Page 1 User Manual for EXL6 & XL6 Prime MAN1 0 32-20 .0 -EN_EXL6_XL6P_UM...
Page 2 Visual Map The datasheet is the first document to refer to for model-specific information related to EXL6/XL6 Prime models for install- ation information. The web version of this manual has all of the d atasheets linked. Find the documents via the Documentation Search page on the Horner website. Datasheet Manual Numbers EXL6 Model 0 MAN1168 XL6 Prime Model 0 MAN1326 EXL6 Model 2 MAN1169 XL6 Prime Model 2 MAN1327 EXL6 Model 3 MAN1170 XL6 Prime Model 3 MAN1328 EXL6 Model 4 MAN1171 XL6 Prime Model 4 MAN1329 EXL6 Model 5 MAN1172 XL6 Prime Model 5 MAN1330 EXL6 Model 6 MAN1173 XL6 Prime Model 6 MAN1331 Visual Map...
Page 3 LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the EXL6/XL6 Prime OCS module manufactured by HE-APG is free from defects in material and workmanship under normal use and service. The obligation of HE-APG under this warranty shall be limited to the repair or exchange of any part or parts which may prove defective under normal use and service within two (2) years from the date of manufacture or eighteen (18) months from the date of installation by the original purchaser whichever occurs first, such defect to be disclosed to the satisfaction of HE-APG after examination by HE-APG of the allegedly defective part or parts. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE-APG NEITHER ASSUMES, NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS EXL6/XL6 PRIME O CS MODULE. THIS WARRANTY SHALL NOT APPLY TO THIS EXL6/XL6 PRIME O CS MODULE O R ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. HE-APG MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE-APG. THE TERM "ORIGINAL PURCHASER", AS USED IN THIS WARRANTY, SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM THE EXL6/XL6 PRIME O CS MODULE I S 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.
Page 4 PREFACE This manual explains how to use the EXL6/XL Prime OCS. Copyright (C) 2013 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any lan- guage 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. Cscape, SmartStack, SmartStix, SmartRail, and CsCAN are trademarks of Horner APG. Ethernet is a trademark of Xerox ® Corporation ® ® microSD and CompactFlash are registered trademarks of SanDisk Corporation ® Published with Madcap Flare . North America Tel: (+) (317) 916-4274 Fax: (+) (317) 639-4279 Web: http://www.hornerautomation.com Email: techsppt@heapg.com Europe Tel: (+) 353-21-4321-266 Fax: (+) 353-21-4321-826...
Page 5: Table Of Contents
System Settings and Adjustments OCS LED Indicator Lights System Menu – Navigation and Editing System Menu Map Set Networks View Status & Diags View Battery Status, I/O Slots & Protocols Set Fkeys Mode, Serial Ports, Ethernet, Time/Date, Beeper & Screen Removable Media Fail – Safe System Clone Unit WebMI License Details Touch Screen Calibration System Register Tables Register Definitions %S Registers %SR Registers Cscape Configuration Cscape Status Bar Establishing Communications Communicating via MJ1 Serial Port Communicating via On Board Ethernet Port Cscape Configuration General I/O Configuration Built-in Digital and Analog I/O Overview Removing the Horner OCS Back Cover Digital / HSC Input Configuration Digital / PWM Output Configuration Solid State Digital Outputs Relay Outputs Digital Output Configuration Analog Inputs Analog Outputs...
Page 6 High Speed I/O (HSC / PWM) Overview High Speed I/O Glossary High Speed Counter (HSC) Functions Frequency Totalize Pulse Width Measurement Period Measurement Quadrature HSC Functions Status Bits HSC Functions Register Maps High Speed Output Functions Stepper Function High Speed Output Functions Register Map HSC I/O Filtering Serial Communications Port Descriptions Wiring Dip Switches RS485 Termination RS485 Biasing Cscape Programming via Serial Port Ladder-Controlled Serial Communication Configuration via Mini-B USB CAN Communications Port Description CAN1 Port Wiring Cscape Programming via CAN Ladder-Controlled CAN Communication Using CAN for I/O Expansion (Network I/O) Ethernet Communications Ethernet Module Protocols and Features Ethernet Module Specifications Ethernet Module Configuration...
Page 7 Screen Saver Screen Brightness Touch Screen Pressure Video Object Video Object Overview Opening Video Object in Cscape Video Properties Configuration Video Object Performance Web Cameras Removable Media microSD Cards Using the Removable Media Manager Log Data View and Capture Screens Removable Media Object Function Blocks in Cscape Filenames System Registers used with RM Clone Unit Make Clone Load Clone Fail-Safe System For the XL Series For the XL Prime Series Fail-Safe System Settings Backup / Restore Data AutoLoad AutoRun Modbus Communications Modbus Slave Overview Modbus Master Overview Modbus Addressing Table EXL6 Rechargeable Battery Storing Register Contents Battery Life Lithium Battery Safety...
Page 8 CsCAN Network USB Interfaces Basic Troubleshooting Technical Support Contacts Change Log...
Page 9 Safety and Compliance Page 9...
Page 10: Safety And Compliance
Safety and Compliance Safety and Compliance Safety Warnings When found on the product, the following symbols specify: Warning: Consult user documentation. Warning: Electrical Shock Hazard. WARNING: EXPLOSION HAZARD – Substitution of components may impair suitability for Class I, Division 2. 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: 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. NOTE: All applicable codes and standards need to be followed in the installation of this product. NOTE: For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG or larger. NOTE: See the "Electrical Installation" on page 22 for more details. Safety Precautions Adhere to the following safety precautions whenever any type of connection is made to the module: ...
Page 11 Introduction to the EXL6 & XL6 Prime Page 11...
Page 12: Intro To The Exl6 & Xl6 Prime
Intro to the EXL6 & XL6 Prime Intro to the EXL6 & XL6 Prime Visual Overview Where to find more information for the EXL6 & XL6 Prime Connectivity to the EXL6 & XL6 Prime Features of EXL6/XL6 Prime OCS Visual Overview 1. ...
Page 13: Where To Find More Information For The Exl6 & Xl6 Prime
Intro to the EXL6 & XL6 Prime Where to find more information for the EXL6 & XL6 Prime Datasheets - The datasheets are the first documents to refer to for key information related to specific models. (A basic datasheet is provided in the box with the unit.) Find the documents via the Documentation Search page on the Horner website. Datasheet Manual Numbers EXL6 Model 0 MAN1168 XL6 Prime Model 0 MAN1326 EXL6 Model 2 MAN1169 XL6 Prime Model 2 MAN1327 EXL6 Model 3 MAN1170 XL6 Prime Model 3 MAN1328 EXL6 Model 4 MAN1171 XL6 Prime Model 4 MAN1329 EXL6 Model 5...
Page 14: Features Of Exl6/Xl6 Prime Ocs
Intro to the EXL6 & XL6 Prime Features of EXL6/XL6 Prime OCS The EXL6/XL6 PRIME 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 EXL6/XL6 PRIME OCS include: Bright, 65,536 color graphical touch sensing LCD display in all models of EXL6/XL6 PRIME. 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 cap- abilities. 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 I/O including high resolution analog, thermocouple, RTD, high-speed counters, PWM outputs and relays (depending upon the EXL6/XL6 PRIME OCS model used). Advanced high speed I/O capabilities. Cscape programming software that allows all aspects of the EXL6/XL6 PRIME OCS to be programmed and configured from one integrated application. Optional communication add-on modules.
Page 15 Mechanical Installation Page 15...
Page 16: Mechanical Installation
Mechanical Installation Mechanical Installation Mounting Requirements Mounting Orientation Dimensions Installation Procedure Factors Affecting Panel Layout Design and Clearances NOTE: The datasheet is the first document to refer to for model-specific information related to EXL6 & XL6 Prime models such as pin-outs, jumper settings, and other key installation information. See the Documentation Search for datasheets. The mechanical installation greatly affects the operation, safety and appearance of the system. I nformation 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. Mounting Requirements Once the panel design has been completed using the criteria and suggestions in the following sections, use the fol- lowing steps to panel mount the EXL6 & XL6 Prime OCS. 1. Remove all connectors from the EXL6 & XL6 P rime OCS unit. 2. ...
Page 17: Mounting Orientation
Mechanical Installation Mounting Orientation OCS Mounting Clip OCS Mounting Orientation NOTE—For panel or DIN rail mounting: The orientation shown above provides for optimum readability of the screen and ease of use of the keypad. CAUTION—For DIN Rail mounting: To prevent the unit from slipping off the DIN Rail, do not install the unit on its sides as shown. Be sure the DIN Rail is in the horizontal position. Page 17 of 196...
Page 18: Dimensions
Mechanical Installation Dimensions *+1mm / -0mm cutout tolerance Page 18 of 196...
Page 19: Installation Procedure
Mechanical Installation Installation Procedure The EXL6/XL6 PRIME utilizes a clip installation method to ensure a robust and watertight seal to the enclos- ure. Please follow the steps below for the proper installation and operation of the unit. This equipment is suitable for Class I, Division 2, Groups A, B, C and D or non-hazardous locations only. Digital outputs shall be supplied from the same source as the operator control station. Jumpers on connector JP1 shall not be removed or replaced while the circuit is live unless the area is known to be free of ignitable concentrations of flammable gases or vapors. 1. Carefully locate an appropriate place to mount the EXL6/XL6 PRIME. Be sure to leave enough room at the top of the unit for insertion and removal of the microSD™ card. 2. Carefully cut the host panel per the diagram, creating a 131.9mm x 175.0mm, with a +1mm/-0mm opening into which the EXL6/XL6 PRIME may be installed. If the opening is too large, water may leak into the enclos- ure, potentially damaging the unit. If the opening is too small, the OCS may not fit through the hole without damage. 3. Remove any burrs and or sharp edges and ensure the panel is not warped in the cutting process. 4. Remove all Removable Terminals from the EXL6/XL6 PRIME. Insert the EXL6/XL6 PRIME through the panel cutout (from the front). The gasket must be between the host panel and the EXL6/XL6 PRIME. 5. Install and tighten the four mounting clips (provided in the box) until the gasket forms a tight seal NOTE: Max torque is 0.8 to 1.13Nm, or 7 to 10 in-lbs. 6. Reinstall the EXL6/XL6 PRIME I/O Removable Terminal Blocks. Connect communications cables to the serial port, USB ports, Ethernet port, and CAN port as required. Factors Affecting Panel Layout Design and Clearances WARNING: ...
