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User Manual for eXL10 OCS

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1. M 26 5 6 Cscape Programming via Serial Port cccccsessscecececessesseaecececscessesaaaececeeseeeseaeaeeeeecesseseaeaeeeesens 26 5 7 Ladder Controlled Serial 26 5 8 Downloadable Serial Communication Protocols 2 26 CHAPTER 6 CAN COMMUNICATIONS 1 stesse sa 27 SOMME SIUS I 27 6 2 Port Descriptio aae uud 27 6 3 lt CAN POPE WINNE iie cedere eese re 27 6 4 Cscape Programming via 28 6 5 Ladder Controlled CAN Communication 2 29 6 6 Using for I O Expansion Network 1 044 2211 nnne entren 29 CHAPTER 7 ETHERNET s enun 30 7 1 Ethernet Module Protocols and 30 7 2 Ethernet System Requirements epe rete etre er esed treten Bee de e 30 7 3 Ethernet Module Specifications ee ee ee ve eee eue vest exe es EUER 30 7 4 Ethernet Module Configuration ssie e e ree er ve rater Gece d ea EE ene 30 CHAPTER 8 COMMUNICATION
2. 82 15 3 1 Communicating via MJ1 Serial 83 Page 8 of 114 HORNER AUTOMATION GROUP exl10 User Manual 15 3 2 Communicating via On Board Ethernet 84 15 5 ConfigutatiODr xiii Lajas edet od 85 15 6 Digital Input HSC Configuration ccccccssccccssccesscecssseecssececseeceeseecsssecesaeeccaeeceseeesseeeesaeeeeaeeesees 85 15 7 Digital Output PWM Configuration essere nnne nennen 86 15 8 Analog Input 2 87 15 9 Analog Output nnnn nass 88 CHAPTER 16 FAIL SAFE SYSTEM 5 05 3c oo paso s ee pao an viss sh ac eeu RR ERU RR RR RSS RA REESE SR 89 MO JUI M 89 OPE dcc E U 89 16 3 Backup Restore cote pa alvei encode 93 164 AutoLogd LP 93 16 5 95 CHAPTER 17 CLONE UNIT 22 55 2222 RRER S NEQU E seseestecaevebtbssesiteeass 96 dE iU 96 pP NES ql
3. nennen nennen tenere nnne 47 11 5 High Speed Output 5 enne 48 71 5 1 NONO 49 11 5 2 sth 49 11 5 3 HSC Output High Speed Counter 52 27 5 Stepper Function sse orbc terr x urgere parre ys tuse eee duo duse 53 11 6 PWM functions register 54 1247 PWM EXAMP 65 54 11 8 STP EXampl8S eir 55 CHAPTER 12 SYSTEM SETTINGS AND ADJUSTMENTS nena sno 56 12 1 System Menu OVerVIeW gt ee eode tee bo e ceo voee ole den egt 56 12 2 System Menu Navigation and 53 12 3 System Menu Details ccccccccccsesssssensececeesesssssasseseceesesssuseesececeesesesusaesesecessesecasanseeeeeeseneaaes 54 12 4 Touchscreen 64 CHAPTER 13 USER INTERFACE 55 5 oo ore sao So ora ai oo rye aa So a Ye ERR oo So Yea RR OD RE eR ANSNES RES 65 sls EE 65 13 2 Displaying and entering 65 13 3 Alpha numeric enee taeae ee kiea ae REN 66 13 4 Screen B FIT Luo TOR
4. 10 Khk Set AQ421 422 16 000 Set AQ423 424 10 000 waveform on PWM1 Example 2 Duty Cycle Frequency 9 To get a 50 Duty Cycle on PW1 16 090 Set AQ423 424 1 000 0 Set AQ431 432 28 800 32000 0 9 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 Set AQ421 422 0 Set AQ423 424 Any Value Page 54 of 114 HORNER AUTOMATION GROUP exl10 User Manual 11 8 STP Examples Example 1 Start Frequency Run Frequency Accel Count Run Count Decel Count 1 0 00 e pe Set AQ421 Set AQ422 Set AQ423 4 Set AQ425 6 Set AQ427 8 2500 Hz 5000 Hz 1 000 000 Steps 8 000 000 Steps 1 0000 000 Steps When the start bit is energized the example starts at 2 5 kHz and ramps up to 5 kHz during the first 1 000 000 steps Then it runs at 5 kHz for the next 8 000 000 steps Finally during the last 1 000 000 steps it slows to a stop Example 2 Start Frequency Run Frequency Accel Count Run Count Decel Count 0 mie pa Set AQ421 Set AQ422 Set AQ423 4 Set AQ425 6 Set AQ427 8 Ee cum 500 Hz 1000 Hz 2 000 000 Steps 2 000 000 Steps 1 000 000 Steps When the start bit is energized the example starts at 0 5 kHz and ramps up
5. 7 Power OCS Application Program absent or Application Program corrupted NO AutoLoad Enabled NO AUTOLOAD PGM present in the RM of the device AutoLoad initiated NO AutoRun OCS put in IDLE mode AutoLoad run sequence failed with reasons for failure v Enabled YES OCS put in RUN Mode OCS put in IDLE Mode Figure 16 8 Flow Chart for AutoLoad Page 97 of 114 HORNER AUTOMATION GROUP exl10 User Manual 16 5 AutoRun This system menu option when enabled YES allows the user to automatically place the OCS into RUN mode after the AutoLoad operation or automatic Restore Data operation When the AutoRun setting is disabled NO the OCS remains in the IDLE mode after a Restore Data or AutoLoad operation SR164 5 can 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 message box the AutoLoad Run sequence will be terminated controller will return to the first user screen and will be placed in IDLE mode System Menu
6. Figure 10 6 Positive amp Negative Inputs ussssessssssesseseeeeeseeeeneee nennen nnne nnns een nnns en nnns Figure 10 7 Analog Input Tranzorb Troubleshooting Figure 11 1 Pulse Width Measurement 14 1 1202 2 2 020 eene 0000000 nnne nennen nennen nnns nennen nn Figure 11 2 Pulse Width Measurement Low Figure 11 3 Period Measurement Rising Edges Figure 11 4 Period Measurement Falling Edges Figure 11 5 Quadrature Figure 11 6 PWM Parameter Duty Cycle m a a os Figure 11 7 PWM Parameter Frequency iiiter reed iem ee PHP LEER EE E E E N E Figure 12 1 System Menu Screenshot 1 Figure 13 1 Example 5 i ER i etc a lest Free erae E Ec sve y ree deed Figure 13 2 Alpha numeric Keypad and ASCII 1 2 411 1 2 040404 20 nennen nnnm nennen nnne nnne Figure 13 3 Typical Screen Jump Object eri re tetendit tede cen he febr de Figure 13 4 Force and Switch Coils in Ladder 02211 eene nnne nenn
7. 96 17 3 Lodd CNE 98 CHAPTER 18 MAINTENANDGE 5 2 2 65s ou sape ERR ra Ie AERA sieas aoa ERR SERM 103 LETTER SEINE 103 18 2 Backup Battety x consed iere tate Tine ee TREE REP ER EROR NER e aan e EUREN TERRE 103 18 2 1 Indications the battery needs replacing 100 CHAPTER 19 TROUBLESHOOTING TECHNICAL 5 106 19 1 Connecting to the 10 106 19 1 1 Connecting Troubleshooting Checklist serial port MJ1 Programming 107 19 1 2 Connecting Troubleshooting Checklist USB Port Mini B Programming 107 19 1 3 Connecting Troubleshooting Checklist ETN port 107 19 2 Local Controller and Local 107 19 2 1 Local I O Troubleshooting Checklist eese eene nnne nennen 108 19 3 CSCAN NetWork 108 19 3 1 Network Troubleshooting Checklist 8 108 19 4 Removable Media iterat tenue dete ka cde Fo aa ede cp 109 19 5 Technical Support Contacts eee ER e e eade nn 10
8. Resource Value Resource Value CsCAN Ping EGD SRTP Modbus TCP Master Downloadable protocol amp Slave ds m emg Ethernet IP FTP or HTTP 10 MBd or 100 MBd SR 448 CsCAN 125 kBd 250 kBd 500 kBd or 1 MBd T 16000 Serial Ports 1 RS232 1 RS485 Ports M 16000 P uu 64 w o repeat 253 w 3 repeaters R 49999 Keypad 5 keys 4 fn keys and a System Key 96K 5 Display 800 x 480 7 TFT 65K colors 96D 1023 Screen Memory 64 MB 961 2048 User Screens 1023 2048 Data Fields Per 1023 User Screen 512 Ladder Code 1024 kB AQ 512 Page 79 of 114 HORNER AUTOMATION GROUP exl10 User Manual NOTES Page 80 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 15 CSCAPE CONFIGURATION 15 1 Overview eXL10 OCS hardware is programmed with a Windows based PC application called Cscape This application can be used to program configure monitor and debug all aspects of the eXL10 OCS unit Please see the on line help provided with Cscape for additional details 15 2 Status Bar When the eXL10 OCS is connected to a PC using Cscape software a Status Bar appears at the bottom of the screen The Cscape Status Bar can be used to determine if communications have been established between the eXL10 OCS and the Cscape program Components of the Cscape Status Bar are explained below Message Line Equal Indicator indicates whether the current program in Cscape is equal to the program T
9. Figure 15 2 USB Programming Connector The PC will detect a new device has been plugged into the USB port Page 82 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual Found New Hardware Wizard Welcome to the Found New Hardware Wizard Windows will search for current and updated software by looking on your computer on the hardware installation CD or on the Windows Update Web site with your permission Read our privacy policy Can Windows connect to Windows Update to search for software O Yes this time only now and every time connect a device Click Next to continue Found New Hardware Wizard This wizard helps you install software for OCS USB COM Port If your hardware came with an installation CD or floppy disk insert it now What do you want the wizard to do Click Next to continue Hardware Installation The software you are installing for this hardware OCS USB COM Port has not passed Windows Logo testing to verify its compatibility with Windows XP Tell me why this testing is important Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing Continue Anyway STOP Installation Page 83 of 114 IM HORNER
10. AUT TONS e ww Auto Enters RUN after AutoLoad or Battery Fail Figure 16 9 AutoRun Menu Page 98 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 17 CLONE UNIT 17 1 Overview Clone Unit feature allows the user to clone the OCS of the exact same model This feature clones application program and unit settings stored in Battery backed RAM of an OCS into the RM refer 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 17 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 added at the end of the main system menu as shown below Set Network ID Set Network Baud Uieu Status Uieu Diags View 1 0 Slots View Protocols Set Fkeys Mode Set Serial Ports Set Time Date Set Beeper Set Screen Removable Media Fail Safe System Clone Unit Figure 17 1 System Menu 2 Selecting Clone Unit menu will open the following menu screen Directory Empty Free 1664257280 Total 1664257280 Clone Cie V A Esc some tame V A ese Figure 17 2 Clone Unit Menu before Cloning Page 99 of 114 HORNER AUTOMATION GROUP exl10 User Manual Free
11. Figure 3 5 eXL10 OCS Dimensions Page 19 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual 3 6 Factors Affecting Panel Layout Design and Clearances Warning It is important to follow the requirements of the panel manufacturer and to follow all applicable electrical codes and standards The designer of a panel layout needs to assess the requirements of a particular system and to consider the following design factors 3 6 1 Clearance Adequate Space Install devices to allow sufficient clearance to open and close the panel door Table 3 1 Minimum Clearance Requirements for Panel Box and Door Minimum Distance between base of device and sides of cabinet 2 inches 50 80mm Minimum Distance between base of device and wiring ducts If more than one device installed in panel box or 1 5 inches 38 10mm on door Minimum Distance between bases of 4 inches between bases of each device 101 60mm each device When door is closed Minimum distance between device and closed 2 inches 50 80mm door Be sure to allow enough depth for the OCS 3 6 2 Grounding Warning Be sure to meet the ground requirements of the panel manufacturer and also meet applicable electrical codes and standards Panel box The panel 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 ens
12. Slot 2 1 O XzC z COM module installed but another COM module configured Slot 2 1 0 XzC z COM module installed and configured properly Slot 3 1 0 ETN300 ETN300 has been configured through Cscape Page 59 of 114 HORNER AUTOMATION GROUP exl10 User Manual View Protocols System Menu S m z None Loaded None Loaded None Loaded Loaded The View Protocols Sub Menu displays two System Settings neither of which may be edited As mentioned in O both the MJ1 MJ2 Port 1 and MJ3 Port 2 serial ports support downloadable protocols To assign a downloadable protocol to an eXL10 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 of MJ1 MJ2 COM board and MJ3 Set Fkeys Mode System Menu Momentary SYS Fn enable Yes lt Use to adjust The Set Fkeys Sub Menu displays two System Settings both of which may be edited Momentary K1 5 bits go On amp Off as F1 F5 are pressed amp released PREYS Toggle K1 5 bits toggle each time F1 F4 are pressed Yes Reset and all clear system functions enabled Reset and all clear system functions disabled
13. AUTOMATION GROUP Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has finished installing the software for 7 OCS USB COM Port lt Click Finish to close the wizard exl10 User Manual Now that the eXL10 is plugged in go to Cscape Tools Application Settings Communications and choose the USB port in this example Com 3 Cscape untitled1 File Program Controller Debug Tools Screens View Window Help Project Na E Proj 12 untitledt 1 Unknown Mod Y Hardware Configuratior Control TBI Logic Modules 25 94 Main Loop main Subroutine Mod SetPoints Names Data Logging H Recipes E E Graphics 9 98 Networking Project Navigator Output Window String Operations Security StpCalc Strip Chart Update SmartStack Module View Data List Project ToolBox ccu Editor Options Application Settings Page 84 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual Add Target Target Name Connection Medium C Com Port Ethemet C Can Interface C Installed Modem 0 5 USB COM Port 0 20 Connected Device Connected Device C Target Node ID 1 Connection Settings Timeout 3000 ms If communication is established the target indicator will show
14. The totalizer supports the following modes Internal This mode ties the input to the counter to an internal 10 2 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 that two inputs can be assigned Either input can cause the counter to increment The second input can also be disabled Count Down This decrements the accumulator when the input is enabled Note that two inputs can be assigned Either input can cause the counter to decrement The second input can also be disabled Up Down In this mode input 1 assigned to any of the four inputs increments the Input 1 Up Input 2 Down counter while input 2 also assigned to any of the 4 inputs decrements the counter CIk Dir This mode uses input 1 as a clock signal to increment or decrement the Input 1 Clk Input 2 Dir counter and then uses input 2 to decide the direction Input 2 disabled increments the counter while input 2 enabled decrements the counter NOTE the totalize mode enables the Disable Latch Preload and Clear special functions Please see section 11 2 for details 11 3 3 Pulse Width Measurement In pulse width measurement mode the high speed input can measure the width of a pulse stream in one of two modes and provides a continuous indication of the last sampled value In this mode the Disable and Latch special functions are allowed Ple
15. 1 amp CAN2 Port Pins Signal Description Direction Use the CAN Connector when V power 2 using CsCAN or other CAN CN L CAN Data Low Blue In Out network SHLD Shield 4 CN H CAN Data High White In Out Torque rating 4 5 7 Lb In V Power 0 50 0 78 N m Page 27 of 114 HORNER AUTOMATION GROUP exl10 User Manual Figure 6 2 CAN1 CAN2 Port Pins Page 28 of 114 HORNER AUTOMATION GROUP exl10 User Manual 6 4 Cscape Programming via CAN The CAN1 port supports CsCAN Programming Protocol If a PC has a CAN interface installed via PCI card or USB and the PC CAN port is connected to the eXL10 OCS 1 port Cscape can access the eXL10 OCS for programming and monitoring In addition the eXL10 OCS supports single point programming of all eXL10 OCS and other OCS RCS devices that are connected to the CAN1 port network If the PC COM port is connected to the eXL10 OCS MJ1 serial port the eXL10 OCS can act as a pass through gateway allowing Cscape to access all eXL10 OCS and OCS RCS devices that are attached to the CAN1 port network 6 5 Ladder Controlled CAN Communication Using Put and Get Network Words function blocks the CAN 1 port can exchange digital and analog global data with other eXL10 OCS or OCS RCS devices nodes attached to the CAN1 port network In addition Put and Get Network Heartbeat function blocks allow nodes on the CAN 1 port network to
16. Meets the electrical code and applicable standards for proper grounding Meets the panel manufacturer s requirements for grounding Is the panel box properly connected to earth ground Is the panel door properly grounded L 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 door be easily opened and closed Is there adequate space between device bases as well as the sides of the panel and wiring ducts L Is the panel box deep enough to accommodate the eXL10 OCS oO Is there adequate ventilation Is the ambient temperature range maintained Are cooling or heating devices required Are noise suppression devices or isolation transformers required Is there adequate distance L between the base of the eXL10 OCS and noisy devices such as relays or motor starters Ensure that power and signal wires are not routed in the same conduit L Are there other requirements that impact the particular system which need to be considered Page 21 of 114 HORNER AUTOMATION GROUP exl10 User Manual NOTES Page 22 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 4 ELECTRICAL INSTALLATION Note The datasheet is the first document to refer to for model specific information related to eXL10 OCS models such as pin outs jumper settings and other key installation information Visi
17. Totaliz 2 menu see Chapter 11 starting on Pulse Width Measurement 3 page 45 of this manual Quadrature 15 6 Digital Output PWM Configuration The following figure illustrates the Digital Output PWM Configuration dialog Digital 7 HSC Input Configuration Digital inputs active mode Positive Logic Note This setting must 5 match that of the jumpers Negative Logic the product HSC 1 0 Mapping Starting Digital In 241601 qus Starting Digital Out 7791601 TE Starting AnalogIn za 40 8 Starting Analog Out 74401 esr x12 Counter Counter2 Type Totalizer X Input2 Mode Up down Input 1 up input 2 down Extemal Input 1 Extemal Input 2 v Disable Function Disabled c gt Polarity Highlevel Latch Function Extemal Input 3 ity Highlevel Preload Function 1 Highlevel Clear Function Disabled 9 Polarity Highlevel Marker m o Polarity la La 4 Match Disable Cancel Figure 15 4 Digital Output PWM Configuration Dialog The Q1 and Q2 group boxes allow the user to specify the operation of the multi function outputs The PWM State On Controller Stop group box contains items that allow 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 that the PWM
18. 001XLEO36 Positive Logic In Negative Logic In Figure 10 6 Positive and Negative Inputs In positive logic mode a positive voltage applied to the input will turn the input The internal design of this mode is basically a resistor from the input to I O ground This mode is sometimes called sourcing In negative logic mode connecting the input to the I O ground or zero volts will turn the input on The internal design of this mode is basically a resistor from the input to the positive I O voltage usually 12 or 24 volts This mode is sometime called sinking Some of the digital inputs may support high speed input functional such as counting or frequency measurement 10 7 Analog Inputs NOTE See the data sheet for the eXL10 OCS model being used for jumper settings and see the appropriate page in this manual see Index for details on how to use Cscape to configure the digital filtering Page 44 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual The analog inputs on the eXL10 OCS allow voltage or current measurement from a variety of devices The voltage or current mode is set though jumpers on the unit and settings in Cscape Each channel can be separately configured for voltage or current mode The analog inputs have a digital filter that can be used to filter electrical noise that may be unavoidable in some installations The downside to digital filtering is the inputs will respond more slowly to sudden changes in the actu
19. 5 1 sensn io 35 8 OVERVIEW EM 35 8 2 Modem COM Module 35 CHAPTER 9 REMOVABLE MEDIA 75 52 5 39x PERSE NER UR ESEESE ER HER EE SEN NINES EESE 36 9 OVENIEW MEME 36 9 2 MicroSD Cards 36 9 3 MicroSD File Systemic 2 reine NN 36 9 4 Using the Removable Media Manager cscssccccccecsssessnaecececsesesesnsaeseceesseecaeaeeeeeeeseeseaeaeeeesens 37 9 5 Using Removable Media to Log Data cccccscssssccccecsssessaecesecseseseeaeeeeeesseesesaeaeeeeecesseseaeaeeeesens 37 9 6 Using Removable Media to Load and Save 37 9 7 Using Removable Media to View and Capture Screens sesenta 38 9 8 Removable Media RM Function Blocks 38 9 9 Filenames used with the Removable Media RM Function 36 9 10 System Registers used with RM cccccccccccssssssssececeeecesseseeaeseeecsceeseaeaeeeeeesseeaaeaeeeesceseeseaeaeeeesens 37 CHAPTER locia T Miio 3
