HORNER EXL10 OCS User manual

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User Manual for EXL10 OCS
MAN1029-09-EN_EXL10_UM
HE-EXV1E0 / HEXT505C100
HE-EXV1E2 / HEXT505C112
HE-EXV1E3 / HEXT505C113
HE-EXV1E4 / HEXT505C114
HE-EXV1E5 / HEXT505C115
HE- EXV1E6 / HEXT505C116

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PREFACE
This manual explains how to use the EXL10 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.
All software described in this document or media is also copyrighted material subject to the
terms and conditions of the Horner Software License Agreement.
Information in this document is subject to change without notice and does not represent a
commitment on the part of Horner APG.
Cscape, SmartStack, SmartStix, SmartRail, SmartMod, and CsCAN are trademarks of Horner
APG.
Ethernet™ is a trademark of Xerox Corporation.
microSD™ and CompactFlash are registered trademarks of SanDisk Corporation.
For user manual updates, please visit our website:
North America:
Tel: (+) [phone]
Fax: (+) [phone]
Website: https://hornerautomation.com
Email: [e-mail]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Website: http://www.hornerautomation.eu
Email: [e-mail]

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LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the EXL10 (HE-
XW/HEXT391) OCS module manufactured by HE-APG is free from defects in material and
workmanship under normal use and service. The obligation of HE-APG under this warranty shall
be limited to the repair or exchange of any part or parts which may prove defective under
normal use and service within two (2) years from the date of manufacture or eighteen (18)
months from the date of installation by the original purchaser whichever occurs first, such
defect to be disclosed to the satisfaction of HE-APG after examination by HE-APG of the
allegedly defective part or parts. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE-APG
NEITHER ASSUMES, NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY
OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS EXL10 OCS module. THIS
WARRANTY SHALL NOT APPLY TO THIS EXL10 OCS module OR ANY PART THEREOF WHICH
HAS BEEN SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. HE-APG
MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT
SUPPLIED BY HE-APG. THE TERM "ORIGINAL PURCHASER", AS USED IN THIS WARRANTY,
SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM THE EXL10 OCS module IS
ORIGINALLY INSTALLED. THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF
THE CONTINENTAL UNITED STATES.
In no event, whether as a result of breach of contract, warranty, tort (including negligence) or
otherwise, shall HE-APG or its suppliers be liable of any special, consequential, incidental or
penal damages including, but not limited to, loss of profit or revenues, loss of use of the
products or any associated equipment, damage to associated equipment, cost of capital, cost
of substitute products, facilities, services or replacement power, down time costs, or claims of
original purchaser's customers for such damages.
To obtain warranty service, return the product to your distributor with a description of the
problem, proof of purchase, postpaid, insured and in a suitable package.
ABOUT PROGRAMMING EXAMPLES
Any example programs and program segments in this manual or provided on accompanying
media are included solely for illustrative purposes. Due to the many variables and requirements
associated with any particular installation, Horner APG cannot assume responsibility or liability
for actual use based on the examples and diagrams. It is the sole responsibility of the system
designer utilizing the EXL10 OCS module to appropriately design the end system, to
appropriately integrate the EXL10 OCS module and to make safety provisions for the end
equipment as is usual and customary in industrial applications as defined in any codes or
standards which apply.
NOTE: The programming examples shown in this manual are for illustrative purposes only.
Proper machine operation is the sole responsibility of the system integrator.

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VISUAL MAP OF KEY CHAPTERS
FIRST STEP of ANY TASK: DATASHEET
Each EXL10 OCS unit is sent with a datasheet in the box. The datasheets are the first
documents to refer to for model-specific information related to EXL10 OCS models for
specific installation information. To obtain updates to datasheets, manuals, and user
documentation, visit a Horner website.
North America https://hornerautomation.com Europe http://www.hornerautomation.eu
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety /
Compliance
Mechanical
Installation
System Settings
Modbus
Communications
Introduction
Electrical Installation
Registers
Back-up Battery
Cscape Configuration
Maintenance
General I/O
Troubleshooting
High-Speed I/O
Serial
Communications
CAN Communications
Ethernet
Communications
Downloadable
Communications
User Interface
Audio Object
Video Object
Removable Media
Clone Unit
Fail-Safe System