Page 20 Mechanical Installation Grounding Panel Box: The panel box must be properly connected to earth ground to provide a good common ground ref- erence. Panel Door: Tie a low impedance ground strap between the panel box and the panel door to ensure that they have the same ground reference. WARNING: Be sure meet the ground requirements of the panel manufactuer and also meet applicable electrical codes and standards. Temperature / Ventilation Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient tem- perature range. Consider the impact on the design of the panel layout if operating at the extreme ends of the ambi- ent 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. 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 OCS and noisy devices such as relays, motor starters, etc. Shock and Vibration The 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 OCS to a location that minimizes shock and/or vibration. Panel Layout Design and Clearance Checklist The following list provides highlights of panel layout design factors: ...
Page 21 Electrical Installation Page 21...
Page 22: Electrical Installation
Electrical Installation Electrical Installation Ground Specifications How to Test for Good Ground Primary Power Port NOTE: The datasheet is the first document to refer to for model-specific information. Refer to the Documentation Search on the Horner website. Ground Specifications Ideally, a ground resistance measurement from equipment to earth ground is 0Ω. In reality it typically is higher. The US National Electrical Code (NEC) states the resistance to ground shall not exceed 25Ω. Horner Automation recom- mends less than 15Ω resistance from the equipment to ground. Resistance greater than 25Ω can cause undesir- able or harmful interference to the device. Grounding Definition - T he term Ground is defined as a conductive connection between a circuit or piece of equip- ment 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 fre- quency interference (RFI). How to Test for Good Ground In order to test ground resistance, a Ground Resistance Tester must be used. A typical Ground Resistance Meter ...
Page 23: Primary Power Port
Electrical Installation Primary Power Port NOTE: The Primary Power Range is 10VDC to 30VDC. Primary Power Port Pins Signal Description Ground Frame Ground Input Power Supply Ground Input Power Supply Voltage DC Input / Frame Solid/Stranded Wire: 12-24 awg (2.5-0.2mm) Strip length: 0.28” (7mm) Torque, Terminal Hold-Down Screws: 4.5 – 7 in-lbs (0.50 – 0.78 N-m) DC- is internally connected to I/O V-, but is isolated from CAN V-. A Class 2 power supply must be used. Power Up 1. OPTION: Attach ferrite core with a minimum of two turns of the DC+ and DC- signals from the DC supply that is powering the controllers. ...
Page 24 System Settings and Adjustments Page 24...
Page 25: System Settings And Adjustments
System Settings and Adjustments System Settings and Adjustments OCS LED Indicator Lights System Menu – Navigation and Editing System Menu Map Set Networks View Status & Diags View Battery Status, I/O Slots & Protocols Set Fkeys Mode, Serial Ports, Ethernet, Time/Date, Beeper & Screen Removable Media Fail –...
Page 26: System Menu - Navigation And Editing
System Settings and Adjustments System Menu – Navigation and Editing As mentioned above, the System Menu is started by pressing the System key on the EXL6/XL6 PRIME. Next press ESC to exit the System Menu or use ↑ and ↓ t o select an item and press Enter 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 Sys- tem Settings are editable, the first System Setting that can be edited is highlighted. If desired, the ↑ and ↓ 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 high- lighted System Setting. If Enter is pressed, the System Setting’s value will be highlighted, indicating that it is ready to be modified. When modifying a System Setting’s value, use either the arrow keys (← → ↑ ↓ ) or the numeric keys, or the appro- priate touch screen icons to select a new value. The arrow keys are used to edit System Settings that have just a few possible values. Each time the arrow key is pressed, a new possible value is displayed. When the desired value appears, press the Enter key to save it; oth- erwise press the ESC key to cancel the edit. The numeric keys are normally used to enter numeric System Settings. I n addition, to edit a single numeric digit, use the ← or → key to select the digit and then either press a numeric key or use ↓ or ↑ 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 27: System Menu Map
System Settings and Adjustments System Menu Map Page 27 of 196...
Page 28: Set Networks
System Settings and Adjustments Set Networks This sub menu allows setting for the CAN and Ethernet network to be viewed or changed. Yes = CAN1 connected to a CAN n etwork and functioning properly No = Not ready to communicate on C AN network CAN ID 1 to 253 = This node’s CsCAN Network ID; must be u nique on network 125kB = 125kBd CAN network 500kB = 500kBd CAN network Baud 250kB = 250kBd CAN network 1MB = 1MBd CAN network MAC ID Displays the E thernet MAC ID of the unit Displays the E thernet IP address of the unit NetM Displays the ...
Page 29: View Status & Diags
System Settings and Adjustments View Status & Diags View Status The View Status Sub-Menu displays up to 19 System Settings. Only the Mode System Setting is editable. XW1yz = Model number of this EXL6/XL6 PRIME OCS unit Model: 1yz = indicates the installed I /O module 00 = no I/O module Idle = EXL6/XL6 PRIME OCS is in Idle mode Mode: DoIO = EXL6/XL6 PRIME OCS is in Do I/O mode Run = EXL6/XL6 PRIME OCS is in Run mode 0.0 = EXL6/XL6 PRIME OCS is not in Run mode Scan Rate (mS): 0.1 to 999.9 = A verage number of mS for each ladder scan Lcl Net Use %: 0.0 to 100.0 = C AN network bandwidth % used by this O CS node All Net Use %: ...
Page 30 System Settings and Adjustments View Diags The View Diags Sub-Menu displays up to 11 System Diagnostics, none of which are editable. The first two System Diagnostics are critical. If any of them indicate a Fault condition, the OCS will not enter or remain in Run mode, and the problem must be investigated and corrected. Ok = A ll executed ladder instructions are legal for loaded firmware Logic E rror: Fault = A ladder instruction not supported by firmware was found Ok = L adder program and I/O configuration loaded successfully User P rogram: Fault = Ladder program or I/O configuration not loaded or load failed The last nine System Diagnostics are informational. If any of them indicate a Warning condition, the OCS can still enter and remain in Run mode, but the problem should be investigated and corrected.
Page 31: View Battery Status, I/O Slots & Protocols
System Settings and Adjustments View Battery Status, I/O Slots & Protocols View Battery See also:"EXL6 Rechargeable B attery" on page 179 The View Battery Status displays the following information. Waiting The c harging system is waiting for voltages and temperatures to stabilize. Battery C harging The b attery is charging. Shows a t the end of a charge cycle. Remains in this state until the battery is s teadily dis- Battery F ull charging. Battery ...
Page 32 System Settings and Adjustments View I/O Slots The View I/O Slots Sub-Menu displays three System Settings, all of which are not editable. Internal to the O CS, there is a CPU board, and up to two installed modules. Model 0 has no installed I/O or COM modules. All other models have an 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 fol- lowing six System Settings should appear for Slot 1: Slot 1: I/O: Empty = No I/O module installed or configured Slot 1:*Unsupported = Unsupported I/O module installed Slot 1:-I/O Missing = No I/O module i nstalled but an I/O module is configured Slot 1:+I/O: XExyy = y y I/O module installed but no I/O module configured Slot 1:?I/O: XExyy = yy I/O module installed but a nother I/O module configured Slot 1: I/O: XExyy = yy I/O module installed and c onfigured 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: ...
Page 33 System Settings and Adjustments View Protocols See also: "Protocol Configuration " on page 128 The View Protocols Sub-Menu displays three System Settings, none of which are editable. As mentioned in Downloadable Serial Communication Protocols section, both the MJ1 (Port 1) and MJ2 (Port 2) serial ports support downloadable protocols. To assign a downloadable protocol to an O CS serial port, select the Protocol Config item in Cscape’s Program menu and then setup 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 both Port 1 and Port 2. Port 1 Protocol Name (None L oaded) or name of the protocol assigned to MJ1 Protocol Version Blank or version of the protocol assigned to M J1 Port 2 Protocol Name (None L oaded) or name of the protocol assigned to MJ2 Protocol Version Blank or version of the protocol assigned to M J2 Page 33 of 196...
Page 34: Set Fkeys Mode, Serial Ports, Ethernet, Time/Date, Beeper & Screen
System Settings and Adjustments Set Fkeys Mode, Serial Ports, Ethernet, Time/Date, Beeper & Screen Set Fkeys Mode The Set Fkeys Sub-Menu displays two System Settings, both of which are editable. Momentary = %K1-5 bits go On & Off as F1-F5 are pressed & released Fkeys Toggle = %K1-5 bits toggle each time F1-F4 are pressed Yes = R eset and all clear system functions enabled SYS_Fn e nable No ...
Page 35 System Settings and Adjustments Set Serial Ports See also: "Serial Communications" on page 115 The Set Serial Ports Sub-Menu displays three System Settings, all of which are editable, 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 Dflt P gm Port Modem = Modem COM m odule i s the default programming port No = M J2 RS485 bias resistors are not switched in MJ2 ...
Page 36 System Settings and Adjustments Set Time/Date The following instructions are to set and display the real-time clock in the controller. M ore details can be found in the Help File in Cscape. Clock and Time Setting Terms Coordinated Universal Abbreviated to UTC, C oordinated Universal Time is the primary time standard by Time (UTC) which the w orld regulates clocks and time. In order to obtain the local time (anywhere in the world), the u ser needs to subtract / Time Offset add a certain number of hours from UTC depending on h ow many time zones user is away from Greenwich. Network Time Protocol A Networking Time Protocol (NTP) for clock synchronization b etween computer sys- (NTP) tems over packet-switched, variable latency data n etworks. Time as adjusted to achieve ...