20. Cscape properly This section will offer some tips and suggestions to configure the I O properly For the register mapping of the I O refer to the Index at the end of this manual for the pages referencing register mapping 10 2 Removing the eXL10 OCS I O Cover WARNING Power including I O power must be removed from the unit prior to removing the back cover Failure to do so could result in electrocution and or damage to equipment Some I O configurations require jumper settings to be changed in the eXL10 OCS unit Examples of these settings are setting positive or negative logic on digital inputs or setting current or voltage on analog inputs Each eXL10 OCS 1 0 jumper is set to a factory default Refer to the eXL10 datasheet to find the default setting to determine if a jumper change is necessary for a particular application To remove the I O cover of the eXL10 OCS remove the four 4 Phillips screws from the I O back It may help to place the eXL10 OCS unit face down on a clean work surface Once the four screws are removed the I O cover can be lifted straight off Figure 10 1 Removing the I O Cover Page 40 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual __ 28 2 TT ntm ili Ln 44 Figure 10 2 eXL10 1 0 Cover Removed sample 1 0 board Once the back is removed the jumper selection can be changed The jumper settings are documented on each data sheet us
21. indicator light or other physical outputs Retentive 16 bit registers AI Analog Input AQ Analog Output D Display Bit l Digital Input K Key Bit M Retentive Bit Q Digital Output R General Purpose Register S System Bit Single bit bit coils predefined for system use SR System Register 16 bit registers predefined for system use T Temporary Bit Non retentive single bit registers 14 2 Useful S and SR registers Register Description S1 Indicate First Scan S2 Network is OK 53 10 5 timebase 54 1005 timebase 55 1 second timebase 96S6 is OK S7 Always ON S8 Always OFF 59 Pause n Load soon S10 Pause n load done S11 O being forced 96512 Forcing is enabled 96513 Network I O is OK S16 Ethernet COM module is OK Table 14 3 SR Registers Register Description MinVal MaxVal SR1 USER_SCR Current User Screen Number 1023 SR2 ALRM_SCR Current Alarm Screen Number 0 o 1023 96SR3 SYS SCR Current System Screen Number 0 14 SR4 SELF_TEST Bit Mapped Self Test Result 0 65535 Page 76 of 114 HORNER AUTOMATION GROUP exl10 User Manual Table 14 3 SR Registers Register Description Min Val MaxVal 5585 CS MODE Control Station Mode 0 1 Do I O 2 Run 0 2 6 SCAN Aver
22. 0 Mapping Starting Digital In 311601 Ig 8 Starting Digital Out x01601 x32 Starting Analog 7741401 8 Starting Analog Out 240401 Gee x12 Counterl Counter2 Type Totalizer Input2 Mode Up down Input 1 up input 2 down External Input 81 x Extemal Input 2 Disable Function Disabled gt Polarity High level Latch Function External Input 3 gt Polarity High level Preload Function nderflow interrupt gt Polarity High level Le Le Le Le Clear Function Disabled gt Polarity High level Marker gt Polarity Match Disable Cancel Figure 15 3 Digital Input HSC Configuration Dialog Page 88 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual The Active mode group box allows the user to select if inputs are active high Positive logic or active low Negative 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 4 available high speed counters on the eXL10 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 Frequency Measurement Period Measurement For detailed descriptions of the High Speed Counter types available within the drop down
23. 1 Cscape Target amp Local eene enne nennen Table 19 2 Removable Media Troubleshooting cccssccsssesseessseesscecsseesseessaeessuecsseesseeesnecsaeesseecsaceseaeeseeseaeesenesseessnesseeesenees Page 114 of 114
24. 8000 would indicate a 25 6 duty cycle a value of 16 000 would indicate a 50 duty cycle turns the output off 32 000 turns the output on Duty Cycle Frequency The Frequency is a 32 bit value indicating the output frequency in Hertz One over the frequency is the period E Period Figures 11 6 amp 11 7 PWM two parameters Duty Cycle amp Frequency At controller power up or during a download the PWM output is maintained at zero until both the Frequency and the Duty cycle are loaded with non zero values When the controller is placed in stop mode the state of the PWM outputs is dependent on the PWM State on Controller Stop configuration This configuration allows for either hold last state or specific frequency and duty cycle counts Specifying zero for either the period or duty causes the PWM output to remain low during stop mode NOTE for standard 1 0 modules 1E3 1 4 and 1E5 models the maximum recommended PWM frequency is 5000Hz due to the limitations of built in output circuitry The HE XHSQ generates 24V pulse outputs with a recommended max of 400 000Hz The HE XHSQ 5 generates 5V pulse outputs with a recommended max of 1 0MHz The addon HSQ and HSQ 5 module can be added to the 1E2 unit for HSC function Page 52 of 114 HORNER AUTOMATION GROUP exl10 User Manual 11 5 3 High Speed Counter Match When either Q1 or Q2 is configured for HSC Output operation their output state is based ona co
25. AUTOMATION GROUP exl10 User Manual NOTES Page 34 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 8 COMMUNICATION OPTIONS 8 1 Overview To supplement the built in MJ1 MJ2 and MJ3 serial ports additional communication options are available This is accomplished by installing a COM module in the eXL10 OCS controller Previous OCS controllers shared a serial port with the communication options The eXL10 has a separate serial port which allows using MJ1 MJ2 MJ3 and the communication options simultaneously Internal to the eXL10 OCS there is a CPU board and up to two installed modules Models HE EXV1EO HEXT505C100 have no installed 1 0 or add on COM modules standard communications are available All other models have an I O module in Slot 1 and could have a user installed COM module in Slot 2 A blank board kit to support a COM module in these models is available This chapter briefly describes the Modem COM module options For detailed information regarding these modules please refer to the individual documents provided with the modules 8 2 Modem COM Module XMC Option A Modem COM module can be installed to allow Cscape programming of an eXL10 OCS over a dial up network In addition the application ladder program can take control of the modem for application specific modem communication The Modem COM module supports the standard AT command set and can connect to the dial up network at speeds up to 14
26. BY HE APG THE TERM ORIGINAL PURCHASER AS USED IN THIS WARRANTY SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM THE EXL10 OCS module IS ORIGINALLY INSTALLED THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES In no event whether as a result of breach of contract warranty tort including negligence or otherwise shall HE APG or its suppliers be liable of any special consequential incidental or penal damages including but not limited to loss of profit or revenues loss of use of the products or any associated equipment damage to associated equipment cost of capital cost of substitute products facilities services or replacement power down time costs or claims of original purchaser s customers for such damages To obtain warranty service return the product to your distributor with a description of the problem proof of purchase postpaid insured and in a suitable package ABOUT PROGRAMMING EXAMPLES Any example programs and program segments in this manual or provided on accompanying diskettes are included solely for illustrative purposes Due to the many variables and requirements associated with any particular installation Horner APG cannot assume responsibility or liability for actual use based on the examples and diagrams It is the sole responsibility of the system designer utilizing the eXL10 OCS module to appropriately design the end system to appropriately integrate the eXL10 OCS module and t
27. Europe Tel 353 21 4321 266 Fax 353 21 4321 826 Web http www horner apg com Email tech support horner apg com Page 3 of 114 HORNER AUTOMATION GROUP exl10 User Manual LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner APG LLC HE APG warrants to the original purchaser that the EXL10 HE XW HEXT391 OCS module manufactured by HE APG is free from defects in material and workmanship under normal use and service The obligation of HE APG under this warranty shall be limited to the repair or exchange of any part or parts which may prove defective under normal use and service within two 2 years from the date of manufacture or eighteen 18 months from the date of installation by the original purchaser whichever occurs first such defect to be disclosed to the satisfaction of HE APG after examination by HE APG of the allegedly defective part or parts THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE APG NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE APG ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS EXL10 OCS module THIS WARRANTY SHALL NOT APPLY TO THIS EXL10 OCS module OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT NEGLIGENCE ALTERATION ABUSE OR MISUSE HE APG MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED
28. Europe http www horner apg com to obtain user documentation and updates 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 features a Serial ports Removable Media Communication Options etc c Configuration and Use of the eXL10 OCS d Maintenance and Support Page 14 of 114 HORNER AUTOMATION GROUP exl10 User Manual 2 1 3 Manual Index Major topics of interest may be found in the Index towards the end of this manual 2 1 4 Table of Figures Location of important drawing illustrations etc may be found in the Table of Figures 2 2 Connectivity to the eXL10 OCS The eXL10 OCS has excellent capabilities for connecting to a variety of devices The diagram below shows some examples of devices that can be used with the eXL10 OCS Other OCS Devices Other OCS Devices Smart Stix I O Serial Drives PLCs OPC Server Bar Code Readers Printers eXL10 OCS SCADA OPC Servers Serial I O Sensors Ethernet Indicators Alarms Cscape Encoders OPC Server Pumps Modbus TCP Devices Relays Solenoids Flash Drive Cscape Figure 2 2 Visual Overview of Types of Devices that can be connected to EXL10 OCS 2 3 Features of eXL10 OCS The eXL10 OCS are all in one industrial control devices They combine control user interface I O and networking into a single integrated package Unique features of the
29. Figure 5 1 Wiring amp Dip Switches S s m 1 2 9 Figure 6 2 CAN Part eei e tener ERE trei cbr ERU SVO Pe ENS VS e eT Eve ONE Figure 7 1 1 0 Configuration Dialog cccccccsccsssssscsssessesssesecsssssecsecssecesssecsescsecsaessesessssesaessesssessesesecaesaeseesesesaessaesesesecesenseeesoas Figure 7 2 Ethernet Module Configuration 2 eter iet iecit eese a cease Rete due Figure 9 1 Removable MicroSD Memory Card 5 202 0 eene eene nennen nennen Figure 9 2 Removable Media Submenu eec e e ttv sts ee ee vt b d ated Figure 10 1 Removing the COover ccccsssssssssssssssessscsesssecssssscesessssesssessessseseaeceesesesaeesaesaesseseeseseseesesscseseaeseeseaeseeseaesaesenseeeeegs Figure 10 2 EXLTO 1 0 Cover Removed ove loe nan Figure 10 3 Example Jumper Figure 10 4 Typical Output ecc roter Resa End aM a M cs Eel age Figure 10 5 Relay FUSIDB
30. GOOD GROUND Figure 4 1 Two Point Ground Connection Test Page 23 of 114 HORNER AUTOMATION GROUP exl10 User Manual 4 4 Primary Power Port Table 4 1 Primary Power Port Pins Description Frame Ground Input power supply ground Input power supply positive voltage Power Connector Power Up Connect to Earth Ground Apply 10 30 VDC Screen lights up Torque rating 4 5 7 Lb In 0 50 0 78 N m Figure 4 2 Power Connector Primary Power Port 24VDC PIN 1 PIN 2 PIN 3 Figure 4 3 Primary Power Port as Viewed Looking at the eXL10 OCS Page 24 of 114 M HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 5 SERIAL COMMUNICATIONS 5 1 Overview All eXL10 OCS models provide two independent serial ports on the first 8 pin modular RJ45 connector which is labeled MJ1 MJ2 The MJ1 serial port is RS232 while the MJ2 port is RS485 By default MJ1 can be connected to the COM port of a PC running Cscape for OCS programming In addition both MJ1 and MJ2 can be used for application specific communication using a variety of standard data exchange 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 5 2 Por
31. O Configuration Dialog 3 Click the Config button to the right of LAN1 for LAN 1 or LAN2 for LAN2 revealing the Ethernet Module Configuration dialog as shown in figure 7 2 Register Usage Default Settings Register Get settings from IPAddess 182 168 254 120 Configuration v Use CAN ID for last Octet NeMasc 25 25 25 9 Nae set Eigen G ewy 0 0 0 9 Nme Status Name eem un Version E Name 7 xc Protocol Support Resident Protocols ICMP Ping O EGD Ethernet Global Data Configure Selected Protocol SRTP Slave 90 30 Service Request O Modbus TCP Slave Ethernet IP File Server HTTP Web Server O ASCI Over TCP IP Downloadable Protocols Device Scan List 1 2 None X Network Device Scan List Cancel Figure 7 2 Ethernet Module Configuration Page 31 of 114 HORNER AUTOMATION GROUP exl10 User Manual 4 Configure the Ethernet Module parameters as follows IP Address Enter the static IP Address for the Ethernet Module being configured Note P Addresses are entered as four numbers each ranging from 0 to 255 These four numbers are called octets and they are always separated by decimal points Net Mask Enter the Net Mask sometimes called Subnet Mask being used by all nodes on the local network Typical lo
32. Page 60 of 114 HORNER AUTOMATION GROUP exl10 User Manual Set Serial Ports System Menu 541 232 MJ2 RS4BS Bias 85485 Bias Use to adjust The Set Serial Ports Sub Menu displays three System Settings all of which may be edited and one optional item For the Dflt Pgm Port System setting only MJ1 232 can be selected unless a Modem XMC COM module is installed MJ1 232 MJ1 RS232 port is the default programming port Dt Modem Modem COM module is the default programming port No MJ2 RS485 bias resistors are not switched in puni Blas Yes MJ2 RS485 bias resistors are switched in No MJ3 R5485 bias resistors are not switched in Bins Yes MJ3 R5485 bias resistors are switched Set Time Date System Menu 16 55 22 9 8 31 May 2013 Friday Use to adjust each field The Set Time Date Sub Menu displays three System Settings Time and Date may be edited and Day is automatically calculated from the Date setting Note that Time and Date are split into three fields each all of which may be edited Use lt or to select a field and then use V or to edit the field Time 16 09 49 Current time hours minutes seconds in 24 hour format Date 10 Jun 2013 Current date day month year Day Monday Current day of week calculated from the Date setting Page 61 of 114 HORNER AUTOMATION GROUP ex
33. Total displays number of free and total bytes in Removable Media 3 Make Create Clone option enables user to duplicate Clone application file all unit settings and all register values from Battery Backed RAM Selecting Make Clone brings up the screen below for the user Clone Files fire You Sure Ok 1 Free 1664257286 Total 1004257280 Load Hake V ese Figure 17 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 CLONE 24570 07 15 09 12 11a Free 1664208128 Total 1004257280 one e V Figure 17 4 Clone Unit Files NOTE Make Create clone operation automatically includes the security in AUTOLOAD PGM file for security enabled files Page 100 of 114 HORNER AUTOMATION GROUP exl10 User Manual 4 Once the cloning is successful OCS gives a message as below Cloning Status SUCCESS MAKE CLONE operation Ok 1664224512 Total 1664257280 Load 1 Clone V A Esc Figure 17 5 Cloning Status Make Create clone can also be triggered by setting SR164 9 bit to 1 from Ladder program or graphics Once the operation is completed thi
34. eXL10 OCS include Bright 65 536 color graphical touch sensing LCD display in all models of eXL10 Display of complex graphical objects including trends gauges meters and animations Very high performance graphic processing Advanced control capabilities including floating point multiple auto tuning PID loops and string handling capabilities Removable media 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 1 including high resolution analog thermocouple RTD high speed counters PWM outputs and relays depending upon the eXL10 OCS model used Advanced high speed 1 0 capabilities Cscape programming software that allows all aspects of the eXL10 OCS to be programmed and configured from one integrated application Optional communication add on modules Page 15 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual Two on board Ethernet ports 10 100Mbps for Cscape programming and application defined communication with Auto MDI MDI X 2 4 Required and Suggested Accessories The following list contains a sampling of required and suggested eXL10 OCS accessories Visit the Horner websites to view updates on
35. filtering to all channels Page 90 of 114 HORNER AUTOMATION GROUP exl10 User Manual 15 8 Analog Output Configuration The following figure illustrates the Analog Output Configuration dialog Analog Output Configuration 4 Output value on STOP Output Mode 1 Goto o Hold Last Value 0 10V X Cancel 2 Goto o Hold Last Value 0 10 Figure 15 6 Analog Output Configuration Dialog The 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 Page 91 of 114 HORNER AUTOMATION GROUP exl10 User Manual Chapter 16 Fail Safe System 16 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 for example an excessive EMI event The Fail Safe System has the following capabilities Manually backup the current Battery Backed RAM Register Settings into Flash memory Manually restore Register Settings fr
36. is the same for all controllers on the network Assure shields are connected at one end of each segment they are not continuous through the network 10 Do not exceed the maximum length determined by the baud rate and cable type Page 108 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual 11 Total drop length for each drop should not exceed 6m 20 feet A drop may include more than one node The drop length adds to the overall network length 12 Network should be wired in straight line fashion not in a star pattern 13 In applications requiring multiple power supplies make sure the V of all supplies is connected together and to earth ground at one place only 14 In some electrically noisy environments it may be necessary to add repeaters to the network Repeaters can be used to add additional nodes and or distance to the network and protect the signal against noisy environments The Horner APG repeater is part HE200CGM100 19 4 Removable Media Basic Troubleshooting Description Action eXL10 OCS does not read media card The media card should be formatted with the eXL10 OCS Make sure the project file is saved as a pgm file and not a csp file eXL10 OCS will not download project file In addition to file must be pgm the file s I O configuration must match the eXL10 configuration for it to download Table 19 2 Removable Media Troubleshooting 19 5 Technical Support Contacts For manua
