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MAN1032-10-EN_EXL6_UserManual

March 12, 2020

160 | 191

CHAPTER 19: FAIL

–

SAFE SYSTEM

19.1 Overview

The Fail-Safe System is a set of features that allow an application to continue running in the
event of certain types of "soft" failures. These "soft" failures include:

-

Battery power loss

-

Battery-Backed Register RAM or Application Flash corruption due to an excessive EMI
event, for example.

The Fail-Safe System has the following capabilities:

-

Manually backup the current Battery-Backed RAM Register Settings into Flash
memory.

-

Manually restore Register Settings from the values previously backed up in Flash to
Battery-Backed RAM.

-

Detect corrupted Register Settings at power-up and then automatically restore
them from Flash.

-

Detect corrupted or empty application in Flash memory at power-up and then
automatically load the AUTOLOAD.PGM application file from Removable Media
(Compact Flash or microSD).

-

If an automatic Register Restore or Application Load occurs, the OCS can
automatically be placed in RUN mode.

The fail-safe system can be accessed by going to the System Menu of the controller. A new

menu “Fail

-

Safe System” has been added at the end of the main

System Menu for this. Selecting

“Fail

-

Safe System” menu will open the fol

lowing menu screen:

Figure 19.1

–

Fail

–

Safe System Menu

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Summary of Contents for EXL6 OCS

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

Page 2: ...ion 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 ...

Page 3: ...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 ...

Page 4: ... 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 Communic...

Page 5: ... 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 SETTI...

Page 6: ...uration 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 SPEE...

Page 7: ...quirements 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 Con...

Page 8: ...2 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 ...

Page 9: ...ails 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 ...

Page 10: ... 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...

Page 11: ... to the circuit to be monitored d Route power wires in a safe manner in accordance with good practice and local codes e Wear proper personal protective equipment including safety glasses and insulated gloves when making connections to power circuits f Ensure hands shoes and floors are dry before making any connection to a power line g Make sure the unit is turned OFF before making connection to te...

Page 12: ...necting controllers to PCs via serial or USB PCs especially laptops may use floating power supplies that are ungrounded This could cause a damaging voltage potential between the laptop and controller Ensure the controller and laptop are grounded for maximum protection Consider using a USB isolator due to voltage potential differences as a preventative measure ...

Page 13: ...al information that is common to EXL6 OCS models and can be downloaded from our web Visit the Horner website to obtain user documentation and updates North America https hornerautomation com Europe http www hornerautomation eu 2 1 2 Four main types of information are covered in this manual a Safety and Installation guidelines instructions Mechanical and Electrical b Descriptions of hardware featur...

Page 14: ...can be used with the EXL6 OCS Figure 2 2 Visual Overview of Types of Devices that can be connected to EXL6 OCS CAN Serial I O EXL6 OCS Other OCS Devices Drives PLCs Bar Code Readers Printers SCADA OPC Servers Serial I O Sensors Indicators Alarms Encoders Pumps Relays Solenoids Other OCS Devices Smart Stix I O RCX116 I O Base OPC Server Ethernet Cscape OPC Server Ethernet I P Modbus TCP Devices USB...

Page 15: ...for 32GB of storage of programs data logging or screen captures CsCAN networking port for communication with remote I O other controllers or PCs High speed USB port for communication with PCs and programming of controller Configurable serial protocols for communication to drives PLCs or other serial peripherals Full featured built in I O including high resolution analog thermocouple RTD high speed...

Page 16: ...p horner apg com en products aspx 2 5 Useful Documents and References Visit the Horner website to obtain user documentation supplemental documents certificates and other documentation North America https hornerautomation com Europe http www hornerautomation eu 2 6 Opening Cscape Help File After opening the Cscape Help file either use the Contest Index or Search tabs to located information The Csca...

Page 17: ...user documentation and updates North America https hornerautomation com Europe http www hornerautomation eu 3 1 Overview The mechanical installation greatly affects the operation safety and appearance of the system Information is provided to mechanically install the unit such as cut out sizes mounting procedures and other recommendations for the proper mechanical installation of the unit 3 2 Mount...

Page 18: ...rom dust and debris Check that the corners of the gasket are secure 3 Pass the unit through the panel 4 Insert each of the ten 10 mounting clips into the slots in the EXL6 OCS case One clip should be installed on each corner Lightly tighten each screw so the clip is held in place 5 Tighten the screws on the clips such that the gasket is compressed against the panel Recommended torque is 4 8 in lbs...

Page 19: ...E There are no orientation restrictions on the EXL6 OCS However the above orientation provides for optimum readability of the screen and ease of use of the keypad 3 4 Panel Cut Out For installations requiring NEMA 4X liquid and dust protection the panel cutout should be cut with a tolerance of 1mm 0mm Figure 3 4 Panel Cutout ...

Page 20: ...MAN1032 10 EN_EXL6_UserManual March 12 2020 20 191 3 5 EXL6 Dimensions Figure 3 5 EXL6 OCS Dimensions ...

Page 21: ...l box must be properly connected to earth ground to provide a good common ground reference Panel Door Tie a low impedance ground strap between the panel box and the panel door to ensure that they have the same ground reference 3 6 3 Temperature Ventilation Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient temperature range Consider the impact o...

Page 22: ...ctors Meets the electrical code and applicable standards for proper grounding etc Meets the panel manufacturer s requirements for grounding etc Is the panel box properly connected to earth ground Is the panel door properly grounded Has the appropriate procedure been followed to properly ground the devices in the panel box and on the panel door Are minimum clearance requirements met Can the panel d...

Page 23: ...ce of equipment and the earth Grounds are fundamentally used to protect an application from harmful interference causing either physical damage such as by lightning or voltage transients or from circuit disruption often caused by radio frequency interference RFI Grounding is also for the safety of the user 4 2 Ground Specifications Ideally a ground resistance measurement from equipment to earth gr...

Page 24: ...ster must be used A typical Ground Resistance Meter Kit contains a meter two or three wire leads and two ground rods Instructions are supplied for either a two point or three point ground test Figure 4 1 Two Point Ground Connection Test METAL WATER PIPE OR OTHER GOOD GROUND GROUND ROD GROUND DISCONNECTED FROM SERVICE GROUND RESISTANCE METER ...

Page 25: ...upply ground 24V Input power supply positive voltage Figure 4 2 Power Connector Primary Power Port Figure 4 3 Primary Power Port 10 30VDC supply D C INPUT FRAME Solid Standard Wire 12 24 awg 2 5 0 2mm Strip Length 0 28 7mm Torque Rating 4 5 7 in lbs 0 50 0 78 N m DC is internally connected to I O V but is isolated from CAN V A Class 2 power supply must be used ...

Page 26: ...o 1 which will display the Main Menu Then use the and Up Arrow or Down Arrow keys to select a Main Menu item and press Enter Return Arrow to display the item s Sub Menu Figure 5 1 System Menu Table 5 1 OCS LEDs RUN OFF indicates OCS is in IDLE STOP mode Flashing indicates DO IO mode or RUN with no ladder program ON indicates ladder code running OK OFF indicates one or more self tests failed ON ind...

Page 27: ...ghlighted System Setting If Enter is pressed the System Setting s value will be highlighted indicating that it is ready to be modified When modifying a System Setting s value use either the arrow keys or the numeric keys or the appropriate touch screen icons to select a new value The arrow keys are used to edit System Settings that have just a few possible values Each time the arrow key is pressed...

Page 28: ...OK Logic Error Ok User Program Ok User Graphics Ok W Dog Trips 0 Net Errors 0 Network State Ok Network ID Ok Dup Net ID Ok Clock Error Ok I O System Ok Battery Ok Slot 1 I O Xex06 Slot 2 I O Empty Slot 3 I O ETN300 MJ1 None Loaded MJ2 None Loaded COM None Loaded MJ3 None Loaded Fkeys Momentary SYS Fn enable Yes Use to adjust Dflt Pgm Port MJ1 232 MJ2 RS485 Bias No MJ3 RS485 Bias No Use to adjust T...

Page 29: ... be unique on network CAN Baud 125kB 125kBd CAN network 250kB 250kBd CAN network 500kB 500kBd CAN network 1MB 1MBd CAN network MAC ID Displays the Ethernet MAC ID of the unit IP Displays the Ethernet IP address of the unit NetM Displays the Ethernet net mask of the unit GatWy Displays the Ethernet gateway of the unit NOTE The IP address Net Mask and Gateway can be changed from the System Menu This...