Page 37 System Settings and Adjustments To Set Time Zone: The Time Zone setting is an hourly offset from UTC time. If using the Time Zone setting, set it first, then set the local time. UTC time will be automatically set based on the time zone and local time settings. If using NTP: NTP utilizes UTC time, therefore when using NTP, the appropriate hourly offset from UTC time must entered into the time zone setting. Daylight Saving Time: If currently observing Daylight Saving Time, set to Yes. If not currently observing Daylight Saving Time, set to No. The OCS controller does not automatically switch to daylight saving time; however, pro- gram logic can be written to accomplish an automatic switchover using system register %SR211. In program logic, move a “1” (INT) into %SR211 to enable Daylight Saving Time. Move a “0” (INT) into %SR211 to disable Daylight Saving Time. Trigger the move to %SR211 based on a compare function to the RTC date according to daylight sav- ing practices in your desired region. To Set Local Time: 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: Time and Date are split into three fields each, all of which may be edited. T ouch the field or use ↓ or ↑ b ut- tons to select a field, then use the ↓ or ↑ buttons 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) Monday = Current day of week calculated from the Date setting Page 37 of 196...
Page 38 System Settings and Adjustments Set Beeper The Set Beeper Sub-Menu displays one System Setting, which is editable. Yes (default) = Enables beeper Beeper Enable No = Disables beeper (does NOT affect ladder access) Page 38 of 196...
Page 39 System Settings and Adjustments Set Screen The Set Screen Sub-Menu displays four System Settings, all of which are editable. Yes = Enable screen saver Saver enable No (default) = Disable screen saver 5 - 1200 = Amount of time in minutes to expire with NO t ouch activity before activating screen Timeout (min) saver (black screen) Off (default) = Disable popup status Popup Status Warning = Display popup status only if controller status changes to NOT Ok or N OT Run mode. On = D isplay popup status on any controller status change. Update Time ...
Page 40: Removable Media
System Settings and Adjustments Removable Media See also: "Removable Media" on page 157 The Removable Media Sub-Menu displays the Removable Media Manager. After selecting Removable Media from the Main Menu, one of four Sub-Menu screens will appear: If a directory name is highlighted, pressing Enter will switch to that directory showing its files and sub-directories. In a sub-directory, highlighting .. (dot dot) and pressing Enter will move up one directory. Fail – Safe System See also: "Fail-Safe System" on page 167 Page 40 of 196...
Page 41 System Settings and Adjustments 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, Elec- tromagnetic Interference, event. Selecting “Fail-Safe System” menu will open the following menu screen: Selecting Backup/Restore Data displays the following screen in: Backup = Copies battery-backed RAM c ontents on to the onboard flash memory of the OCS. Restore = Copies the backed-up data from o nboard flash to the battery-backed RAM. Clear Backup = The backup data will be e rased from the onboard flash. Exit = Goes back to previous menu Page 41 of 196...
Page 42 System Settings and Adjustments Enable AutoRun “Enable AutoRun” displays the following options which can be selected: No = OCS will be in IDLE mode after AutoLoad or Automatic R estore. Enable AutoRun Yes = OCS will a utomatically be placed into RUN mode after AutoLoad or Automatic Restore. Page 42 of 196...
Page 43 System Settings and Adjustments Enable AutoLoad “Enable AutoLoad” displays the following options which can be selected: No = Does not l oad AUTOLOAD.PGM automatically when application program is absent or c or- Enable rupted. Yes = Loads A UTOLOAD.PGM file automatically from RM when application program is absent or AutoLoad c orrupted. Page 43 of 196...
Page 44: Clone Unit
System Settings and Adjustments Clone Unit See also: "Clone Unit" on page 163 ‘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 to"Removable Media" on page 157 for details on using RM. It can then be used to clone a different OCS (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. Make Clone Selecting “Clone Unit” menu will open the following menu screen: Load Clone and Make Clone virtual buttons are below the screen. Free/Total: Displays number of Free and Total bytes in Removable Media. Selecting Make Clone brings up the screen below for the user: Page 44 of 196...
Page 45 System Settings and Adjustments 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 u nit settings and register values from battery-backed RAM Page 45 of 196...
Page 46 System Settings and Adjustments Load Clone Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone” (one of the virtual buttons beneath the screen). NOTE: For security enabled files, Load Clone asks for password validation before loading the application. Page 46 of 196...
Page 47: Webmi License Details
System Settings and Adjustments WebMI License Details License details page displays the information about the WebMI license. Please refer to MAN1036 for the WebMI Manual using Horner's Documentation Search page. T he information can also be viewed from Cscape using the fol- lowing %SR registers: %SR209.3 WebMI server status %SR209.4 WebMI user logged in status %SR209.9 to SR209.16 Number of Users %SR218 Number of Webpages %SR219 Number of Data Points %SR220-SR222 Expiry Date of WebMI License Page 47 of 196...
Page 48: Touch Screen Calibration
System Settings and Adjustments 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. Ensure SYS_fn Enable is set to YES in System Menu. 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 the figure below will appear. For best results in screen calibration, use a stylus with a plastic tip. When the crosshair appears, touch the center of the crosshair as exactly as possible and release. A small “+” should appear and will move closer to the center of the crosshair. Once it has done so and disappeared again, repeat the process until “+” appears in the center of the crosshair. Then move on to the next step. Page 48 of 196...
Page 49 System Registers Page 49...
Page 50: System Register Tables
System Register Tables System Register Tables Register Definitions %S Registers %SR Registers here are two types of System Registers that may be u sed during programming. %S registers indicate the status of several system o perations. %SR egisters indicate the state of many system operations a nd can be used to control them in several cases. Some of the system registers h ave predefined I/O names, though they may still be changed if desired. Register Definitions When programming the an 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. Types of Registers 16-bit input ...
Page 51: %S Registers
System Register Tables %S Registers %S registers indicate s ystem status as follows: Name Predefined Notes I/O Name First Scan FST_SCN On for 1 scan only each time the program is first run Network OK NET_OK If on, the Network is OK 10ms pulse T_10MS Cycling pulse that is high for 5ms and low for 5ms 100ms pulse T_100MS Cycling pulse that is high for 50ms and low for 50ms 1 second pulse T_1SEC Cycling pulse that is high for 500ms and low for 500ms I/O OK IO_OK If on, the I/O system is OK Always On ALW_ON This bit is always on Always OFF ALW_OFF This bit is always off Pause Scan PAUSING_SCN On for at least 1 scan prior to Pause 'n Load %S10 Resume Scan...
Page 52: %Sr Registers
System Register Tables %SR Registers %SR registers are special word-length registers that d isplay and/or control system operations in the controller. Not all controllers s upport all defined system registers. Click on the name of the register t o see more information on that register. SR # Name and Description Default Min - Max Program Display (Read/Write) Name I/O Name Values (Read/Write) %SR1 User S creen Number (0=none) USER_SCR 0 to 1023 Read/Write...
Page 53 System Register Tables %SR6 Average Scan Rate ms ( / 10) Read Only Read Only %SR7 Minimum Scan Rate ms ( / 10) Read Only Read Only %SR8 Maximum Scan Rate ms ( / 10) Read Only Read Only %SR9 Current T ouch Pressure TCH_PRESSURE 0 to 3000 Read Only Read Only %SR10 Threshold T ouch Pressure TCH_ 0 to 3000 Read/Write Read/Write...
Page 54 System Register Tables %SR43 Keypad Type Read Only Read Only %SR44 Real-Time-Clock Second RTC_SEC 0 to 59 Read Only Read Only %SR45 Real-Time-Clock Minute RTC_MIN 0 to 59 Read Only Read Only %SR46 Real-Time-Clock Hour RTC_HOUR 0 to 23 Read Only Read Only %SR47 Real-Time-Clock Date RTC_DATE 1 to 31 Read Only Read Only %SR48 Real-Time-Clock Month RTC_MONTH 1 to 12 Read Only Read Only %SR49 Real-Time-Clock Year RTC_YEAR 1996 to ...
Page 55 System Register Tables %SR57 LCD Backlight Dimmer Register 0 to 255 Read Only Read Only 0-100 = 0% to 100% On 100-255 = 100% On %SR57.16 Temporarily disable Screen Saver Read/Write Read/Write %SR58 User LEDs USER_LEDS Read/Write Read/Write %SR59 Engine Build Number Read Only Read Only (Only last three numbers displayed) %SR60 Build Option 0 to 2 Read Only Read Only Build Test = 0 Build Beta = 1 Build Product = 2 %SR61 Number of CsCAN Network IDs NUM_IDS ...
Page 56 System Register Tables %SR164.10 LOAD_CLONE trigger bit – LOAD_CLONE Read/Write Read/Write Setting TRUE does a LOAD CLONE (if a media card is present that con- tains clone files) %SR164.11 Make Clone Fail MK_CLN_FL Read/Write Read/Write (This bit goes high when Make/Create Clone fails) %SR164.12 Load Clone Fail LD_CLN_FL Read/Write Read/Write (This big goes high when Load Clone fails) %SR164.14 Reserved Read/Write Read/Write %SR164.15 Reserved Read/Write Read/Write %SR165-166 Reserved ...
Page 57 System Register Tables EXTENDED SYSTEM REGISTERS %SR193 Online Change ONLINE_CHG %SR193.1 TRUE if 2 programs in target FLASH Read Only Read Only %SR193.2 TRUE to switch programs, FALSE when Read Only Read Only complete %SR193.3 TRUE if executing program is temporary Read Only Read Only test %SR193.4 TRUE during last scan of switched-from Read Only Read Only program %SR193.5 TRUE during first scan of switched-to pro- ...
Page 58 System Register Tables Daylight Saving: NO = 0 (If daylight saving is enabled, one hour will be added to the local time). %SR212 UTC - Seconds Read Only Read Only %SR213 UTC - Minutes Read Only Read Only %SR214 UTC - Hours Read Only Read Only %SR215 UTC - Date Read Only Read Only %SR216 UTC - Month Read Only Read Only %SR217 UTC - Year Read Only Read Only %SR218...
Page 59 Cscape Configuration Page 59...
Page 60: Cscape Configuration
Cscape Configuration Cscape Configuration Cscape Status Bar Establishing Communications Cscape Configuration Overview EXL6/XL6 Prime OCS hardware is programmed with a Windows based PC application called Cscape. This applic- ation can be used to program, configure, monitor, and debug all aspects of the EXL6/XL6 Prime OCS unit. Please see the Online Help provided with Cscape for additional details. Cscape Status Bar When the EXL6/XL6 Prime 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 EXL6/XL6 Prime OCS and the Cscape program. Components of the Cscape Status Bar are explained below: Page 60 of 196...