37. new products and accessories NOTE The eXL10 OCS is not shipped with a programming cable in the box To obtain a programming cable order HE500CBL300 Table 2 1 eXL10 OCS Accessories Part Number Description HE MC1 Removable Media card compatible with eXL10 OCS Card capacity is 2GB or larger HE MR1 Media Card Reader for HE MC1 Portable device allows HE MC1 to be plugged into the USB port of personal computers as a portable hard drive HE X24 AS Power supply 100 240VAC or 140 340VDC Switching supply that outputs 1 5 HE X24 AS AL at 24 VDC Mounts on Standard DIN rail Designed for X Family products HE X24 AL Power supply 100 240 VAC or 140 340 VDC Switching supply that outputs 1 5 HE X24 AS AL at 24VDC Mounts on Standard DIN rail Designed for X Family products HECSP Cscape Software Package on a reusable USB flash drive with symbol library HE XCK Programming cables for all X products including a USB to serial adapter in a travel case Cscape on a reusable USB flash drive HE CPK s 1 Programming cables for all X products including a USB to serial adapter a travel case 2 5 Useful Documents and References The following information serves as a general listing of Horner controller products and other references of interest with their corresponding manual numbers Visit the Horner websites to obtain user documentation and updates Table 2 2 OCS Reference Documen
38. soft failures include e Battery power loss e Battery Backed Register RAM or Application Flash corruption due to for example an excessive EMI event Selecting Fail Safe System menu will open the following menu screen System Menu wer i i V Enable AutoRun Enable AutoLoad ESC to exit Esc Enter 1 2 3 Ls pes pn Selecting Backup Restore Data displays the following screen in Backup Restore Data Backup Restore Clear Backup Backup Copies Battery Backed RAM contents on to the onboard FLASH memory of the OCS Restore Copies the backed up data from onboard FLASH to the battery backed RAM Clear Backup The backup data will be erased from the onboard FLASH Exit Goes back to previous menu Page 64 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual Enable AutoRun displays the following options which can be selected System Menu emm AUT TONS Auto Enters RUN after AutoLoad or Battery Fail No OCS will be in IDLE mode after AutoLoad or Automatic Restore Enable AutoRun Yes OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore Enable AutoLoad displays the following options which can be selected System Menu nable Autoload AutoLoad fron Removable Media s AUTOLOAD PGM File when triggered No Does not load AUTOLOAD PGM automatically when applica
39. the mode of the controller Target yy R as shown in the status section above in this chapter section Cscape Status Bar If the controller is not communicating ensure the target ID is set correctly If not 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 configured r To check or change the ID on the eXL10 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 Page 85 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual View Status View Diags View 1 0 Slots View Protocols Set fkeys Mode Set Serial Ports Set Time Date Set Beeper Set Soreen Removable Media Fail Safe System Clone Unit Press ESC to exit To change the Target ID of Cscape use the Controller Set Target Network ID dialog 00000 m Ex mr EL 4 s e 4 1 7 wxy Ef 58 92 0 Eso Enter 15 3 1 Communicating via MJ1 Serial Port Start by configuring Cscape to use the correct communications port This can be done using the Tools Options Communication Port dialog in Cscape Next connect the PC s serial port to the port labeled MJ1 on the eXL10 If communications are succe
40. to 1 kHz during the first 2 000 000 steps Then it runs at 1 kHz for the next 2 000 000 steps 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 nm Set AQ421 Set AQ422 Set AQ423 4 Set AQ425 6 Set AQ427 8 MAD 50 Hz 250 Hz 150 000 Steps 5 500 000 Steps 350 000 Steps When the start bit is energized the following example starts at 50 Hz and ramps up to 250 Hz during the first 150 000 steps Then it runs at 250 Hz for the next 5 500 000 steps During the last 350 000 steps it slows to a stop Note Prior to the start of a move the Ready Done bit for that channel must be ON 9611617 or 9611619 for channel 1and 2 respectfully The Ready Done bit will turn OFF during the move and then back ON once the move is completed Note The pulse generation hardware on the eXL10 can generate any frequency that can be evenly divided into 10Mhz 10 000 000 Hz under the maximum recommended frequencies for each model This results in a very smooth operation at lower frequencies with a progressively choppier operation at higher frequencies as the units reach their maximum recommended frequency Page 55 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 12 SYSTEM SETTINGS AND ADJUSTMENTS 2 12 11 System Menu Overview The eXL10 has a built in System Menu which lets the user view System Settings and makes adjustments To
41. value unchanged and the alpha numeric keypad disappears NOTE Each numeric entry object has a configured minimum and maximum value If the operator enters a value outside of the configured range the new value is ignored when Enter is pressed and the current object value is NOT changed Page 69 of 114 HORNER AUTOMATION GROUP exl10 User Manual Since the alpha numeric keypad services several different graphical objects certain keys on the alpha numeric keypad may be disabled grayed when the keypad is invoked for certain objects The following describes the alpha numeric keypad variation based on object Numeric Object When editing a numeric value the or the key are disabled grayed if the object is NOT configured for 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 and alpha In Alpha mode the Caps Lock button may be pressed to access capital letters When you first enter this editor typing a character will overwite the entire old string and start a new entry You may press the back space arrow to delete the previous character Pressi
42. 1 Visual Overview of eXL10 14 2 1 1 Where to Find Information about the eXL10 14 2 1 2 Four main types of information are covered the manual sss 14 2 1 3 e EEAS 15 2 14 T ble of Figures io RARE NERONE TN GT E ET 15 2 2 Connectivity to the eXL10 OCS 15 2 3 Features Of eXL10 OCS iine e ee Ee eee eed 15 2 4 Required and Suggested 55 16 2 5 Useful Documents and 16 CHAPTER 3 MECHANICAL 5 1 sone sea sre nena ns 17 JOVeEIVIBW ceci IRURE 17 3 2 MOUNTING Requirements rte ete enatibus ianine 17 3 2 1 Mounting Procedures Installed in a Panel Door sess 17 3 3 Mounting eet tiere eser dee repu iere sra puse aeo tisse e 18 3 31 eXL10 OCS Mounting 18 3 3 2 eXL10 OCS Mounting 18 3 4 Panel C t OUt esses ER 19 3 5 EER roD 19 3 6 Factors Affecting Panel Layout Design and Clearance 44440 19 3 6 1 Clearance Adequate Space 19 3 6 2 Groundi
43. 4 KBaud Connection speed is auto negotiated The Modem COM module connects to the dial up network phone line via a cable with a standard RJ11 modular plug To enable Cscape programming via a dial up network the Modem COM module should first be configured as the Default Programming Port using the eXL10 OCS System Menu Doing this puts the Modem COM module in auto answer mode so Cscape can call the eXL10 OCS via a remote modem To program the ladder application to communicate via the Modem COM module standard Cscape Serial and Modem function blocks can be used Additional XL Series COM options are shown below Part Number Description HE XDACOO7 2 channel Analog Out mA V HE XDAC107 4 channel Analog Out mA V HE HXSQ 24V Dual High Speed Output HE XHSQ 5 5V Dual High Speed Output HE XEC Add on Ethernet HE XPBS Profibus DP Slave HE XRC9 900 MHz I W Radio Modem HE GSM04 GSM GPRS Cellular Modem HE 200GPS183 GPS Receiver add ANT suffix to include antenna external unit Table 8 1 XL Series COM Options Page 35 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 9 REMOVABLE MEDIA 9 1 Overview All eXL10 OCS models provide a Removable Media slot labeled Memory Card which supports standard MicroSD Flash memory cards MicroSD cards can be used to save and load applications to capture graphics screens and to log data for later retrieval Figure 9 1 Removable M
44. 6 08 Free 511672320 Total 511959040 The Removable Media Sub Menu displays the Removable Media Manager Having selected Removable Media from the Main Menu one of four Sub Menu screens will appear HR aes No MicroSD card has been installed in the Memory slot MicroSD card is installed but it is still initializing Media Directory Dir Empty MicroSD card is installed and initialized but contains no files MicroSD card is installed and initialized and it contains files Media Directory 5 80000 JPG SCR0001 SCROOO2 JPG 15209 SCRO003 JPG 29708 SCROOON JPG 29582 SCROOOS JPG 23263 SCROO06 JPG 14643 SCROOO7 JPG 14976 SCROO008 JPG 15994 SCROOO9 JPG 17561 07 10 08 12 h7 v Free 511672320 Total 511959040 14272 Shows size of highlighted file or shows DIR if directory is highlighted Shows the date file or directory was created or last modified Shows the time file or directory was created or last modified Page 63 of 114 HORNER AUTOMATION GROUP exl10 User Manual If a directory name is highlighted pressing Enter will switch to that directory showing its files and sub n directories In a sub directory highlighting dot dot and pressing Enter will move up one directory Fail Safe System 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
45. 8 dos EE 38 10 2 Removing the EXL10 OCS I O Cover 38 10 3 Model and OVerview ccccssscccccsecscsssensececcesceessnnaececececsessnanaeceeececeesentuaeceeeesesessntaeeeeeeeeeenens 42 10 4 Solid State Digital 42 10 5 Relay xen rere Te uae re HR 43 10 6 Digital oet eer teneri im ve e EER 44 10 7 Analog Iripts reri EP 44 10 71 cause of analog input tranzorb failure 43 10 8 Universal Analog 45 10 9 45 Page 7 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 11 HIGH SPEED 1 0 HSC PWM 47 duele EE 47 m 47 11 3 High Speed Counter HSC 5 45 T Jude 45 LL32 EE 45 11 3 3 Pulse Width 45 11 34 Period Me s remleht 46 PERE RE e e I E IE E I OAA A A A I A T A NI S E T 47 1136 Regsiter Match ie 47 114 HSC Functions Register
46. 9 Main 110 Index of eerta 113 Page 9 of 114 HORNER AUTOMATION GROUP exl10 User Manual Visual map of major tasks and the key chapters to assist you FIRST STEP of ANY TASK DATASHEET Each eXL10 OCS unit is sent with a datasheet in the box The datasheet MAN1028 02 EN is the first document to refer to for model specific information related to eXL10 OCS models such as pin outs jumper settings and other key installation information To obtain updates to datasheets manuals and user documentation visit a Horner website US http www heapg com and Europe com www horner a QUICK START Safety Compliance page 11 INSTALLATION Safety Compliance page 11 PROGRAMMING Safety Compliance page 11 TROUBLESHOOTING Safety Compliance page 11 Introduction page 13 Introduction page 13 Introduction page 13 Introduction page 13 Mechanical Installation page 16 Serial Communications page 24 Maintenance page 100 Electrical Installation page 22 CAN Communications page 26 Troubleshooting page 102 Ethernet page 28 Communication Options page 33 Removable Media page 34 High Speed 1 0 page 44 System Settings page 53 User Interface page 65 Registers page 74 Cscape Configuration page 79 Fail Safe Sys
47. C 12 24VDC ON J1 D 001XLE015 Page 43 of 114 HORNER AUTOMATION GROUP exl10 User Manual Figure 10 5 Relay Fusing Protection for Inductive Loads Inductive loads can cause reverse currents when they shut off that can shorten the life of relay contacts Some protective measures need to be determined by an engineer If you have questions on protection from inductive load consult an application engineer or HEAPG Technical Support Details on devices that may protect outputs can be found in MANO962 01 Output State on Controller Stop 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 predetermined state By default relay outputs turn off For more information on stop state see the Index for Cscape settings pages 10 6 Digital Inputs NOTE Refer to the datasheet for eXL10 OCS model being used for details on jumper settings Note The digital inputs on the eXL10 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 Positive Logic vs Negative Logic Wiring The XL SERIES OCS can be wired for Positive Logic inputs or Negative Logic inputs 4 12 24VDC
48. Digital Input HSC Configuration 85 Digital Output PWM Configuration 86 Establishing Communications 80 Overview 79 Status Bar 79 Cscape Configuration 79 Datasheet 9 13 Default Gateway 30 Device Manager 103 Devices to Connect to EXL10 14 Digital Inputs 42 Dimensions 18 Duty Cycle 49 51 Duty Cycle Examples 51 Electrical Installation 22 Ethernet 28 54 80 84 103 Ethernet Communication 28 Ethernet Module Default Gateway 30 Get Settings From 30 IP Address 30 Net Mask 30 Status Register 30 Version Register 30 Ethernet Communication 28 Module Configuration 28 Module Protocols and Features 28 Module Specifications 28 Protocol Configuration 31 System Requirements 28 Fail Safe 61 89 AutoLoad 93 AutoRun 95 Backup Restore Data 90 Overview 89 System Settings 89 Features 14 Firmware Updates 100 Frequency 44 45 49 51 Fusing 41 General I O 38 Analog Inputs 42 Analog Outputs 43 Digital Inputs 42 Model 1 0 Overview 40 Overview 38 Page 110 of 114 HORNER AUTOMATION GROUP Relay Outputs 40 Removing the 1 Cover 38 Solid State Digital Outputs 40 Universal Analog Inputs 43 Glossary High Speed 1 0 44 Grounding 12 19 Definition 22 Specification 22 Testing for Good Ground 22 High Speed PWM 44 High Speed Counting 45 High Speed I O 44 HSC 44 45 47 85 Cover Removal 38 IP Address 30 Jumpers 38 42 43 Limited Warranty 3 Load Clone 63 98
49. E Graphics String Table Size 8 58117118 GBMP SIZE GraphicsBitmapTableSze 4 25 SR119 120 GTXT SUE Graphics Text Table Size 8 SR121 122 GFNT SIE GraphicsFontTablesize 8 5k 58125 GOBJCRC Graphics Object Table CRC 0 65535 58126 GSTRCRC Graphics String Table CRC 0 65535 58127 GBMP Graphics Bitmap Table CRC 0 65535 5818 GTXT_CRC_ Graphics Text Table CRC 0 65535 58129 Graphics Font Table CRC 0 65555 indicating Auto Restore of Register Data has 0 SR164 4 Read bit indicating Backup of Register Data has been performed Fail Safe 96581645 Enable AUTORUN Fail Safe Enable AUTOLOAD FailSafe SR1647 Backuptriggerbit SR164 8 Clear Backup trigger bit SR164 9 MAKE CLONE triggerbit_ SR164 10 LOAD CLONEtriggerbit_ Status indicating Make Clone Fail This bit goes high 0 581841 when Make Create clone fails SR164 12 Status indicating Load Clone Fail This bit goes high when Load clone fails 58165 174 Reserved o SR175 Removable Media Current Removable Media interface status 6 5 176 177 Removable Media free space on the Removable Media card in P SR178 179 Removable Media Indicates the total card capacity in
50. Frequency or Clear Period Measurement Disable Encoder Frequency Input Latch strobe Marker Polarity Preload load Quadrature Totalizer A special function to prevent the counter from running A sensor or transducer for converting rotary motion or position to a series of electronic pulses The number of times an electromagnetic signal repeats an identical cycle in a unit of time usually one second A special function that uses a digital logic circuit to store one or more bits A latch has 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 Input into the OCS that indicates a particular position Typically an encoder has a marker output that represents a specific point in the rotation A Polarity pull down box is associated with each function and indicates the manner in which the trigger happens e g High level Low Level Falling Edge Rising Edge A special function used to trigger loading of a value into a register upon an event Not used with Frequency or Period Measurement A high speed device that expresses the phase relationship between two periodic quantities of the same period when the phase difference between them is one fourth of a period A coupl
51. HSC inputs can be assigned for this purpose Quadrature mode works much like the totalizer except the accumulator will automatically increment or decrement based on the rotation phase of the two inputs See the following example for more details Quadrature inputs are typically used for reporting the value of an encoder Two modes are available for quadrature that select whether the accumulator counts up or down when the phase of input 1 leads input 2 Check your encoder s documentation to determine the output form it uses or try both modes to determine if the encoder counts up when expected 1 leading lagging Figures 11 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 So in order to determine the number of cycles the accumulator would have to be divided by 4 Marker reset operation is configured in the special operations and can be assigned to any of the 4 high speed iputs or can be assigned to be controlled by a Q bit in ladder Note the quadrature mode enables the Disable Latch Preload Clear and Marker special functions Please see section 11 2 for details 11 3 6 Register Match All counter modes support a register match function When the accumulator value m
52. IM HORNER AUTOMATION GROUP User Manual for eXL10 OCS MAN1029 01 EN HE EXV1EO HEXT505C100 HE EXV1E2 HEXT505C112 HE EXV1E3 HEXT505C113 HE EXV1EA HEXT505C114 HE EXV1E5 HEXT505C115 HE EXV1E6 HEXT505C116 dr E j a e a E HORNER AUTOMATION GROUP exl10 User Manual Page 2 of 114 HORNER AUTOMATION GROUP exl10 User Manual PREFACE This manual explains how to use the EXL10 OCS Copyright 2013 Horner APG LLC 59 South State Avenue Indianapolis Indiana 46201 All rights reserved No part of this publication may be reproduced transmitted transcribed stored a retrieval system or translated into any language or computer language in any form by any means electronic mechanical magnetic optical chemical manual or otherwise without the prior agreement and written permission of Horner APG Inc All software described in this document or media is also copyrighted material subject to the terms and conditions of the Horner Software License Agreement Information in this document is subject to change without notice and does not represent a commitment on the part of Horner APG Ethernet is a trademark of Xerox Corporation MicroSD and CompactFlash are registered trademarks of SanDisk Corporation For user manual updates contact Technical Support North America Tel 317 916 4274 Fax 317 639 4279 Web http www heapg com Email techsppt heapg com
53. K bytes 0 SR180 Reseved co 5 181 ALM UNACK Unacknowledged Alarm high bit indicates what group 8 96SR182 Active Alarm high bit indicates what group 96SR183 SYS BEEP System Beep Enable O disabled 1 enabled USER_BEEP Software configurable 0 OFF 1 SCR_SAVER Screen Saver Enabled O disabled 1 enabled SCR SA TM Screen Saver Time in minutes delay NET USE Average Net Usage of all units on the CAN network NET MIN Minimum Net Usage of all units on the CAN network NET MAX Maximum Net Usage of all units on the CAN network NT TX AVG Average Net Usage of this unit NT TX MIN Minimum Net Usage of this unit 96SR192 NT TX MAX Maximum Net Usage of this unit Page 78 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual For additional information on system bits and registers refer to the on line help found in Cscape 14 3 Register Map for eXL10 OCS 1 0 Table 14 4 Register Map for EXL10 OCS I O igi i EXL10 Model aa Digital Inputs 1 13 32 13 31 25 31 13 31 ESCP Alarm aq Digital Outputs 13 24 17 24 13 24 Analog Inputs Reserved 5 12 3 12 3 12 3 12 1 Reserved n a 1 8 1 8 1 8 Analog Outputs n a n a n a 9 10 Reserved areas maintain backward compatibility with other XL Series OCS models 14 4 Resource Limits Table 14 5 Resource Limits
54. Maintenance 100 Make Clone 63 97 Mechanical Installation 16 Micro SD Cards 34 Minimum Clearance Requirements 19 Model I O Overview 40 Modem COM Module Option 33 Mounting Orientation 17 Mounting Requirements 16 Panel Door 16 Net Mask 30 OCS Reference Document Numbers 15 Orientation of EXL10 OCS 17 Panel Box 19 20 Panel Box Shock and Vibration 20 Panel Cut out 18 Panel Cutout Tolerances 18 Panel Design Checklist 20 Panel Layout Clearances 19 Panel Mounting of an EXL10 Series OCS 16 Period Measurement 46 Power Connector 23 Primary Power Port 23 Primary Power Port Pins 23 Programming Examples 3 Pulse Mode 45 Pulse Stream 45 46 Pulse Width Measurement 45 86 Pulse Width Modulation 44 PWM 44 49 51 86 Examples 51 Frequency Formula 51 exl10 User Manual Registers 51 Quadrature 44 45 47 86 References Useful Documents 15 Register Map 47 51 77 Register Mapping 38 40 Registers 37 47 70 74 96S SR 74 Definitions 74 I O 77 Register Map 47 51 77 Resource Limits 77 Relay Outputs 41 Removable Media 14 15 34 60 70 105 Filenames 37 File System 34 Function Blocks in Cscape 36 Load Save Applications 35 Log Data 35 Manager 35 Manager Submenu 35 Micro SD Cards 34 Overview 34 Save Applications EXL10 36 System Registers 37 Troubleshooting 105 View Capture 36 RS485 Biasing 25 RS485 Termination 25 Safety Compliance 11 Safety Warnings Guidelin