Page 30: ...e x Number of bytes in application ladder program Config Size x Number of bytes in application I O configuration Graphics Size x Number of bytes in application graphic screens String Size x Number of bytes in application string table Bitmap Size x Number of bytes in application bitmaps Text Tbl Size x Number of bytes in application text tables Font Tbl Size x Number of bytes in application font ta...

Page 31: ...aphics Ok Application graphics objects loaded successfully Fault Application graphics objects not loaded or load failed W Dog Trips 0 Watchdog timer has not tripped since the last power up x Number of times watchdog timer has tripped Net Errors 0 No CAN network bus off errors have occurred x Number of CAN network bus off errors that have occurred Network State Ok At least one other node was found ...

Page 32: ... following information Waiting The charging system is waiting for voltages and temperatures to stabilize Battery Charging The battery is charging Battery Full Shows at the end of a charge cycle Remains in this state until the battery is steadily discharging Battery Discharging The battery is steadily discharging ...

Page 33: ...e installed but an I O module is configured Slot 1 I O XExyy yy I O module installed but no I O module configured Slot 1 I O XExyy yy I O module installed but another I O module configured Slot 1 I O XExyy yy I O module installed and configured properly Depending on the COM module that is installed and the COM module that has been configured by Cscape one of the following six System Settings appea...

Page 34: ... Communication Protocols both the MJ1 MJ2 Port 1 and MJ3 Port 2 serial ports support downloadable protocols To assign a downloadable protocol to an EXL6 OCS serial port select the Protocol Config item in Cscape s Program menu and then set up a protocol for Port 1 or Port 2 or both In the View Protocols Sub Menu the currently downloaded protocol if any and its version number are displayed for each ...

Page 35: ...enu displays two System Settings both of which may be edited Fkeys Momentary K1 5 bits go On Off as F1 F5 are pressed released Toggle K1 5 bits toggle each time F1 F4 are pressed SYS_Fn enable Yes Reset and all clear system functions enabled No Reset and all clear system functions disabled ...

Page 36: ...ting only MJ1 232 can be selected unless a Modem XMC COM module is installed Dflt Pgm Port MJ1 232 MJ1 RS232 port is the default programming port Modem Modem COM module is the default programming port MJ2 RS485 Bias No MJ2 RS485 bias resistors are not switched in Yes MJ2 RS485 bias resistors are switched in MJ3 RS485 Bias No MJ3 R5485 bias resistors are not switched in Yes MJ3 R5485 bias resistors...

Page 37: ... data networks Daylight Saving Time Time as adjusted to achieve longer evening daylight especially in summer by setting the clocks an hour ahead of the standard time Apply Daylight Saving DST Daylight Saving Time DST is the practice of setting the clocks forward one hour from standard time during the summer months and back again in the fall in order to make better use of natural daylight Selecting...

Page 38: ...an be written to accomplish an automatic switchover using system register SR211 In program logic move a 1 INT into SR211 to enable Daylight Saving Time Move a 0 INT into SR211 to disable Daylight Saving Time Trigger the move to SR211 based on a compare function to the RTC date according to daylight saving practices in your desired region To Set Local Time The Set Time Date sub menu displays three ...

Page 39: ..._EXL6_UserManual March 12 2020 39 191 5 12 Set Beeper The Set Beeper Sub Menu displays one System Setting which may be edited Beeper enable Yes default Enables beeper No Disables beeper does NOT affect ladder access ...

Page 40: ...screen saver Timeout min 5 1200 Amount of time in minutes to expire with NO touch activity before activating screen saver black screen Popup Status Off default Disable popup status Warning Display popup status only if controller status changes to NOT Ok or NOT Run mode On Display popup status on any controller status change Update Time mS 2 50 Maximum amount of time to allow for graphics update pe...

Page 41: ...ighting dot dot and pressing Enter will move up one directory Media Directory No Card Media Directory Dir Empty Media Directory Initializing No microSD card has been installed in the Memory slot microSD card is installed but it is still initializing microSD card is installed and initialized but contains no files Shows size of highlighted file or shows DIR if directory is highlighted Shows the date...

Page 42: ...M or Application Flash corruption due to for example an excessive EMI event Selecting Fail Safe System menu will open the following menu screen Selecting Backup Restore Data displays the following screen in Backup Copies battery backed RAM contents on to the onboard flash memory of the OCS Restore Copies the backed up data from onboard flash memory to the battery backed RAM Clear Backup The backup...

Page 43: ...91 5 16 AutoRun Enable AutoRun displays the following options which can be selected Enable AutoRun No OCS will be in IDLE mode after AutoLoad or Automatic Restore Yes OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore ...

Page 44: ...le AutoLoad displays the following options which can be selected Enable AutoLoad No Does not load AUTOLOAD PGM automatically when application program is absent or corrupted Yes Loads AUTOLOAD PGM file automatically from RM when application program is absent or corrupted ...

Page 45: ...t same model This feature can be used when Replacing an OCS by another unit of the same model Duplicating or clone units without a PC Clone Selecting Clone Unit menu will open the following menu screen NOTE Free Total displays number of free and total bytes in Removable Media Selecting Make Clone brings up the confirmation screen Upon confirmation the OCS will create two new files in the root dire...

Page 46: ...anual March 12 2020 46 191 5 19 Load Clone Selecting Clone Unit menu will open the following menu screen Select Load Clone NOTE For security enabled files Load clone asks for password validation before loading the application ...

Page 47: ...bMI license The information can also be viewed from Cscape using the following SR registers SR209 3 WebMI server status SR209 4 WebMI user logged in status SR209 8 to SR209 16 Number of Users SR218 Number of Webpages SR219 Number of Data Points SR220 222 Expiry Date of WebMI License Table 5 3 System Registers with WebMI Registers ...

Page 48: ...ring out the function keys then press and hold the SYSTEM key for longer than five 5 seconds and a menu with several advanced functions will appear Select TOUCH CALIBRATION to calibrate the touch screen For best results in screen calibration use a stylus with a plastic tip When the crosshair appears touch the center of the crosshair as exactly as possible and release A small should appear and will...

Page 49: ...nalog Output 16 bit output registers used to send analog information such a voltages levels or speed settings to an attached device D Display Bit These are digital flags used to control the displaying of screens on a unit which has the ability to display a screen If the bit is SET the screen is displayed I Digital Input Single bit input registers Typically an external switch is connected to the re...

Page 50: ... Excludes RCC Units 0 to 1023 Read Write Read Write SR2 ALRM_SCR Alarm Screen Number 0 none Excludes RCC Units 0 to 1023 Read Only Read Only SR3 SYS_SCR System Screen Number 1 Main System Menu 2 Set Network ID Network Status SR29 3 Set Network Baud SR30 4 Set Contrast SR32 5 View OCS Status 6 View OCS Diagnostics 7 View I O Slots 8 Set Function Key Mode SR33 9 Set Serial Ports SR34 10 Set Time Dat...

Page 51: ...ead Only Read Only SR9 TCH_PRESSURE Current Touch Pressure 0 to 3000 Read Only Read Only SR10 TCH_PRESSURE _TSH Threshold Touch Pressure 0 to 3000 Read Write Read Write SR11 12 Ladder Size 32 Bit DINT Read Only Read Only SR13 14 User Text Screen Size 32 Bit DINT Excludes RCC Units Read Only Read Only SR15 16 System Text Screen Size 32 Bit DINT Excludes RCC Units Read Only Read Only SR17 18 I O Con...

Page 52: ...rtical Pixel Count Excludes RCC Units Read Only Read Only SR42 Horizontal Pixel Count Excludes RCC Units Read Only Read Only SR43 Keypad Type Excludes RCC Units Read Only Read Only SR44 RTC_SEC Real Time Clock Second 0 to 59 Read Only Read Only SR45 RTC_MIN Real Time Clock Minute 0 to 59 Read Only Read Only SR46 RTC_HOUR Real Time Clock Hour 0 to 23 Read Only Read Only SR47 RTC_DATE Real Time Cloc...

Page 53: ...xcludes RCC Units SR57 LCD Backlight Dimmer Register 0 100 0 to 100 On 100 255 100 On Excludes RCC Units 0 to 255 Read Write Read Write 57 16 Temporarily disable Screen Saver Excludes RCC Units Read Write Read Write SR58 USER_LEDS User LEDs Read Write Read Write SR59 Engine Build Number Only last three numbers displayed Read Only Read Only SR60 Build Option Build Test 0 Build Beta 1 Build Product ...

