HORNER EXL6 User manual

Page 1
EXL6 Datasheet - Model 2
12 DC In, 6 Relay Out, 4 – 12-bit Analog In
MAN1169-EN-21_EXL6_Mod2
Part Numbers
Global Part Number HE-EXL1E2
European Part Number HEXT371C112
User Manual and Add-Ons
Find the documents via the Documentation Search.
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.
Battery Maintenance
The EXL6 has an advanced battery system that uses a
rechargeable lithium battery. The battery powers the real
time clock when power is removed, and it is needed for
register data retention. Manual MAN1032 via the Docu-
mentation Search for more details on battery replacement.
Table of Contents
User Manual and Add-Ons 1
Battery Maintenance 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

Page 2
TECHNICAL SPECIFICATIONS
General Specifications
Required Power
(Steady State)
420mA @ 12VDC
230mA @ 24VDC
Required Power
(Inrush)
25A for < 1ms @ 24VDC, DC
switched
Primary Power Range 10 - 30VDC
Max. Current 1100mA, Class 2
Relative Humidity 5 to 95% non-condensing
Typical Power Back-
light 100% 6.816W @ 24VDC
Power Backlight 50% 6.169W @ 24VDC
Power Backlight OFF 5.472W @ 24VDC
Clock Accuracy
+ / - 20 ppm maximum at 25°C
(+/- 1 min/month)
Real Time Clock Battery Backed, Rechargeable
Lithium
Operating Air Temp -10°C to +60°C
Storage Temp -20°C to +60°C
Weight 1.59 lbs (721.2g)
Altitude Up to 2000m
Rated Pollution
Degree
Evaluated for Pollution Degree 2
Rating
Certifications (UL/CE) North America or Europe
Enclosure Type 1, 3R, 4, 4X, 12, 12K & 13
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 .04ms/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
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
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

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
NOTE: See Precaution #12 about USB and grounding.
Power Wiring
NOTE: The Primary Power Range is 10VDC to 30VDC.
Primary Power Port Pins
PIN Signal Description
1Ground Frame Ground
2DC- Input Power Supply Ground
3DC+ Input Power Supply Voltage
DC Input / Frame
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.
Power Up
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.
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
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
Response Time
One update per ladder scan
plus 10ms
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.
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
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.
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)
Jumper Settings for Model 2
Location of I/O jumpers (JP1 & JP2) and wiring connectors
(J1 & J2) with back cover removed.
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.
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)

Wiring:Model 2
Page 6
J1 Wiring - Digital In / Analog In
NOTE: The 0V terminals are internally connected.
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).
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.
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
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.

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 [phone]
[phone]
www.hornerautomation.com
[email protected]
Europe
[phone]
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.