HORNER XL6 Prime Instruction Manual

Page 1
XL6 Prime Datasheet - Model 2
12 DC In, 6 Relay Out, 4 – 12-bit Analog In
MAN1327-21-EN_XL6P_Mod2
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Part Numbers
Global Part Number HE-XPL1E2
European Part Number HEXP371C112
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User Manual and Add-Ons
FindthedocumentsviatheDocumentationSearch.
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Part # Description
MAN1032 EXL6&XL6PrimeUserManual
MAN1142 RechargeableBatteryManual
HE-BAT019 Rechargeable3.6VLithiumBattery
HE-XCK ProgrammingCables
HE-XDAC 2channelAnalogOutputI/Ooptionkit,
selectable0-10V,+/-10V,4-20mA.
HE-XDAC107 4channelAnalogOutputI/Ooptionkit,
selectable0-10V,+/-10V,4-20mA.
HE-XKIT BlankI/OBoard
HE200MJ2TRM Adapter,RJ45(8P8C)maleto8-pos-
itionterminalstrip.
HE-FBD001 Ferritecoreforfilteringoutelectrical
noise.
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Backup Battery
TheXL6PrimeusesaRenataCR2032lithiumbatteryto
runtheRealTimeClock.Thebatterylifeis7-10years.
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Table of Contents
UserManualandAdd-Ons 1
BackupBattery 1
TECHNICAL SPECIFICATIONS 2
GeneralSpecifications 2
ControlandLogic 2
UserInterface 2
Connectivity 2
CONTROLLER OVERVIEW 3
OverviewofOCS 3
PowerWiring 3
MODEL 2 SPECIFICATIONS 4
DigitalDCInput 4
DigitalRelayOutputs 4
AnalogInputs,MediumResolution 4
WIRING: INPUTS AND OUTPUTS 5
AnalogInputsInformation 5
DigitalInputs 5
RelayLife 5
JumperSettingsforModel2 5
BackPanelTorqueRatings 5
J1Wiring-DigitalIn/AnalogIn 6
J2Wiring-RelayOut/AnalogorDigitalIn 6
WiringDetails 6
BUILT-INI/O 6
AnalogInputTranzorbFailure 6
COMMUNICATIONS 7
SerialCommunication 7
Ethernet 7
DipSwitches 7
CANCommunications 7
DIMENSIONS & INSTALLATION 8
Dimensions&PanelCutout 8
InstallationInformation 8
InstallationProcedure 8
SAFETY & MAINTENANCE 9
Warnings 9
FCCCompliance 9
TechnicalSupport 9
Precautions 9
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Page 2
TECHNICAL SPECIFICATIONS
General Specifications
TypicalPowerBack-
light100%
415mA@10VDC(4.15W)
191mA@24VDC(4.58W)
PowerBacklight@
50% 111mA@24VDC(2.66W)
PowerBacklightOFF 105mA@24VDC(2.52W)
RequiredPower
(Inrush)
25Afor<1ms@24VDC,DC
switched
PrimaryPowerRange 10-30VDC
Max.Current 1000mA,Class2
RelativeHumidity 5to95%,Non-Condensing
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ClockAccuracy
+/-20ppmmaximumat25°C
(+/-1min/month)
RealTimeClock BatteryBacked,LithiumCoin
Operating
Temperature -10°Cto+60°C
Storage
Temperature -20°Cto+60°C
Weight 1.59lbs(721.2g)
Altitude Upto2000m
RatedPollution
Degree Degree2Rating
Certifications(UL/CE) NorthAmericaorEurope
EnclosureType 1,3R,4,4X,12,12K&13
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Control and Logic
ControlLang.Support
Register-BasedAdvanced
LadderLogic;
Variable-BasedAdvanced
Ladder;
IEC61131-3Languages
LogicProgramSize 2MB,maximum
ScanRate .02ms/kB
DigitalInputs 2048
DigitalOutputs 2048
AnalogInputs 512
AnalogOutputs 512
Gen.Purpose
Registers
50,000(words)Retentive
16,384(bits)Retentive
16,384(bits)Non-retentive
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User Interface
DisplayType 5.77”VGATFT(450nittypical)
Resolution 640x480
Color 16-bit(65,536)
ScreenMemory 17MB
User-Program.
Screens
1023maxpages;1023objects
perpage
Backlight LED-50,000hourlife
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Connectivity
SerialPorts
1RS-232&1RS-485onfirst
ModularJack(MJ1/2)
1RS-232or1RS-485onsecond
ModularJack
USBmini-B USB2.0(480MHz)Programming
&DataAccess
USBA(500mAmax) USB2.0(480MHz)forUSBflash
drives(2TB)
CANPort
Isolated1kV
RemoteI/O,Peer-to-peer
Comms,Cscape
CANProtocols CsCAN,CANopen,DeviceNet,
J1939
Ethernet 10/100Mb(Auto-MDX)
EthernetProtocols TCP/IP,ModbusTCP,FTP,
SMTP,EGD,ICMP,ASCII
RemoteI/O SmartRail,SmartStix,
SmartBlock,SmartMod
RemovableMemory
microSD,SDHC,SDXCIN
FAT32format,supportfor32GB
max.ApplicationUpdates,
Datalogging
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USB Webcams
USBWebcamssupportedshouldsupporttheUVC(USB
Videoclass)protocolfortheOCStobeabletodisplay
video.MostUSBbasedvideodevicessupportthistoday.
Specialfeaturesuchaszoomandhighdefinitionarenot
supportedbytheOCS