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TABLE OF CONTENTS
PREFACE .....................................................................................................................................................2
LIMITED WARRANTY AND LIMITATION OF LIABILITY........................................................................3
ABOUT PROGRAMMING EXAMPLES.......................................................................................................3
VISUAL MAP OF KEY CHAPTERS............................................................................................................4
TABLE OF CONTENTS...............................................................................................................................5
CHAPTER 1: SAFETY / COMPLIANCE .................................................................................................10
1.1 Safety Warnings and Guidelines..............................................................................................10
1.2 Grounding....................................................................................................................................... 11
1.3 Compliance .................................................................................................................................... 11
CHAPTER 2: INTRODUCTION................................................................................................................ 12
2.1 Visual Overview of EXL10 OCS................................................................................................. 12
2.2 Connectivity to the EXL10 OCS................................................................................................ 14
2.3 Features of EXL10 OCS .............................................................................................................. 15
2.4 Accessories................................................................................................................................... 16
2.5 Useful Documents and References......................................................................................... 16
2.6 Opening Cscape Help File.......................................................................................................... 16
CHAPTER 3: MECHANICAL INSTALLATION...................................................................................... 17
3.1 Overview........................................................................................................................................ 17
3.2 Mounting Requirements ............................................................................................................ 17
3.3 Mounting Orientation .................................................................................................................18
3.4 EXL10 Dimensions ....................................................................................................................... 19
3.5 Installation Procedure...............................................................................................................20
3.6 Factors Affecting Panel Layout Design and Clearances ................................................... 21
CHAPTER 4: ELECTRICAL INSTALLATION ...................................................................................... 23
4.1 Grounding Definition ................................................................................................................. 23
4.2 Ground Specifications ............................................................................................................... 23
4.3 How to Test for Good Ground .................................................................................................24
4.4 Primary Power Port................................................................................................................... 25
CHAPTER 5: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................ 26
5.1 System Menu - Overview..........................................................................................................26
5.2 System Menu –Navigation and Editing................................................................................. 27
5.3 Set Networks ...............................................................................................................................29
5.4 View Status..................................................................................................................................30
5.5 View Diags..................................................................................................................................... 31
5.6 View Battery Status................................................................................................................... 32
5.7 View I/O Slots.............................................................................................................................. 33
5.8 View Protocols ............................................................................................................................34
5.9 Set Fkeys Mode........................................................................................................................... 35
5.10 Set Serial Ports .......................................................................................................................36
5.11 Set Time/Date ............................................................................................................................. 37
5.12 Set Beeper................................................................................................................................39
5.13 Set Screen....................................................................................................................................40

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5.14 Removable Media ....................................................................................................................41
5.15 Fail –Safe System ..................................................................................................................42
5.16 Enable AutoRun and AutoLoad...........................................................................................43
5.17 Clone Unit.....................................................................................................................................44
5.18 Load Clone ...............................................................................................................................45
5.19 WebMI License Details...........................................................................................................46
5.20 Touch screen calibration .....................................................................................................47
CHAPTER 6: REGISTERS.......................................................................................................................48
6.1 Register Definitions ...................................................................................................................48
6.2 Useful %S and %SR registers.................................................................................................48
6.3 Register Map for EXL10 OCS I/O ............................................................................................56
6.4 Resource Limits.......................................................................................................................... 57
CHAPTER 7: CSCAPE CONFIGURATION ...........................................................................................58
7.1 Overview.......................................................................................................................................58
7.2 Cscape Status Bar......................................................................................................................58
7.3 Establishing Communications .................................................................................................59
7.4 Configuration ..............................................................................................................................67
7.5 Digital / HSC Input Configuration...........................................................................................68
7.6 Digital / PWM Output Configuration......................................................................................69
7.7 Analog Input Configuration .....................................................................................................70
7.8 Analog Output Configuration................................................................................................... 71
7.9 Scaling Analog Inputs................................................................................................................ 72
CHAPTER 8: GENERAL I/O................................................................................................................... 74
8.1 Overview.......................................................................................................................................74
8.2 Removing the EXL10 OCS I/O Cover......................................................................................74
8.3 Model and I/O Overview ........................................................................................................... 76
8.4 Solid-State Digital Outputs ......................................................................................................76
8.5 Relay Outputs..............................................................................................................................78
8.6 Digital Inputs................................................................................................................................79
8.7 Analog Inputs ..............................................................................................................................80
8.8 Universal Analog Inputs.............................................................................................................81
8.9 Analog Outputs...........................................................................................................................82
CHAPTER 9: HIGH SPEED I/O (HSC / PWM).....................................................................................83
9.1 Overview.......................................................................................................................................83
9.2 Glossary ........................................................................................................................................84
9.3 High-Speed Counter (HSC) Functions ...................................................................................85
9.4 HSC Functions Register Map ...................................................................................................93
9.5 High Speed Output Functions .................................................................................................96
9.6 High Speed Output Functions Register Map...................................................................... 100
9.7 HSC I/O Filtering........................................................................................................................103
CHAPTER 10: SERIAL COMMUNICATIONS ..................................................................................... 106
10.1 Overview..................................................................................................................................... 106
10.2 Port Descriptions.................................................................................................................. 106
10.3 Wiring and Dip Switches ..................................................................................................... 106
10.4 RS485 Termination...............................................................................................................107
10.5 RS485 Biasing........................................................................................................................107
10.6 Cscape Programming via Serial Port............................................................................... 108
10.7 Ladder-Controlled Serial Communication...................................................................... 108
10.8 Configuration via Mini-B USB ............................................................................................ 108