Page 61: Establishing Communications
The EXL6/XL6 Prime OCS can communicate with Cscape using USB to USB, USB to serial adapters, serial port communications via MJ1 Port, Ethernet (with an Ethernet adapter board), onboard Ethernet Port, CAN (CsCAN), or modems. If a direct USB connection is to be used, connect the Mini-USB port on the OCS (only on select models) to an open USB port on the PC. (A cable for doing this is included in HE-CPK, the programming kits.) The OCS will install as a device once plugged in. Drivers for it are normally found automatically by the Windows operating system as long as an Internet connection is established. See also the Tools of the Trade on the Horner website. The PC will detect a new device has been plugged into the USB port. Now that the EXL6/XL6 Prime is plugged in, go to Cscape > Controller > Connection Wizard. If you are just open- ing Cscape, Connection Wizard usually opens by default. Select USB and click Next >>. Page 61 of 196...
Page 62 Cscape Configuration If the Connection Wizard does not pop up upon opening Cscape, then select Controller (in the Cscape tool bar) > Connection Wizard, choose your connection method. If you are connecting for the first time, we suggest con- necting via USB. If Controller USB COM Port is not present in the dropdown list, the Windows operating system has not yet recog- nized the OCS as an installed device. Be sure the installation process is complete and that the correct drivers are installed. The Connection Wizard must be completely closed and reopened to refresh the USB dropdown list. An alternate way to select the COM setting is to go to Cscape > Tools > Application Settings > Communication > Configure and choose connection method in Add Target. Page 62 of 196...
Page 63 Cscape Configuration Page 63 of 196...
Page 64 Select this option to communicate to t he device through the internal modem of the computer. Cscape will a utomatically detect the internal modem attached with PC and list in the Installed Modem attached drop down. User can select modem and telephone number for target c ontroller. NOTE: Cscape will do necessary i nitialization for the selected internal modem. Select this option to communicate o ver USB. Now Horner devices and Horner USB to serial converters are r ecognized and can be specifically selected. Connected Device NOTE: This configuration is required if the c ontroller to which Cscape is communicating is connected to a CsCAN network. Connected Device By default, this option is selected a nd networking feature of Cscape is disabled. On s electing this option, Networking feature of Cscape is enabled. CsCAN ID for t he target ...
Page 65 Cscape Configuration If communications are successful, the message line should show “USB (COM8)” for this example, and an (R) should follow the Target number. If the controller is not communicating, you may need 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 EXL6/XL6 Prime OCS, press the System Menu key. The first item in the menu is Set Networks. Pressing Enter allows you to view or modify the ID of the unit. To change the Target ID of Cscape, highlight CAN ID and press Enter t o provide a new number. Page 65 of 196...
Page 66: Communicating Via Mj1 Serial Port
Cscape Configuration Communicating via MJ1 Serial Port If a serial programming connection is to be used and the PC has a 9-pin serial COM port, which is increasingly rare, there is nothing to install assuming the port already works. All that is needed is a programming cable to go from the COM port to the OCS programming port. If a serial programming connection is to be used and the PC does not have a COM port, a USB-to-Serial adapter may be used. D rivers for it are normally found automatically by the Windows operating system as long as an inter- net connection is established. Otherwise, the drivers may be loaded from the Horner FTP site at https://hornerauto- mation.com/support-files. Connect the PC’s serial port or the USB-to-Serial adaptor to the port labeled MJ1 on the EXL6/XL6 Prime. The instructions are similar to using a USB port, as shown above. In the Connection Wizard, select the “Serial” option. If communications are successful, the target indicator should show the mode of the controller Target: yy(R) as shown in the "Cscape Status Bar" on page 60. If the controller is not communicating, you may need 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 EXL6/XL6 Prime OCS, press the System Menu Key. The first item in the menu is Set Networks. Pressing Enter allows you to view or modify the ID of the unit. Pressing Enter allows you to view or modify the ID of the unit. To change the Target ID of Cscape use the Controller > Set Target Network ID dialog.
Page 67: Communicating Via On Board Ethernet Port
Cscape Configuration Communicating via On Board Ethernet Port From Cscape go to Controller > Hardware Configuration and do auto configuration for the connected controller, Click on Config of Ethernet and select Module Setup. 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. Page 67 of 196...
Page 68 Cscape Configuration In Module configuration dialog, go to IP Address field enter unused IP Address and configure unused registers in Register field & then click OK. Screen shot for the same as follows: 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 as shown in the " Cscape Status Bar" on page 60 section. Page 68 of 196...
Page 69: Cscape Configuration
Cscape Configuration Cscape Configuration An overview of configuration: 1. Start the configuration by selecting the Controller > Hardware Configuration menu item. 2. If the EXL6/XL6 Prime OCS is connected to the PC, press the Auto Config System button to automatically detect the Base model, I/O, and any communication options. 3. If the EXL6/XL6 Prime 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. 4. Select either EXL6/XL6 Prime OCS CsCAN from the type drop down box. 5. Once the type of EXL6/XL6 Prime OCS is selected, the model # drop down box will provide the EXL6/XL6 Prime OCS model numbers from which to choose. 6. Once the EXL6/XL6 Prime OCS CPU is selected, press OK to exit the dialog and configure the I/O that is present in the first slot. 7. The I/O configure dialog (specifically the Module Setup tab) provides four (4) buttons to configure all of the I/O. Go through each area of I/O and configure it. 8. Once done configuring the I/O, OK out of configuration dialogs. Configuring the EXL6/XL6 Prime OCS I/O has four main portions that are covered in this chapter. For additional information on I/O, refer to "General I/O Configuration" on page 1 or "High Speed I/O (HSC / PWM) " on page 93. The four areas of Hardware configuration are Digital in / HSC, Digital out / PWM, Analog In, Analog Out. Page 69 of 196...
Page 70 General I/O Configuration ...
Page 71: General I/O Configuration
General I/O Configuration General I/O Configuration Built-in Digital and Analog I/O Overview Removing the Horner OCS Back Cover Digital / HSC Input Configuration Digital / PWM Output Configuration Analog Inputs Analog Outputs Built-in Digital and Analog I/O Overview The Horner OCS is a compact unit that contains high density and very versatile I/O. Using the I/O properly requires ...
Page 72: Removing The Horner Ocs Back Cover
General I/O Configuration Removing the Horner OCS Back 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 inside the Horner OCS unit. Examples of these set- tings are setting positive or negative logic on digital inputs or setting current or voltage on analog inputs.
Page 73: Digital / Hsc Input Configuration
General I/O Configuration Digital / HSC Input Configuration Horner controllers vary greatly on series and model numbers. Refer to the datasheets on the Document Search table on the Horner website. The inputs are designed to support both positive and negative input modes. For many models, the mode is set by a jumper setting and a configuration parameter in Cscape. The Model 6 does not require jumpers, and only requires a configuration parameter in Cscape. All the inputs on the unit must be configured to the same mode. 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 24V). This mode is some- times called sinking. Some of the digital inputs may support high-speed input functional such as counting or frequency measurement. Page 73 of 196...
Page 74 General I/O Configuration Digital Input Configuration Home > Hardware Configuration [select Device Type/Model#] > Local I/O Tab > I/O / Config Button > Mod- ule Setup > Digital In/HSC Select Hardware Configuration from the Home menu and ensure that the correct Device Type and Model# are selec- ted. Then select the Local I/O tab. After selecting Local I/O, select the Config button next to the I/O connector. The Module Configuration screen will appear, select the Module Setup tab. See below. Page 74 of 196...
Page 75 General I/O Configuration The Module Setup allows a user to configure four types of I/O. NOTE: Not all controllers offer all four types. Refer to the controller's datasheet on the using Horner's Documentation Search page. Page 75 of 196...
Page 76 General I/O Configuration Select Digital In/HSC to open the Digital / HSC Input configuration dialog for a specific controller. 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 matches the jumper settings on the hardware. The High-Speed Counters group box contains all the windows that are used to configure the four available high- speed counters on the Horner OCS. To configure a counter, the user needs to set the type, mode, and counts per rev. The type drop down includes the following options: Disabled Frequency Totalize Pulse Quadrature Marker (Only available in counter #3 if counter #1 is set to quadrature.) The mode drop-down items are set according to the type selection. The Counts Per Rev. window is enabled/dis- abled according to the type selection as well. Page 76 of 196...
Page 77: Digital / Pwm Output Configuration
General I/O Configuration Digital / PWM Output Configuration Solid State Digital Outputs Solid-state digital outputs are generally used to activate lamps, low voltage solenoids, relays, and other low voltage and low current devices. NOTE: The digital outputs used on some controllers 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. Use the Documentation Page t o view the datasheet for a specific controller for specifics on a mod- ule's I/O. The digital outputs used in the OCS have electronic short circuit protection and current limiting. While these elec- tronic protections work in most applications, some application may require external fusing on these outputs. The digital outputs in the 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. 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. NOTE: The digital outputs feature an output fault bit. %I32 will turn on if any of the outputs experience a short circuit, over-current or the output driver overheats. Page 77 of 196...
Page 78: Relay Outputs
Relay Life – Relays are mechanical devices that have a long but limited life. Typically, switching more cur- rent 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 over- loads. WARNING: T o protect the module and associated wiring from load faults, use external (5A) fuse(s) as shown. Fuses of 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 I/O pins. Below is an example of 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. Below you will find recommendations that will work for many applications. If you have additional questions on protection from inductive load, consult an application engineer or Horner Technical Support. Details on devices that may protect outputs can be found in the Spark Quencher Datasheet, MAN0962, which is located on the website. Page 78 of 196...
Page 79: Digital Output Configuration
General I/O Configuration 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. Digital Output Configuration Home > Hardware Configuration [select Device Type/Model#] > Local I/O Tab > I/O / Config Button > Mod- ule Setup > Digital Out/PWM Select Hardware Configuration from the Home menu and ensure that the correct Device Type and Model# are selec- ted. Then select the Local I/O tab. ...
Page 80 General I/O Configuration The Module Setup allows a user to configure four types of I/O. NOTE: Not all controllers offer all four types. Refer to the controller's datasheet the using Horner's Documentation Search page. Select Digital Out/PWM to open the Digital / PWM Output Configuration dialogue. Page 80 of 196...