55. Media function blocks to rename and delete files 9 6 Using Removable Media to Load and Save Applications A special file type with a PGM extension is used to store eXL10 OCS application programs on MicroSD To load an application from MicroSD to the eXL10 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 eXL10 to MicroSD open the Removable Media Manager the System Save Menu and press the Save F9 function key The application will be saved in a file called DEFAULT PGM in the MicroSD root directory NOTE Saving an application to MicroSD can only be done from the Removable Media System Menu and is not available on a Removable Media Manager object that was placed on an application graphics screen by Cscape Page 37 of 114 HORNER AUTOMATION GROUP exl10 User Manual Cscape can also save an application directly to a MicroSD card which is plugged into the PC s MicroSD compatible card reader by selecting the Export to Removable Media item on the Cscape File menu 9 7 Using Removable Media to View and Capture Screens The eXL10 OCS File System uses bitmap files with the BMP extension or JPEG files with the JPG extension to store eXL10 OCS graphic screen captures To view a captured eXL10 OCS screen use the Removable Media Manager to find and highlight the desire
56. Modbus EIP FTP HTTP 40 Version Register Enter an OCS Register reference such as R101 to indicate which 16 bit OCS register will have the Ethernet Firmware Version written to it The value stored in the Version Register is Ethernet Firmware Version 100 For example for Ethernet Firmware Version 4 30 the Version register will contain 430 Get Settings From Get settings from allows the programmer to either configure the IP Address Net Mask or Gateway for 2 functions Configuration or Register Page 32 of 114 HORNER AUTOMATION GROUP exl10 User Manual Configuration The configuration for the IP Address Net Mask or the Gateway will be assigned using 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 Ethernet Module Protocol Configuration The Protocol Support area contains a list of all the protocols supported by the platform being configured To activate a protocol check its checkbox For protocols that require additional configuration click on a listed protocol to select it and then click the Configure Selected Protocol button This will open a new dialog with configuration options for the selected protocol For detailed information on individual protocol configuration refer latest version of ETN 300 Manual SUP0740 Page 33 of 114 HORNER
57. NG Setting outputs ON in Do I O mode can result in injury or cause machinery to engage in an unsafe manner depending on the application and the environment 19 3 CsCAN Network For complete information on setting up CsCAN network refer to CAN Networks manual 0799 by visiting the Horner websites for the address to obtain documentation and updates Network status node ID errors and baud rate in the controller system menu are all in reference to the CsCAN network These indications can provide performance feedback on the CsCAN network and can also be used to aid in troubleshooting 19 3 1 CsCAN Network Troubleshooting Checklist 1 2 Use the proper Belden wire type or equivalent for the network as specified in MANO799 The eXL10 OCS does not provide 24VDC to the network An external voltage source must be used for other devices such as SmartStix 1 0 Check voltage at both ends of the network to insure that voltage meets specifications of attached devices Proper termination is required Use 121 ohm or 120 ohm resistors at each end of the network The resistors should be placed across the CAN HI and CAN LO terminals Measure the resistance between CAN HI and CAN LO If the network is properly wired and terminated there should be around 60 ohms Check for duplicate node ID s Keep proper wires together One twisted pair is for V and V and the other twisted pair is used for CAN and CAN 10 Make sure the baud rate
58. OLOAD PGM Application file CLONE DAT File having all unit settings and register values from Battery Backed RAM Load Clone Selecting Clone Unit menu will open the following menu screen Select Load Clone CLONE DRT 25570 07 15 09 12 11a Free 1004208128 Total 1005257280 Load Make Clone Clone V Esc NOTE For security enabled files Load clone asks for password validation before loading the application Page 66 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual 12 4 Touch screen calibration The touch screen is calibrated at the factory and rarely needs modification However if actual touch locations do not appear to correspond with responding objects on the display field adjustment is available To access the field adjustable touch screen calibration dialog press and hold both the SYS and F1 key for longer than 2 seconds and a dialog similar to figure 9 2 should appear Thereafter use a plastic tip stylus and follow the dialog instructions Note that special system keys may be locked out from user access If the SYS F1 combination does NOT respond verify that the system menu s Set Fkeys sub menu s parameter SYS Fn is enabled Touch Calibration Screen Please touch extreme Top Right corner point Page 67 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 13 USER INTERFACE 13 1 Overview This chapter presents the user interface or operator view of the eXL10 and som
59. Primary Power Port 5 0 0 2 Table 7 1 Ethernet Module Protocols amp Features Table 7 2 Ethernet Module Specifications Table 7 3 Ethernet Status Word Register Format Table 8 1 XL Series COM Options T ble 9 1 Filename Special Val es rtr heces rn eder Re RU Table 9 2 RM Status ValUCS Table 10 1 1 0 amp Model Overview cccccccccccccccecccssssccsscccessescesseasccsussccceeuececsusuceususseseseseceususeusssseuuasecsusssecassssessesesseseeeeusaesenees Table 11 1 Glossary of High Speed Tert creen iie E Ree t e ees dee eats Table 11 2 HSC Functions Register Map enne nennen nennen inen innen nns nennen nnns Table 11 3 Functions Register Map i c ee secede petuo edu e ee Eb Table 14 1 Type of Registers found in the EXL10 OCS Table 14 2 Common 96S Register Definitions sesesssssssseseeseeeeeeeenne nennen nennen nennt rne tnr ernst stre tne enne Table 14 3 SRREBISTEFS ce EE Table 14 4 Register Map for EXLIO i tt edite ey desde dee ed Table 14 5 Resource ce Table 19
60. Q1618 Preload Counter 2 Q1619 Clear Counter 2 Q1620 Disable Counter 2 901621 Direction C2 901622 Output Reset Counter 2 901623 Preload Disable Counter 2 901624 Latch Disable Counter 2 901625 Disable Marker C2 901626 Latch Marker C2 901627 Preload Marker C2 901628 Clear Marker C2 2611601 Overflow Flag Counter 1 2611602 Underflow Flag Counter 1 2611603 High Speed Out 1 2611604 Reserved 2611605 Overflow Flag Counter 2 9611606 Underflow Flag Counter 2 2611607 High Speed Out 2 2611608 Reserved 11 5 M High Speed Output Functions On units that support High Speed Output functions two dedicated outputs are available that can be configured for one of four modes of operation Those modes are Normal PWM HSC Match and Stepper Page 51 of 114 HORNER AUTOMATION GROUP exl10 User Manual 11 5 1 Normal When either Q1 or Q2 is configured for Normal operation the digital output registers Q1 and Q2 drives that respective output 11 5 2 PWM When either Q1 or Q2 is configured for PWM the PWM function drives that respective output Both PWM channels may be individually enabled and can have independent frequency and duty cycles The PWMs require two parameters 96AQs 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
61. RE T TT 67 13 5 Ladder Based Screen 68 13 6 Beeper 68 13 7 TOUCH Slip SefisiblViIy ER YR 68 13 88 ALANS T 69 13 9 Removable Media eere ora Pads TR Ta Fu 73 12210 Sereen ER 71 13 11 Screen 55 72 CHAPTER 14 REGISTERS 55 voii soseassecosvscticosvcstesoeudsss So Ry Ya EE S RE So YER EUER EOS MR SE ISEE 74 14 1 Register Definitions ioter dee PEE YER ERA TRA ERR TN X EE 74 14 2 Useful96S and ASR registers eec ree ie e XR 74 14 3 Register Map for EXL10 OCS 1 0 woo cecccccsscceesseceescecsseeccssececaseceeseeesseeccsaecssasecesseeesaeeseaeeecaneesaes 77 14 4 Resource e eee torret venere EAE ENEE SERERE 77 CHAPTER 15 CSCAPE CONFIGURATION 4 22 55 2 5 ee oan no ee nau n ee hanh or heh anu nn ee ha RR ron RR RR IR 79 NECI e E 79 15 2 Cscape Status nena win 79 15 3 1 4
62. S Horizontal Pixel Count 5583 KEY TYPE KeypdType 55844 RTCSEC Real Time ClockSecond 0 59 5585 RTCMIN Real Time Clock Minute 0 59 55846 RTCHOUR Real Time ClockHour 0 23 SR51 Network Error Count 0 65535 55852 WDOG CNT WetchdogTrppedErrorCount 0 6555 585354 BAD LADDER BadladderCodetrrorindex 0 65534 55855 F SELF TEST Filtered Bit MappedSelf TestResuit_ 0 65535 5856 LASTKEY Key Code of Last Key Press or Release 0 255 t Backlight Dimmer Register 0 Aor 096 On 25 25 On 100 255 100 On iid SR58 USER LEDS User LED Control Status 0 6555 sR59 60 Reserved Page 77 of 114 HORNER AUTOMATION GROUP exl10 User Manual Table 14 3 SR Registers Register Description Min Val MaxVal 55863 55 BASE SmartStack I O Base Selector 0 7 sR64 55 STATUS SmartStack I O Base Status 0 2 SR65 76 55 INFO 1 SmartStack I O Module 1 Information Structure SR77 88 55 INFO 2 SmartStack O Module 2 Information Structure 5889100 55 INFO 3 SmartStack I O Module 3 Information Structure SR101 112 55 INFO 4 SmartStack O Module 4 Information Structure SR113 114 GOBJSUE Graphics Object Table Size 8 25 SR115 116 GSTR SU
63. T ONLY BE CHANGED IN AN AREA KNOWN TO BE NON HAZARDOUS WARNING Battery May Explode If Mistreated Do Not Recharge Disassemble or Dispose Of In Fire WARNING Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life a All applicable codes and standards need to be followed in the installation of this product b For I O wiring discrete use the following wire type or equivalent Belden 9918 18 AWG or larger Adhere to the following safety precautions whenever any type of connection is made to the module a Connectthe green safety earth ground first before making any other connections b When connecting to electric circuits or pulse initiating equipment open their related breakers Do not make connections to live power lines c Make connections to the module first then connect 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 Mak
64. XL10 OCS uses a lithium ion battery available from Horner APG Below are the steps to replace the battery 1 Make sure the user program and any data stored in retentive memory is backed up 2 Disconnect all power from the eXL10 OCS unit including I O power 3 On the back of the eXL10 model unscrew the battery plate cover using a Phillips head screwdriver 4 Slide battery plate cover off the bottom of the unit 5 Remove the old battery and replace with a new 14500 Li ion battery on left on right NOTE Do not use an alkaline AA battery only use the proper battery type listed above and on the unit battery plate cover 6 Dispose of the old battery properly see the above warning on disposal regulations 7 Install the new battery 8 Slide battery plate cover back on the unit from the bottom up and re tighten the screw in place 9 Apply power to the unit Check that the battery error is no longer reported If the unit still reports the error remove the battery immediately and contact Technical Support Page 104 of 114 HORNER AUTOMATION GROUP exl10 User Manual Page 105 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 19 TROUBLESHOOTING TECHNICAL SUPPORT Chapter 19 provides commonly requested troubleshooting information and checklists for the following topics Connecting to the eXL10 OCS controller Local controller and local I O CsCAN Network Removable media In the event t
65. ad failed The last nine System Diagnostics are informational If any of these indicate a warning condition the eXL10 OCS can still enter and remain in Run mode but the problem should be investigated and corrected User Graphics 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 on the CAN network Warning No other nodes were found on the CAN network Network ID Ok This node s CAN Network ID is in the range 1 to 253 Warning This node s CAN Network ID was out of range at power up Dup Net ID Ok This node s Network ID is unique on the CAN network Warning This node s Network ID is duplicated in another node Page 58 of 114 HORNER AUTOMATION GROUP exl10 User Manual Clock Error Ok Time and date have been set Warning Time and date need to be set 1 0 System Ok 1 0 configuration matches the installed and COM modules Warning O configuration needs updating to match installed modules Battery Ok Backup battery operating properly Warning Backup battery needs to be replaced Vie
66. ad operation 16 3 Backup Restore Data Selecting this option brings up a screen having four operations Backup OCS Data Restore OCS Data Clear Backup Data Exit Backup Restore Data Clear Backup Figure 16 2 Backup Restore Data Backup OCS Data When initiated this will allow the user to manually 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 1 when backup operation is performed Backup Restore Data Backup Register Data Overwrite Backup Figure 16 3 Backup Registers Page 93 of 114 HORNER AUTOMATION GROUP exl10 User Manual Restore OCS Data When initiated this will allow the user to manually copy the backed up data from the onboard FLASH to the Battery Backed RAM A restore operation will be automatically initiated if a backup has been previously created and on power up the Battery Backed RAM registers fail their check The following process will be followed for restoring data The controller will be placed in IDLE mode Data will be copied from onboard FLASH to OCS Battery Backed RAM controller will reset The controller will be put in RUN mode if the AutoRun setting is Yes else it will remain in IDLE mode Backup Restore Data Restore R
67. ageScanRate 10 1000 MATE Minin sean Rate 10 Nd 96SR8 MAX RATE Maximum Scan Rate 10 96SR9 10 EDIT BUF Data Field Edit Buffer 0 96SR11 12 LADDER SIZE Ladder Code Size 2 96SR 13 16 Reserved 96SR17 18 SIZE Configuration Table Size 16 96SR19 20 NET SIZE Network Configuration Table Size 34 96SR21 22 SD SIZE Security Data Table Size _ Reened PS oce sm NET cR Network Configuration Table o 65535 socre Security Data Table cRE_ o Network Baud Rate CsCAN Network Mode O network not required 1 network 96SR31 NET MODE required 2 network optimized 3 3 network required and optimized SR32 LCD_CONT LCD Display Contrast setting 255 SR33 FKEY_MODE Function Key Mode 0 Momentary 1 Toggle 0 RS232 Serial Protocol Mode 96SR34 SERIAL PROT O Firmware Update RISM 1 CsCAN 2 Generic Ladder Controlled 3 Modbus RTU 4 Modbus ASCII SR35 36 SERIAL_NUM___ This Station s 32 bit Serial Number 0 24 SR37__ This Station s Binary Model Number 0 65535 55839 cCPLD REV BlOSRevNumber 00 00 25 55830 FPGA REV FPGA Image Rev Number 10 00 255 558 Vertical Pixel Count 42 ICD ROW
68. al input 10 7 1 Common cause of analog input tranzorb failure Models 2 3 amp 4 Ifa 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 tranzorb This can be solved by not connecting loop power prior to load connection or by installing a low cost PTCin series between the load and the analog input Digi Key 235 1074 ND or equiv Figure 10 7 Analog input tranzorb troubleshooting 10 8 Universal Analog Inputs Model 5 Note See the data sheet for the eXL10 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 analog inputs These inputs include voltage current thermocouple RTD and millivolt Each channel can be configured separately using jumpers and configuration settings in Cscape Like the standard analog inputs these inputs have a digital filter that can be used to filter electrical noise that may be unavoidable in some installations The downside to digital filtering is the inputs will respond more slowly to sudden changes in the actual input 10 9 Universal Analog Inputs Model 6 Universal Analog Inputs The Universal Analog Inputs on the model 6 IO board are unique from other Horner X series input output cards in that they ar
69. an COE Eo e dated eee Figure 16 5 Clear Backup ecrit eren AE E EXE ERES EHE VES EY ised Rede Figure 16 6 Flow Chart for Automatic Restore Figure 16 7 AutoLoad Figure 16 8 Flow Chart for AutoLoad e iter ioter Exe x ER 16 9 AUTORUN MENU senii eissii Page 113 of 114 HORNER AUTOMATION GROUP exl10 User Manual Figure 17 1 System Figure 17 2 Clone Unit Menu Before Cloning Figure 17 3 Clone Unit Confirm Screeh iiiter eth Figure 17 4 Cloning Status Figure 17 5 System Mense e RR eR Er I tee e Figure 17 6 Clone Unit Menu After Cloning etre iecit EE E datei eee gs Figure 17 7 Load Clone Confirm Screen cscccesccsssessssecssecseesssecsseecssecseessaeecsueccaeeseaeesneceseeseessaeeseueecseeseseesaeessaeesseesseeeseneeeseeess Table 2 1 pilo Tergeste Table 2 2 OCS Reference Document Numbers Table 3 1 Minimum Clearance Requirements for Panel amp Door Table 4 1
70. aracters Page 36 of 114 HORNER AUTOMATION GROUP exl10 User Manual 9 4 Using the Removable Media Manager The Removable Media Manager is an interactive eXL10 OCS screen that performs the following functions Display number of total and free K bytes Browse file and directory lists Delete files and directories Format a MicroSD card Load and save application programs View screen capture bitmaps ow The Removable Media Manager be accessed via the System Menu or by using Cscape to place Removable Media Manager object on an application graphics screen Media Directory SCROODO 262 07 10 08 12 46 SCROO01 JPG 14272 07 10 08 SCROO0802 JPG 15209 07 10 08 12 SCRO803 JPG 29708 07 10 08 12 SCROO0A JPG 29582 07 10 08 12 SCROOB05 JPG 23263 07 10 08 SCROODG JPG 145653 07 10 08 SCROO007 JPG 14976 07 10 08 SCROO88 JPG 15994 07 10 08 SCROO89 JPG 17561 807 10 08 Free 511672326 Total 511959040 V Del For Save l Del 811 Esc Figure 9 2 Removable Media Submenu 9 5 Using Removable Media to Log Data Using Read and Write Removable Media function blocks an application ladder program can read and write eXL10 OCS register data in the form of comma delimited files with a CSV extension These files are compatible with standard database and spreadsheet PC programs In addition an application ladder program can use Rename and Delete Removable
71. ase see section 11 2 for a description of these functions Page 48 of 114 HORNER AUTOMATION GROUP exl10 User Manual Width High 1 us Counts In this sub mode the accumulator value will contain the number of 1 us counts the pulse is high width High Width Low 1 us Counts In this sub mode the accumulator value will contain the number of 1 us counts the pulse is low J LI Width Low Figures 11 1 11 2 Pulse Width Measurements High amp Low 11 3 4 Period Measurement In period measurement mode the high speed input can measure the period of a pulse stream in one of two modes and provides a continuous indication of the last sampled value In this mode the Disable and Latch special functions are allowed Please see section 11 2 for a description of these functions Period Rising Edges 1 us Counts In this sub mode the period of the input signal is reported in one 1 us units The period measurement will start on the rising edge of the input Period from Rising Edge Period Falling Edges 1 us Counts In this sub mode the period of the input signal is reported in one 1 us units The period measurement will start on the falling edge of the input M Period from Falling Edge Figures 11 3 11 4 Period Measurement Rising Edges amp Falling Edges Page 49 of 114 HORNER AUTOMATION GROUP exl10 User Manual 11 3 5 Quadrature Quadrature mode uses two HSC inputs any of the four
