HORNER EXL6 OCS User manual

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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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.
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.
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]
Web: http://www.hornerautomation.com
Email: [e-mail]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Web: 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 EXL6 (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 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. THE TERM "ORIGINAL PURCHASER", AS USED IN THIS WARRANTY,
SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM THE EXL6 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
diskettes 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 EXL6 OCS module to appropriately design
the end system, to appropriately integrate the EXL6 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 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. To obtain datasheets and user manuals, Horner website.
North America: https://hornerautomation.com Europe: https://www.hornerautomation.eu
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety /
Compliance
Mechanical
Installation
System Settings
Modbus
Communications
Introduction
Registers
Electrical Installation
Cscape Configuration
Back-up Battery
General I/O
Maintenance
High Speed I/O
Troubleshooting
Serial
Communications
CAN Communications
Ethernet
Communications
Downloadable
Communication
Options
User Interface
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 CHAPTERS ....................................................................................................................4
TABLE OF CONTENTS...............................................................................................................................5
CHAPTER 1: SAFETY AND 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 EXL6 .......................................................................................................... 12
2.2 Connectivity to the EXL6 OCS .................................................................................................14
2.3 Features of EXL6 OCS................................................................................................................ 15
2.4 Required and Suggested 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 Panel Cut-Out............................................................................................................................... 19
3.5 EXL6 Dimensions........................................................................................................................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 System Menu –Details ..............................................................................................................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 AutoRun....................................................................................................................................43
5.17 AutoLoad......................................................................................................................................44
5.18 Clone Overview .......................................................................................................................45
5.19 Load Clone ...............................................................................................................................46
5.20 License Details ........................................................................................................................47
5.21 Touch Calibration Screen .....................................................................................................48
CHAPTER 6: REGISTERS.......................................................................................................................49
6.1 Register Definitions ...................................................................................................................49
6.2 Useful %S and %SR registers.................................................................................................50
6.3 Register Map for EXL6 OCS I/O..............................................................................................58
6.4 Resource Limits..........................................................................................................................59
CHAPTER 7: CSCAPE CONFIGURATION ...........................................................................................60
7.1 Overview.......................................................................................................................................60
7.2 Cscape Status Bar......................................................................................................................60
7.3 Establishing Communications ..................................................................................................61
7.4 Configuration ..............................................................................................................................69
7.5 Digital / HSC Input Configuration............................................................................................ 71
7.6 Digital / PWM Output Configuration...................................................................................... 72
7.7 Analog Input Configuration ..................................................................................................... 73
7.8 Analog Output Configuration..................................................................................................74
CHAPTER 8: GENERAL I/O................................................................................................................... 75
8.1 Overview....................................................................................................................................... 75
8.2 Removing the EXL6 OCS I/O Cover....................................................................................... 75
8.3 Model and I/O Overview ........................................................................................................... 77
8.4 Solid-State Digital Outputs ......................................................................................................78
8.5 Relay Outputs.............................................................................................................................. 79
8.6 Digital Inputs................................................................................................................................80
8.7 Analog Inputs ...............................................................................................................................81
8.8 Universal Analog Inputs Model 5.............................................................................................81
8.9 Universal Analog Inputs Model 6 Universal Analog Inputs.............................................82
8.10 Analog Outputs .......................................................................................................................83
CHAPTER 10: HIGH SPEED I/O ............................................................................................................84
10.1 Overview.......................................................................................................................................84
10.2 Glossary ....................................................................................................................................85
10.3 High Speed Counter (HSC) Functions................................................................................86
10.4 Frequency.................................................................................................................................86
10.5 Totalize......................................................................................................................................86
10.6 Pulse Width Measurement....................................................................................................88
10.7 Period Measurement .............................................................................................................89
10.8 Quadrature...............................................................................................................................90
10.9 Register Match ......................................................................................................................... 91
10.10 HSC Functions .........................................................................................................................92
10.11 Status Bits ................................................................................................................................93
10.12 HSC Functions Register Map ...............................................................................................94
10.13 High Speed Output Functions.............................................................................................. 97
10.14 High-Speed Output Functions Register Map....................................................................101
10.15 PWM Examples .......................................................................................................................102