Page 3
CONTROLLER OVERVIEW
Overview of OCS
1. Touchscreen
2. FunctionKeys
3. USB2.0“A”:FlashDrive
4. LANPort
5. PWR:10-30VDCIn
6. CANPort
7. MJ3:RS-232/485
8. DipSwitches
9. MJ1/MJ2:RJ45SerialPort
10. microSD:DataStorage
11. USBmini“B”:Programming
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NOTE:SeePrecaution#12aboutUSBandgrounding.
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Power Wiring
NOTE:ThePrimaryPowerRangeis10VDCto30VDC.
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Primary Power Port Pins
PIN Signal Description
1Ground FrameGround
2DC- InputPowerSupplyGround
3DC+ InputPowerSupplyVoltage
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DC Input / Frame
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lSolid/StrandedWire:12-24awg(2.5-0.2mm)
lStriplength:0.28”(7mm)
lTorque,TerminalHold-DownScrews:4.5–7in-lbs
(0.50–0.78N-m)
lDC-isinternallyconnectedtoI/OV-,butisisolated
fromCANV-.AClass2powersupplymustbeused.
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Power Up
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1. OPTION:Attachferritecorewithaminimumoftwo
turnsoftheDC+andDC-signalsfromtheDCsupply
thatispoweringthecontrollers.
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2. Connecttoearthground.
3. Applyrecommendedpower.

Wiring:Model 2
Page 4
MODEL 2 SPECIFICATIONS
Digital DC Input
InputsperModule 12including4configurableHSC
inputs
CommonsperModule 1
InputVoltageRange 12VDC/24VDC
AbsoluteMax.
Voltage 30VDCMax.
InputImpedance 10kΩ
InputCurrent PositiveLogic NegativeLogic
UpperThreshold
LowerThreshold
0.8mA
0.3mA
-1.6mA
-2.1mA
Max.UpperThreshold 8VDC
Min.LowerThreshold 3VDC
OFFtoONResponse 1ms
ONtoOFFResponse 1ms
HighSpeedCounter
MaxFreq* 1MHz
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Digital Relay Outputs
OutputsperModule 6Relay
CommonsperModule 6
Max.OutputCurrent
perRelay 3A@250VAC,resistive
Max.TotalOutput
Current 5Acontinuous
Max.OutputVoltage 275VAC,30VDC
Max.SwitchedPower 1000VAC,150W
ContactIsolationto
Ground 1000VAC
Max.VoltageDropat
RelatedCurrent 0.5V
ExpectedLife(see
belowderatingchart
fordetails)
NoLoad:5,000,000
RatedLoad:100,000
Max.SwitchingRate 300CPMatnoload20CPMat
ratedload
Type MechanicalContact
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ResponseTime
Oneupdateperladderscan
plus10ms
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Analog Inputs, Medium Resolution
NumberofChannels 4
InputRanges 0-10VDC,0-20mA,4-20mA
SafeInputVoltage
Range -0.5Vto12V
InputImpedance
(clamped@-0.5VDC
to12VDC)
Current Mode:100Ω
Voltage Mode:500kΩ
NominalResolution 12Bits
%AIFullScale 0V,20mA,100mV:
32,000countsfullscale
Max.OverCurrent 35mA
ConversionSpeed OnceperLadderScan
MaxErrorat25˚C
(excludingZero)
AdjustingFiltering
maytighten
4–20mA1.00%
0-20mA1.00%
0-10VDC1.50%
Filtering
160HzHash(noise)Filter,1-128
ScanDigitalRunningAverageFil-
ter