72. atches the Match 1 or Match 2 value setup in AQ registers a high speed output with either turn on turn off or toggle based on settings in Cscape 11 4 HSC Functions Register Map The register assignments for the high speed I O can be moved via a setting in Cscape The values shown are the DEFAULT values and may not match the same starting point as the values shown below Page 50 of 114 HORNER AUTOMATION GROUP exl10 User Manual Table 11 2 HSC Functions Register Map Register Frequency Pulse Totalize 1401 402 Accumulator Counter 1 1403 404 Latch Value Counter 1 1405 406 Accumulator Counter 2 1407 408 Latch Value Counter 2 AQ401 402 Preload Counter 1 AQ403 404 Match1 Counter 1 AQ405 406 Match2 Counter 1 AQ401 402 Preload Counter 2 AQ403 404 Match1 Counter 2 AQ405 406 Match2 Counter 2 Q1601 Latch Counter 1 Q1602 Preload Counter 1 Q1603 Clear Counter 1 901604 Disable Counter 1 901605 Direction Cnt 1 9601606 Output Reset Counter 1 92601607 Preload Disable Counter 1 901608 Latch Disable Counter 1 901609 Disable Marker C1 901610 Latch Marker C1 9601611 Preload Marker C1 901612 Clear Marker C1 Q1613 1616 Reserved Q1617 Latch Counter 2
73. cal networks use Class C IP Addresses in which case the low octet rightmost number is used to uniquely identify each node on the local network In this case the default Net Mask value of 255 255 255 0 should be used Gateway Enter the IP Address of a Gateway Server on the local network that allows for communication outside of the local network To prevent the Ethernet Module from communicating outside the local network set the Default Gateway IP Address to 0 0 0 0 the default setting Status Register 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 7 3 Ethernet Status Word Register Format High Byte Low Byte Bit Bit Bit Bit Bit Bit Bit 16 15 14 13 12 11 10 Bit 9 Bit8 Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 0 0 Dup Spd 0 Rx Tx Link TCP Connections Status Bit s Status Indication Status Values Minimum Maximum 0 Reserved Always 0 Dup Link Duplex Auto Negotiated 0 Half Duplex 1 Full Duplex Spd Link Speed Auto Negotiated 0 10 MHz 1 100 MHz Rx Receive State 0 Inactive 1 Active Tx Transmit State 0 Inactive 1 Active Link Link State 0 Down 1 Total Number of Active TCP Connections TSE Connections CSCAN SRTP
74. cation or hardware failures during the firmware update process can cause the controller to behave erratically resulting in injury or equipment damage Make sure the functions of the equipment work properly after a firmware update before returning the device to an operational mode Steps for updating the firmware 1 Loading new firmware will erase any program stored in the OCS for safety and compatibility reasons Please backup the application prior to performing a firmware update 2 Copythe supplied files onto a FAT32 formatted MicroSD or USB based flash device 3 Insert the flash device into the eXL10 making sure no other memory or drives are connected to the device 4 Press and hold the system menu for at least 6 seconds and a firmware update menu will be presented 5 f you are just updating the firmware press the Update Firmware button If you are updating the bootloader firmware and FPGA press the Update Bootloader button On early versions of firmware this can take several minutes This will take about 15 seconds on newer firmware 18 2 Backup Battery The eXL10 has an advanced battery system It uses a rechargeable lithium battery The battery powers the real time clock when power is removed To store registers the battery continues to power the OCS for less than a second after external power is removed In this time the registers and other retentive data is saved to internal flash memory This battery will need about 8 hou
75. cation string table Bitmap Size x Number of bytes in application bitmaps Page 57 of 114 HORNER AUTOMATION GROUP exl10 User Manual Text Tbl Size x Number of bytes in application text tables Font Tbl Size x Number of bytes in application font tables Protocol Size x Number of bytes in application downloaded protocols SMS File Size x Number of bytes in application SMS protocol configuration Firmware Rev XX yy Current firmware version OS Ver a b cd yz Current Operating System version FPGA Rev x y Current FPGA version High Speed IO Sub System InitRD Rev X yz Bootloader version Self Test Ok All power on self tests passed Fault One or more power on self tests failed View Diags System Menu Logic Error User Program User Graphics W Dog Trips Clock Error 1 0 System Battery The View Diags Sub Menu displays up to 11 System Diagnostics none of which are editable The first two System Diagnostics are critical If either of these indicate a Fault condition the eXL10 OCS will not enter or remain in Run mode and the problem must be investigated and corrected Logic Error Ok All executed ladder instructions are legal for loaded firmware Fault A ladder instruction not supported by firmware was found User Program Ok Ladder program and 1 0 configuration loaded successfully Fault Ladder program or 1 0 configuration not loaded or lo
76. cept 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 slider object requires the operator to touch and slide the control in Page 68 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual the direction desired Alternately alpha numeric entry objects invoke a pop up alpha numeric keypad for additional user input The alpha numeric keypad is discussed below Note that if the numeric entry object displays gt gt gt gt gt gt gt the value is too big to display in the field or is above the maximum for an editable field Likewise if the numeric entry object displays lt lt lt lt lt lt lt in a numeric field the value is too small to display or is below the minimum for an editable field 13 3 Alpha numeric keypad To allow entry of a specific number or text several of the input objects invoke a pop up alpha numeric keypad when the object is touched An example of the alpha numeric keypad invoked from a numeric input object is shown in Figure 13 2 Once invoked the operator may touch the appropriate keys to enter a specific value When entering a value the alpha numeric keypad is in one of two modes new value or edit value New value mode Generally when
77. d BMP or JPG file and then press Enter To capture eXL10 OCS screen turning On the assigned Screen Capture Control Register will capture the current eXL10 OCS graphics screen and write it to the MicroSD card using the assigned Screen Capture Filename Before capturing an eXL10 OCS screen Cscape must first be used to assign a Screen Capture Control Register and Filename in the application To do this first open the Graphics Editor by selecting the View Edit Screens item on the Cscape Screens menu Next select the Screen Capture item of the Graphics Editor Config menu and then enter a Control Register and Filename 9 8 Removable Media RM Function Blocks in Cscape NOTE For detailed information regarding RM function blocks and parameters refer to the help file in Cscape Software Refer USB Flash Media support for RM Functions for USB flash drive access details The following RM functional blocks are available in Cscape Software These function blocks will reference MicroSD when filename is prefixed with A or nothing OR USB A Flash Drive when filename is prefixed with B Read RM csv Allows reading of a comma separated value file from the MicroSD interface into the controller register space Write RM csv Allows writing of a comma separated value file to the MicroSD interface from the controller register space Rename RM csv Allows renaming a file on the RM card The data in the file i
78. e Controller 1 O Configure menu item If the eXL10 OCS is connected to the PC press the Auto Config System button to automatically detect the Base model 1 0 and any communication options If the eXL10 OCS is not connected press the Config button to the right of the top of the unit This allows the base CPU to be selected Select either eXL10 OCS Cscan from the type drop down box Once the type of eXL10 OCS is selected the model drop down box will provide the eXL10 OCS model numbers from which to choose from Once the eXL10 OCS CPU is selected press OK to exit the dialog and configure the I O that is present in the first slot The I O configure dialog Specifically the Module Setup tab provides 4 buttons to configure all of the 1 0 Go through each area of I O and configure it Once done configuring the I O OK out of configuration dialogs Configuring the eXL10 OCS I O has four main portions that are covered in this chapter For additional information on I O refer the chapters covering General I O or High Speed I O in this manual The four areas of I O configuration 15 5 Digital in HSC Digital out PWM Analog in Analog out Digital Input HSC Configuration The following figure illustrates the Digital Input HSC Configuration dialog Digital HSC Input Configuration Digital inputs active mode Positive Logic Note This setting must x E match that of the jumpers C Negative Logic onthe product HSC 1
79. e 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 Page 45 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual Analog Input Configuration i il Channel 1 Filter Constant Jo a 21 4 20mA 0 Disable D B mV PT100 DIN RTD PT1000 DIN RTD 0 Type J Thermocouple Type K Thermocouple Type N Thermocouple D Type T Thermocouple 0 E Thermocouple Type Thermocouple Type S Thermocouple Type B Thermocouple Channel B Disable X 0 uc G 3 Ensure the proper wiring is used for each of the 3 pins and C on the Universal Analog Inputs as seen in the reference image below mA Connection mV Connection V Connection T C Connection RTD Connection 10 10 Analog Outputs Note Refer to the datasheet for eXL10 OCS model being used for details on jumper settings The analog outputs on eXL10 OCS devices provide high resolution voltage or current outputs The voltage or current selection is controlled with jumpers and configuration settings in Cscape Note that each channel can be separately configured for voltage or current mode When the controller is st
80. e of the model specific characteristics of the eXL10 as compared 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 graphics editor help file The following aspects are discussed e Displaying and entering data e Alarm log dialog e Alpha numeric data entry e RM dialog e Navigating around screens e Screen Saver e Beeper acknowledgement e Dimmer e Touch slip sensitivity 13 2 Displaying and entering Data Roller 2 A Start Stop Manual Running Hours 1274 B Cleaning Hours 34 RY Figure 13 1 Example Screen Multiple objects are provided for displaying data such as virtual panel lights push buttons numeric value displays bar graphs meters graphs and animated bitmaps On the eXL10 these graphical objects through ladder manipulation of attribute bits can change color flash or change visibility to attract operator attention On objects that accept user input the input is provided by touching the object or alternately changing an OCS register i e Function key registers Objects that allow input generally have a raised 3D appearance An exception is the binary type objects such as buttons which are shown in a depressed 3D appearance when in the ON state Objects that normally ac
81. e sure the unit is turned OFF before making connection to terminals Make sure all circuits are de energized before making connections Page 12 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual h Before each use inspect all cables for breaks or cracks in the insulation Replace immediately if defective 1 2 Grounding Grounding is covered in various chapters within this manual 1 3 Compliance To check for compliance and updates visit the Horner website US http www heapg com or Europe http www horner apg com Page 13 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 2 INTRODUCTION 2 1 Visual Overview of eXL10 OCS Power CANT MJ3 MJ1 RS 232 MicroSD USB mini B CAN2 10 30VDC Input CAN I O amp RS 232 485 MJ2 1 2 Duplex RS 485 Data Storage Programming CAN I O Fieldbus Port Audio Out In USB 2 0 Flash LAN1 LAN2 Storage Figure 2 1 Overview of the eXL10 2 1 1 Where to Find Information about the eXL10 OCS a Datasheet The datasheet is the first document to refer to for key information related to specific eXL10 OCS models a The datasheets for all eXL10 OCS models are available on the Horner websites b Datasheets contain pin outs jumper settings and other model specific information b User Manual This manual provides general information that is common to eXL10 OCS models and can be downloaded from our web Visit the Horner website US http www heapg com or
82. egister Data fire You Sure This will cause System Reset Figure 16 4 Restore OCS Data SR164 3 is set to 1 only when an automatic restore operation is performed not on a manual one This bit is reset to O when a new backup is created Restoring of data can be manually performed by selecting RESTORE option from the Backup Restore Data menu This will cause the controller to reset Clear Backup Data When initiated the backup data will be erased from the onboard Flash and no backup will exist SR164 4 and SR164 3 is reset to O when backed up data is erased Backup Restore Data Clear Backup fire You Sure Figure 16 5 Clear Backup Data Exit Goes back to the previous screen Page 94 of 114 HORNER AUTOMATION GROUP exl10 User Manual The OCS follows the following sequence in execution of Automatic Restore C OCS Power Cycle Battery Backed RAM Registers check failed Backup NO exists YES Controller placed in Application IDLE mode Program erased Data copied from Onboard FLASH to OCS Battery backed RAM Controller Resets NO Y AutoRun OCS put in IDLE Enabled Mode YES OCS put in RUN Mode Figure 16 6 Flow Chart for Automatic Restore Page 95 of 114 HORNER AUTOMATION GROUP exl10 User Manual 16 4 AutoLoad This system menu option allo
83. en nennen Figure 13 5 Alarm Fig re eB ESAE IRURE UTE m Em Figure 13 7 Removable Media Object eiii d iiun an ir SERES Y Ran es Figure 13 8 Removable Media Viewer eerte eire EE souk Ie padece react dbs eese ee Figure 13 9 Example application segment for safe removal of removable media essen Figure 15 1 Cscape Status ve Figure 15 2 USB Programming Connector cccccccccseseeessseeeceeaeeeseaaeeeseaeeeceeaeeeseaueeeseaeeseeaneeeeaeeeseaeeeseeaeeeseaeeesesaeeseeaeeesseeeeseaees Figure 15 3 Digital Input HSC Configuration Dialog ccccccsscsssssscsscssscssscsscssesecssecsecssessesessssescseseessaeseseaesaeseaeseessseseseatenesoas Figure 15 4 Digital Output PWM Configuration Dialog c cccescssscesssssessecsscssessesesecssessecsesesessessseseessseseeseaesaessaesessseseseateesegs Figure 15 5 Analog Input Configuration Figure 15 6 Analog Output Configuration Dialog Figure 16 1 Fail Safe System Menu Figure 16 2 Backup Restore Data ae s i ts m Figure 16 3 Backup Registers REM Figure 16 4 Restore OCS rU Ope teaver e Cere eoe TEX Ve o
84. er in which the two output signals are 90 out of phase A counter that sums the total number of cycles applied to its input Table 11 1 Glossary of High Speed I O Terms Page 47 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual 11 3 High Speed Counter HSC Functions The eXL10 supports two very high speed configurable counters There are four dedicated inputs that can be configures to a number of different options Each of the two counters can run in one of five modes Those modes are Totalizer Frequency Counter Pulse Width Measurement Period Measurement and Quadrature measurement For some modes more than one HSC input may be consumed The measurement values are provided to ladder in a AI register see page 49 11 3 1 Frequency In frequency mode the frequency of the input signal is written to the accumulator in terms of Hertz cycles second When using frequency mode four update selections are provided which specify the width of the sample window Note that selecting a shorter sample window provides a quicker measurement faster response but lowers the frequency accuracy resolution and increases the minimum frequency measurement limit In this mode the Disable and Latch special functions are allowed Please see section 11 2 for a description of these functions 11 3 2 Totalize In totalize mode the accumulator is simply incremented or decremented each time the input transitions in a specific direction
85. es 11 Screen Brightness 72 Screen Saver 71 Screen Navigation 67 Serial Communications 24 Cscape Programming 25 DIP Switches 24 Downloadable Protocols 25 Ladder Controlled 25 Overview 24 Ports 24 Wiring 24 Set Network ID 84 Slip 65 Solid State Digital Outputs 40 Sourcing 40 42 Status Bar Cscape 79 Stepper 44 48 50 Stop state 41 43 Sub Menus 54 System Menu 53 Page 111 of 114 HORNER AUTOMATION GROUP Clone Unit 62 Fail Safe System 61 Load Clone 63 Removeable Media 60 Set Beeper 59 Set Date Time 58 Set Fkeys Mode 57 Set Networks 54 Set Screen 59 Set Serial Ports 58 View Diags 55 View I O Slots 56 View Protocols 57 View Status 54 System Settings and Adjustments 53 Overview 53 Details 54 Navigate Edit 53 Table of Contents 5 Target ID 83 Target Indicator 83 Technical Support 2 15 42 101 102 105 Contacts 2 107 Testing for Good Ground 22 Totalize 45 Touch screen calibration 63 Touch slip sensitivity 65 Troubleshooting 102 Common problems 102 Connecting Checklist 103 exl10 User Manual CsCAN Checklist 104 CsCAN Network 104 Ethernet port programming 103 Local Controller 1 0 103 Local I O Checklist 104 Removable Media 105 Serial Port MJ1 103 USB Port Mini B 103 Two Point Ground Connection Test 22 Types of Devices that can be connected to EXL10 14 Universal Analog Inputs 43 USB 14 15 25 27 36 80 82 100 103 User Inter
86. et 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 is designed for commissioning or temporary field changes The actual parameters are defined in Cscape under the Ethernet configuration and are reverted to whenever the unit goes from idle to run mode View Status System Menu Model Scan Rate mS Ladder Size Config Size Graphics Size String Size Bitmap Size Text Tbl Size Font Tol Size Protocol Size SMS File Size Firmware Rev FPGA Rev InitRO Rev The View Status Sub Menu displays up to 19 System Settings Only the OCS Mode System Setting is editable XW1yz Model number of this eXL10 OCS unit Model 1yz indicates the installed I O module 00 1 0 module Idle EXL10 OCS is Idle mode OCS Mode DolO EXL10 OCS is in Do 1 0 mode Run EXL10 OCS is in Run mode 0 0 EXL10 OCS is not in Run mode 0 1 to 999 9 Average number of mS for each ladder scan Scan Rate mS OCS Net Use 0 0 to 100 0 CAN network bandwidth 96 used by this eXL10 OCS node All Net Use 0 0 to 100 0 CAN network bandwidth 96 used by all nodes Ladder Size 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 appli
87. f required NOTE the backlight life may be shorted when screen is dimmed or screen brightness is varied on a repetitive basis Page 75 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 14 REGISTERS 14 1 Register Definitions When programming the eXL10 OCS data is stored in memory that is segmented into different types This memory in the controller is referred to as registers Different groups of registers are defined as either bits or words 16 bits Multiple registers can usually be used to handle larger storage requirements For example 16 single bit registers can be used to store a Word or two 16 bit registers can be used to store a 32 bit value Table 14 1 Types of Registers found in the EXL10 OCS 16 bit input registers used to gather analog input data such as voltages temperatures and speed settings coming from an attached device 16 bit output registers used to send analog information such a voltages levels or speed settings to an attached device 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 Single bit input registers Typically an external switch is connected to the registers Single bit flags used to give the programmer direct access to any front panel keys appearing on a unit Retentive single bit registers Single bit output registers Typically these bits are connected to an actuator