Page 54: ...imeout Read Only Read Only SR138 148 Reserved SR149 150 Free running 10kHz count 1 count 0 1ms 32 Bit DINT Read Only Read Only SR151 Reserved SR152 RS 485 Termination Read Write Read Write SR152 1 MJ2 Termination Enable Excludes RCC972 Read Write Read Write SR152 2 MJ3 Termination Enable XL Only RS485 Termination Enable X4 X7 Only Read Write Read Write SR152 3 MJ1 Termination Enable XL XLE XLT RCC...

Page 55: ...SR164 15 to 1 Set to 0 to abort restore operation RCC Units Only Read Write Read Write SR164 15 Set to 1 for manual restore of data Set to 0 to complete the restore operation RCC Units Only Read Write Read Write SR165 166 Reserved SR167 Screen Update Time Default 5 X4 X7 Only Default 10 2 to 50 Read Write Read Write SR168 170 Reserved SR171 X Coordinate Touched Read Only Read Only SR172 Y Coordina...

Page 56: ...is temporary test Read Only Read Only SR193 4 TRUE during last scan of switched from program Read Only Read Only SR193 5 TRUE during first scan of switched to program Read Only Read Only SR193 6 TRUE to revert to FLASH and delete all RAM FALSE when complete Read Only Read Only SR193 9 TRUE if error in temporary program Read Only Read Only SR194 Battery Charge Temp Low XL Only Frequency in MHz Read...

Page 57: ...0 If daylight saving is enabled one hour will be added to the local time Read Write Read Write SR212 UTC Seconds Read Only Read Only SR213 UTC Minutes Read Only Read Only SR214 UTC Hours Read Only Read Only SR215 UTC Date Read Only Read Only SR216 UTC Month Read Only Read Only SR217 UTC Year Read Only Read Only SR218 Number of Webpages license detail XLE XLT X2 X4 X7 use SR101 SR108 112 for WebMI ...

Page 58: ...PWM Table Below Q1 Q6 Unused Digital Outputs Q7 Q12 Unused Reserved Digital Outputs Q13 Q16 Unused Reserved Digital Outputs Reserved Q17 Q20 Unused HSC Table Below Q21 Q24 Unused Reserved AI1 AI2 Unused HSC Table Below AI33 AI38 Unused Analog Inputs AQ1 AQ8 Unused PWM Table Below AQ9 AQ10 Unused Analog Outputs Unused These registers can be used as general purpose registers Electronic Short Circuit...

Page 59: ...Accumulator Quad 2 Acc AI11 12 HSC4 function Accumulator AQ1 2 HSC1 Preset AQ3 4 HSC2 Preset Q17 Clear HSC1 Clear Quad 1 Q18 Clear HSC2 Set Quad 1 Q19 Clear HSC3 Clear Quad 2 Q20 Clear HSC4 Set Quad 2 6 4 Resource Limits Table 6 7 Resource Limits Resource Value Resource Value S 13 Ethernet CsCAN Ping EGD SRTP Modbus TCP Master Downloadable Protocol Slave Ethernet IP FTP or HTTP 10MBd or 100MBd SR ...

Page 60: ...nt status of the pass through Connector Local xx indicates the Network ID of the OCS to which the Cscape program is physically connected through its serial port It can serve as a pass through device to other nodes on the network Target yy R indicates the Network ID of the device with which the Cscape program is exchanging data NOTE The Local unit and Target unit can be the same unit or they can be...

Page 61: ...port on the OCS only on select models to an open USB port on the PC A cable for doing this is included in the HE XCK and HE CPK programming kits The OCS will install as a device once plugged in Drivers for it are normally found automatically by the Windows operating system as long as an Internet connection is established Otherwise the drivers may be loaded from the HE XEC Ethernet Utility HTTP Web...

Page 62: ...2 191 The PC will detect a new device has been plugged into the USB port Now that the EXL6 is plugged in go to Cscape Controller Connection Wizard If you are just opening Cscape Connection Wizard usually opens by default Select USB and click Next ...

Page 63: ...t time we suggest connecting via USB Figure 7 3 Cscape Connection Wizard Screenshots If Controller USB COM Port is not present in the dropdown list the Windows operating system has not yet recognized the OCS as an installed device Be sure the installation process is complete and that the correct drivers are installed The Connection Wizard must be completely closed and reopened to refresh the USB d...

Page 64: ...nection method in Add Target Figure 7 4 Cscape Alternative Connection Method Screenshot Figure 7 5 Add Target Screenshot in Cscape NOTE The following fields Target Name Connection Medium Connected Device and Connection Settings need to be filled for communication configuration if Cscape Connection Wizard was not used Table 7 1 below explains the information needed in each field ...

Page 65: ...Select this option to communicate over CAN This option requires additional hardware to be installed with the PC to be able to do so Select the type of hardware installed from the dropdown Installed Modem Select this option to communicate to the device through the internal modem of the computer Cscape will automatically detect the internal modem attached with PC and list in the attached drop down U...

Page 66: ...e Target ID allows directing communications to a particular unit when multiple units are connected via a CsCAN network Units without CsCAN network ports respond to any network ID and do not require the ID to be configured To check or change the ID on the EXL6 OCS press the System Menu key The first item in the menu is Set Networks Pressing Enter allows the ID of the unit to be viewed or modified T...

Page 67: ... the controller Target yy R as shown in the status section above If the controller is not communicating it may be required to set the target ID of the controller in Cscape or on the unit The Target ID allows directing communications to a particular unit when multiple units are connected via a CsCAN network Units without CsCAN network ports respond to any network ID and do not require the ID to be ...

Page 68: ...e configuration dialog go to IP Address field enter unused IP Address and configure unused registers in Register field then click OK Screenshot for the same as follows Figure 7 6 LAN1 Configuration Dialog Download the configuration in to Controller Connect LAN cable to the Controller in default LAN Port From Cscape go to Tools Editor Options Communication Port Hardware Configure Select Ethernet an...

Page 69: ...N from the type drop down box 5 Once the type of EXL6 OCS is selected the model drop down box will provide the EXL6 OCS model numbers from which to choose from 6 Once the EXL6 OCS CPU is selected press OK to exit the dialog and configure the I O that is present in the first slot 7 The Hardware Configure dialog Specifically the Module Setup tab provides four 4 buttons to configure all of the I O Go...

Page 70: ...MAN1032 10 EN_EXL6_UserManual March 12 2020 70 191 To access the I O Setup Screen select Config from the Hardware Configuration Local I O dialog Then select the Module Setup tab see screenshot below ...

Page 71: ...gative logic It is important that this setting match what the jumper settings are on the hardware The High Speed Counters group box contains all of the windows that are used for configuring the four 4 available high speed counters on the EXL6 OCS In configuring a counter the user needs to set the type mode and counts per rev The type drop down includes the following options Disabled Totalizer Freq...

Page 72: ...low the user to specify how the PWM outputs behave when the controller is stopped These items can either hold their value or default to some value when the controller is stopped NOTE The PWM outputs are set to the OFF state at power up and during program download and remain in that state until the unit is placed in RUN The Output State On Controller Stop group box contains items to allow the user ...

Page 73: ...hannels are outlined below Table 7 2 Analog In for Models 5 6 Model 5 Model 6 Channels 1 2 Channels 1 6 0 10V 0 10V 0 20mA 0 20mA 4 20mA 4 20mA 100mV Disable PT100 DIN RTD 1 20 C 0 60mV Type J Thermocouple 1 20 C PT100 DIN RTD 1 20 C Type K Thermocouple 1 20 C PT1000 DIN RTD 1 20 C Type N Thermocouple 1 20 C Type J Thermocouple 1 20 C Type T Thermocouple 1 20 C Type K Thermocouple 1 20 C Type E Th...

Page 74: ...he Output value on Stop group box contains items that allow the user to specify how the analog output channels behave when the controller is stopped The outputs can either hold their value or default to a value when the controller is stopped The Output Mode group box allows the user to select the operating modes for each of the analog outputs The modes include the following 0 10V 0 20mA 4 20mA Dis...