Wiring:Model 2
Page 5
WIRING: INPUTS AND OUTPUTS
Analog Inputs Information
Rawinputvaluesforchannels1-4arefoundintheregisters
asInteger-typedatawitharangefrom0–32000.
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AnaloginputsmaybefiltereddigitallywiththeFilterCon-
stantfoundintheCscapeHardwareConfigurationforAna-
logInputs.Validfiltervaluesare0-7andactaccordingto
thefollowingchart:
Data Values
InputMode: DataFormat,12-bitINT:
0-20mA,4-20mA 0-32000
0-10V 0-32000
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Digital Inputs
DigitalinputsmaybewiredineitheraPositiveLogicorNeg-
ativeLogicfashionasshown.ThesettingintheCscape
HardwareConfigurationfortheDigitalInputsmustmatch
thewiringusedinorderforthecorrectinputstatestobe
registered.NojumpersettingsarerequiredforXLEe/XLTe.
Whenusedasanormalinputandnotforhighspeedfunc-
tions,thestateoftheinputisreflectedinregisters%I1–
%I12.
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Relay Life
WARNING:Exposuretosomechemicalsmaydegradethe
sealingproper-tiesofmaterialsusedintheTycorelayPCJ.
Cover/Case & Base:MistubishiengineeringPlasticsCorp.
5010GN6-30or5010GN6-30M8(PBT)
Sealing Material:Kishimoto4616-50K(Ipartepoxyresin)
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Jumper Settings for Model 2
LocationofI/Ojumpers(JP1&JP2)andwiringconnectors
(J1&J2)withbackcoverremoved.
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NOTE:TheCscapeModuleConfigurationmustmatchthe
selectedI/O(JP)jumpersettings.
NOTE:WhenusingJP2(A1-A4),eachchannelcanbeinde-
pendentlyconfigured.
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Back Panel Torque Ratings
XLE/XLT:3.0-4.0in-lbs(0.34-0.45N-m)
XL4/XL4 Prime:3.0-4.0in-lbs(0.34-0.45N-m)
EXL6/XL6 Prime:3.0-4.0in-lbs(0.34-0.45N-m)
EXLW/ XLW Prime:3.0-3.5in-lbs(0.34-0.40N-m)
XL7/XL7 Prime:3.0-3.5in-lbs(0.34-0.40N-m)
EXL10/XL10 Prime:3.0-3.5in-lbs(0.34-0.40N-m)
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Wiring:Model 2
Page 6
J1 Wiring - Digital In / Analog In
NOTE:The0Vterminalsareinternallyconnected.
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J2 Wiring - Relay Out / Analog or
Digital In
Wiring Details
Solid/Stranded Wire:12-24awg(2.5-0.2mm2).
Strip Length:0.28”(7mm).
Torque, Terminal Hold-Down Screws:4.5–7in-lbs
(0.50–0.78N-m).
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BUILT-IN I/O
TheI/OismappedintoOCSRegisterspace,inthreesep-
arateareas–Digital/AnalogI/O,High-SpeedCounterI/O,
andHigh-speedOutputI/O.Digital/AnalogI/Olocationis
fixedstartingat1,butthehigh-speedcounterandhigh-
speedoutputreferencesmaybemappedtoanyopen
registerlocation.
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Digital and Analog I/O Functions
DigitalInputs %I1-12
Reserved %I13-32
ESCPAlarm n/a
DigitalOutputs %Q1-6
Reserved %Q7-24
AnalogInputs %AI1-4
Reserved %AI5-12
AnalogOutputs n/a
Reserved n/a
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Analog Input Tranzorb Failure
AcommoncauseofAnalogInputTranzorbFailureonAna-
logInputsModel2,3,4&5:Ifa4-20mAcircuitisinitially
wiredwithlooppower,butwithoutaload,theanaloginput
couldsee24VDC.Thisishigherthantheratingofthetran-
zorb.ThiscanbesolvedbyNOTconnectinglooppower
priortoloadconnection,orbyinstallingalow-costPTCin
seriesbetweentheloadandanaloginput.
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Page 7
COMMUNICATIONS
Serial Communication
MJ1/2 Serial Ports
MJ1/2IndependentSerialPorts