88. f the cycles within this mode is constant at the specified Run frequency The Run count may be any value Setting this value to zero disables this phase Deceleration Count Sets the number of cycles to occur within the deceleration phase The frequency of the cycles within this phase will vary linearly between the specified Run and Stop frequency The Decel count must not equal 1 or an error is generated Setting this value to zero disables this phase The stepper provides two Boolean registers to provide stepper status A high indication on this register indicates the stepper sequence can be started Ready Done v i e not currently busy and also when the move is completed A high indication on this register indicates that one of the analog parameters Error specified above is invalid or the stepper action was aborted before the operation was complete This register is cleared on the next start command if the error was corrected 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 Page 53 of 114 HORNER AUTOMATION GROUP exl10 User Manual NOTE Setting the PLC mode to stop while the stepper is in operation causes the stepper output to immediately drop to zero a
89. f the RS485 network should be terminated 5 5 RS485 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 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 screen that writes to SR164 can do the same thing Setting SR164 1 enables MJ2 biasing and setting SR164 2 enables MJ3 biasing If biasing is used it should be enabled in only one of the devices attached to the RS485 network 5 6 Cscape Programming via Serial Port The 0110 OCS MJ1 and MJ3 serial ports support CsCAN Programming Protocol If a PC COM port is connected to the EXL10 OCS or serial port Cscape can access the eXL10 OCS for programming and monitoring Programming can also be done via the CAN port USB A port or Ethernet 5 7 Ladder Controlled Serial Communication Using Serial Communication function blocks MJ1 MJ2 and MJ3 serial ports support Generic Modbus Master and Modbus Slave Protocols In addition external modems can be connected and accessed using Init Dial and Answer Modem function blocks 5 8 Downloadable Serial Communication Protocols MJ1 MJ2 MJ3 also support downloadable protocols such as Allen Bradley DF1 CSCAN Master GE Fanuc SNP and M
90. face 65 Alarms 69 Alpha numeric keypad 66 Beeper Acknowledgement 68 Displaying and entering data 65 Ladder Based Navigation 68 Screen Navigation 67 Touch slip sensitivity 68 Visual Overview of EXL10 and Topics 13 Where to Find Information 13 Wiring amp Dip Switches 24 EXL10 Dimensions 18 EXL10 OCS Accessories 15 EXL10 OCS Dimensions 18 EXL10 OCS Mounting Clip 17 EXL10 OCS Mounting Orientation 17 XMC 33 Page 112 of 114 HORNER AUTOMATION GROUP exl10 User Manual Index of Figures amp Tables Figure 2 1 Visual Overview of the EXL10 OCS ccccsscccsssssseesssecsseesssecseeseneecsuecsaeessneesneccaeeseessaeeseusecsesesaeesenessaeesseesseeeseneesseeess Figure 2 2 Visual Overview of Types of Devices that can be connected to EXL10 OCS Figure 3 1 Panel Mounting of an EXL10 Series OCS cccccsccsssecsseeseseecssecsseecsneesseeceeeesnessaeessuecsaeecueecseeeeaeesneseaeessaessaeesenseeneeess Figure 3 2 EXL10 OCS with MOUNTING Clips rade ceeds Figure 3 3 Orientation of EXL10 OCS Figure 3 4 Cutout Tolerances cci ce i eie pec e eU ez ctae e e tends civ e ete es Figure 3 5 EXL10 OCS Dimensions Figure 4 1 Two Point Ground Connection Test Figure 4 2 Power Connector Primary Power Port Figure 4 3 Primary Power Port as Viewed Looking at the EXL10 OCS
91. gister Usage Default Settings Register Get settings from IP Address 192 168 254 128 Name Configuration gt Use CAN ID for last Octet NetMask 255 255 255 0 c Configuration v Gateway 0 0 0 0 Name ce Configuration Status Version Name Us Protocol Support Resident Protocols Ping EGD Ethernet Global Data Configure Selected Protocol SRTP Slave 90 30 Service Request O Modbus TCP Slave O Ethernet IP File Server HTTP Web Server ASCI Over TCP IP Downloadable Protocols ETNI 1 None Scan List ETN1 2 None joo new Cancel 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 configure Select Ethernet and enter IP address which is configured in the file Select mode as XL Series mode from drop down list The controller should get connected to Cscape If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above Page 87 of 114 HORNER 15 4 AUTOMATION GROUP exl10 User Manual Configuration An overview of configuration 1 2 Start the configuration by selecting th
92. h a blank project Check Local If idle R run or D do I O shows next to Target number then communication is established to the Target LR D target controller Communication is not established to the target controller Check node ID of controller and set Target to match Make sure local connection is established Target Table 19 1 Cscape Target amp Local Numbers Page 106 of 114 HORNER AUTOMATION GROUP exl10 User Manual 19 1 1 1 2 3 19 1 2 19 1 3 n 19 2 Connecting Troubleshooting Checklist serial port MJ1 Programming Programming and debugging must use MJ1 or USB Mini B Port Controller must be powered up Ensure that the correct COM port is selected in Cscape Tools Editor Options Communications Port Ensure that a straight through non null modem serial cable is being used between PC and controller port MJ1 Check that a Loaded Protocol or ladder is not actively using MJ1 Taking the controller out of run mode from the System Menu on the controller will make MJ1 available to Cscape Make sure the COM port of the PC is functioning An RS232 serial loopback and Microsoft HyperTerminal can determine positively if the COM port is working Or connect to an alternate device to determine if the port is working Successful communications with USB to serial adapters vary If in doubt Horner APG offers a USB to serial adapter Part n
93. hat this information is not enough please contact Technical Support at the locations indicated at the end of this chapter 19 1 Connecting to the eXL10 OCS Cscape connects to the local controller automatically when the serial connection is made The status bar below shows an example of a successful connection This status bar is located in the bottom right hand corner of the Cscape window lLocal 253 Target 253 R no Forces In general the Target number should match the Local number The exception to this is when the controller is being used as a pass through unit where other controllers on a CsCAN network could be accessed through the local controller Determine connection status by examining feedback next to Local amp Target in the status bar of Cscape Local If a number shows next to Local then communication is established to the local controller Cscape is unable to access the COM port of the PC This could mean that Cscape is configured for a Local Port 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 Cscape has accessed a PC COM port but is not communicating with the controller This typically occurs Local No Com when the controller is not physically connected Unknown communication error Close Cscape power cycle the controller and reopen Cscape wit
94. he contents of stored in the Target Controller these messages e f Equal the program in Cscape is the same as the program stored in the Target Controller are context e f Not Equal the program in Cscape is not the same as the program stored in the Target sensitive The Controller Message line can e f Unknown there may have been a change since the last time the program Cscape was be empty compared to the Target Controller Current User File Modified Indicator indicates that indicates who is logged the file in the selected window has for security purposes been modified but has not been saved Ready User HE XExx1 CsCAN Model Equal Local 1 Target 2 R no MOD forces Controller Model Network Model Confirmation Communications Status indicates the current status of the pass through Connector Controller Model indicates the controller model for which the program in Cscape is configured e Local xx indicates the Network ID of the OCS to which the Cscape program is physically connected through its e Network indicates the type of network that the program serial port It can serve as a pass through device to other in Cscape expects to use e g CSCAN nodes on the network e Model Confirmation provides the following e Target yy R indicates the Network ID of the device with indications which the Cscape program is exchanging data Note The Local unit and Target unit can be the e the actua
95. hernet 100 Mbps Modes Half or Full Duplex Auto Negotiation Both 10 100 Mbps and Half Full Duplex Connector Type Shielded RJ 45 Cable Recommended Port Auto MDI MDI X Auto Crossover Table 7 2 Ethernet Module Specifications Speeds CATS or better UTP 7 4 Ethernet Module Configuration Note The following configuration is required for all applications regardless of the protocols used Additional configuration procedures must be performed for each protocol used To configure the Ethernet Module use Cscape Programming Software to perform the following steps 1 On the main Cscape screen select the Controller menu and its I O Configure sub menu to open the I O Configuration dialog Figure 7 1 2 If configuring a different OCS Model than the one shown in the I O Configuration dialog click on the topmost Config button select the desired OCS Model and then click OK Page 30 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual Series Series Description EE Touch screen Operator Control Station with Device Type fixed 1 0 Properties Model HEEXVIE2 Display 480 by 640 LCD Network Ports Keypad Type 7 7 CAN1 5 Config Program Memory 1024 K Bytes cava aca LAN1 ETN300 Cone _Config ed Tine Cock Suppor Serial Ports Config Figure 7 1 I
96. icroSD Memory Card Slot 9 2 MicroSD Cards When the MicroSD card format was introduced it was originally called TransFlash Cards labeled either MicroSD or TransFlash with up to 32 GB of Flash memory are compatible with the eXL10 OCS Memory slot larger sizes were not tested at time of publication The Memory slot is equipped with a push in push out connector and a MicroSD card can be safely inserted into the Memory slot whether the eXL10 OCS power is On or Off To install a MicroSD card Align its 8 pin gold edge connector down facing the front of the eXL10 OCS unit as shown in Figure 9 2 then carefully push it all the way into the Memory slot Ensure that it clicks into place To remove the MicroSD card Push in on the top of the card gently to release the spring The card pops out for removal 9 3 MicroSD File System The MicroSD Memory slot uses the PC compatible FAT32 File System This means that a PC with a MicroSD compatible card reader can read files that have been written by the eXL10 OCS and can write files that can be read by the eXL10 OCS However the eXL10 OCS does not support long filenames but instead implements the 8 3 filename format This means that all file and directory names must consist of up to 8 characters followed by an optional dot and an optional extension with up to 3 characters Directories and sub directories can be nested up to 16 levels deep as long as each pathname string does not exceed 147 ch
97. ing a diagram such as Figure 9 4 below and a description of the jumper settings A 8 Figure 10 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 counter clockwise until it clicks into the threads This prevents the screw from being cross threaded Now turn the screw clock wise until the cover is firmly secured Repeat this process for all four 4 screws Ensure not to exceed the recommended max torque of 7 10 Ib in 0 8 1 13 Nm Page 41 of 114 HORNER AUTOMATION GROUP exl10 User Manual 10 3 Model and 1 0 Overview Table 10 1 1 0 and Model Overview EXL10 Models DCIn DCOut Relays HS In HSOut mA V In RTD Tc mA V Out HE EXV1EO HEXT505C100 HE EXV1E2 HEXT505C112 12 2 HE EXV1E3 HEXT505C113 12 12 2 2 HE EXV1E4 505 114 24 18 s 2 2 HE EXV1E5 HEXT505C115 12 12 2 2 HE EXV1E6 HEXT505C116 12 12 4 2 6 Table 10 1 shows the different types of I O included with the various eXL10 OCS models Specific specifications jumper settings and wiring diagrams can be found on the data sheets attached at the end of the manual Descriptions and applications of the different type of I O can be found below up to six mA V In mA V RTD Tc and 4 mA V Out 10 4 Solid State Digital Outputs Solid state digital outp
98. l Target Controller matches the same unit or they can be separate units configured Controller Model and Network The following are status indicators e Model Not the actual Target Controller does not match the configured Controller Model and Network R Running D Do l o e Model there have been a change since the 1 Idle last time the Target Controller was compared to the Cscape is not communicating with the remote unit configured Controller Model and Network no forces indicates no I O has been forced Figure 15 1 Cscape Status Bar Page 81 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual 15 3 Establishing Communications The preferred method of communicating between Cscape and an eXL10 OCS is via USB port The eXL10 OCS can communicate with Cscape using USB to USB USB to serial adapters serial port communications via MJ1 Port Ethernet CAN CsCAN or modems For communications other than USB or the MJ1 port please refer to the manual which ships with the communications adapter hardware being used for programming To communicate with the eXL10 via USB you will need the automated driver installer located on the Horner APG web site For eXL10 use Cscape Ver 9 30 SP6 or newer Next connect a PC s Personal Computer running a Windows Microsoft operating system USB port via USB cable to the USB mini B port on the eXL10 OCS Audio Out In USB 2 0 A Flash LAN1 LAN2 Storage
99. l updates and assistance contact Technical Support at the following locations North America Tel 317 916 4274 Fax 317 639 4279 www heapg com Email techsppt heapg com Europe Tel 353 21 4321 266 Fax 353 21 4321826 www horner apg com Email tech support hornerapg com Page 109 of 114 IM HORNER AUTOMATION GROUP Main Index Q bits 40 96S amp 96SR 74 Accessories 15 Accumulator 44 46 Alarms 69 Alpha numeric keypad 66 Analog Inputs 42 Analog Input Tranzorb Failure 43 Analog Outputs 43 AutoLoad 93 AutoRun 95 Backup Restore 90 Backup OCS data 90 Battery 100 Backup 100 Replacement 101 Warnings 101 When to Replace 100 Battery backed RAM 61 96 98 Beeper Acknowledgement 68 CANT 26 27 54 2 26 27 CAN Communications 26 Cscape Programming 27 Expansion Network I O 27 Ladder Controlled 27 Overview 26 Ports 26 Wiring 26 CE 12 Clone Unit 96 Clone 96 Load Clone 98 CLONE DAT 63 97 COM port s 24 80 102 MJ1 Serial Port 24 27 33 57 58 80 83 103 Communication Options 28 33 Modem COM Module XMC 33 Overview 33 Communications Port 80 103 Compliance 12 Count 46 47 Cscape Programming Via Serial Port 25 Via CAN Port 27 Cscape 14 15 24 28 33 35 36 38 41 44 51 54 56 57 65 68 76 79 80 84 89 102 104 Analog Input Configuration 87 exl10 User Manual Analog Output Configuration 88 Configuration Procedures 85
100. l10 User Manual Set Beeper System Henu eeper enable Use 4 to adjust The Set Beeper Sub Menu displays one System Setting which may be edited Yes default Enables beeper Bebe eliable No Disables beeper does NOT affect ladder access Set Screen The Set Screen Sub Menu displays four System Settings all of which may be edited System Menu Timeout min Popup Status Update Time mS Update time sets the maximum tine used by graphics in the logic scan Yes Enable screen saver Saver enable No default Disable screen saver 5 1200 Amount of time in minutes to expire with NO touch activity Timeout min ES fmin before activating screen saver black screen Off default Disable popup status Warning Display popup status only if controller status changes to kopup Status 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 per scan Page 62 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual Removable Media Media Directory SCRO661 67 16 08 SCROG62 JPG 15209 67 16 08 12 46 SCR0003 JPG 29708 67 16 08 12 46 SCROGO4 JPG 29582 67 16 08 12 57 SCR0O005 JPG 23263 07 10 08 12 57 SCR0O006 JPG 145643 07 10 08 12 57 SCR0007 JPG 14976 07 10 08 12 57 5 0008 JPG 15994 67 16 08 12 SCR0009 JPG 17561 67 1
101. lename DataSMSD csv Data0301 csv Filename Year SYNMonth MNaaSD Sh csv Year04 Month03 aa01_15 csv Filename Month_SM Day_SD Sh_Sm_Ss csv Month_03 Day_01 15_ 45 34 5 9 10 System Registers used with RM SR175 Status This shows the current status of the RM interface 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 Table 9 2 RM Status Values RM interface OK Card present but unknown format No card in slot Card present but not supported Card swapped before operation was complete Unknown error For additional status information consult the help file Page 39 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 10 GENERAL I O Note Each eXL10 OCS unit is sent with a datasheet in the box The datasheet is the first document to refer to for model specific information related to eXL10 OCS models such as pin outs jumper settings and other key installation information Visit the Horner websites to obtain datasheets user documentation and updates 10 1 Overview eXL10 OCS is a compact unit that contains high density very versatile I O Using the 1 0 properly requires wiring to the proper terminals configuring jumpers inside the eXL10 OCS unit and configuring
102. mparison between the counter accumulator and match registers See details above in the high speed input section 11 5 4 Stepper Function The eXL10 supports two stepper functions one on each high speed output The Stepper requires five parameters AQs to be set for operation These parameters may be set at run time but are latched when the stepper is commanded to start Start Frequency pulses per second Sets the frequency for the first cycle during the acceleration phase and the frequency of the last cycle during the deceleration phase When an acceleration or deceleration count is specified the Start Frequency must be greater than O and must not exceed the run frequency or an error is generated Run Frequency pulses 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 O 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 frequency of the cycles within this mode will vary linearly between the specified Start and Run frequency The Accel count must not equal 1 or an error is generated Setting this value to zero disables this phase Run Count Sets the number of cycles to occur within the run phase The frequency o
103. n 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 a new possible value is displayed When the desired value appears press the Enter key to save it otherwise press the ESC key to cancel the edit The numeric keys are normally used to enter numeric System Settings 0 Enter In addition to edit a single numeric digit use the key to select the digit and then either press numeric key or use or f to modify the digit In any case after entering the new desired value press the Enter key to save it otherwise press the ESC key to cancel the edit Page 56 of 114 HORNER AUTOMATION GROUP exl10 User Manual 12 3 System Menu Details The following sections describe each of the Sub Menus in detail Set Networks This sub menu allows setting for the CAN and Ethernet network to be viewed or changed CAN Ok Yes CAN1 connected to a CAN network and functioning properly No Not ready to communicate on CAN network CAN ID 1 to 253 This node s CsCAN Network ID must be unique on network CAN Baud 125 KB 125 KBaud CAN network 500 KB 500 KBaud CAN network 250 KB 250 KBaud CAN network 1MB 1MBaud CAN network Displays the Ethernet MAC ID of the unit IP Displays the Ethernet IP address of the unit NetM Displays the Ethern
104. nd which aids in identifying the object as one that causes a screen change Figure 13 3 Typical Screen Jump Object 13 5 Ladder Based Screen Navigation Ladder logic can use several techniques to control screen navigation Coils can be tied to registers to make them screen coils These coils have two modes switch and alarm If the ladder program energizes an alarm display coil the screen associated with this coil is displayed and overrides the normal user Page 70 of 114 HORNER AUTOMATION GROUP exl10 User Manual screens This is designed to show alarm conditions 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 Input 1 1 Force Screen 1 52 9 Screen 1 Input 2 1 Switch Screen 2 T0002 Screen 2 Figure 13 4 Force and Switch Coils in Ladder Programming There is also a system register that can be used to for control based screen navigation SR1 can be read to determine the current screen or written to change the current screen Refer to the on line help in Cscape for more information on control based screen navigation 13 6 Beeper Acknowledgement The eXL10 contains an internal beeper that provides an audible acknowledgment when an