Page 81 General I/O Configuration The Q1 and Q2 group boxes allow the user to specify the operation of the multifunction outputs. PWM State On Controller Stop - 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: The PWM outputs are set to the OFF state at power-up and during program download and remain in that state until the unit is placed in RUN. Output State On Controller Stop - 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. NOTE: The number of Output States on Controller Stop vary by product. Stop State - When a controller stops running ladder logic, the state of most output I/O modules can be configured. By default digital outputs turn OFF and analog outputs go to a zero output level. Outputs can be configures to hold the last state the outputs was in when the controller stopped, or it can be configured to go to a predefined state. NOTE: When a controller is in DO I/O mode the outputs are still controlled by the values in the controller's registers. NOTE: The number of Output State on Controller Stop varies by controller. See the datasheet on the Docu- mentation Page for more details. Page 81 of 196...
Page 82: Analog Inputs
General I/O Configuration Analog Inputs The analog inputs on the OCS allow voltage or current measurement from a variety of devices. The voltage or cur- rent 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 actual input. Home > Hardware Configuration [select Device Type/Model#] > Local I/O Tab > I/O / Config Button > Mod- ule Setup > Analog In Select Hardware Configuration from the Home menu and ensure that the correct Device Type and Model# are selec- ted. Then select the Local I/O tab. After selecting Local I/O, select the Config button next to the I/O connector. ...
Page 83 General I/O Configuration The Module Configuration screen will appear, select the Module Setup tab. See below. Page 83 of 196...
Page 84 General I/O Configuration The Module Setup allows a user to configure four types of I/O. NOTE: Not all controllers offer all four types. Refer to the controller's datasheet on the Horner website's Documentation Page f or more information regarding specific models. Select Analog In to open the Analog Input Configuration dialogue: The Channel x drop down windows allow the user to specify the mode for each analog input to operate. The Chan- nel 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 the XL series, the Model 5 and Model 6 modules have more channel options. Page 84 of 196...
Page 85 General I/O Configuration Universal Analog Inputs Model 5 The universal analog inputs provide a high resolution, very flexible interface for a variety of analog inputs. T hese inputs include voltage, current, theremocouple, 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 sud- den changes in the actual input. Analog In for Model 5 Channels 1 & 2 0..10V 0..20mA 4..20mA 100mV PT100 D IN RTD, 1/20°C Type J Thermocouple, 1/20°C Type K Thermocouple, 1/20°C Type ...
Page 86 General I/O Configuration Model 5 Universal Analog Input Configuration 1. Select Analog In to access the Analog Input Configuration menu. 2. Select any of the Analog input types from the drop-downs by clicking the down arrow beneath each cor- responding Channel, as seen below: 3. Ensure the proper wiring is used for each of the pins on the Universal Analog Inputs as seen in the image and table below: Page 86 of 196...
Page 87 General I/O Configuration Table for Model 5 Universal Wiring J3 Connector for Universal Wiring TC (1+) or RTD (1+) or 100mV (1+) TC (1-) or RTD (1-) or 100mV (1-) TC (2+) or RTD (2+) or 100mV (2+) TC (2-) or RTD (2-) or 100mV (2-) 10V or 20mA OUT (1) 10V or 20mA OUT (2) Common 0-20mA IN (1) 0-10V IN (1) Common 0-20mA IN (2) 0-10V IN (2) Common Page 87 of 196...
Page 88 General I/O Configuration Universal Analog Inputs Model 6 The Universal Analog Inputs on the Model 6 IO board are unique from other Horner XL-series input/output cards in that they are configurable through the module configuration instead of having to change jumper settings in order to setup the input type. Analog In for Model 6 Channels 1-6 0..10V 0..20mA 4..20mA Disable 0-60mV PT100 D IN RTD, 1/10°C PT1000 D IN RTD, 1/10°C Type J Thermocouple, 1/10°C Type K Thermocouple, 1/10°C Type N Thermocouple, 1/10°C Type ...
Page 89 General I/O Configuration 3. Ensure the proper wiring is used for each of the 3 pins A , B, and C on the Universal Analog Inputs as seen in the reference image below: Scaling Analog Inputs & Examples To access the Advanced Math Scaling function, select Home > View > Project Toolbox. This will open a side bar, and then select Advanced Math > Scale. Page 89 of 196...
Page 90 General I/O Configuration Example 1 The Cscape Scale function, found in the Advanced Math functions, allows for very easy conversion of the raw input value into a meaningful reading. For example, a pressure transducer may be specified as a 4-20mA signal to signify a 0-2000 psi pressure reading. W ith the analog channel set to the 4..20mA range, the raw analog input value, which is in INT format ranges from 0 to 4mA to 32000 for 20mA. Use the Scale function to obtain an Integer pressure read- ing using the 0-32000 raw input range and the sensor’s 0-2000psi output range. Example 2: If readings with fractions are required, the raw Integer input value must first be translated in REAL, or Floating Point Format, see note below. . The Cscape INT-to-REAL Conversion function may be used to convert the raw input value from INT to REAL format in an intermediate memory location. The SCALE function, specified as REAL type, may be used to scale the converted raw value into a reading that supports digits beyond the decimal place, i.e. 475.25psi. Page 90 of 196...
Page 91: Analog Outputs
General I/O Configuration Analog Outputs NOTE: Refer to the datasheet for details on jumper settings. The analog outputs on Horner OCS devices provide high resolution voltage or current outputs. The voltage or cur- rent selection is controlled with jumpers and configuration settings in Cscape. NOTE: Each channel can be separately configured for voltage or current mode. When the controller is stopped, the operation of each output is configurable. The outputs can hold the state they were in before the controller stopped or they can go to a predetermined value. By default, analog outputs are set to a value of zero (0). The following figure illustrates the Analog Output Configuration dialog. To open the I/O configuration dialogs, select Controller > Hardware Configuration > Local I/O > Config > Module Setup. 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 con- troller 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 ...
Page 92 High Speed I/O (HSC & PWM) Page 92...
Page 93: High Speed I/O (Hsc / Pwm)
HSC Functions Register Maps High Speed Output Functions High Speed Output Functions Register Map HSC I/O Filtering Overview In addition to the compliment of simple analog and digital I/O, several of the 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 (lim- ited functionality) with variable acceleration and deceleration rates. The OCS contains a Field-Programmable Gate Array (FPGA), which is an integrated configurable circuit that allows the OCS to be programmed to have either two high-speed counters or four high-speed counters. The OCS ships with two high-speed counters, but a customer can contact Horner Technical Support to receive a file that will configure the unit to have four. These modes are not supported simultaneously. Two counter mode supports Quad- rature mode and two stepper outputs, while four counter mode does not support Quadrature mode and supports only one stepper output. This chapter describes the operation of these high level I/O functions. For configuration details of these functions, see"Cscape Configuration" on page 1. Page 93 of 196...
Page 94: High Speed I/O Glossary
High Speed I/O (HSC / PWM) High Speed I/O Glossary Glossary of High Speed I/O Terms Accumulator Register used to accumulate or store up a sum or count of m any items or events. A special function to zero out the value in a specific r egister. (Not used with Frequency or Period Clear Measurement.) Disable A special function to prevent the counter from running. Encoder A sensor or transducer for converting rotary motion or p osition to a series of electronic pulses An integrated, configurable circuit that allows the c ontroller to be programmed to have either two FPGA high-speed counters or four h igh-speed counters. Frequency The number of times an electromagnetic signal repeats an i dentical cycle in a unit of time, usually Input one second.
Page 95: High Speed Counter (Hsc) Functions
High Speed I/O (HSC / PWM) High Speed Counter (HSC) Functions The s upports two h igh speed, configurable counters. There are four dedicated inputs that can be configured to a number of different options. Each of the two counters can run in one of five modes. Those modes are Totalizer, Fre- quency 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. Refer to the "System Register Tables" on page 50 for more details. 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: Selecting a shorter sample window provides a quicker measurement (faster response) but lowers the fre- quency accuracy (resolution) and increases the minimum frequency measurement limit. In this mode the Disable and Latch special functions are allowed. Refer to the "High Speed I/O Glossary " on the previous pagey for a description of these functions. Totalize In totalize mode, the accumulator is simply incremented or decremented each time the input transitions in a specific direction. The totalizer supports the following modes: This mode ties the i nput to the counter to an internal 10MHz or 1MHz clock. The special f unc- Internal tions can be used to accurately time events.
Page 96 High Speed I/O (HSC / PWM) Three different options are available to reset the current count: a. Configured reset value - When configuring the Totalize function, a value may be specified under the Counts per Rev column. When the totalizer accumulator reaches this value - 1, the accumulator will reset to zero on the next count. Specifying zero for this value allows the totalizer to count through the full 32-bit range before resetting. b. Ladder Control - Setting registers %Q17-20 reset HSC1-4 (respectively) with no additional configuration. When these registers are asserted, the associated totalizer accumulator is reset and held at zero (level sens- itive). c. Direct digital input control ( HSC1 and HSC2 only) - HSC3 (%I11) and HSC4 (%I12) may be configured as hardware digital reset signals for HSC1 and HSC2 (respectively). To enable these inputs as reset signals, specify the type as Totalize Reset (NOTE: The corresponding Totalize HSC must be previously configured before this option is available). The direct digital reset controls are edge sensitive with the edge polarity con- figurable. Maximum direct digital reset latency is 100μs. The totalize function also supports an option which compares the current accumulator value with a supplied Preset Value (PV), which is provided through a %AQ, and drives a physical digital output based on the that comparison. NOTE: T his option (available for HSC1 and HSC2 only) drives Q1 or Q2 output point (respectively) once the asso- ciated totalizer accumulator reaches (or exceeds) the PV value. To enable this function, the corresponding PWM function output (Q1 or Q2) must be configured for HSCx Output. ...
Page 97: Pulse Width Measurement
High Speed I/O (HSC / PWM) 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. Refer to the "High Speed I/O Glossary " on page 94 for a description of these functions. Width High 1 μs Counts – In this sub-mode the accumulator value will contain the number of 1 μs counts the pulse is high. Width Low 1 μs Counts - In this sub-mode the accumulator value will contain the number of 1 μs counts the pulse is low. Page 97 of 196...