Page 75: ...perly For the register mapping of the I O refer to the Index at the end of this manual for the pages referencing register mapping 8 2 Removing the EXL6 OCS I O Cover Some I O configurations require jumper settings to be changed in the EXL6 OCS unit Examples of these settings are setting positive or negative logic on digital inputs or setting current or voltage on analog inputs Each EXL6 OCS I O ju...

Page 76: ...scription of the jumper settings Figure 8 3 Example Jumper Diagram To re install the cover place the I O cover back on the unit Place the screw back into the hole and turn the screw slowly counterclockwise until it clicks into the threads This prevents the screw from being cross threaded Now turn the screw clockwise until the cover is firmly secured Repeat this process for all four 4 screws Ensure...

Page 77: ... HE EXV1E3 HEXT505C113 12 12 4 2 2 HE EXV1E4 HEXT505C114 24 16 4 2 2 HE EXV1E5 HEXT505C115 12 12 4 2 2 2 HE EXV1E6 HEXT505C116 12 12 4 2 6 6 4 Table 8 1 shows the different types of I O included with the various EXL6 OCS models Specific specifications jumper settings and wiring diagrams can be found on the data sheets Descriptions and applications of the different type of I O can be found below Up...

Page 78: ...ation may require external fusing on these outputs The digital outputs in the EXL6 OCS are typically controlled via Q bits in the register mapping Some of the outputs are designed for high speed applications and can be used for PWM or frequency output applications Please see the data sheet and the chapter on High Speed I O for additional information When the controller is stopped the operation of ...

Page 79: ... containing relays often have total current limits based on the ambient temperature of the application Please see the product data sheet for current temperature de rating information for relays Fusing External fusing is generally required to protect the relays devices and wiring from shorts or overloads Figure 8 5 Relay Fusing 001XLE015 0V ON J1 12 24VDC R2 C2 R3 C3 R6 C6 R4 C4 R5 C5 R1 C1 H4 H2 H...

Page 80: ... the EXL6 OCS are designed for low voltage DC inputs The inputs are designed to support both positive and negative input modes The mode is set by a jumper setting and a configuration parameter in Cscape All the inputs on the unit must be configured to the same mode Figure 8 6 Positive and Negative Inputs In positive logic mode a positive voltage applied to the input will turn the input The interna...

Page 81: ...will respond more slowly to sudden changes in the actual input 8 8 Universal Analog Inputs Model 5 NOTE See the data sheet for the EXL6 OCS model being used for jumper settings and see the appropriate pages in this manual see Index for details on how to use Cscape to configure the digital filtering The universal analog inputs provide a high resolution very flexible interface for a variety of analo...

Page 82: ...that they are configurable through the module configuration instead of having to change jumper settings in order to setup the input type To configure the Universal Analog input type 1 Select Analog In to access the Analog Input Configuration menu 2 Select any of the Analog input types from the dropdowns by clicking the down arrow beneath each corresponding Channel as seen below Figure 8 7 Analog I...

Page 83: ...ide high resolution voltage or current outputs The voltage or current selection is controlled with jumpers and configuration settings in Cscape NOTE Each channel can be separately configured for voltage or current mode When the controller is stopped the operation of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermin...

Page 84: ...ity refer to the associated model s Specification Installation sheet Digital DC Input Output sections The OCS contains a Field Programmable Gate Array FPGA which is an integrated configurable circuit that allows the EXL6 to be programmed to have either two high speed counters or four high speed counters The EXL6 ships with two high speed counters but a customer can contact Horner Technical Support...

Page 85: ...as a data input a clock input and an output When the clock input is active data on the input is latched or stored and transferred to the output register either immediately or when the clock input goes inactive The output retains its value until the clock goes active again Marker Input into the OCS that indicates a particular position Typically an encoder has a marker output that represents a speci...

Page 86: ... 5 Totalize In totalize mode the accumulator is simply incremented or decremented each time the input transitions in a specific direction The totalizer supports the following modes Internal This mode ties the input to the counter to an internal 10MHz or 1MHz clock The special functions can be used to accurately time events Count Up This increments the accumulator when the input is enabled NOTE Two...

Page 87: ... signals specify the type as Totalize Reset NOTE The corresponding Totalize HSC must be previously configured before this option is available The direct digital reset controls are edge sensitive with the edge polarity configurable Maximum direct digital reset latency is 100μs The totalize function also supports an option which compares the current accumulator value with a supplied Preset Value PV ...

Page 88: ...the last sampled value In this mode the Disable and Latch special functions are allowed Refer to the HSC Glossary for more details Width High 1μs Counts In this sub mode the accumulator value will contain the number of 1μs counts the pulse is high Width Low 1μs Counts In this sub mode the accumulator value will contain the number of 1μs counts the pulse is low Figures 10 1 10 2 Pulse Width Measure...

Page 89: ...ed Refer to the HSC Glossary for more details Period Rising Edges 1μs Counts In this sub mode the period of the input signal is reported in one 1 μs units The period measurement will start on the rising edge of the input Period Falling Edges 1μs Counts In this sub mode the period of the input signal is reported in one 1 μs units The period measurement will start on the falling edge of the input Fi...

Page 90: ...output form it uses or try both modes to determine if the encoder counts up when expected Figure 10 5 Quadrature Using the above waveforms and a HSC input configuration of Quadrature 1 leads 2 count up the accumulator will count up when 1 is rising and 2 is low 1 is high and 2 is rising 1 is falling and 2 is high and when 1 is low and 2 is falling This results in 4 counts per revolution In order t...

Page 91: ...nters 1 and 2 3 The High Speed Outputs are Q1 for Counter 1 and Q2 for Counter 2 They operate as high speed outputs independent of the controller scan rate when configured as HSC Output in the Digital Out PWM configuration in Cscape 4 The High Speed Output state reflects in the status register High Speed Out e g I1603 for Counter 1 the update speed of the status bit is scan rate dependent 5 The Hi...

Page 92: ...s active it takes the current value of the Accumulator and moves it into the Latch Value register Preload When the pre load function is active it will take the value from the Preload register and put it into the Accumulator for the corresponding Counter Clear When the clear function is active it will move a value of 0 into the Accumulator for the corresponding counter Marker When the marker functi...

Page 93: ...his bit can also be reset with the Output Reset Bit NOTE For the Overflow and Underflow flag registers if using some sort of counter that counts both up and down going over the threshold to go negative triggers the underflow and then going back over the threshold back into positive numbers will trigger the positive register to go active High Speed Out This register will follow the high speed outpu...

Page 94: ...1 412 Match2 Counter 2 AQ413 424 Reserved Q1601 Latch Counter 1 Q1602 Preload Counter 1 Q1603 Clear Counter 1 Q1604 Disable Counter 1 Q1605 Direction C 1 Q1606 Output Reset Counter 1 Q1607 Preload Disable Counter 1 Q1608 Latch Disable Counter 1 Q1609 Disable Marker C1 Q1610 Latch Marker C1 Q1611 Preload Marker C1 Q1612 Clear Marker C1 Q1613 1616 Reserved Q1617 Latch Counter 2 Q1618 Preload Counter...

Page 95: ...unter 3 AQ415 416 Match1 Counter 3 AQ417 418 Match2 Counter 3 AQ419 420 Preload Counter 4 AQ421 422 Match1 Counter 4 AQ421 424 Match2 Counter 4 Q1601 Latch Counter 1 Q1602 Preload Counter 1 Q1603 Clear Counter 1 Q1604 Disable Counter 1 Q1605 Direction C1 Q1606 Output Reset Counter 1 Q1607 Preload Disable Counter 1 Q1608 Latch Disable Counter 1 Q1609 1616 Reserved Q1617 Latch Counter 2 Q1618 Preloa...

Page 96: ...ounter 4 Q1657 1664 Reserved I1601 Overflow Flag Counter 1 I1602 Underflow Flag Counter 1 I1603 High Speed Out 1 I1604 Reserved I1605 Overflow Flag Counter 2 I1606 Underflow Flag Counter 2 I1607 High Speed Out 2 I1608 Reserved I1609 Overflow flag Counter 3 I1610 Underflow flag Counter 3 I1611 High Speed Out 3 I1612 Reserved I1613 Overflow flag Counter 4 I1614 Underflow flag Counter 4 I1615 High Sp...

Page 97: ...drives that respective output Both PWM channels may be individually enabled and can have independent frequency and duty cycles The PWMs require two parameters AQs to be set for operation These parameters may be set at run time Duty Cycle The Duty Cycle is a 32 bit value from 0 to 32 000 indicating the relative duty cycle of the output For example a value of 8000 would indicate a 25 duty cycle a va...