105. nd the current stepper count to be lost NOTE The stepper output level may cause damage or be incompatible with some motor drive inputs Consult drive documentation to determine if output level and type is compatible 11 6 High Speed Output Functions Register Map The register assignments for the high speed I O can be moved via a setting in Cscape The values shown are the DEFAULT values and may not match the same starting point as the values shown below Table 11 3 PWM Functions Register Map Register PWM Stepper 0421 422 PWM 1 Duty Cycle 32 bit Start Frequency Stepper 1 AQ423 424 PWM 1 Frequency Run Frequency Stepper 1 0425 426 Acceleration Count Stepper 1 0427 428 Run Count Stepper 1 0429 430 Deceleration Count Stepper 1 AQ431 432 PWM 2 Duty Cycle 32 bit Start Frequency Stepper 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 ees Q1 Start Move Bit Stepper 1 Q2 Start Move Bit Stepper 2 aS la EE 2611617 Ready Done Stepper 1 961618 Error Stepper 1 2611619 Ready Done Stepper 2 961620 Error Stepper 2 Q30 and Q31 for model 2 using HSQ or HSQ 5 necessary to start move 11 7 PWM Examples Example 1 Duty Cycle Frequency To geta S0
106. ng recese 19 3 6 3 Temperature Ventilation cesses eee 19 3 6 4 Orientation 19 3 6 5 E R a a 20 3 6 6 Shock Vibration e Re teri E 21 3 6 7 Panel Layout Design and Clearance Checklist 21 CHAPTER 4 ELECTRICAL INSTALLATION nu shine sena sone 23 4 1 Grounding 23 4 2 Ground 5 5 23 4 3 Howto Test for Good 23 4 4 24 Page 6 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 5 SERIAL COMMUNICATIONG ccssssscccssssecccsssssccccsssecccsssseccccssssccssssssccaesssseceussseeeaeenss 25 MMC Iu E 25 5 2 22204 nee 25 5 3 Wiring and Dip Switches 25 Ey MEE vni Earum T 26 5 5 R5485 O
107. ng Enter will save the entry pressing ESC will cancel the edit and return the string to the previous value Text Table Object When editing a Text Table Object all the keys except the Up and Down arrow keys are grayed and disabled The next text selection is made by pressing either the Up or Down arrow Time Date Object When editing a Time Date Table Object all the keys except the Up Down Left and Right arrow keys are grayed and disabled The specific field i e hour or minutes is selected using the Left and Right arrows The value in the selected field is changed by pressing either the Up or Down arrow 13 4 Screen Navigation To allow the operator to change screens a screen jump object is generally used This object may be visually represented as a 3 D button responding to touch or remain invisible and logically tied to an OCS register An optional system ICON may be configured for display along with the legend which aids in identifying the object as one that causes a screen change shown below in figure 13 3 Screen jumps can also be triggered on other keys or based on control logic for more advanced ETE E applications To allow the operator to change 100 or j 15 screens 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 ICON may be configured for display along with the lege
108. o make safety provisions for the end equipment as is usual and customary in industrial applications as defined in any codes or standards which apply Note The programming examples shown in this manual are for illustrative purposes only Proper machine operation is the sole responsibility of the system integrator Page 4 of 114 HORNER AUTOMATION GROUP exl10 User Manual INTENTIONALLY LEFT BLANK Page 5 of 114 HORNER AUTOMATION GROUP exl10 User Manual TABLE OF CONTENTS 3 For user manual updates contact Technical 3 LIMITED WARRANTY AND LIMITATION OF LIABILITY sesenta 4 ABOUT PROGRAMMING EXAMPLES esses 4 TABLE 8 22228 5 6 CHAPTER 1 SAFETY COMPLIANCE eei ener en eaae NER kx YR ey RRRN PARE FER FAEERE RENE EXER PARERE RN PARE 12 1 1 Safety Warnings and 12 1 2 C 13 1 3 Compliance ci E 13 CHAPTER 2 INTRODUCTION sssciccsssscsccsssscesssssssnssssssacsssssssacnssstacessosssncnsstsaccssssssasnasssasssaatesnesastiaeesaazs 14 2
109. odbus Master NOTE Refer to the download section of the Horner websites for the list of latest supported protocols Page 26 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 6 CAN COMMUNICATIONS Note For additional CAN information refer to the CAN Networks manual 0799 on the Horner websites 6 1 Overview All eXL10 OCS models provide two CAN network ports which are implemented with 5 pin connectors The connectors are labeled CAN1 and CAN2 Power CANI MJ1 RS 232 ipiam mmc 10 30VDC Input CANI O amp RS 232 485 MJ2 1 2 Duplex RS 485 Data Storage Programming Fieldbus Port Figure 6 1 CAN1 amp CAN2 Connector Locations CAN2 I O Like the MJ1 serial port the CAN1 port can be used for eXL10 OCS programming by connecting it to the CAN port of a PC running Cscape The 1 port also allows the eXL10 OCS to exchange global data with other OCS RCS controllers Both CAN1 and CAN2 support accessing of remote network I O devices SmartStix SmartBlock and SmartRail Modules CAN2 port supports CsCAN CANopen J1939 and DeviceNet Master layer 3 as a selectable option one only 6 2 Port Description The eXL10 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 6 3 CAN Port Wiring CAN Connector
110. odified range 1 Low to 5 High to the desired slide amount If a value outside the valid range is entered in the touch sensitivity register it is ignored and the last valid value is used 13 8 Alarms Alarm presentation to the operator is highly configurable and beyond the scope of this document to describe fully For more information refer to the graphics editor help file This section presents a typical configuration thereby providing an introductory description on what 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 these states o Figure 13 5 Alarm Object To view acknowledge and or clear alarms the operator must access the alarm viewer This is accomplished by touching an enabled alarm object When accessed the alarm viewer is displayed as pop up alarm viewer dialog similar to that shown in Figure 13 6 Alarms Figure 13 6 Alarm Viewer The currently selected entry is indicated by a yellow highlight which can be moved up or down by touching the arrow buttons or by directly touching an entry If more entries exist than can fit on the page a scroll bar is dis
111. om 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 following menu screen System Menu Enable AutoRun Enable Autoload ESC to exit Figure 16 1 Fail Safe System Menu 16 2 Settings To use the fail safe feature the user needs to do the following 1 Backup the current Battery Backed RAM Register contents in On Board Flash memory using System Menu options 2 From Cscape create AUTOLOAD PGM for the application program using Export to Removable Media 3 Place the Removable Media with AUTOLOAD PGM in the device 4 Setthe Enable AutoLoad option in the device to YES Page 92 of 114 HORNER AUTOMATION GROUP exl10 User Manual 5 Set the Enable AutoRun option to YES if the controller needs to be placed in RUN mode automatically after automatic restore of data or AutoLo
112. ontinuous use If the application does not require interaction with the eXL10 for long periods of time the backlight life can be extended by using the screen saver function When enabled through the system menu the backlight is shut off screen goes black after a specified time of no touch activity on the screen When the screen saver shuts off the backlight any operator touch on the screen or function keys reactivates the backlight Note that when the screen saver is active backlight shut off any initial touch activity on the screen or function key to reactivate the backlight is otherwise ignored by the eXL10 Any additional touch activity is also ignored by the eXL10 for approximately one second thereafter Page 74 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual 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 13 11 Screen Brightness The eXL10 provides a feature that allows screen dimming for night operation To enable this feature the application must access and control system register SR57 Display Backlight Brightness Screen brightness is continuously variable by driving SR57 through the range of 100 full bright to O full off It is left to the screen designer on how to present a Screen Brightness control to the user i
113. operator touches a graphic object that accepts touch input When the graphic object is enabled a short 5ms tone is emitted When the graphic object is disabled a longer 100ms tone is emitted to enounce that graphical object is not currently accepting the touch input If beep acknowledgement is not desired the beeper function can be disabled from the system menu 13 7 Touch Slip Sensitivity Touch slip sensitivity is preset to meet most applications however adjustment is available to reduce the sensitivity for touch release That is once a graphical object button is touched and held by a finger the default touch slip sensitivity allows for a slight slip of the finger on the graphical object before the eXL10 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 To increase the amount of tolerable slip and prevent false releases of the button the eXL10 allows adjustment of the allowable slide up to 5x the default value Page 71 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual To enable the touch slip sensitivity first an OCS data register must be allocated through the Graphics editor Configuration menu for Display Settings Once a Touch Sensitivity register is assigned that register may be m
114. opped 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 predetermined value By default analog outputs are set to a value of zero For more information on Stop State refer to the appropriate pages see Index for the configuration chapter for Cscape settings Page 46 of 114 HORNER AUTOMATION GROUP CHAPTER 11 HIGH SPEED 1 0 HSC PWM 11 1 Overview In addition to the compliment of simple analog and digital I O several of the eXL10 OCS I O modules support High Speed Counting HSC I O functions and may also support Pulse Width Modulation PWM Output functions non relay modules The HSC functions include internal timing frequency totalizing pulse width period and quadrature measurement The PWM functions include traditional PWM with variable rate and duty cycle and a stepper limited functionality with variable acceleration and deceleration rates To determine function availability refer to the associated model s Specification Installation sheet Digital DC Input Output sections exl10 User Manual This chapter describes the operation of these high level I O functions For configuration details of these functions see Cscape Configuration 11 2 Glossary WWE Register used to accumulate or store up a sum or count of many items or events A special function to zero out the value in a specific register Not used with
115. 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 Page 89 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual The Output State On Controller Stop group box contains items to allow the user to specify how the remaining digital outputs behave when the controller is stopped These items can either hold their value or default to some value when the controller is stopped 15 7 Analog Input Configuration The following figure illustrates the Analog Input Configuration dialog Analog Input Configuration Channel 1 us Channel 2 0 Channel 3 Channel 4 z Filter Constant 0 Figure 15 5 Analog Input Configuration Dialog The Channel x drop down windows allow the user to specify the mode for each analog input to operate The Channel x drop down windows are enabled disabled according to which model is being configured All of the models have the following modes available 0 10V 0 20mA 4 20mA On model 005 all channels 1 4 also have the following modes available 100mV PT100 DIN RTD 1 20 Type J Thermocouple 1 20 c Type K Thermocouple 1 20 c Type N Thermocouple 1 20 c Type T Thermocouple 1 20 c E Thermocouple 1 20 c Type R Thermocouple 1 20 c S Thermocouple 1 20 c B Thermocouple 1 20 c The Filter Constant provides
116. ovable viewer This is accomplished by either touching an enabled removable media object or through the system menu When accessed the removable media viewer is displayed as pop up removable media dialog similar to that shown in Figure 13 8 Note that 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 Media Directory SCREENGO1 153654 01 13 96 1 13p SCREEN26 BHP 153654 61 13 96 1 08p Free 992287808 Total 992739328 D 1 For 5 4 A V Del ail nat Fan Esc Figure 13 8 Removable media viewer The currently selected entry is indicated by a yellow highlight which can be moved up or down by touching the arrow buttons or by directly touching an entry If more entries exist than can fit on the page a scroll bar is displayed on the right side that also indicates the current relative position Page 73 of 114 HORNER AUTOMATION GROUP exl10 User Manual File operations are accomplished by pressing the appropriate button at the bottom of the removable media viewer The configuration of the removable media object that invokes the removable media viewer defines what buttons are enabled and available to the user A button is grayed and does not respond to touch if configured as disabled The lt Enter button if enabled
117. performs certain operations based on the selected file s type 5 change display to parent directory DIR change display to child directory bmp jpeg display bitmap if compatible format pgm load application if compatible model and version Alternately the enter button can be configured to simply load the ASCII representation of the file path including the file name to a group of OCS registers That pathname can then be used by ladder for opening and manipulating that file Once view 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 media This prevents corruption to the file system if the removable media is removed during a file write sequence The graphic objects should set OCS register SR174 1 when requesting the card be removed and provide an indicator based on OCS register SR174 2 which indicates that it is safe to remove the removable media Halt RM Activity Safe for Removal Xx Figure 13 9 Example application segment for safe removal of removable media 13 10 Screen Saver The eXL10 screen backlight life is typically 5 years when in c
118. played on the right side that also indicates 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 are grayed and do not respond Page 72 of 114 HORNER AUTOMATION GROUP exl10 User Manual to touch Once view operations are complete simply touch the Esc button to remove the pop up alarm viewer Note that OCS registers SR181 and SR182 are available for ladder use which indicate presence of unacknowledged or acknowledged alarm respectively The screen designer may implement these registers to switch screens or activate the beeper to attract the operator s attention 13 9 Removable Media The removable media object is generally used to inform the operator on the current state of the removable media device and allow access to its file structure The removable media object is displayed as a button that changes colors to indicate the current state of the removable media device The following indicates the device states and the default colors associated with these states Bruges Figure 13 7 Removable Media Object To view and perform file operations the operator must access the rem
119. regularly announce their presence and to detect the presence or absence of other nodes on the network 6 6 Using CAN for I O Expansion Network I O Connecting Network I O devices SmartStix SmartBlock or SmartRail to the eXL10 OCS 1 or CAN2 port allows the eXL10 OCS I O to be economically expanded and distributed A variety of modules are available for this purpose Page 29 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 7 ETHERNET COMMUNICATION 7 1 Ethernet Module Protocols and Features The following table describes the Ethernet Module Protocols and features supported by the two Ethernet ports on the eXL10 Protocol Feature Protocol Feature Description ICMP Ping Internet Control Message Protocol EGD Peer Ethernet Global Data SRTP Server Service Request Transfer Protocol CsCAN TCP Server Horner APG CsCAN over Ethernet Modbus TCP Slave Modbus over Ethernet Ethernet IP Server ODVA CIP over Ethernet FTP Server File Transfer Protocol HTTP Server HyperText Transfer Protocol Web Server Table 7 1 Ethernet Module Protocols amp Features 7 2 Ethernet System Requirements Full Ethernet functionality requires PCrunning Cscape Programming Software Version 9 3 SP6 or later for configuration eXL10 controller with onboard Ethernet port FTP amp HTTP protocols 7 3 Ethernet Module Specifications 10 BaseT Ethernet 10 Mbps 100 BaseTx Fast Et
120. rs from the eXL10 OCS unit 2 Make sure the gasket is installed on the eXL10 OCS and is free from 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 eXL10 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 7 10 Ib in 0 8 1 13 Page 17 of 114 IM HORNER AUTOMATION GROUP exl10 User Manual 3 3 Mounting Orientation 3 3 1 eXL10 OCS Mounting Clip Slots for mounting clips Figure 3 2 eXL10 OCS with Mounting Clips 3 32 eXL10 OCS Mounting Orientation Figure 3 3 Orientation of eXL10 OCS NOTE There are no orientation restrictions on the eXL10 OCS However the above orientation provides for optimum readability of the screen and ease of use of the keypad Page 18 of 114 HORNER 3 4 AUTOMATION GROUP exl10 User Manual Panel Cut Out For installations requiring NEMA 4X liquid and dust protection the panel cutout should be cut witha tolerance of 0 005 0 1 mm 3 5 11 360 288 5mm 5555555 1 8 505 216 Figure 3 4 Panel Cutout Tolerances eXL10 Dimensions 8 51 89 1mm 9 08 230 6mm F4 a g g g 3 11 94 243 303 3mm 61 7mm
121. rs of charging to last approximately 2 years when powered off NOTE For the registers to be retentive the battery only need to be charged and present at power down Under normal conditions the battery in the eXL10 OCS should last approximately seven years Higher operating temperatures or variations in batteries may reduce this time 18 2 1 Indications the battery needs replacing The eXL10 OCS indicates the battery is low failed or missing in a variety of ways At power up an error message is displayed indicating the low or missing battery The user program can monitor the battery using SR55 13 This bit will turn on if the battery is low or missing The system menu also contains a battery status message under the diagnostics sub menu see the chapter on System Settings and Adjustments Page 103 of 114 HORNER AUTOMATION GROUP exl10 User Manual 18 2 2 Battery Replacement Warning Lithium Batteries may explode or catch fire if mistreated Do not recharge disassemble heat above 100 C 212 F incinerate or puncture Warning Disposal of lithium batteries must be done in accordance with federal state and local regulations Be sure to consult with the appropriate regulatory agencies before disposing batteries In addition do not re charge disassemble heat or incinerate lithium batteries Warning Do not make substitutions for the battery Be sure to only use the authorized part number to replace the battery The e