MJ1:RS-232w/FullHandshaking
MJ2:RS-485Half-Duplex

MJ1 PINS MJ2 PINS
PIN SIGNAL DIRECTION SIGNAL DIRECTION
8TXD OUT -- --
7RXD IN -- --
60V GROUND 0V GROUND
5+5V@
60mA OUT +5V@ 60mA OUT
4RTS OUT -- --
3CTS IN -- --
2-- -- RX-/TX- IN/OUT
1-- -- RX+/
TX+ IN/OUT



MJ3 Serial Port
2MultiplexedSerialPortsonOneModularJack(8posn)
MJ3 PINS
PIN SIGNAL DIRECTION
8 TXDRS232 OUT
7 RXDRS232 IN
6 0V GROUND
5 +5V@60mA OUT
4 TX-RS485 OUT
3 TX+RS485 OUT
2 RX-RS485 IN
1 RX+RS485- IN

NOTE:Attachoptionalferritecorewithaminimumoftwo
turnsofserialcable.

Ethernet
Green LED indicates link-whenillu-
minated,datacommunicationisavailable.
Yellow LED indicates activity-when
flashing,dataisintransmission.
Dip Switches
DIP Switches
PIN NAME FUNCTION DEFAULT
1MJ3RS-485
Termination
ON=
Terminated OFF
2MJ3Duplex ON=Half
OFF=Full
OFF
3OFF
4MJ2RS485Ter-
mination
ON=
Terminated OFF

TheDIPswitchesareusedtoprovideabuilt-intermination
toboththeMJ1,MJ2&MJ3portsifneeded.Theter-
minationfortheseportsshouldonlybeusedifthisdeviceis
locatedateitherendofthemultidrop/daisy-chainedRS-
485network.

CAN Communications
CAN Pin Assignments
PIN SIGNAL DESCRIPTION
1V- CANGround–Black
2CN_L CANDataLow–Blue
3SHLD ShieldGround–None
4CN_H CANDataHigh–White
5V+(NC) NoConnect–Red

Solid/Stranded Wire:12-24awg(2.5-0.2mm).
Strip Length:0.28”(7mm).
Lockingspring-clamp,two-terminatorsperconductor.
Torque, Terminal Hold-Down Screws:4.5–7in-lbs
(0.50–0.78N-m).

V+pinisnotinternallyconnected,theSHLDpiniscon-
nectedtoEarthgroundviaa1MΩresistorand10nFcapa-
citor.

Page 8
DIMENSIONS & INSTALLATION
Dimensions & Panel Cutout

*+/-0.1mmcutouttolerance

Installation Information

lTheEXL6/XL6Primeutilizesaclipinstallation
methodtoensurearobustandwatertightsealtothe
enclosure.Pleasefollowthestepsbelowforthe
properinstallationandoperationoftheunit.
lThisequipmentissuitableforClassI,Division2,
GroupsA,B,CandDornon-hazardouslocations
only.
lDigitaloutputsshallbesuppliedfromthesame
sourceastheoperatorcontrolstation.
lJumpersonconnectorJP1shallnotberemovedor
replacedwhilethecircuitisliveunlesstheareais
knowntobefreeofignitableconcentrationsofflam-
mablegasesorvapors.
lWARNING-TheUSBportsareforoperationalmain-
tenanceonly.Donotleavepermanentlyconnected
unlessareaisknowntobenon-hazardous.