Page 98: ...ts Specifying zero for either the period or duty causes the PWM output to remain low during stop mode NOTE For standard I O models 1E3 1E4 1E5 and 1E6 the maximum recommended PWM frequency is 10kHz due to the limitations of built in output circuitry The HE XHSQ generates 24V pulse outputs with a recommended max of 400kHz The HE XHSQ 5 generates 5V pulse outputs with a recommended max of 1MHz The a...

Page 99: ...per second Sets the frequency for the last cycle during the acceleration phase the consistent frequency during the run phase and the frequency of the first cycle during the deceleration mode The Run Frequency must be greater than 0 and must not exceed 5000Hz standard 400 000Hz HE XHSQ or 1 0 MHz HE XHSQ 5 Acceleration Count Sets the number of cycles to occur within the acceleration phase The frequ...

Page 100: ...t start command if the error was corrected Table 10 7 Boolean Registers The stepper requires one discrete register to control the stepper action Setting this register starts the stepper cycle This register must remain set to complete the entire cycle Clearing this register before the cycle is complete aborts the step sequence and sets the error bit NOTE Setting the PLC mode to stop while the stepp...

Page 101: ...er 2 AQ433 434 PWM 2 Frequency Run Frequency Stepper 2 AQ435 436 Acceleration Count Stepper 2 AQ437 438 Run Count Stepper 2 AQ439 440 Deceleration Count Stepper 2 Q1 Start Move Bit Stepper 1 Q2 Start Move Bit Stepper 2 I1617 Ready Done Stepper 1 I1618 Error Stepper 1 I1619 Ready Done Stepper 2 I1620 Error Stepper 2 Table 10 9 PWM Functions Register Map Four Counter Register PWM Stepper AQ451 452 P...

Page 102: ...y To get a 50 Duty Cycle on PW1 and 90 Duty Cycle on PWM2 1kHz waveform Set AQ421 422 16 000 Set AQ431 432 28 800 duty cycle 32000 0 9 Set AQ423 424 1 000 Set AQ433 434 1 000 Example 3 Duty Cycle Frequency To turn PWM 1 output ON all the time Set AQ421 422 32 000 Set AQ423 424 Any Value Example 4 Duty Cycle Frequency To turn PWM 1 output OFF all the time Set AQ421 422 0 Set AQ423 424 Any Value Tab...

Page 103: ...eps Finally during the last 1 000 000 steps it slows to a stop Example 3 Start Frequency Run Frequency Accel Count Run Count Decel Count 6 000 000 steps control sequence Set AQ421 50Hz Set AQ422 250Hz Set AQ423 4 150 000 Steps Set AQ425 6 5 500 000 Steps Set AQ427 8 350 000 Steps When the start bit is energized the following example starts at 50Hz and ramps up to 250Hz during the first 150 000 ste...

Page 104: ...s available Input signal is filtered based on the filter frequency and Number of samples selected User has to select Filter Frequency and Number of samples based on the frequency of the Input signal Filter Frequency To set the filter choose a value that is 4 Number of Samples Expected Max Hz on the high speed inputs Number of samples The input must be stable for this many samples before the HSC ac...

Page 105: ...1MHz Number of samples 4 If user selects filter frequency as 1MHz and Number of samples as 4 then Input signal is sampled for 4 samples and if the signal is stable for 4 samples i e 4μs then the signal is passed to Accumulator If the Input state is changed in between the sampling counts then the count is reset and the Input state is again checked for given number of samples Refer to Dotted lines i...

Page 106: ...MAN1032 10 EN_EXL6_UserManual March 12 2020 106 191 Figure 3 Input signal before filtering Figure 4 Input signal after filtering This delay will be 4μs ...

Page 107: ...ange protocols The second 8 pin modular RJ45 connector which is labeled MJ3 provides a multiplexed serial port which can be configured for either RS232 or RS485 MJ3 can be optionally set for OCS programming via the System Menu for connection to the COM port of a PC running Cscape 11 2 Port Descriptions The MJ1 serial port contains an RS232 interface with RTS CTS handshaking The MJ2 serial port con...

Page 108: ...85 Biasing RS485 biasing passively asserts a line idle state when no device is actively transmitting which is useful for multi drop RS485 networking Both the MJ2 and MJ3 serial ports allow internal bias resistors to be switched in pulling pin 1 up to 3 3V and pulling pin 2 down to ground The Set Serial Ports item in the System Menu can be used to enable RS485 biasing Also an application graphics s...

Page 109: ...otocols In addition external modems can be connected and accessed using Init and Dial and Answer Modem function blocks 11 8 Configuration via Mini B USB NOTE The unit must be connected via the mini USB port to the PC or laptop It is possible to load the program and monitor data via the Mini B USB To load via Mini B USB configure the communications port in Cscape as follows Select Tools from the to...

Page 110: ... OCS controllers over the CsCAN network Also the CAN port supports CsCAN CANopen J1939 and DeviceNet Master layer 3 as a selectable option 12 2 Port Description The EXL6 OCS CAN ports implement the ISO 11898 2 physical layer and the CAN 2 0A data link layer standards Also since the CAN ports are powered by an internal isolated power supply external CAN power is not required NOTE The CAN port does ...

Page 111: ...scape to access all EXL6 OCS and OCS RCS devices that are attached to the CAN port network 12 5 Ladder Controlled CAN Communication Using Put and Get Network Words function blocks the CAN port can exchange digital and analog global data with other EXL6 OCS or OCS RCS devices nodes attached to the CAN port network In addition Put and Get Network Heartbeat function blocks allow nodes on the CAN port...

Page 112: ...Modbus over Ethernet Ethernet IP ODVA CIP over Ethernet FTP File Server File Transfer Protocol ASCII over TCP IP ASCII Data over Ethernet NTP Protocol Network Time Protocol Obtain clock from web based server HTTP Web Server Hypertext Transfer Protocol Web Server 13 2 Ethernet System Requirements Full Ethernet functionality requires PC running Cscape Programming Software Version 9 3 SP6 or later fo...

Page 113: ...ol used To configure the Ethernet Module use Cscape Programming Software to perform the following steps 1 On the main Cscape screen select the Controller Hardware Configuration sub menu to open the Hardware Configuration dialog Figure 7 1 2 If configuring a different OCS Model than the one shown in the Hardware Configuration dialog click on the topmost Config button select the desired OCS Model an...

Page 114: ...2 10 EN_EXL6_UserManual March 12 2020 114 191 3 Click the Config button to the right of LAN1 revealing the Ethernet Module Configuration dialog as shown in Figure 7 2 Figure 13 2 Ethernet Module Configuration ...

Page 115: ...ister Enter an OCS Register reference such as R100 to indicate which 16 bit OCS register will have the Ethernet Status word written to it Table 7 3 shows how this register value is formatted and explains the meaning of each bit in the Status Word Table 13 3 Ethernet Status Word Register Format High Byte Low Byte Bit 16 Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8 Bit 7 Bit 6 Bit 5 Bit 4 B...

Page 116: ...g the value in the Default Settings in this window Register The configuration for the IP Address Net Mask or the Gateway will be assigned using the values in the registers assigned NOTE While assigning registers to IP address Net Mask Gateway Status and Version are optional it is highly recommended to assign registers to these fields for the purpose of troubleshooting NOTE The low octet of the IP ...

Page 117: ... any edits made from System Menu Set Networks is not retained through a power cycle After power cycle the unit reverts to the last downloaded Cscape LAN Config that was loaded into non volatile RAM at power down Cscape LAN Config Get Settings from Register When Get settings from is set to Register the IP parameters are retrieved from the OCS registers assigned in LAN Config Configured registers mu...

Page 118: ...s part of a Cscape application by selecting it from a list of installed protocol device drivers and attaching it to the desired serial port Program Protocol Config menu Only one protocol device driver can be associated with a serial port though some OCS models support multiple protocols on a single Ethernet port Once the protocol is selected for a specific port that port must be configured to matc...

Page 119: ...anges from one ladder scan to another In this case the new OCS value is written to the target device For triggered operations only a Read or Write action is available When downloaded to the OCS the Scan List is scanned sequentially to generate data transactions with the remote device This transaction scanning can be on a continual basis automatic or controlled from ladder logic manual once a compl...