Page 98: Period Measurement
High Speed I/O (HSC / PWM) 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 func- tions are allowed. Refer to the "High Speed I/O Glossary " on page 94 for a description of these functions. Period Rising Edges 1 μs Counts – In this sub-mode the period of the input signal is reported in one (1) μs units. The period measurement will start on the rising edge of the input. Period Falling Edges 1 μs Counts – In this sub-mode the period of the input signal is reported in 1 μs units. The period measurement will start on the falling edge of the input. Page 98 of 196...
Page 99: Quadrature
High Speed I/O (HSC / PWM) Quadrature Quadrature mode uses two HSC inputs, any of the four 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 typ- ically 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. 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 inputs 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. Refer to the "High Speed I/O Glossary " on page 94 for a description of these functions. Page 99 of 196...
Page 100: Hsc Functions
High Speed I/O (HSC / PWM) Register Match Totalizer & Quadrature counter modes support a register match function. When the accumulator value matches either the Match 1 or Match 2 value configured in the corresponding %AQ registers, a high-speed output can Turn On, Turn Off, or Toggle. An internal %I register mirrors the output state whether the high-speed output is configured or not. The output can be reset in program logic using the corresponding %Q registers. 1. 2-Counter Mode has Register Match support for both counters. 2. 4-Counter Mode has Register Match support only for counters 1 and 2. 3. The High-Speed Outputs are %Q1 for Counter 1 and %Q2 for Counter 2. They operate as high-speed out- puts, independent of the controller scan rate, when configured as ‘HSC Output’ in the Digital Out/PWM con- figuration in Cscape. 4. The High-Speed Output state reflects in the status register “High Speed Out”, e.g. %I1603 for Counter 1 (the update speed of the status bit is scan rate dependent) 5. The High-Speed Output can be reset through ladder with the assigned output, e.g. %Q1606 for Counter 1 6. Both Match 1 and Match 2 values will trigger the match function. 7. If the output is already triggered by any Match register while using ‘Turn On’ or ‘Turn Off’ modes, subsequent matches will not affect the output. 8. If using ‘Toggle’ mode, every match of either Match value will toggle the output to the opposite state. HSC Functions The high-speed input on the OCS contains many optional tasks. All of which can be disabled, or set to an internal pre-assigned register (Assigned %Q) or to one of the external high speed inputs (External Input #1, 2, 3, or 4), or ...
Page 101: Status Bits
High Speed I/O (HSC / PWM) Status Bits There are three status bits (%I registers for each high-speed counter): Overflow Flag: This status bit turns high when the Accumulator “overflows”, it moves from 4,294,967,295 (- 1 if Signed) to 0, this bit can be reset with the “Output Reset Bit”. See Table 9.4. Underflow Flag: This status bit turns high when the Accumulator “underflows”, it moves from 0 to 4,294,967,295 (-1 if Signed), this bit can also be reset with the “Output Reset Bit”. NOTE: For the Overflow and Underflow flag registers, if using some sort of counter that counts both up and down, going over the threshold to go negative, triggers the underflow, and then going back over the threshold back into positive numbers will trigger the positive register to go active. High Speed Out: This register will follow the high-speed output assigned to the counter, it is important to note that this register is still populated within the scan time so the value in this register may not be up to date depending on the timing of the output (it should be up to date within one scan). Page 101 of 196...
Page 102: Hsc Functions Register Maps
High Speed I/O (HSC / PWM) HSC Functions Register Maps 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. HSC Functions Register Map for 2 HSC Configuration Register Frequency Pulse Totalize Quad %AI401-402 Accumulator - C ounter 1 %AI403-404 Latch Value – C ounter 1 %AI405-406 Accumulator – C ounter 2 %AI407-408 Latch Value – C ounter 2 ...
Page 103 High Speed I/O (HSC / PWM) %I1601 Overflow Flag – C ounter 1 %I1602 Underflow Flag – C ounter 1 %I1603 High Speed Out 1 %I1604 Reserved %I1605 Overflow Flag – C ounter 2 %I1606 Underflow Flag – Counter 2 %I1607 High Speed Out 2 %I1608 Reserved Page 103 of 196...
Page 104 High Speed I/O (HSC / PWM) HSC Functions Register Map for 4 HSC Configuration NOTE: Four Count Mode requires FPGA update. See "Overview" on page 93. Register Frequency Pulse Totalize %AI401-402 Accumulator - C ounter 1 %AI403-404 Latch Value – C ounter 1 %AI405-406 Accumulator – C ounter 2 %AI407-408 Latch Value – C ounter 2 %AI409-410 Accumulator – C ounter 3 %AI411-412 Latch Value – ...
Page 105 High Speed I/O (HSC / PWM) %Q1633 Latch – Counter 3 %Q1634 Preload – Counter 3 %Q1635 Clear – Counter 3 %Q1636 Disable – Counter 3 %Q1637 Direction – C3 %Q1638 Output Reset – C ounter 3 %Q1639 Preload Disable – C ounter 3 %Q1640 Latch Disable – C ounter 3 %Q1641-1648 Reserved %Q1649...
Page 106: High Speed Output Functions
High Speed I/O (HSC / PWM) 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. Normal When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives that respective output. 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 (%AQs) to be set for operation. These parameters may be set at run-time. Duty Cycle - The Duty Cycle is a 32-bit value from 0 to 32,000 indicating the relative duty cycle of the output. For example, a value of 8000 would indicate a 25% duty cycle, a value of 16,000 would indicate a 50% duty cycle. Zero (0) turns the output off, 32,000 turns the output on. Frequency - The Frequency is a 32-bit value indicating the output frequency in Hertz. One over the frequency is the period. 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 out- puts 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 out- put to remain low during stop mode. NOTE: For standard I/O models (1E3, 1E4, 1E5, and 1E6) the maximum recommended PWM frequency is 10kHz, due to the limitations of built-in output circuitry. The HE-XHSQ generates 24V pulse outputs with a recommended max of 400kHz. The HE-XHSQ-5 generates 5V pulse outputs with a recommended max of 1.0MHz. The add-on ...
Page 107 High Speed I/O (HSC / PWM) PWM Output Waveform PWM Output Waveform Table Rise Time 150ns Max Fall Time 150ns Max PWM Period Frequency = 1/Period High Speed Counter Match When either Q1 or Q2 is configured for HSC Output operation, their output state is based on a comparison between the counter accumulator and match registers. R efer to the "HSC Functions Register Maps" on page 102 for more details. Page 107 of 196...
Page 108: Stepper Function
High Speed I/O (HSC / PWM) Stepper Function The OCS supports two stepper functions, one on each high-speed output when in two counter mode. In four counter mode, the OCS supports one stepper function 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 Fre- Sets the frequency f or the first cycle during the acceleration phase and the frequency of the l ast cycle during the deceleration phase. When an acceleration or d eceleration count is specified, the quency (pulses per Start Frequency m ust b e greater than 0 and must not exceed the run frequency or an error is g en- second) erated. Run Fre- Sets the frequency f or the last cycle during the acceleration phase, the consistent frequency d ur- quency ing the run phase, and the frequency of the first cycle during the ...
Page 109: High Speed Output Functions Register Map
High Speed I/O (HSC / PWM) 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. PWM Functions Register Map, Two Counter Register Stepper %AQ421-422 PWM 1 Duty Cycle ( 32-bit) Start Frequency – Stepper 1 %AQ423-424 PWM 1 Frequency Run Frequency – Stepper 1 %AQ425-426 Acceleration Count – Stepper 1 %AQ427-428 Run Count – Stepper 1 %AQ429-430 Deceleration Count – Stepper 1 %AQ431-432 PWM 2 Duty Cycle ( 32-bit) Start Frequency – Stepper 2 %AQ433-434 PWM 2 Frequency...
Page 110 High Speed I/O (HSC / PWM) PWM Examples Example 1 Duty Cycle Frequency To get a 50% Duty Cycle @ 10kHz waveform Set % AQ421-422 = 16,000 Set % AQ423-424 = 10,000 on PWM1: Example 2 Duty Cycle Frequency Set %AQ421-422 = 1 6,000 To get a 50% Duty Cycle o n PW1 and Set %AQ423-424 = 1 ,000 ...
Page 111 High Speed I/O (HSC / PWM) STP Examples Start Example 1 Accel Count Run Count Decel Count Frequency Frequency Set %AQ423-4 = Set %AQ425-6 = Set %AQ427-8 = 10,000,000 s teps Set %AQ421 = Set %AQ422 = 1,000,000 8,000,000 1,0000,000 control sequence 2500 ( Hz) 5000 ( Hz) (Steps) (Steps) (Steps) When the start bit ...
Page 112: Hsc I/O Filtering
High Speed I/O (HSC / PWM) HSC I/O Filtering This feature is used to enable digital Filter for HSC Inputs. Selecting Digital In/HSC configuration opens up the following dialog where in HSC I/O Filtering is available. Input signal is filtered based on the filter frequency and Number of samples selected. User has to select Filter Fre- quency and Number of samples based on the frequency of the Input signal. Filter Frequency: To set the filter, choose a value that is: 4*Number of Samples*Expected Max Hz on the high- speed inputs. Number of samples: The input must be stable for this many samples before the HSC accumulator is affected by any change. The state (high or low) of the high-speed input is sampled with every rising input edge of the filter frequency. The rising edges of the filter frequency are totaled in a sample counter, and when that total equals the number of samples configured, the sample counter is reset. I f the high-speed input state did not change by the time of the sample counter reset, that state, high or low, is passed on to the high-speed accumulator. I f the high-speed input state changes during the sample counting, the sample counter is reset to zero and the process starts over. Page 112 of 196...
Page 113 High Speed I/O (HSC / PWM) If user selects filter frequency as 1MHz and Number of samples as 4, then Input signal is sampled for 4 samples and if the signal is stable for 4 samples i.e. 4μs then the signal is passed to Accumulator. If the Input state is changed in between the sampling counts, then the count is reset, and the Input state is again checked for given number of samples. Refer to Dotted lines in the Figure 2, after 2 samples the state of input signal changes to 1, so the counter is again started to count 4 samples, to pass the signal to accumulator. There will be a delay in passing the input signal to accumulator since we are filtering the Input signal and the delay is based on the selected filter frequency and Number of samples. In the above example filter frequency is 1MHZ (1μs) and number of samples: 4, so the minimum delay in input signal will be 4μs. Page 113 of 196...
Page 114 Serial Communications Page 114...