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CHAPTER 11: CAN COMMUNICATIONS ............................................................................................ 109
11.1 Overview..................................................................................................................................... 109
11.2 Port Description........................................................................................................................ 109
11.3 CAN Port Wiring..........................................................................................................................110
11.4 Cscape Programming via CAN ................................................................................................110
11.5 Ladder-Controlled CAN Communication ..............................................................................110
11.6 Using CAN for I/O Expansion (Network I/O)........................................................................110
CHAPTER 12: ETHERNET COMMUNICATION.....................................................................................111
12.1 Ethernet Overview ......................................................................................................................111
12.2 Ethernet Module Protocols and Features .............................................................................111
12.3 Ethernet System Requirements ..............................................................................................111
12.4 Ethernet Module Specifications...........................................................................................111
12.5 Ethernet Module Configuration ..........................................................................................113
12.6 Ethernet Configuration –IP Parameters ..........................................................................116
12.7 Ethernet Module Protocol Configuration .............................................................................116
CHAPTER 13: DOWNLOADABLE COMMUNICATION PROT0COLS..............................................117
13.1 Overview.......................................................................................................................................117
13.2 Protocol Config...........................................................................................................................119
13.3 Network Configuration.............................................................................................................120
13.4 Device List and Device Configuration ..............................................................................122
13.5 Scan List ......................................................................................................................................123
13.6 Data Mapping Configuration (Scan List Entry) ..............................................................124
CHAPTER 14: USER INTERFACE.........................................................................................................126
14.1 Overview......................................................................................................................................126
14.2 Screen Specifications ...........................................................................................................126
14.2 Displaying and Entering Data .............................................................................................126
14.3 Alpha-Numeric Keypad ........................................................................................................127
14.4 Screen Navigation .................................................................................................................129
14.5 Ladder Based Screen Navigation ......................................................................................130
14.6 Beeper Acknowledgement ..................................................................................................130
14.7 Touch (Slip) Sensitivity .........................................................................................................131
14.8 Alarms ......................................................................................................................................132
14.9 Removable Media ..................................................................................................................134
14.10 Screen Saver...........................................................................................................................136
14.11 Screen Brightness .................................................................................................................136
14.12 Touch Screen Pressure........................................................................................................137
CHAPTER 15: AUDIO PLAYBACK CONFIGURATION......................................................................139
15.1 Audio Overview..........................................................................................................................139
15.2 Audio Configuration in Cscape...........................................................................................139
15.3 Audio Config Details ................................................................................................................ 140
15.4 Audio Files................................................................................................................................141
CHAPTER 16: VIDEO OBJECT .............................................................................................................143
16.1 Video Object Overview.............................................................................................................143
16.2 Opening Video Object in Cscape....................................................................................... 144
16.3 Video Properties: Video Type............................................................................................ 146
16.4 Video Properties: Control....................................................................................................147
16.5 Configuring Display Properties ......................................................................................... 148
16.6 Video Object Performance................................................................................................. 148
16.7 Web Cameras............................................................................................................................. 148