Page 120: ...layed in the dropdown selection Some OCS models can be limited in the number of ports or number of protocol device drivers that can be selected Once a protocol is selected the Network Devices and Data Scan List must be configured through corresponding dialogs accessible through the respective buttons Network Device and Scan List Figure 14 1 Protocol Config Dialog Three fields must be configured af...

Page 121: ... 3 Network Configuration Network Configuration provides the required parameters to configure the network Each protocol is different and may not require all the Network Config field Please refer to the table below for the options in the Network Config field ...

Page 122: ...transaction is retried on a failed response Timeout Specifies the amount of time for a device to wait for a valid response Update Scan Automatic Update Interval Specifies the update interval at which all the mapped entries are executed Reacquire Time Specifies the amount of time to wait before attempting communications with an offline device Manual Trigger Specifies the binary register that a sing...

Page 123: ...ocol Config screen and provides a list of the configured devices on the Network Devices must be created and exist in this list before corresponding Scan List entries can be created for this device Typically the number of entries is limited to 64 devices Device Configuration This configuration is reached from the Device List when adding or modifying an existing device ...

Page 124: ...pping entry transaction contains the source and destination registers the number of consecutive registers transferred the direction of the transfer and what triggers the transfer Typically the number of entries is limited to 512 NOTE The order of the Scan List is the order in which the transactions occur Sort functions are provided to change the order of the list Each entry also has an identifying...

Page 125: ... a local register value has changed The write transaction only updates those local registers that have changed in value If several non consecutive local registers contained in a single mapping entry change value between transaction scans it takes several consecutive transaction scans to write each changed register When the OCS is placed in RUN mode the initial action for this mapping type is a rea...

Page 126: ...e OCS This allows registers to be initialized locally before Writing to the target device register s Triggered Read A read transaction is triggered by a high level on a separately designated OCS binary trigger register Once the read transaction is complete or the device is offline the OCS trigger register is cleared by the OCS This update type can be used for occasion data accesses such as retriev...

Page 127: ...ed to the rest of the OCS line This chapter does NOT cover building screens or using the Cscape graphics editor For instructions on creating screens and using the graphics editor refer to the Cscape help file Editing Graphics Based OCS Screens 15 2 Screen Specifications Display Type 5 77 VGA TFT 450 nit typical Resolution 640x480 Color 16 bit 65 536 Screen Memory 17MB User Programmable Screens 102...

Page 128: ...in a depressed 3D appearance when in the ON state Objects that normally accept touch input may be disabled through program control through ladder manipulation of an attribute bit If an object is disabled the object s representation changes to a 2D appearance On objects that represent non discrete information more action may be required beyond that of simply touching the object For example the slid...

Page 129: ... displays the current value with all the digits being highlighted Once the first digit is entered the current value is erased from the display and the new digit is placed in the first location Thereafter no digits are highlighted and new digits are added to the rightmost position while the other digits are shifted left Edit value Mode Edit value mode may be entered from the initial new value mode ...

Page 130: ...r floating point value or a signed value Password Object When editing a password value the arrow keys and the keys are disabled Additionally overwrite mode is disabled When entering digits the pop up keypad hides the value by displaying alternately for each digit ASCII Object When editing an ASCII value an ASCII keypad is displayed as shown Figure 13 2 The ASCII keypad has 3 modes numeric symbols ...

Page 131: ...ifying the object as one that causes a screen change shown below Screen jumps can also be triggered on other keys or based on control logic for more advanced applications To allow the operator to change screens a screen jump object is generally used This object may be visually represented as a button responding to touch or remain invisible and logically tied to an OCS register An optional system I...

Page 132: ...ons or to display other ladder detected events When the text coil is de energized the previous screen that was being viewed before the alarm is returned The switch display coil switches to the associated screen when it is energized Once it is de energized the screen remains until it is switched by the user or ladder Figure 15 4 Force and Switch Coils in Ladder Programming There is also a system re...

Page 133: ... the default touch slip sensitivity allows for a slight slip of the finger on the graphical object before the EXL6 assumes touch has been released equates to approximately a quarter inch of movement with a stylus In some applications such as jog buttons where the operator is pushing a button for a period of time the amount of slip while holding a button pressed may exceed the default sensitivity T...

Page 134: ... the operator should expect The alarm object is generally used to enunciate alarms to the operator While the display characteristics of this object is configurable it is generally displayed as a button that changes colors to indicate the highest state of the alarm s in the alarm group it is monitoring The following indicates the priority of the alarm states and the default colors associated with t...

Page 135: ...dicates the current relative position The current state of the displayed alarm is indicated by its color and optionally by an abbreviated indicator after the date time stamp ALM ACK RTN The operator can acknowledge an alarm by selecting it from the list and touching the ACK button The operator can also clear an alarm if that function is enabled in the alarm object If not enabled the Clear buttons ...

Page 136: ... viewer is displayed as pop up removable media dialog similar to that shown in Figure 13 8 NOTE The removable media object can be configured to open the removable media viewer at a certain directory complete with restrictions on transversing back up the file path This may be used to restrict operator access to non critical files Figure 15 8 Removable media viewer The currently selected entry is in...

Page 137: ...operations are complete simply touch the Esc button to remove the pop up removable media viewer If the removable media is used in an application the removable media device requires changing by the operator and the application is attempting to write to the removable media when it is removed the screen designer should create objects that allow the operator to temporally halt access to the removable ...

Page 138: ... the backlight is otherwise ignored by the EXL6 Any additional touch activity is also ignored by the EXL6 for approximately one second thereafter It is possible for the application to temporarily disable the screen saver by generating a positive transition to SR57 16 coil only at a rate faster than the screen saver timeout value This may be desired while waiting for alarm acknowledgement 15 11 Scr...

Page 139: ...ture Minimum Firmware Version 15 xx or later Minimum OS Version 2 6 35 49 Minimum Cscape Version 9 80 SP1 Figure 15 10 Touch Screen Pressure NOTE Touch creates contact between resistive circuit layers closing a switch With a unique change to the touch monitoring firmware user can measure the pressure being exerted on the touch screen This feature has been added in some Horner XL series controllers...

Page 140: ... to 3000 Zero 0 indicates no pressure and 3000 is the maximum amount of pressure that can be measured SR10 I O Name TCH_PRESSURE_TSH This register sets the pressure threshold to indicate a touch A value of 200 is typically the lightest touch 600 is moderate and 1000 is a heavy touch These new features allow customizing the feel of the touch screen and can be used to add unique user interface featu...

Page 141: ...igger is used to start stop and pause video and the System Register provides the status of the video object which supports various resolutions and frames per second Table 16 1 Features and Specifications of Video Properties Streaming Channels 4 channels supported through USB hub 1 channel can be viewed at a time Playback Formats mp4 mov mpg wmv Resolution 320x240 QVGA Frames per Seconds 10 15 20 2...

Page 142: ... Firmware 14 03 or newer to use with the EXL6 devices In Cscape select the EXL6 and model number by selecting Controller Hardware Configuration from the toolbar 1 Open the Graphics Editor by selecting the T button from the toolbar 2 In Graphic Editor select the video button from the toolbar 3 Then click on the grid ...

Page 143: ...MAN1032 10 EN_EXL6_UserManual March 12 2020 143 191 4 Then double click on the icon in the middle to open the Video Properties dialog ...

Page 144: ...nter Channel Number directly or through registers in the Enter Channel No field Playback This option can be selected to view videos that are stored in Removable Media on the controller Videos present in both A microSD and B USB drives are supported and can be viewed Supported formats including mp4 mov mpg and wmv can be played Select Playback and enter video name in the Enter Target Path field eit...

Page 145: ...s NOTE The least significant bit is Bit 1 Definitions are as follows Bit 1 High Start Low Stop Bit 2 High Pause Low Play System Register The Video Control System Register provides the status of the Video Object The status word is 16 bits and should be viewed in hexadecimal format The status definitions are as follows 0x0001 Video is currently playing 0x0002 Video is paused 0x00010 Channel number c...

Page 146: ...opup window causes Video Object to be inactive 2 Video Object can be made active in both Idle and Run modes 3 If actual Frames Per Second of the configured video is different from the one that is configured in Cscape few frames will be missed when video is played 16 7 Web Cameras If multiple web cameras are directly connected to the EXL6 then only one web cam will be considered If user needs to co...

