). 12.2 Port Description The EXL6 OCS CAN ports implement the ISO 11898-2 physical layer and the CAN 2.0A data link layer standards. Also, since the CAN ports are powered by an internal isolated power supply, external CAN power is not required.

  • Page 111: Cscape Programming Via Can

    The CAN 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 EXL6 OCS CAN port, Cscape can access the EXL6 OCS for programming and monitoring.

  • Page 112: Chapter 13: Etherenet Communication

    Ethernet Global Data Data) SRTP Slave (90-30 Service Request Transfer Protocol Service Request) CsCAN TCP Server Horner APG CsCAN over Ethernet (for Cscape to OCS programming) Modbus Slave Modbus over Ethernet Ethernet / IP ODVA CIP over Ethernet FTP (File Server)

  • Page 113: Ethernet Module Configuration

    MAN1032-10-EN_EXL6_UserManual 13.4 Ethernet Module Configuration NOTE: The following configuration is required for all applications regardless of the protocols used. Additional configuration procedures must be performed for each protocol used. To configure the Ethernet Module, use Cscape Programming Software to perform the following steps: On the main Cscape screen, select the Controller →...
  • Page 114 MAN1032-10-EN_EXL6_UserManual Click the Config button to the right of LAN1, revealing the Ethernet Module Configuration dialog as shown in Figure 7.2. Figure 13.2 – Ethernet Module Configuration March 12, 2020 114 | 191...
  • Page 115 MAN1032-10-EN_EXL6_UserManual 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.
  • Page 116 MAN1032-10-EN_EXL6_UserManual Get Settings From: “Get settings from” allows the programmer to either configure the IP Address, Net Mask, or Gateway for 2 functions: Configuration or Register. 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.

  • Page 117: Ethernet Configuration - Ip Parameters

    MAN1032-10-EN_EXL6_UserManual 13.5 Ethernet Configuration – IP Parameters For primary operation, the IP address, Net Mask, and Gateway should be set in the LAN config of the Cscape Hardware Configuration. There are options to get IP parameters from the LAN Config or to get parameters from registers. It is possible to set the Ethernet IP parameters from the OCS System Menu, but only as a temporary measure.

  • Page 118: Chapter 14: Downloadable Communication Protocols

    MAN1032-10-EN_EXL6_UserManual CHAPTER 14: DOWNLOADABLE COMMUNICATION PROTOCOLS 14.1 Overview Through loadable protocol device drivers, certain models of the OCS family can provide the ability to exchange data with remote devices such as variable-frequency drives, PLCs, and remote I/O devices. This feature greatly expands the OCS ’s control capability with negligible effect on the OCS ’s ladder scan time.
  • Page 119 (automatic) or controlled from ladder logic (manual) once a complex connection is programmatically created (i.e., dialup modem). The specific transaction-scanning mode is selected from the Network Config menu. The following Horner Automation websites offer OCS Protocol Software Downloads. North America: http://hornerautomation.com/support-files/ Europe: http://horner-apg.com/en/products/software/ocs-protocols.aspx...

  • Page 120: Protocol Config

    MAN1032-10-EN_EXL6_UserManual 14.2 Protocol Config After opening Cscape, choose Program → Protocol Config, and select the port drop-down box to select a protocol device driver. All protocol device drivers currently loaded in Cscape are displayed in the dropdown selection. Some OCS models can be limited in the number of ports or number of protocol device drivers that can be selected.

  • Page 121: Network Configuration

    MAN1032-10-EN_EXL6_UserManual 14.3 Network Configuration Network Configuration provides the required parameters to configure the network. Each protocol is different and may not require all the Network Config field. Please refer to the table below for the options in the Network Config field. March 12, 2020 121 | 191...
  • Page 122 MAN1032-10-EN_EXL6_UserManual Table 14.1 – Network Protocols Baud Rate, Data Bits, Stop These field define the bit level transfer over the serial port. Bits, Parity None – No handshake lines are used Handshake Multidrop Full – Rx remains active while Tx is occurring. Multidrop Half –...