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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........................................................................................................................... 108
11.6 Cscape Programming via Serial Port .................................................................................. 109
11.7 Ladder-Controlled Serial Communication.......................................................................... 109
11.8 Configuration via Mini-B USB ................................................................................................ 109
CHAPTER 12: CAN Communications ..................................................................................................110
12.1 Overview.......................................................................................................................................110
12.2 Port Description..........................................................................................................................110
12.3 CAN Port Wiring..........................................................................................................................110
12.4 Cscape Programming via CAN .............................................................................................111
12.5 Ladder-Controlled CAN Communication ...........................................................................111
12.6 Using CAN for I/O Expansion (Network I/O).....................................................................111
CHAPTER 13: ETHERENET COMMUNICATION .................................................................................112
13.1 Ethernet Module Protocols and Features ............................................................................112
13.2 Ethernet System Requirements .............................................................................................112
13.3 Ethernet Module Specifications..............................................................................................112
13.4 Ethernet Module Configuration ..........................................................................................113
13.5 Ethernet Configuration –IP Parameters ..............................................................................117
13.6 Ethernet Module Protocol Configuration .........................................................................117
CHAPTER 14: DOWNLOADABLE COMMUNICATION PROTOCOLS..............................................118
14.1 Overview.......................................................................................................................................118
14.2 Protocol Config ......................................................................................................................120
14.3 Network Configuration..........................................................................................................121
14.4 Device List and Device Configuration ..............................................................................123
14.5 Scan List ..................................................................................................................................124
14.6 Data Mapping Configuration (Scan List Entry) ..............................................................125
CHAPTER 15: USER INTERFACE.........................................................................................................127
15.1 Overview......................................................................................................................................127
15.2 Screen Specifications ...........................................................................................................127
15.2 Displaying and Entering Data .............................................................................................128
15.3 Alpha-numeric Keypad.............................................................................................................129
15.4 Screen Navigation ..................................................................................................................131
15.5 Ladder Based Screen Navigation ......................................................................................132
15.6 Beeper Acknowledgement ..................................................................................................133
15.7 Touch (Slip) Sensitivity ............................................................................................................133
15.8 Alarms ......................................................................................................................................134
15.9 Removable Media ..................................................................................................................136
15.10 Screen Saver...........................................................................................................................138
15.11 Screen Brightness .................................................................................................................138
15.12 Touch Screen Pressure........................................................................................................139
CHAPTER 16: VIDEO OBJECT for EXL6 ...........................................................................................141
16.1 Video Object Overview..............................................................................................................141
16.2 Opening Video Object in Cscape........................................................................................142

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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 .....................................................................................................147
17.3 File System for microSD cards.............................................................................................. 148
17.4 Using the Removable Media Manager............................................................................. 148
17.5 Using Removable Media to Log Data................................................................................... 149
17.6 Using Removable Media to Load and Save Applications................................................ 149
17.7 Using Removable Media to View and Capture Screens .................................................. 150
17.8 Configuration of a Removable Media .............................................................................. 150
17.9 Removable Media (RM) Function Blocks in Cscape ...........................................................151
17.10 Removable Media (RM) Features—Program Features ...................................................151
17.11 Removable Media (RM) Features—Graphic/Screen Editor ...........................................151
17.12 Removable Media (RM) Features—Additional Configuration ......................................152
17.13 Filenames used with the Removable Media (RM) Function Blocks ...........................152
17.14 System Registers used with RM.........................................................................................153
CHAPTER 18: CLONE UNIT ................................................................................................................. 154
18.1 Overview..................................................................................................................................... 154
18.2 Clone........................................................................................................................................ 154
18.3 Load Clone ............................................................................................................................. 158
CHAPTER 19: FAIL –SAFE SYSTEM ................................................................................................. 160
19.1 Overview..................................................................................................................................... 160
19.2 Settings.....................................................................................................................................161
19.3 Backup / Restore Data ..........................................................................................................161
19.4 Backup OCS Data...................................................................................................................162
19.5 Restore OCS Data..................................................................................................................163
19.6 Clear Backup Data................................................................................................................ 164
19.7 AutoLoad.................................................................................................................................... 166
19.8 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 EXL6 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 Battery Charging Cycle ........................................................................................................173
21.6 Battery Charging Status ......................................................................................................173
21.7 Battery Charging State............................................................................................................173
21.8 Battery Status in System Registers..................................................................................173
CHAPTER 22: MAINTENANCE ............................................................................................................174
22.1 Firmware Updates.....................................................................................................................174

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22.2 How to Check for Current Firmware Revision................................................................174
22.3 Updating Firmware Details..................................................................................................175
22.4 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 Technical Support Contacts................................................................................................183
CHANGE LOG............................................................................................................................................ 184
MAIN INDEX .............................................................................................................................................. 185
INDEX OF FIGURES AND TABLES........................................................................................................ 189

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CHAPTER 1: SAFETY AND 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.