Page 115: Serial Communications
Serial Communications Serial Communications Port Descriptions Wiring Dip Switches RS485 Termination RS485 Biasing Cscape Programming via Serial Port Ladder-Controlled Serial Communication Configuration via Mini-B USB All EXL6/XL6 PRIME 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 con- nected 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. Port Descriptions The MJ1 serial port contains an RS232 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 ...
Page 116: Dip Switches
Serial Communications Dip Switches The DIP switches are used to provide a built-in termination to both the MJ1, MJ2 & MJ3 ports if needed. The ter- mination for these ports should only be used if this deviced is located at either end of the multidrop/daisy-chained RS-485 network. 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 of the RS485 network should be terminated. 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 and MJ3 serial ports allow internal bias resistors to be switched in, pulling pin 1 up to 3.3V and pulling pin 2 down to ground. The Set Serial Ports item in the System Menu can be used to enable RS485 biasing. A lso, 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. Page 116 of 196...
Page 117: Cscape Programming Via Serial Port
Serial Communications Cscape Programming via Serial Port The EXL6/XL6 PRIME OCS MJ1 and MJ3 serial ports support CsCAN Programming Protocol. If a PC COM port is connected to the EXL6/XL6 PRIME OCS MJ1 or MJ3 serial port, Cscape can access the EXL6/XL6 PRIME OCS for programming and monitoring. Programming can also be done via the CAN port, USB A port, or Ethernet. 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 and Dial and Answer Modem function blocks. Configuration via Mini-B USB NOTE: The unit must be connected via the mini-USB port to the PC or laptop. It is possible to load the program and monitor data via the Mini-B USB. To load via Mini-B USB, configure the com- munications port in Cscape as follows: Select Tools from the toolbar > Application Settings > Communications > USB button It is possible to download or upload and use the data monitoring functions once connected. NOTE: It is advisable to use an isolated USB cable between the PC or laptop and the EXL6/XL6 PRIME when third party devices are connected to the EXL6/XL6 PRIME to avoid damage to the PC or laptop and/or the EXL6/XL6 ...
Page 118 Communications Page 118...
Page 119: Can Communications
CAN Communications CAN Communications Port Description CAN1 Port Wiring Cscape Programming via CAN Ladder-Controlled CAN Communication Using CAN for I/O Expansion (Network I/O) NOTE: For additional CAN information, refer to the CAN Networks manual, MAN0799 (MAN0799) using Horner's Documentation Search page. OCS models provide A CAN network port, which is implemented with 5-pin connectors. T he CAN port allows the OCS to exchange global data with other OCS controllers and to access remote Network I/O devices (SmartStix, Smart Blocks and Smart Rail Modules). T he port also supports pass-through communications for programming mul- tiple OCS controllers over the CsCAN network. Also, the CAN port supports CsCAN, CANopen, J1939, and DeviceNet Master (layer 3 as a selectable option). Port Description The ...
Page 120: Cscape Programming Via Can
CAN Communications Cscape Programming via CAN The CAN 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 O CS CAN port, Cscape can access the O CS for programming and mon- itoring. In addition, the O CS supports single-point-programming of all O CS d evices that are connected to the CAN port net- work. If the PC COM port is connected to the OCS MJ1 serial port, the O CS can act as a pass-through gateway allowing Cscape to access all O CS d evices that are attached to the CAN port network. Ladder-Controlled CAN Communication Using Put and Get Network Words function blocks, the CAN1 port can exchange digital and analog global data with other devices (nodes) attached to the CAN network. In addition, Put and Get Network Heartbeat function blocks allow nodes on the CAN network to regularly announce their presence and to detect the presence (or absence) of other nodes on the network. ...
Page 121 Ethernet Communication Page 121...
Page 122: Ethernet Communications
Protocol / Feature Description ICMP (Ping) Internet C ontrol Message Protocol Ethernet G lobal Data SRTP Slave (90-30 Service Request) Service R equest Transfer Protocol CsCAN TCP Server Horner A PG CsCAN over Ethernet (for Cscape to OCS programming) Modbus Slave Modbus o ver Ethernet Ethernet / IP ODVA C IP over Ethernet FTP (File Server) File T ransfer Protocol HTTP (Web Server) HyperText ...
Page 123: Ethernet Module Specifications
Ethernet Communications Ethernet Module Specifications Speeds 10 BaseT Ethernet (10Mbps) 1 00 BaseTx Fast Ethernet (100Mbps) Modes Half or Full Duplex Auto-Negotiation Both 10/100Mbps and Half/Full Duplex Connector Type Shielded RJ-45 Cable Type CAT5 (or better) UTP (Recommended) Port Auto MDI/MDI-X (Auto C rossover) Ethernet Module Configuration NOTE: The following configuration is required for all applications regardless of the protocols used. Additional con- figuration 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 Hardware Configuration sub-menu to open the Hardware Configuration dialog. 2. If configuring a different OCS Model than the one shown in the Hardware Configuration dialog, click on the topmost Config button, select the desired OCS Model, and then click OK. ...
Page 124 Ethernet Communications 3. Click the Config button to the right of the LAN1 for LAN 1 or LAN2 for LAN 2, revealing the Ethernet Module Configuration dialog. 4. Configure the Ethernet Module parameters as follows: IP Address: Enter the static IP Address for the Ethernet Module being configured. NOTE: IP Addresses are entered as four numbers, each ranging from 0 to 255. These four numbers are called oct- ets, 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. Typ- ical local 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. The table shows how this register value is formatted and explains the meaning of each bit in the Status Word. Page 124 of 196...
Page 125 Ethernet Communications Ethernet Status Word Register Format High Byte Low Byte Bit 16 Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Link TCP Connections Status Values Status Bit Status Indication Minimum Maximum Reserved Always 0 Link Duplex (Auto-Negotiated) 0 = Half Duplex 1 = Full Duplex Link Speed (Auto-Negotiated) 0 = 10 Mbps...
Page 126: Ethernet Configuration - Ip Parameters
Ethernet Communications Ethernet Configuration – IP Parameters For primary operation, the IP address, Net Mask, and Gateway should be set in the LAN config of the Cscape Hard- ware Configuration. There are options to get IP parameters from the LAN Config or to get parameters from registers. It is possible to set the Ethernet IP parameters from the OCS System Menu, but only as a temporary measure. The following points on IP parameter configuration should be considered. IP Parameters in Non-Volatile RAM: The IP parameters of the Cscape LAN Config are written to non-volatile RAM on power down. IP parameter settings made in the System Menu are not written to non-volatile RAM. Any IP parameters settings made in the System Menu will be lost after cycling power to the unit. It will revert to the last downloaded Cscape LAN Config that was loaded into non-volatile RAM at power down. “Cscape LAN Config”/ “Get Settings from” Configuration: When ‘Get settings from’ is set to Configuration, the IP parameters specified under ‘Default Settings’ is used after downloading to the controller. The IP parameters are represented in System Menu / Set Networks and can be edited. However, any edits made from System Menu / Set Networks is not retained through a power cycle. After power cycle, the unit reverts to the last downloaded Cscape LAN Config that was loaded into non-volatile RAM at power down. “Cscape LAN Config” / “Get Settings from” Register: When ‘Get settings from’ is set to Register, the IP para- meters are retrieved from the OCS registers assigned in LAN Config. Configured registers must be populated with ...
Page 127 Downloadable Protocols Page 127...
Page 128: Protocol Configuration
Protocol Configuration Protocol Configuration Overview Protocol Device Driver Selection Network Configuration Device List and Device Configuration Scan List Overview Through loadable protocol device drivers, certain models of the OCS family can provide the ability to exchange data with remote devices such as variable-frequency drives, PLCs and remote I/O devices. This feature greatly expands the OCS ’s control capability with negligible effect on the OCS ’s ladder scan time. Remote devices that communicate serially must do so under certain rules of data transfer known as a protocol. Many device manufactures have created their own protocol for communications with their device. F or a OCS to com- municate with a specific device, it must be loaded with the corresponding serial communications protocol device driver that supports that protocol. A limited number of protocol device drivers are packaged with the Cscape distribution; however, as more are developed, they will be made available as add-on packages. A device driver is typically distributed as a Windows module, which contains the configuration menus, help files and the target executable driver code. W hen updating device drivers, an install routine loads the device driver to the Cscape directory structure and makes that driver avail- able to Cscape applications. Once installed, the protocol device driver can be included as part of a Cscape application by selecting it from a list of installed protocol device drivers and attaching it to the desired serial port (Home >...
Page 129: Protocol Device Driver Selection
Protocol Configuration These basic types are also subdivided into read or write operations. For polled operations, a Read operation only reads from a remote device. L ikewise a Read/Write operation continuously reads from the remote device unless the target OCS register value changes from one ladder scan to another. In this case, the new OCS value is written to the target device. For triggered operations, only a read or write action is available. When downloaded to the OCS , the Scan List is scanned sequentially to generate data transactions with the remote device. T his transaction scanning can be on a continual basis (automatic) or controlled from ladder logic (manual) once a complex connection is created via a program. The specific transaction-scanning mode is selected from the Network Config menu. Protocol Device Driver Selection From the Cscape Home > Protocols m enu, select the port drop-down box to select a protocol device driver. A ll pro- tocol device drivers currently loaded in Cscape are displayed in the drop down selection along with their version numbers. A selected protocol can be removed by selecting None from the drop-down selection. S ome OCS models can be limited in the number of ports or number of protocol device drivers that can be selected. O nce a protocol is selected, the Network, Devices and Data (Scan List) must be configured through corresponding dialogues access- ible through the respective buttons (Network, Devices and Scan List).
Page 130: Network Configuration
Protocol Configuration Network Configuration Network Configuration provides the required parameters to configure the network. Each protocol is different and may not require the entire Network Config field. Please refer to the table below for the options in the Network Config field. Page 130 of 196...
Page 131 Protocol Configuration Network Protocols Baud Rate, Data Bits, These field define the bit level transfer over the serial port. Stop Bits, Parity None – No h andshake lines are used Multidrop F ull – Rx remains active while Tx is occurring. Handshake Multidrop H alf – Rx is shut off while Tx is occurring. Radio M odem – Wait for CTS acknowledgment before transmitting (legacy r adio modem support). Protocol If a driver supports multiple protocols, it is selected here, ( i.e. Modbus supports RTU or ANSI). Mode Specifies if port operates in RS232 or RS485 mode. Retries Specifies number of times a transaction is retried on a failed r esponse. Timeout Specifies the amount of time for a device to wait for a valid r esponse. Update Interval – ...