  • Page 123: Device List And Device Configuration

    MAN1032-10-EN_EXL6_UserManual 14.4 Device List and Device Configuration Device List The Device List is reached from the Device button on the Protocol Config screen and provides a list of the configured devices on the Network. Devices must be created and exist in this list before corresponding Scan List entries can be created for this device.

  • Page 124: Scan List

    MAN1032-10-EN_EXL6_UserManual 14.5 Scan List This can be accessed from the Scan List button on the Protocol Config screen or the Mapping button on the Device List screen and provides a Scan List of the Data Mapping entries. To transfer data between the OCS and remote target, a Scan List must be created that defines each transaction.

  • Page 125: Data Mapping Configuration (Scan List Entry)

    MAN1032-10-EN_EXL6_UserManual 14.6 Data Mapping Configuration (Scan List Entry) Update Type This field specifies the direction and what triggers the transfer of data between the OCS and target device for a mapping entry. Polled Read On every transaction scan, a read-only target device register(s) transaction occurs. Polled Read/Write On every transaction scan, a read target device register transaction occurs unless a local register value has changed.
  • Page 126 MAN1032-10-EN_EXL6_UserManual Polled Read/Write/Init On every transaction scan, a read target device register transaction occurs unless a local register value has changed. The write transaction only updates those local registers that have changed in value. If several non-consecutive local registers (contained in a single mapping entry) change value between transaction scans, it takes several consecutive scans to write each changed register.

  • Page 127: Chapter 15: User Interface

    MAN1032-10-EN_EXL6_UserManual CHAPTER 15: USER INTERFACE 15.1 Overview This chapter presents the user interface (or operator view) of the EXL6 and some of the model specific characteristics of the EXL6 as compared to the rest of the OCS line. This chapter does NOT cover building screens or using the Cscape graphics editor.

  • Page 128: Displaying And Entering Data

    MAN1032-10-EN_EXL6_UserManual 15.2 Displaying and Entering Data Figure 15.1 – Example Screen Multiple objects are provided for displaying data such as virtual panel lights, push buttons, numeric value displays, bar graphs, meters, graphs and animated bitmaps. On the EXL6, these graphical objects (through ladder manipulation of attribute bits) can change color, flash, or change visibility to attract operator attention.

  • Page 129: Alpha-Numeric Keypad

    MAN1032-10-EN_EXL6_UserManual 15.3 Alpha-numeric Keypad To allow entry of a specific number or text, several of the input objects invoke a pop-up alpha- numeric keypad when the object is touched. An example of the alpha-numeric keypad invoked from a numeric input object is shown in Figure 13.2. Once invoked, the operator may touch the appropriate keys to enter a specific value.
  • Page 130 MAN1032-10-EN_EXL6_UserManual Enter Once the desired value is entered, pressing the key moves that value into the object (and the corresponding OCS register) and the alpha-numeric keypad disappears. Alternately, Enter pressing the key any time before the key cancels the operation, leaves the objects current value unchanged, and the alpha-numeric keypad disappears.

  • Page 131: Screen Navigation

    MAN1032-10-EN_EXL6_UserManual 15.4 Screen Navigation To allow the operator to change screens, a screen jump object is generally used. This object may be visually represented as a 3-D button (responding to touch) or remain invisible and logically tied to an OCS register. An optional system ICON may be configured for display along with the legend, which aids in identifying the object as one that causes a screen change, shown below).

  • Page 132: Ladder Based Screen Navigation

    MAN1032-10-EN_EXL6_UserManual 15.5 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.