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CHAPTER 17: REMOVABLE MEDIA ................................................................................................... 149
17.1 Overview..................................................................................................................................... 149
17.2 microSD Cards .......................................................................................................................... 149
17.3 microSD File System................................................................................................................ 149
17.4 Using the Removable Media Manager............................................................................. 150
17.5 Using Removable Media to Log Data................................................................................... 150
17.6 Using Removable Media to Load and Save Applications..................................................151
17.7 Using Removable Media to View and Capture Screens ....................................................151
17.8 Configuration of a Removable Media ...............................................................................152
17.9 Removable Media (RM) Function Blocks in Cscape ..........................................................152
17.10 Removable Media (RM) Features—Program Features ..................................................153
17.11 Removable Media (RM) Features—Graphic/Screen Editor ..........................................153
17.12 Removable Media (RM) Features—Additional Configuration ......................................153
17.13 Filenames used with the Removable Media (RM) Function Blocks .......................... 154
17.14 System Registers used with RM.........................................................................................155
CHAPTER 18: CLONE UNIT ..................................................................................................................156
18.1 Overview......................................................................................................................................156
18.2 Clone.........................................................................................................................................156
18.3 Load Clone ..............................................................................................................................159
CHAPTER 19: FAIL –SAFE SYSTEM ...................................................................................................161
19.1 Overview.......................................................................................................................................161
19.2 Settings....................................................................................................................................162
19.3 AutoLoad ................................................................................................................................ 166
19.4 AutoRun.................................................................................................................................. 168
CHAPTER 20: MODBUS COMMUNICATIONS ................................................................................ 169
20.1 Modbus Overview ................................................................................................................. 169
20.2 Modbus Slave Overview...................................................................................................... 169
20.3 Modbus Master Overview ....................................................................................................170
20.4 Modbus Addressing Table for EXL10 Units ......................................................................171
CHAPTER 21: BACK-UP BATTERY .....................................................................................................172
21.1 Overview......................................................................................................................................172
21.2 Storing Register Contents.......................................................................................................172
21.3 Battery Life.................................................................................................................................172
21.4 Lithium Battery Safety.........................................................................................................172
21.5 OCS Battery Charging Cycle...............................................................................................173
21.6 Battery Charging Status ......................................................................................................174
21.7 Battery Status in System Registers......................................................................................175
CHAPTER 22: MAINTENANCE ............................................................................................................176
22.1 Firmware Updates.....................................................................................................................176
22.2 How to Check for Current Firmware Revision................................................................176
22.3 Firmware Update Files .........................................................................................................177
22.4 Steps for Firmware Update.................................................................................................178
22.5 Backup Battery Replacement.............................................................................................179
CHAPTER 23: TROUBLESHOOTING / TECHNICAL SUPPORT .....................................................181
23.1 Connecting to the EXL10 OCS .................................................................................................181
23.2 Local Controller and Local I/O ...........................................................................................183
23.3 CsCAN Network..................................................................................................................... 184
23.4 Removable Media - Basic Troubleshooting.................................................................... 185
23.5 USB Interfaces....................................................................................................................... 185

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23.6 Technical Support Contacts............................................................................................... 185
CHANGE LOG............................................................................................................................................ 186
INDEX.......................................................................................................................................................... 188

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CHAPTER 1: SAFETY / COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
Warning: Consult user documentation.
Warning: Electrical Shock Hazard.
WARNING –EXPLOSION HAZARD –Do not disconnect equipment unless power has been
switched off or the area is known to be non-hazardous
WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth)
ground before making any other connections.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly
recommended to fuse the voltage measurement inputs. Be sure to locate fuses as close to
the source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk of
fire and shock hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated
failure indicates a defective condition that will not clear by replacing the fuse.
WARNING –EXPLOSION HAZARD –Substitution of components may impair suitability for
Class I, Division 2
WARNING: The USB parts are for operational maintenance only. Do not leave permanently
connected unless area is known to be non-hazardous
WARNING –EXPLOSION HAZARD - BATTERIES MUST ONLY BE CHANGED IN AN AREA
KNOWN TO BE NON-HAZARDOUS
WARNING: Battery May Explode If Mistreated. Do Not Recharge, Disassemble or Dispose Of In
Fire
WARNING: Only qualified electrical personnel familiar with the construction and operation of
this equipment and the hazards involved should install, adjust, operate, or service this
equipment. Read and understand this manual and other applicable manuals in their entirety
before proceeding. Failure to observe this precaution could result in severe bodily injury or
loss of life.