Installation Procedure
1. Carefullylocateanappropriateplacetomountthe
OCS.Besuretoleaveenoughroomatthetopofthe
unitforinsertionandremovalofthemicroSD™card.
2. Carefullycutthehostpanelperthediagram,cre-
atinga31.9mmx175.0mm,witha+1mm/-0mm
openingintowhichtheOCSmaybeinstalled.Ifthe
openingistoolarge,watermayleakintotheenclos-
ure,potentiallydamagingtheunit.Iftheopeningis
toosmall,theOCSmaynotfitthroughthehole
withoutdamage.
3. Removeanyburrsandorsharpedgesandensure
thepanelisnotwarpedinthecuttingprocess.
4. RemoveallRemovableTerminalsfromtheOCS.
InserttheOCSthroughthepanelcutout(fromthe
front).Thegasketmustbebetweenthehostpanel
andtheEXL6.
5. Installandtightenthefourmountingclips(provided
inthebox)untilthegasketformsatightseal.NOTE:
Maxtorqueis0.8to1.13Nm,or7to10in-lbs.
6. ReinstalltheI/ORemovableTerminalBlocks.Con-
nectcommunicationscablestotheserialport,USB
ports,EthernetportandCANportasrequired.




Page 9
SAFETY & MAINTENANCE
Warnings
1. Toavoidtheriskofelectricshockorburns,alwayscon-
nectthesafety(orearth)groundbeforemakinganyother
connections.
2. 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.
3. Replacefusewiththesametypeandratingtoprovidepro-
tectionagainstriskoffireandshockhazards.
4. Intheeventofrepeatedfailure,doNOTreplacethefuse
againasrepeatedfailureindicatesadefectivecondition
thatwillNOTclearbyreplacingthefuse.
5. Onlyqualifiedelectricalpersonnelfamiliarwiththecon-
structionandoperationofthisequipmentandthehazards
involvedshouldinstall,adjust,operate,orservicethis
equipment.
6. 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.
7. WARNING-Batterymayexplodeifmistreated.Donot
recharge,disassemble,ordisposeofinfire.
8. WARNING - EXPLOSION HAZARD-Batteriesmustonly
bechangedinanareaknowntobenon-hazardous.
9. WARNING-Donotdisconnectwhilecircuitisliveunless
areisknowtobenon-hazardous.

FCC Compliance
ThisdevicecomplieswithPart15oftheFCCRules.Operationis
subjecttothefollowing
twoconditions:
1. Thisdevicemaynotcauseharmfulinterference.
2. Thisdevicemustacceptanyinterferencereceived,includ-
inginterferencethatmaycauseundesiredoperation.


Technical Support
North America
1(317)916-4274
(877)665-5666
www.hornerautomation.com
[email protected]

Europe
+353(21)4321-266
www.hornerautomation.eu
[email protected]



Precautions
Allapplicablecodesandstandardsneedtobefollowedinthe
installationofthisproduct.Adheretothefollowingsafetypre-
cautionswheneveranytypeofconnectionismadetothemodule:
1. Connectthesafety(earth)groundonthepowerconnector
firstbeforemakingany
2. otherconnections.
3. Whenconnectingtotheelectriccircuitsorpulse-initiating
equipment,opentheir
4. relatedbreakers.
5. DoNOTmakeconnectiontolivepowerlines.
6. Makeconnectionstothemodulefirst;thenconnecttothe
circuittobemonitored.
7. Routepowerwiresinasafemannerinaccordancewith
goodpracticeandlocalcodes.
8. Wearproperpersonalprotectiveequipmentincluding
safetyglassesandinsulatedgloveswhenmakingcon-
nectionstopowercircuits.
9. Ensurehands,shoes,andflooraredrybeforemakingany
connectiontoapowerline.
10. MakesuretheunitisturnedOFFbeforemakingcon-
nectiontoterminals.
11. Makesureallcircuitsarede-energizedbeforemakingcon-
nections.
12. Beforeeachuse,inspectallcablesforbreaksorcracksin
theinsulation.Replace
13. immediatelyifdefective.
14. UsecopperconductorsinFieldWiringonly,60/75˚C.
15. UsecautionwhenconnectingcontrollerstoPCsviaserial
orUSB.PCs,especiallylaptops,mayuse“floatingpower
supplies”thatareungrounded.Thiscouldcauseadam-
agingvoltagepotentialbetweenthelaptopandcontroller.
Ensurethecontrollerandlaptoparegroundedformax-
imumprotection.ConsiderusingaUSBisolatordueto
voltagepotentialdifferencesasapreventativemeasure.