  • Page 133: Beeper Acknowledgement

    MAN1032-10-EN_EXL6_UserManual 15.6 Beeper Acknowledgement The EXL6 contains an internal beeper that provides an audible acknowledgment when an operator touches a graphic object that accepts touch input. When the graphic object is enabled, a short 5ms tone is emitted. When the graphic object is disabled, a longer 100ms tone is emitted to enounce that graphical object is not currently accepting the touch input.

  • Page 134: Alarms

    MAN1032-10-EN_EXL6_UserManual 15.8 Alarms Alarm presentation to the operator is highly configurable and beyond the scope of this document to describe fully. For more information refer to the graphics editor help file. This section presents a typical configuration thereby providing an introductory description on what the operator should expect.
  • Page 135 MAN1032-10-EN_EXL6_UserManual Alarm Viewer To view, acknowledge and/or clear alarms, the operator must access the alarm viewer. This is accomplished by touching an (enabled) alarm object. When accessed, the alarm viewer is displayed as pop-up alarm viewer dialog similar to that shown in Figure 13.6. Figure 15.6 –...

  • Page 136: Removable Media

    MAN1032-10-EN_EXL6_UserManual 15.9 Removable Media The removable media object is generally used to inform the operator on the current state of the removable media device and allow access to its file structure. The removable media object is displayed as a button that changes colors to indicate the current state of the removable media device.
  • Page 137 MAN1032-10-EN_EXL6_UserManual (Enter) button (if enabled) performs certain operations based on the selected file’s type: change display to parent directory <DIR> change display to child directory bmp, jpeg display bitmap (if compatible format) load application (if compatible model and version) Alternately, the Enter button can be configured to simply load the ASCII representation of the file path (including the file name) to a group of OCS registers.

  • Page 138: Screen Saver

    MAN1032-10-EN_EXL6_UserManual 15.10 Screen Saver The EXL6 screen backlight life is typically five (5) years when in continuous use. If the application does not require interaction with the EXL6 for long periods of time, the backlight life can be extended by using the screen saver function. When enabled through the System Menu, the backlight is shut off (screen goes black) after a specified time of no touch activity on the screen.

  • Page 139: Touch Screen Pressure

    With a unique change to the touch monitoring firmware user can measure the pressure being exerted on the touch screen. This feature has been added in some Horner XL series controllers. This allows the OCS programmer to be notified of the touch pressure and it can configure the pressure required to accept a touch event.
  • Page 140 MAN1032-10-EN_EXL6_UserManual There are two system registers that provide this touch feature: %SR9 (I/O Name - TCH_PRESSURE) Records the highest pressure level of the last touch on the screen that exceeds the threshold value set in %SR10. This is a range of 0 to 3000. Zero (0) indicates no pressure and 3000 is the maximum amount of pressure that can be measured.

  • Page 141: Chapter 16: Video Object For Exl6

    MAN1032-10-EN_EXL6_UserManual CHAPTER 16: VIDEO OBJECT for EXL6 16.1 Video Object Overview The Video Object feature allows two options for video type: Stream and Playback. The Video Object trigger is used to start, stop, and pause video, and the System Register provides the status of the video object, which supports various resolutions and frames per second.

  • Page 142: Opening Video Object In Cscape

    MAN1032-10-EN_EXL6_UserManual 16.2 Opening Video Object in Cscape NOTE: Video Object requires Firmware 14.03 or newer to use with the EXL6 devices. In Cscape, select the EXL6 and model number by selecting Controller → Hardware Configuration from the toolbar. Open the Graphics Editor by selecting the “T” button from the toolbar. In Graphic Editor, select the video button from the toolbar.
  • Page 143 MAN1032-10-EN_EXL6_UserManual Then double click on the icon in the middle to open the Video Properties dialog. March 12, 2020 143 | 191...

  • Page 144: Video Properties: Video Type

    MAN1032-10-EN_EXL6_UserManual 16.3 Video Properties: Video Type Figure 16.1 – Configuring Video Type There are two options for video type: Stream and Playback Stream – This option can be selected to view live video from a web cam. Four channels are supported through the USB hub.