Page 147: ...called TransFlash Cards labeled either microSD or TransFlash with up to 32GB of Flash memory are compatible with the EXL6 OCS memory card slot larger sizes were not tested at time of publication The memory card slot is equipped with a push in push out connector and a microSD card can be safely inserted into the Memory slot whether the EXL6 OCS power is On or Off To install a microSD card Align its...

Page 148: ...nal dot and an optional extension with up to three 3 characters Directories and sub directories can be nested up to 16 levels deep as long as each pathname string does not exceed 147 characters 17 4 Using the Removable Media Manager The Removable Media Manager is an interactive EXL6 OCS screen that performs the following functions a Display number of total and free K bytes b Browse file and direct...

Page 149: ...o load an application from microSD to the EXL6 OCS use the Removable Media Manager open the Removable Media Manager in the System Menu to find and highlight the desired PGM file and then press the Enter key To save an application from the EXL6 to microSD open the Removable Media Manager in the System Menu and press the Save Pgm function key The application will be saved in a file called DEFAULT PG...

Page 150: ...me To capture an EXL6 OCS screen turning On the assigned Screen Capture Control Register will capture the current EXL6 OCS graphics screen and write it to the microSD card using the assigned Screen Capture Filename To view a captured EXL6 OCS screen use the Removable Media Manager to find and highlight the desired BMP or JPG file and then press Enter 17 8 Configuration of a Removable Media The con...

Page 151: ...M card The data in the file is not changed Table 17 1 RM Functional Blocks 17 10 Removable Media RM Features Program Features a Datalog Configuration This feature allows the controller to periodically log register values to Removable Media The register data is stored in CSC comma separated value format which is compatible with 3rd party PC applications such as Microsoft Excel b Report Editor This ...

Page 152: ...cters a period then a three character extension The entire filename including any path must be less than or equal to 147 characters When creating filenames and directories it is sometimes desirable to include parts of the current date or time There are six special symbols that can be entered into a filename that are replaced by the OCS with current time and date information Table 17 2 Filename Spe...

Page 153: ...nterface SR176 Free Space This 32 bit register shows the free space on the RM card in bytes SR178 Card Capacity This 32 bit register shows the total card capacity in kilobytes Possible status values are shown in the table NOTE For additional status information consult the Cscape Help file Table 17 3 RM Status Values 0 RM interface OK 1 Card present but unknown format 2 No card in slot 3 Card prese...

Page 154: ...efer Removable Media Chapter 9 for details in using RM It can then be used to clone a different OCS exact same model This feature can be used for Replacing an OCS by another unit of the same model Duplicating or clone units without a PC 18 2 Clone User needs to perform the following to Clone 1 The Clone Unit can be accessed by going to the System Menu of the OCS A new menu Clone Unit has been adde...

Page 155: ..._EXL6_UserManual March 12 2020 155 191 2 Selecting Clone Unit menu will open the following menu screen Figure 18 2 Clone Unit Menu before Cloning Free Total displays number of free and total bytes in Removable Media ...

Page 156: ... below for the user Figure 18 3 Clone Unit Confirm Screen After confirmation the OCS will create two new files in the root directory of the Removable Media Drive as shown below AUTOLOAD PGM Application file CLONE DAT File having all unit settings and register values from battery backed RAM Figure 18 4 Clone Unit Files NOTE Make Create clone operation automatically includes the security in AUTOLOAD...

Page 157: ...pleted this bit is made zero by the firmware When Make clone operation is triggered by this SR bit it does not ask the user for confirmation for making clone The success failure of the operation is also not notified on screen to the user In case of failure of Make Clone operation SR164 11 bit is set to 1 by the firmware and never reset NOTE Backup of registers in flash memory is not performed by C...

Page 158: ... battery backed RAM Regardless of AutoLoad settings and then resets the OCS for the settings to take effect User needs to perform the following to Load Clone 1 Select Clone Unit from main System Menu of OCS as shown below Figure 17 6 System Menu 2 Selecting Clone Unit menu will open the following menu screen Select Load Clone Figure 18 7 Clone Unit Menu after Cloning ...

Page 159: ...r security enabled files Load clone asks for password validation before loading the application Load Clone can also be triggered by setting SR164 10 bit to 1 from Ladder program or graphics Once the operation is completed this bit is made zero by the firmware When Load clone operation is triggered by this SR bit it does not ask the user for confirmation for loading clone The success failure of the...

Page 160: ...egister Settings from the values previously backed up in Flash to Battery Backed RAM Detect corrupted Register Settings at power up and then automatically restore them from Flash Detect corrupted or empty application in Flash memory at power up and then automatically load the AUTOLOAD PGM application file from Removable Media Compact Flash or microSD If an automatic Register Restore or Application...

Page 161: ... the Enable AutoLoad option in the device to YES 4 Set the Enable AutoRun option to YES if the controller needs to be placed in RUN mode automatically after automatic restore of data or AutoLoad operation 5 Backup the current Battery Backed RAM Register contents in On Board Flash memory using System Menu options 19 3 Backup Restore Data Selecting this option brings up a screen having four operatio...

Page 162: ...y copy Battery Backed RAM contents on to the onboard FLASH memory of the OCS This will have the effect of backing up all the registers and controller settings Network ID etc that would otherwise be lost due to a battery failure SR164 4 is set to the value of 1 when backup operation is performed Figure 19 3 Backup Registers ...

Page 163: ...restoring data The controller will be placed in IDLE mode Data will be copied from onboard flash memory to OCS Battery Backed RAM The controller will reset The controller will be put in RUN mode if the AutoRun setting is Yes else it will remain in IDLE mode Figure 19 4 Restore OCS Data SR164 3 is set to the value of 1 only when an automatic restore operation is performed not on a manual one This b...

Page 164: ...9 6 Clear Backup Data When initiated the backup data will be erased from the onboard flash memory and no backup will exist SR164 4 and SR164 3 is reset to 0 when backed up data is erased Figure 19 5 Clear Backup Data Exit Goes back to the previous screen ...

Page 165: ...re Figure 19 6 Flow Chart for Automatic Restore OCS Power Cycle Battery Backed RAM Registers check failed Backup exists Controller placed in IDLE mode Data copied from Onboard FLASH to OCS Battery backed RAM Controller Resets AutoRun Enabled OCS put in RUN Mode OCS put in IDLE Mode NO YES YES NO Application Program erased ...

Page 166: ...e program residing in onboard memory is corrupted and a valid AUTOLOAD PGM is available in the removable media of the device AutoLoad can be manually initiated when the SYS F3 key is pressed OCS can be in any of the following mode Idle Run DOIO This also requires a valid AUTOLOAD PGM to be present in the removable media of the device When the AutoLoad setting is not enabled set to NO OCS will be i...

Page 167: ...Flow Chart for AutoLoad Power up OCS Application Program absent or Application Program corrupted AutoLoad Enabled AUTOLOAD PGM present in the RM of the device AutoLoad initiated OCS put in IDLE mode AutoLoad run sequence failed with reasons for failure NO NO YES YES AutoRun Enabled OCS put in RUN Mode OCS put in IDLE Mode NO YES ...

Page 168: ...n be set by putting the system into RUN mode automatically once an AutoLoad has been performed or an Automatic Restore has occurred If for any reason the AutoLoad Run Loading the AUTOLOAD PGM automatically and OCS put in RUN mode sequence does not succeed a pop up message box saying AUTO LOAD RUN SEQUENCE FAILED will be displayed It will also show the reason for its failure On acknowledging this m...

Page 169: ...able to complete the request it returns the appropriate error response Should the slave be unable to respond the master s timeout timer expires to provide an indication of No Response 20 2 Modbus Slave Overview For complete Modbus Slave instructions please refer to the Help file in Cscape The Modbus slave function block when used with the appropriate Modem and or Open function blocks allows the pr...

Page 170: ...figuration details are added in the Devices dialog box This includes Slave ID serial Under Device Type the Modbus addressing style matching that specified in the slave s user documentation may be selected For instance some slaves specify Modbus addresses i e 40 001 and others specify offsets i e 0000 o Hex or Decimal Some specify addresses in hex and others in decimal By allowing the user to selec...

Page 171: ...aditional Modbus Reference column of the Table 20 1 Method 2 The second method requires the Modbus Master to be configured with a specific Modbus Command and Modbus Offset Table 20 1 Modbus Master Mapping EXL6 Reference Maximum Range Trad Modbus Reference 5 Digits Expanded Modbus Ref 6 Digits Modbus Commands Modbus Offset I1 2048 10001 010001 Read Input Status 2 0 IG1 256 13001 013001 3000 S1 256 ...