122. s 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 Clone Feature If user desires Backup should be done as explained in Chapter 16 Fail Safe System 17 3 Load Clone This option loads the application all unit settings and register values from Removable media to the 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 Set Network ID Set Network Baud View Status View Diags View I 0 Slots View Protocols Fkeys Mode Serial Ports Time Date Beeper Screen Removable Fail Safe System Clone Unit Figure 17 6 System Menu Page 101 of 114 HORNER AUTOMATION GROUP exl10 User Manual 2 Selecting Clone Unit menu will open the following menu screen Select Load Clone CLONE 24570 07 15 09 12 11a Free 1804208128 Total 1004257280 me e V Figure 17 7 Clone Unit Menu after Cloning 3 User needs to confirm Load Clone as sho
123. s not changed Delete RM csv Allows deleting a file on the RM card Copy RM csv Allows copying a file on the RM card The data in the file is not changed 9 9 Filenames used with the Removable Media RM Function Blocks The RM function blocks support the flash with a DOS Windows standard FAT 16 file system All names must be limited to the 8 3 format where the filename contains eight characters 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 Page 38 of 114 HORNER AUTOMATION GROUP exl10 User Manual Symbol Description Example SY Substitutes the current 2 digit year 2004 04 SM Substitutes the current month with a 2 digit code March 03 SD Substitutes the current day 22 22 h Substitutes the current hour in 24 hour format 4 pm 16 m Substitutes the current minute 45 45 s Substitutes the current second 34234 Note that all the symbols start with the dollar sign character Date symbols are in upper case time symbols are in lower case The following are examples of the substituted time date filenames Current date and time March 1 2013 3 45 34 PM Fi
124. ssful the target indicator should show the mode of 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 configured To check or change the ID on the eXL10 press the System Button to enter the system menu The first item in the menu is Set Network ID Pressing Enter allows the ID of the unit to be viewed or modified To change the Target ID of Cscape use the Controller Set Target Network ID dialog 15 3 2 Communicating via On Board Ethernet Port From Cscape go to Controller gt I O Configure and do auto configuration for the connected controller Click on Config of Ethernet amp go to Module Setup Page 86 of 114 HORNER AUTOMATION GROUP exl10 User Manual The IP address Net Mask and Gateway of the controller may be temporarily set from the system menu under the Set Networks menu item Once running or power cycled the configuration will come from the Cscape configuration stored in the unit In Module configuration dialog go to IP Address field enter unused IP Address and configure unused registers in Register field amp then click OK Screen shot for the same as follows Re
125. start the System Menu press the SYSTEM key or set SR3 to 1 which will display the Main Menu Then use the and 7 Up Arrow or Down Arrow keys to select a Main Menu item and press Enter Return Arrow to display the item s Sub Menu System Menu et Networks View Status View Diags View I 0 Slots View Protocols Set Fkeys Mode Set Serial Ports Set Time Date Set Beeper Set Screen Removable Media Fail Safe System Clone Unit Press ESC to exit Figure 12 1 System Menu eXL10 Screenshot 12 2 System Menu Navigation and Editing As mentioned above the System Menu is started by pressing the System key on the eXL10 Next press ESC to exit the System Menu or use V and to select an item and press to display the item s Sub Menu A Sub Menu generally shows a list of System Settings and their values After opening a Sub Menu if any of its System Settings are editable the first System Setting that can be edited is highlighted If desired the 4 and 7 keys can be used to select a different System Setting to be edited At this point either press ESC to exit the Sub Menu returning to the Main Menu or press Enter to edit the highlighted 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 lt gt T Ea or the numeric keys or the appropriate touch scree
126. t Descriptions The MJ1 serial port contains 5232 interface with RTS CTS handshaking The MJ2 serial port contains a half duplex RS485 interface with no handshaking The MJ3 serial port can be configured as either RS232 or RS485 The MJ2 and MJ3 RS485 interfaces provide switchable termination and bias resistors internally which can be enabled disabled with DIP switches 5 3 Wiring and Dip Switches 1 2 Independent Serial Ports Ns Port 1 RS232 w Full Handshaking Two multiplexed Serial Ports on One Modular Jack 8posn 2 RS485 Half Duplex 2 PINS PINS PIN SIGNAL DIRECTION 8 TXDRS232 OUT 7 RXDRS232 IN 6 Ground 5 45V amp 60mA OUT 4 TX RS485 OUT 3 TX RS485 OUT 2 RX RS485 IN 1 RX RS485 IN RX TX IN OUT IN OUT DIP Switches ED ma 1234 SWITCH NAME FUNCTION DEFAULT 1 MI3RS485 Termination ON Terminated ON Half s Duplex OFF Full OFF MJ2 RS485 Termination ON Terminated Figure 5 1 Wiring amp Dip Switches Page 25 of 114 HORNER AUTOMATION GROUP exl10 User Manual 5 4 RS485 Termination Proper RS485 termination minimizes signal reflections and improves reliability Both the MJ2 and MJ3 serial ports allow an internal termination resistor to be placed across pins 1 and 2 by DIP Switch Setting Only the two devices physically located at the endpoints o
127. t numbers NOTE This list is not intended for users to determine which products are appropriate for their application controller products differ in the features that they support If assistance is required refer to Technical Support Manual Description Manual Number User Manual for XLe XLt OCS models MANO878 User Manual for XL6 XL6e OCS models 0883 User Manual for 4 OCS models MANO964 Other Useful References Manual Number Page 16 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 3 MECHANICAL INSTALLATION Note The datasheet is the first document to refer to for model specific information related to eXL10 OCS models such as pin outs jumper settings and other key installation information Visit the Horner websites to obtain datasheets user documentation and updates 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 Mounting Requirements 3 2 1 Mounting Procedures Installed in a Panel Door we a Figure 3 1 Panel Mounting of an eXL10 Series OCS Once the panel design has been completed using the criteria and suggestions in the following sections use the following steps to panel mount the eXL10 OCS 1 Remove all connecto
128. t the Horner websites to obtain datasheets user documentation and updates 4 1 Grounding Definition Ground The term ground is defined as a conductive connection between a circuit or piece 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 ground is ohms In reality it typically is higher The U S National Electrical Code NEC states the resistance to ground shall not exceed twenty five 25 ohms Horner APG recommends less than fifteen 15 ohms resistance from our equipment to ground Resistance greater than twenty five 25 ohms can cause undesirable or harmful interference to the device 4 3 How to Test for Good Ground In order to test ground resistance a Ground Resistance Tester 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 GROUND RESISTANCE METER i GROUND xi DISCONNECTED CN FROM SERVICE LY 68 29 GROUND ROD METAL WATER PIPE OR OTHER
129. tem page 89 Clone Unit page 96 Page 10 of 114 HORNER AUTOMATION GROUP exl10 User Manual INTENTIONALLY LEFT BLANK Page 11 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 1 SAFETY COMPLIANCE 1 1 Safety Warnings and Guidelines When found on the product the following symbols specify Warning Consult user documentation Warning Electrical Shock Hazard WARNING EXPLOSION HAZARD Do not disconnect equipment unless power has been switched off or the area is known to be non hazardous WARNING To avoid the risk of electric shock or burns always connect the safety or earth ground before making any other connections WARNING To reduce the risk of fire electrical shock or physical injury it is strongly recommended to fuse the voltage measurement inputs Be sure to locate fuses as close to the source as possible WARNING Replace fuse with the same type and rating to provide protection against risk of fire and shock hazards WARNING In the event of repeated failure do not replace the fuse again as a repeated failure indicates a defective condition that will not clear by replacing the fuse WARNING EXPLOSION HAZARD Substitution of components may impair suitability for Class Division 2 WARNING The USB parts are for operational maintenance only Do not leave permanently connected unless area is known to be non hazardous WARNING EXPLOSION HAZARD BATTERIES MUS
130. the alpha numeric keypad is first invoked it is placed in new value mode Initially the alpha numeric keypad 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 by pressing either the left or right arrow key before any digit key is pressed The result will be a single character highlighted The user may then either touch a key to change the digit at the selected position or the up and down arrows may be used to add or subtract respectively from the selected digit The user may then use the left or right arrow keys to select a new position head e 1 2 3 4 5 6 7 8 9 0 q w e r t y ulijo p 719151 2 5 Shift lt Space gt Figure 13 2 Alpha numeric Keypad and ASCII Keypad 00000 EARE 25 agel Once the desired value is entered pressing the Enter key moves that value into the object and the corresponding OCS register and the alpha numeric keypad disappears Alternately pressing the ESC key any time before the Enter key cancels the operation leaves the objects current
131. tion program is absent or corrupted Yes Loads AUTOLOAD PGM file automatically from RM when application program is absent or corrupted Enable AutoLoad Clone Unit Clone Unit feature allows the user to clone the OCS of the exact same model This feature clones application program and unit settings stored in Battery backed RAM of an OCS into the RM refer Removable Media Chapter 9 for details on using RM It can then be used to clone a different OCS exact 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 Page 65 of 114 HORNER AUTOMATION GROUP exl10 User Manual Clone Selecting Clone Unit menu will open the following menu screen Directory Empty Free 1004257280 Total 1005257280 Load Make Clone Clone V A Esc 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 directory of the Removable Media Drive as shown below Make Clone Files fire You Sure CLONE DAT 24570 07 14 09 12 11a Ok Cancel Free 1005257280 Total 1005257280 Free 1004208128 Total 1005257280 imel V A Load Hake Clone Clone V A Esc AUT
132. tput fault bit 96132 will turn on if any of the outputs experience a short circuit over current or the output driver overheats 10 5 Relay Outputs Relay outputs are designed to switch loads that typically have high voltage or current requirements or require the isolation that relays provide NOTE The design of the eXL10 OCS does not require external coil power for the relays to function The relays will activate anytime the eXL10 OCS is powered There are several factors that should be considered when using relays Relay Life Relays are mechanical devices that have a long but limited life Typically switching more current limits the life of relays Please check the data sheets at the end of this manual for expected relay life Current Temperature De Rating Products 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 Warning To protect the module and associated wiring from load faults use external 5 A fuse s as shown Fuses o lower current or fusing for the entire system need to be in place to assure the maximum current rating of the unit is not exceeded Warning Connecting high voltage to any I O pin can cause high voltage to appear at other 1 0 pins 230VA
133. umber HESOOUSB600 eXL10 OCS units without Ethernet must use MJ1 or the Mini B USB Port for programming and debugging If Ethernet is installed it can be selected as the programming port The selection is made in the controller s System Menu If there are difficulties connecting make sure that the default programming port is set correctly with the connection method being attempted Connecting Troubleshooting Checklist USB Port Mini B Programming Programming and debugging must use Mini B USB Port or MJ1 Controller must be powered up Ensure that the correct COM port is selected in Cscape Tools Editor Options Communications Port Be sure that the USB cable is connected between the PC and controller and check the Windows Device Manager to find out if the USB driver is properly installed and which port it set itself up on Make sure the USB port of the PC is functioning and or connect to an alternate device to determine if the port is working eXL10 OCS units without Ethernet must use the Mini B USB Port or MJ1 for programming and debugging If Ethernet is installed it can be selected as the programming port The selection is made in the controller s System Menu If there are difficulties connecting make sure that the default programming port is set correctly with the connection method being attempted Connecting Troubleshooting Checklist ETN port programming Programming and debugging must use MJ1 or Ethernet Port Controller must be po
134. ure that they have the same ground reference 3 63 Temperature Ventilation Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient temperature range Consider the impact on the design of the panel layout if operating at the extreme ends of the ambient temperature range For example if it is determined that a cooling device is required allow adequate space and clearances for the device in the panel box or on the panel door 3 6 4 Orientation When panel mounted there are no orientation restrictions on the eXL10 OCS 3 6 5 Noise Consider the impact on the panel layout design and clearance requirements if noise suppression devices are needed Be sure to maintain an adequate distance between the eXL10 OCS and noisy devices such as relays motor starters etc For details on output protection especially when using contactors solenoids see 962 01 Page 20 of 114 HORNER AUTOMATION GROUP exl10 User Manual 3 6 6 Shock and Vibration The eXL10 OCS has been designed to operate in typical industrial environments that may inflict some shock and vibration on the unit For applications that may inflict excessive shock and vibration please use proper dampening techniques or relocate the eXL10 OCS to a location that minimizes shock and or vibration 3 6 7 Panel Layout Design and Clearance Checklist The following list provides highlights of panel layout design factors
135. uts are generally used to activate lamps low voltage solenoids relays and other low voltage and low current devices NOTE The digital outputs used on the eXL10 OCS are sourcing outputs This means the output applies a positive voltage to the output pin when turned ON When turned off the output applies approximately zero volts with respect to the I O ground 10 30VDC t 4 y n se 4 S Figure 10 4 Typical Output Wiring The digital outputs used in the eXL10 OCS have electronic short circuit protection and current limiting While these electronic protections work in most applications some application may require external fusing on these outputs Page 42 of 114 HORNER AUTOMATION GROUP exl10 User Manual The digital outputs in the eXL10 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 each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state By default digital outputs turn off For more information on stop state see the Index to find pages referencing Cscape settings The digital outputs feature an ou
136. w I O Slots System Menu 1 0 XWx02 1 0 Empty 1 0 ETN300 The View I O Slots Sub Menu displays three System Settings none of which may be edited Internal to the eXL10 OCS there is a CPU board and up to two installed modules Model HE EXV1E0 HEXT505C100W100 has no installed 1 0 or COM modules All other models have I O module and can have a user installed COM module Depending on which I O module is installed and which I O module has been configured by Cscape one of the following six System Settings should appear for Slot 1 Slot 1 1 0 Empty Slot 1 Unsupported Slot 1 1 Missing Slot 1 1 0 XExyy Slot 1 1 O XExyy Slot 1 1 0 XExyy No module installed or configured Unsupported I O module installed No module installed but an 1 0 module is configured 1 0 module installed but no 1 0 module configured 1 0 module installed but another I O module configured 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 appears for Slot 2 Slot 2 1 0 Empty Slot 2 Unsupported No COM module installed or configured Unsupported COM module installed Slot 2 1 O Missing No COM module installed but a COM module is configured Slot 2 1 0 XzC z COM module installed but no COM module configured
137. wered up Ensure that correct IP address is given in the Ethernet field and correct Mode is selected in Cscape Tools Editor Options Communications Port Ensure that the Ethernet Cable is connected between the controller and the Ethernet Hub Make sure the Ethernet cable is functioning properly Local Controller and Local I O The system menu provides the following status indications that are useful for troubleshooting and system maintenance Self test results diagnostics RUN and OK status Network status and usage Page 107 of 114 HORNER AUTOMATION GROUP exl10 User Manual Average logic scan rate Application memory usage Loaded firmware versions Loaded protocols Removable media access To view the system menu press the System key 19 2 1 Local I O Troubleshooting Checklist 1 2 D ur d s Verify the controller is in RUN mode Check diagnostics to insure controller passed self tests View diags in System Menu or in Cscape click Controller Diagnostics Check data sheets to insure proper wiring Insure that hardware jumpers and software configuration for I O match Check data sheets for voltage and current limits Take ladder out of the picture From Cscape set controller to Do I O mode In this mode inputs can be monitored and outputs set from a data watch window in Cscape without interference from the ladder program Some I O problems are only a result of a mistake in the ladder program WARNI
138. wn below Load Clone Files fire You Sure Ok Cancel Free 1664208128 Total 1004257280 atone Pme V Figure 17 8 Load Clone Confirm Screen 4 After confirmation all unit settings and register values will be loaded from Removable media to the Battery backed RAM Regardless of AutoLoad settings and then OCS resets for the settings to take effect NOTE For 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 operation is also not notified on screen to the user In case of failure of Load Clone operation SR164 12 bit is set to 1 by the firmware and never reset Page 102 of 114 HORNER AUTOMATION GROUP exl10 User Manual CHAPTER 18 MAINTENANCE 18 1 Firmware Updates The eXL10 OCS products contain field updatable firmware to allow new features to be added to the product at a later time Firmware updates should only be performed when a new feature or correction is required Warning Firmware updates should only be performed when the equipment being controlled by the eXL10 OCS is in a safe non operational state Communi
139. ws the user to specify whether the OCS automatically loads the application AUTOLOAD PGM located in Removable Media When the AutoLoad setting is enabled set to YES it can either be manually initiated or automatically initiated at power up The automatic initiation will happen only in the following two cases e When there is no application program in the OCS and a valid AUTOLOAD PGM is available in the removable media of the device e When the 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 in IDLE mode and the application is not loaded If the AUTOLOAD PGM is security enabled the user will be prompted to enter the password before loading the application The application will be loaded from the Removable media only after getting the correct password 96SR164 6 can be set to enable AutoLoad feature System Menu nable AutoLoad AutoLoad fron Removable Media s AUTOLOAD PGM File when triggered Figure 16 7 AutoLoad Menu Page 96 of 114 HORNER AUTOMATION GROUP exl10 User Manual The OCS follows the following sequence in execution of AutoLoad

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