  • Page 145: Video Properties: Control

    MAN1032-10-EN_EXL6_UserManual 16.4 Video Properties: Control Figure 16.2 – Configuring Control Trigger The Video Properties: The video control trigger is used to start, stop and pause video. Video trigger is done by bit level addressing. The trigger reserves eight (8) bits and uses the first two (2) bits.

  • Page 146: Configuring Display Properties

    MAN1032-10-EN_EXL6_UserManual 16.5 Configuring Display Properties Figure 16.3 – Configuring Display Properties Resolution Options 320x240 (QVGA) Frames per Seconds 10, 15, 20, 24, 30 & MAX_FPS 16.6 Video Object Performance 1. When Video Object is active, navigating to System Menu or any popup window, causes Video Object to be inactive.

  • Page 147: Chapter 17: Removable Media

    OCS memory card slot (larger sizes were not tested at time of publication). The memory card slot is equipped with a “push-in, push-out” connector and a microSD card can be safely inserted into the Memory slot whether the EXL6 OCS power is On or Off. To install a microSD card: Align its 8-pin gold edge connector down, facing the front of the EXL6 OCS unit;...

  • Page 148: File System For Microsd Cards

    OCS and can write files that can be read by the EXL6 OCS. However, the EXL6 OCS does not support long filenames, but instead implements the 8.3 filename format. This means that all file and directory names must consist of up to eight (8) characters, followed by an optional dot, and an optional extension with up to three (3) characters.

  • Page 149: Using Removable Media To Log Data

    17.6 Using Removable Media to Load and Save Applications A special file type, with a .PGM extension, is used to store EXL6 OCS application programs on microSD. To load an application from microSD to the EXL6 OCS, use the Removable Media Manager (open the Removable Media Manager in the System Menu) to find and highlight the desired .PGM file, and then press the Enter key.

  • Page 150: Using Removable Media To View And Capture Screens

    17.7 Using Removable Media to View and Capture Screens The EXL6 OCS File System uses bitmap files with the .BMP extension or JPEG files with the .JPG extension to store EXL6 OCS graphic screen captures. To view a captured EXL6 OCS screen, use the Removable Media Manager to find and highlight the desired .BMP or .JPG file, and then press Enter.

  • Page 151: Removable Media (Rm) Function Blocks In Cscape

    MAN1032-10-EN_EXL6_UserManual 17.9 Removable Media (RM) Function Blocks in Cscape NOTE: For detailed information regarding RM function blocks and parameters, refer to the Help File in Cscape Software. Refer ‘USB Flash Media support for RM Functions’ for USB flash drive access details. The following RM functional blocks are available in Cscape Software.

  • Page 152: Removable Media (Rm) Features-Additional Configuration

    MAN1032-10-EN_EXL6_UserManual 17.12 Removable Media (RM) Features—Additional Configuration a. Alarms—Alarm data can be logged to a .CSV file stored on Removable Media. b. Screen Capture—The screen capture function allows a bitmap or jpeg image of the displayed OCS screen to be written to the Removable Media card. c.

  • Page 153: System Registers Used With Rm

    MAN1032-10-EN_EXL6_UserManual 17.14 System Registers used with RM %SR174 Removable Write a 1 to %SR174 to prohibit read/write access to the Media Protect removable media card. Write a zero (0) to allow access. %SR175 Status This shows the current status of the RM interface %SR176 Free Space This 32-bit register shows the free space on the RM card in bytes %SR178 Card...

  • Page 154: Chapter 18: Clone Unit

    MAN1032-10-EN_EXL6_UserManual CHAPTER 18: CLONE UNIT 18.1 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).
  • Page 155 MAN1032-10-EN_EXL6_UserManual 2. Selecting “Clone Unit” menu will open the following menu screen: Figure 18.2 – Clone Unit Menu before Cloning Free/Total – displays number of free and total bytes in Removable Media. March 12, 2020 155 | 191...
  • Page 156 MAN1032-10-EN_EXL6_UserManual 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 18.3 – 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...
  • Page 157 MAN1032-10-EN_EXL6_UserManual 4. Once the cloning is successful, OCS gives a message as below: Figure 18.5 – 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.