Page 172: ...emory The clock continues to run on the battery at a much lower power The battery is designed to last well over a year in this state Once power is restored the battery recharges in eight 8 hours or less 21 3 Battery Life The battery is designed to last 300 full charges to 1000 partial charge cycles or 7 to 10 years Because typical operation does not drain the battery the 1000 charge cycles should ...

Page 173: ...ally 10 C to 35 C 21 6 Battery Charging Status Viewed in the System Menu under View Battery Status Table 21 1 Charging State Table Waiting The charging system is waiting for voltages and temperatures to stabilize Battery Charging The battery is charging Battery Full Shows at the end of a charge cycle Remains in this state until the battery is steadily discharging Battery Discharging The battery is...

Page 174: ... Current Firmware Revision To check the firmware revision on a controller open System Menu View Status Warning Firmware updates should only be performed when the equipment being controlled by the EXLW OCS is in a safe non operational state Communication or hardware failures during the firmware update process can cause the controller to behave erratically resulting in injury or equipment damage Mak...

Page 175: ... come as a ZIP file which need to be unzipped and placed in the root of the drive for them to function properly Method B RS232 Serial Connection Serial firmware updates are done from Cscape software to the controller s primary serial port MJ1 in most cases STEP ONE In North America visit https hornerautomation com Then click Support Downloads Controller Firmware and download the most recent firmwa...

Page 176: ... NOTE DO NOT press the Install Firmware option This has the potential to create a scenario where the unit will not boot up If this is pressed by mistake contact Tech Support for the recovery procedure e When Operation Completed appears press OK f Power cycle the OCS controller and wait for it to boot up g Press SYSTEM key select View Status and press the Enter button h Scroll down to see the versi...

Page 177: ... temperatures and humidity can affect battery life If the battery is older than seven 7 to ten 10 years old it is recommended that it be replaced as preventative maintenance NOTE Do not use an alkaline AA battery only the proper battery type listed WARNING DO NOT USE IF BATTERY IS LEAKING OR HAS BEEN DAMAGED WARNING LITHIUM BATTERIES MAY EXPLODE OR CATCH FIRE IF MISTREATED DO NOT RECHARGE DISASSEM...

Page 178: ...er back panel by carefully aligning the four 4 screws into the guide posts If an insert came off be sure to slide it back into the cover before replacing 10 This unit has self tapping screws Once the screws are aligned gently turn the screw counterclockwise until it clicks Then turn the screw clockwise until screw is seated 11 Once the larger back panel is replaced gently replace the I O circuit b...

Page 179: ...shows next to Local then communication is established to the local controller Local No Port Cscape is unable to access the COM port of the PC This could mean that Cscape is configured for a COM port that is not present or that another program has control of the COM port Only one Cscape window can access a port at a time Subsequent instances of Cscape opened will indicate No Port Local No Com Cscap...

Page 180: ...PG offers a USB to serial adapter Part numbers HE XCK and HE CPK 23 1 2 Connecting Troubleshooting Checklist USB Port Mini B Programming 1 Controller must be powered up 2 Ensure that the correct COM port is selected in Cscape Tools Applications Settings Communications 3 Be sure that the USB cable is connected between the PC and controller Check the Windows Device Manager to find out if the USB dri...

Page 181: ...k diagnostics to ensure controller passed self tests View Diags in System Menu or in Cscape click Controller Diagnostics 3 Check data sheets to ensure proper wiring 4 Ensure that hardware jumpers and software configuration for I O match 5 Check data sheets for voltage and current limits 6 Take ladder out of the picture From Cscape set controller to Do I O mode In this mode inputs can be monitored ...

Page 182: ...ould be placed across the CAN_HI and CAN_LO terminals 5 Measure the resistance between CAN_HI and CAN_LO If the network is properly wired and terminated there should be around 60Ω 6 Check for duplicate node ID s 7 Keep proper wires together One twisted pair is for V and V and the other twisted pair is used for CAN_HI and CAN_LO 8 Make sure the baud rate is the same for all controllers on the netwo...

Page 183: ...ile is saved as a pgm file and not a csp file In addition to file must be pgm the file s I O configuration must match the EXL6 configuration for it to download 23 5 Technical Support Contacts For manual updates and assistance contact Technical Support at the following locations North America Tel 317 916 4274 Fax 317 639 4279 Website https hornerautomation com Email techsppt heapg com Europe Tel 35...

Page 184: ...te Rev Description of Revision Location in Doc 3 6 2020 R9 1 Added more Firmware Install Steps per new Firmware Update Manual Mantis 2209 2 Updated Panel Cutout size and tolerance Mantis 2750 Firmware Updates Panel Cutout 4 23 2020 R10 Reordered Chapters Mantis 3029 Throughout ...

Page 185: ...ations Port 63 64 180 Compliance CE 11 Configuration of a Removable Media 150 Configuration via Mini B USB 109 Configured reset value 87 Configuring Video Properties 144 Count 97 99 Csape Program Via Serial Port 109 Cscape 15 33 34 57 60 66 75 78 80 81 83 84 107 109 111 132 148 149 150 179 180 181 Alternative Connection Method Screenshot 64 Analog In Configuration 73 Analog Out Configuration 74 Co...

Page 186: ...ocations of Information 11 Grounding Definition 23 Hardware Configuration Dialog 113 High Speed Configure Inputs 86 Frequency 86 High Speed PWM Overview 84 High Speed Counting 84 HIGH SPEED I O 84 High Speed I O 84 HSC 71 84 86 90 94 97 99 HSC Functions Register Map for 2 HSC configuration 94 HSC Functions Register Map for 4 HSC configuration 95 I O Cover Removal 75 IP Address 115 IP Parameters 11...

Page 187: ...ia Manager Submenu 148 Removable Media XL6 41 Removable Memory Card Slot Photograph 147 Removing the I O Cover 76 RM Additional Configuration 152 Files Names and Function Blocks 152 Function Blocks 151 Graphic Screen Editor 151 Program Features 151 System Registers 153 RS 485 Biasing 108 RS 485 Termination 108 safety compliance 10 Safety Warnings Guidelines 10 Scan List 124 Scan List Entry 125 Scr...

Page 188: ...gramming 180 Troubleshooting Checklist serial port MJ1 Programming 180 Troubleshooting Checklist USB Port Mini B Programming 180 Two Point Ground Connection Test 24 Types of Devices that can be connected to EXL6 14 Typical Output Wiring 78 Universal Analog Inputs 81 USB 15 62 111 180 User Interface Ladder Based Navigation 132 Screen Navigation 131 Using Removable Media to View and Capture Screens ...

Page 189: ...Digital HSC Input Configuration Dialog 71 Figure 07 08 Digital PWM Output Configuration Dialog 72 Figure 07 09 Analog Input Configuration Dialog 73 Figure 07 10 Analog Output Configuration Dialog 74 Figure 08 1 Removing the I O Cover 76 Figure 08 2 EXL6 I O Cover Removed sample I O board 76 Figure 08 3 Example Jumper Diagram 76 Figure 08 4 Typical Output Wiring 78 Figure 08 5 Relay Fusing 79 Figur...

Page 190: ...ure 19 5 Clear Backup Data 164 Figure 19 6 Flow Chart for Automatic Restore 165 Figure 19 7 AutoLoad Menu 166 Figure 19 8 Flow Chart for AutoLoad 167 Figure 19 9 AutoRun Menu 168 Table 03 1 Minimum Clearance Requirements for Panel Box and Door 21 Table 04 1 Primary Power Port Pins 25 Table 05 01 Clock and Time Setting Terms 37 Table 05 02 System Registers for UTC Coordinated Universal Time 37 Tabl...

Page 191: ...rotocols Features 112 Table 13 2 Ethernet Module Specifications 112 Table 13 3 Ethernet Status Word Register Format 115 Table 14 1 Network Protocols 122 Table 15 1 Alpha Numeric Keypad Variations 130 Table 17 1 RM Functional Block 151 Table 17 2 Filename Special Symbols 152 Table 20 1 Modbus Master Mapping 171 Table 21 1 Charging State Table 173 Table 21 2 Battery Status 173 Table 23 1 Cscape Targ...

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