  • Page 158: Load Clone

    MAN1032-10-EN_EXL6_UserManual 18.3 Load Clone This option loads the application, all unit settings and register values from Removable media to the battery-backed RAM (Regardless of AutoLoad settings) and then resets the OCS for the settings to take effect. User needs to perform the following to Load Clone: Select “Clone Unit”...
  • Page 159 MAN1032-10-EN_EXL6_UserManual 3. User needs to confirm Load Clone as shown below: Figure 18.8 – 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.

  • Page 160: Chapter 19: Fail - Safe System

    MAN1032-10-EN_EXL6_UserManual CHAPTER 19: FAIL – SAFE SYSTEM 19.1 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 an excessive EMI event, for example.

  • Page 161: Settings

    MAN1032-10-EN_EXL6_UserManual 19.2 Settings To use the fail – safe feature, the user needs to do the following: From Cscape, create AUTOLOAD.PGM for the application program using ‘Export to Removable Media’. 2. Place the Removable Media with AUTOLOAD.PGM in the device. 3.

  • Page 162: Backup Ocs Data

    MAN1032-10-EN_EXL6_UserManual 19.4 Backup OCS Data When initiated, this will allow the user to manually copy Battery-Backed RAM contents on to the onboard FLASH memory of the OCS. This will have the effect of backing up all the registers and controller settings (Network ID, etc.) that would otherwise be lost due to a battery failure. %SR164.4 is set to the value of 1 when backup operation is performed.

  • Page 163: Restore Ocs Data

    MAN1032-10-EN_EXL6_UserManual 19.5 Restore OCS Data When initiated, this will allow the user to manually copy the backed-up data from the onboard flash memory 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.

  • Page 164: Clear Backup Data

    MAN1032-10-EN_EXL6_UserManual 19.6 Clear Backup Data When initiated, the backup data will be erased from the onboard flash memory and no backup will exist. %SR164.4 and %SR164.3 is reset to 0 when backed up data is erased. Figure 19.5 – Clear Backup Data Exit: Goes back to the previous screen.
  • Page 165 MAN1032-10-EN_EXL6_UserManual The OCS follows the following sequence in execution of Automatic Restore: OCS Power Cycle Battery Backed RAM Registers check failed Backup exists? Controller placed in Application IDLE mode Program erased Data copied from Onboard FLASH to OCS Battery backed Controller Resets AutoRun OCS put in IDLE...

  • Page 166: Autoload

    MAN1032-10-EN_EXL6_UserManual 19.7 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.
  • Page 167 MAN1032-10-EN_EXL6_UserManual The OCS follows the following sequence in execution of AutoLoad: Power up OCS Application Program absent Application Program corrupted AutoLoad OCS put in IDLE mode Enabled? AutoLoad run sequence AUTOLOAD.PGM present in failed (with reasons for the RM of the device ? failure) AutoLoad initiated.

  • Page 168: Autorun

    MAN1032-10-EN_EXL6_UserManual 19.8 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.

  • Page 169: Chapter 20: Modbus Communications

    MAN1032-10-EN_EXL6_UserManual CHAPTER 20: MODBUS COMMUNICATIONS 20.1 Modbus Overview For complete Modbus instructions, please refer to the Help file in Cscape. Modbus (serial) is a popular, de-facto standard protocol that allows industrial devices from multiple manufacturers to easily share data in real-time. For Modbus serial communications, the EXL6 can act as either a Master or a Slave.

  • Page 170: Modbus Master Overview

    Modbus addressing style for each slave on the network, minimal address conversion is required. Also, if the slave is another Horner product (i.e. another OCS), the “Native Addressing” option can be selected (i.e. %R1, %M17, etc.), and this skips the conversion to Modbus style altogether.

  • Page 171: Modbus Addressing Table For Exl6 Units

    MAN1032-10-EN_EXL6_UserManual 20.4 Modbus Addressing Table for EXL6 Units To access EXL6 registers, a Modbus Master must be configured with the appropriate register type and offset. This is usually accomplished with one of two methods: Method 1: The first method uses Traditional Modbus References, in which the high digit represents the register type and the lower digits represent the register offset (starting with Register 1 for each type).

  • Page 172: Chapter 21: Back-Up Battery

    The OCS has safety circuitry built into the charging IC and additional external protection including fusing. These circuits were closely evaluated by UL and Horner engineering for use in hazardous environments. March 12, 2020 172 | 191...

  • Page 173: Battery Charging Cycle

    MAN1032-10-EN_EXL6_UserManual 21.5 Battery Charging Cycle The battery is charged at unit power up. The first two minutes after boot there is a wait period before charging begins. 2. In all charge cycles, battery is charge fully to 4.2V (4200mV). 3. Charging mA should be 100mA. 4.

  • Page 174: Chapter 22: Maintenance

    MAN1032-10-EN_EXL6_UserManual CHAPTER 22: MAINTENANCE 22.1 Firmware Updates The EXLW 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.

  • Page 175: Updating Firmware Details

    2) Save Firmware files to microSD card or USB, these are the removable media devices. 3) Update the firmware through the controller’s Firmware Update function NOTE: Files from the Horner website come as a .ZIP file which need to be unzipped and placed in the root of the drive for them to function properly.

  • Page 176: Steps For Updating The Firmware

    If any of the version numbers are incorrect, verify the correct files were copied to the removable media device and repeat the steps above. For more Firmware Update information refer to the Firmware Update Manual, MAN1011, which can be found on the Horner website. March 12, 2020 176 | 191...

  • Page 177: Replacing Backup Battery

    MAN1032-10-EN_EXL6_UserManual 22.2 Replacing Backup Battery The EXL6 has an advanced battery system that uses a rechargeable lithium-ion battery. The battery powers the real time clock when power is removed. To store registers, the battery continues to power the OCS for less than a second after external power is removed. In this time the registers and other retentive data is saved to internal flash memory.
  • Page 178 Below are the steps to replace the backup battery: Make sure the user program and any data stored in retentive memory is backed up. 2. Disconnect all power from the EXL6 OCS unit including I/O power. Unplug I/O connections. 3. Using a small Phillips screwdriver, remove the I/O back panel, which is the smaller back panel, by turning four (4) corner screws counterclockwise.

  • Page 179: Chapter 23: Troubleshooting / Technical Support

    MAN1032-10-EN_EXL6_UserManual CHAPTER 23: TROUBLESHOOTING / TECHNICAL SUPPORT 23.1 Connecting to the EXL6 OCS Cscape connects to the local controller automatically when the serial connection is made. The status bar below shows an example of a successful connection. This status bar is located in the bottom right hand corner of the Cscape window.
  • Page 180 Run Mode from the System Menu on the controller will make MJ1 available to Cscape. 5. Successful communications with USB-to-serial adapters vary. If in doubt, Horner APG offers a USB to serial adapter. Part numbers HE-XCK and HE-CPK.

  • Page 181: Local Controller And Local I/O

    MAN1032-10-EN_EXL6_UserManual 23.2 Local Controller and Local I/O The System Menu provides the following status indications that are useful for troubleshooting and system maintenance. - Self-test results, diagnostics. - RUN and OK status - Network status and usage - Average logic scan rate - Application memory usage - Loaded firmware versions - Loaded protocols...

  • Page 182: Cscan Network

    Use the proper Belden wire type or equivalent for the network as specified in MAN0799. 2. The EXL6 OCS does not provide 24VDC to the network. An external voltage source must be used for other devices such as SmartStix I/O.

  • Page 183: Technical Support Contacts

    23.4 Removable Media - Basic Troubleshooting Table 23.2 – Removable Media Troubleshooting Description Action EXL6 OCS does not read media The media card should be formatted with the EXL6 card. OCS. Make sure the project file is saved as a .pgm file and EXL6 OCS will not download project not a .csp file.

  • Page 184: Change Log

    MAN1032-10-EN_EXL6_UserManual CHANGE LOG Change Log Date Rev # Description of Revision Location in Doc 3/6/2020 1. Added more Firmware Install Steps per new Firmware Updates Firmware Update Manual (Mantis 2209) 2. Updated Panel Cutout size and tolerance Panel Cutout (Mantis 2750) 4/23/2020 Reordered Chapters (Mantis 3029) Throughout...

  • Page 185: Main Index

    MAN1032-10-EN_EXL6_UserManual MAIN INDEX %Q bits, 78 Configuration of a Removable Media, 150 Accessories, 16 Configuration via Mini-B USB, 109 accumulator, 86, 88, 90 Configured reset value, 87 Add Target Screenshot in Cscape, 64 Configuring Video Properties, 144 Alarms, 134 Count, 97, 99 Analog Input Configuration Dialog, 73 Csape Program Analog Input Configuration Screen, 82...
  • Page 186 EXL6 OCS Mounting Clip, 18 Micro SD System, 148 EXL6 OCS Mounting Orientation, 19 Minimum Clearance Requirements for Panel Box EXL6 OCS with Mounting Clips, 18 and Door, 21 Fail – Safe System, 42 Modbus Addressing Table, 171 Fail Safe System Overview, 160...
  • Page 187 MAN1032-10-EN_EXL6_UserManual Panel Design Checklist, 22 Program Features, 151 Panel Layout / Clearances, 21 System Registers, 153 Panel Mounting of an EXL6 Series OCS, 17 RS-485 Biasing, 108 Polled Read, 125 RS-485 Termination, 108 Polled Read/Write, 125 safety / compliance, 10 Polled Read/Write/Init, 126 Safety Warnings, Guidelines, 10 Scan List, 124...
  • Page 188 MAN1032-10-EN_EXL6_UserManual Touch Screen Pressure, 139 Types of Devices that can be connected to EXL6, Triggered Read, 126 Triggered Write, 126 Typical Output Wiring, 78 Universal Analog Inputs, 81 Troubleshooting USB, 15, 62, 111, 180 Common problems, 179 User Interface Connecting Checklist, 180 Ladder Based Navigation, 132 CsCAN Checklist, 182 Screen Navigation, 131...

  • Page 189: Index Of Figures And Tables

    Figure 02.2 – Visual Overview of Types of Devices that can be connected to EXL6, 14 Figure 03.1 – Panel Mounting of an EXL6 Series OCS, 17 Figure 03.2 – EXL6 OCS with Mounting Clips, 18 Figure 03.3 – Orientation of EXL6 OCS, 19 Figure 03.4 –...
  • Page 190 Table 05.1 - OCS LEDs, 26 Table 05.3 – System Registers with WebMI, 47 Table 06.1 - Types of Registers found in the EXL6 OCS, 49 Table 06.2 – Common %S Register Definitions, 50 Table 06.3 - %SR Registers, 50 Table 06.4 –...
  • Page 191 MAN1032-10-EN_EXL6_UserManual Table 10.08 – PWM Functions Register Map, 101 Table 10.09 – PWM Functions Register Map, Four Counter, 101 Table 10.10 – PWM Examples, 102 Table 10.11 – STP Examples, 103 Table 12.1 - CAN Port Pins, 110 Table 13.1—Ethernet Module Protocols & Features, 112 Table 13.2 –...

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