Page 132: Device List And Device Configuration
Protocol Configuration Device List and Device Configuration Device List This configuration list is reached from the Device button on the Protocol Config screen and provides a list of the con- figured devices on the Network. D evices must be created and exist in this list before corresponding Scan List entries can be created for this device. T ypically, the number of entries is limited to 128 devices. Add - Opens the Device Config dialog to add a new device to the list. Delete - Remove selected device from list (all corresponding Scan List entries are also removed). Config - Invoke the Device Config dialog for the currently selected device. T his can also be accomplished by double-clicking a device entry. Mapping - Invoke the Scan List limiting the entries displayed for the selected device. Page 132 of 196...
Page 133 Protocol Configuration Device Configuration This configuration is reached from the device list when adding or modifying an existing device. W hile each protocol is somewhat different and can contain protocol specific field, all protocols typically support at least: Device Name - Specifies a tag name for this device. T his tag name is used in the Data Mapping con- figuration to identify this device. T his allows device addresses to be modified without the need to update all associated Data Mapping entries. Device ID - Specifies the target device communications ID or station address. Swap Words on 32-bit Data - I f a Scan List e ntry is configured to transfer 32-bits and this option is checked, the high and low 16-bit values are swapped when transferred between the target and OCS. Disable Device - From Cscape 9.90 SP3 and firmware 15.40 onwards, disable device feature has been added in protocol device configuration. This option is used to disable a particular slave configured in the net- work. Single bit register has to be configured to use this function. Setting the bit high disables the slave and OCS will not send any serial ( TCP for ethernet protocols) packets only to this slave until the bit is high. Set- ting the bit low enables the communication with the slave again.
Page 134: Scan List
Protocol Configuration Scan List This configuration list is reached from the Scan List b utton on the Protocol Config screen or the Mapping button on the Device List screen and provides a Scan List of the Data Mapping entries. T o transfer data between the OCS and remote target, a Scan List must be created that defines each transaction. E ach mapping entry (transaction) con- tains the source and destination registers, the number of consecutive registers transferred, the direction of the trans- fer and what triggers the transfer. Typically, the number of entries is limited to 512. NOTE: The order of the Scan List is the order in which the transactions occur. S ort functions are provided to change the order of the list. ...
Page 135 Protocol Configuration Menu Edit > Copy All - Copies Scan List to clipboard in a tab delimited format suitable for pasting into an applic- ation like Microsoft Excel. Edit > Paste - Loads Scan List from clipboard. P asted items are added to the scan list even if they are duplic- ates. View > Toggle All Name View - Expands Scan List such that each point and corresponding local name is displayed. Sort Scan List b y different criteria. T he firmware will scan the devices based on the order they are displayed or sorted. T here are four ways to sort the scan list: a. By Local Address – Sorts the list by local register address in increasing order. b. By Target Address – Sorts the list by target register address in increasing order. c. ...
Page 136 Protocol Configuration Data Mapping Configuration (Scan List Entry) Target Device Name - Selects the target device (by tag name) to use for this transaction. O nly those device entries previously created from the Device Config menu are available. Device Register - Specifies the target device’s register to use for this transaction. T his designation is target- specific. T he configuration menu displays an error if a specified address is unacceptable. G enerally, the data type of the local (OCS ) register must match the data type of the device register. ...
Page 137 Protocol Configuration types, only the local register(s) that change in value are written. M ore specifically, only one write trans- action occurs per scan per mapping entry for the register or consecutive sub-group of local registers that changed in value. D epending on the protocol, the number of points written with that write trans- action are limited either to one or the number of consecutive points that changed value. d. Therefore, if several local registers (specified in a single mapping entry) change in value prior to a transaction scan, it takes SEVERAL transaction scans to complete all the write operations.
Page 138 User Interface Page 138...
Page 139: User Interface
User Interface User Interface Screen Specifications Displaying and Entering Data Alpha-Numeric Keypad Screen Navigation Ladder-Based Screen Navigation Beeper Acknowledgement Touch (Slip) Sensitivity Alarms Removable Media Screen Saver Screen Brightness Touch Screen Pressure This chapter presents the user interface (or operator view) of the EXL6/XL6 Prime a nd some of the model specific characteristics of the EXL6/XL6 Prime a s compared to the rest of the OCS line. This chapter does NOT cover build- ing screens or using the CSCAPE graphics editor. For instructions on creating screens and using the graphics ...
Page 140: Displaying And Entering Data
User Interface Displaying and Entering Data 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 EXL6/XL6 Prime , these graphical objects (through lad- der 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 accept touch input may be disabled through program control (through ladder manipulation of an attribute bit). If an object is disabled, the object’s representation changes to a 2D appearance. On objects that represent non-discrete information, more action may be required beyond that of simply touching the object. For example, the slider object requires the operator to touch and slide the control in 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: If the numeric entry object displays >>>>>>>, the value is too big to display in the field or is above the max- imum for an editable field. Likewise, if the numeric entry object displays <<<<<<< in a numeric field, the value is too small to display or is below the minimum for an editable field. Page 140 of 196...
Page 141: Alpha-Numeric Keypad
User Interface 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 below. 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 the alpha-numeric keypad is first invoked, it is placed in new-value mode. Ini- tially, 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 sub- tract (respectively) from the selected digit. The user may then use the left or right arrow keys to select a new pos- ition. 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 value unchanged, and the alpha-numeric keypad dis- appears. NOTE: Each numeric entry object has a configured minimum and maximum value. If the operator enters a value out- side of the configured range, the new value is ignored when Enter is pressed and the current object value is NOT changed. Page 141 of 196...
Page 142: Screen Navigation
User Interface 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. Alpha-Numeric Keypad Variations Numeric When editing a numeric value, the [ +/-] or the [.] key are disabled (grayed) if the object is NOT con- Object figured f or floating-point value or a signed value. When editing a password value, the a rrow keys, [+/-], and the [.] keys are disabled. A dditionally, over- Password write mode is disabled. W hen entering digits, the pop-up keypad hides the value by displaying ‘*’ Object alternately for each digit. When editing an ASCII value, an A SCII keypad is displayed as shown Figure 14.2. The ASCII keypad has 3 modes: n umeric, symbols and alpha. In Alpha mode, the Caps Lock button may be ASCII pressed t o access capital letters. Typing a character will overwrite the entire old s tring and start a Object new entry. Press the backspace arrow to delete the ...
Page 143: Ladder-Based Screen Navigation
User Interface Ladder-Based Screen Navigation Ladder logic can use several techniques to control screen navigation. Coils can be tied to %D 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 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. 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. R efer to the On-Line help in Cscape for more information on control-based screen navigation. Beeper Acknowledgement The EXL6/XL6 Prime c ontains an internal beeper that provides an audible acknowledgment when an 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 announce that the graphical object is not cur- rently accepting the touch input. If beep acknowledgement is not desired, the beeper function can be disabled from the System Menu. Page 143 of 196...
Page 144: Touch (Slip) Sensitivity
User Interface 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 EXL6/XL6 Prime a ssumes touch 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 EXL6/XL6 Prime a llows adjustment of the allowable slide up to 5x the default value. To enable the touch (slip) sensitivity, first an OCS data register must be allocated through the Graphics Editor Con- figuration menu for Display Settings. Once a Touch Sensitivity register is assigned, that register may be modified [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. 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 in CSCAPE. 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 col- ors associated with these states. 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. Page 144 of 196...
Page 145 User Interface 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 displayed 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 touch- ing 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 to touch. Once view operations are complete, simply touch the Esc button to remove the pop-up alarm viewer. NOTE: OCS registers %SR181 and %SR182 are available for ladder use, which indicate presence of unac- knowledged or acknowledged alarm (respectively). The screen designer may implement these registers to switch screens or activate the beeper to attract the operator’s attention. Page 145 of 196...
Page 146: Removable Media
User Interface 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 col- ors to indicate the current state of the removable media device. The following indicates the device states and the default colors associated with these states. To view and perform file operations, the operator must access the removable 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. NOTE: The Removable Media Object can be configured to open the removable media viewer at a certain directory complete with restrictions on transversing back up the file path. This may be used to restrict operator access to non- critical files. 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. 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 ( Enter) button (if enabled) performs certain operations based on the selected file’s type: Change display to parent directory <DIR> Change display to child directory bmp, jpeg Display bitmap (if compatible format) Load application (if compatible model and version) Page 146 of 196...
Page 147 User Interface 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 temporarily 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). Screen Saver The EXL6/XL6 Prime s creen backlight life is typically five (5) years when in continuous use. If the application does not require interaction with the EXL6/XL6 Prime f or 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: 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 EXL6/XL6 Prime . Any additional touch activity is also ignored by the EXL6/XL6 Prime f or approximately one second thereafter. It is possible for the application to temporarily disable the screen saver by generating a positive transition to %SR57.16 (coil only) at a rate faster than the screen saver timeout value. This may be desired while waiting for alarm acknowledgement. Screen Brightness The EXL6/XL6 Prime ...
Page 148 User Interface Touch Screen Pressure The Horner XL series OCS controllers have a resistive touch screen that allows mechanically detecting touch events. The resistive touch screen works by measuring the resistance between two layers of conductive film. NOTE: T ouch creates contact between resistive circuit layers, closing a switch. With a unique change to the touch monitoring firmware user can measure the pressure being exerted on the touch screen. This feature has been added in some Horner XL series controllers. This allows the OCS programmer to be notified of the touch pressure and it can configure the pressure required to accept a touch event. There are two system registers that provide this touch feature: %SR9 (I/O Name - TCH_PRESSURE) - Records the highest-pressure level of the last touch on the screen that exceeds the threshold value set in %SR10. This is a range of 0 to 3000. Zero (0) indicates no pressure and 3000 is the maximum amount of pressure that can be measured. %SR10 (I/O Name - TCH_PRESSURE_TSH) - This register sets the pressure threshold to indicate a touch. A value of 200 is typically the lightest touch, 600 is moderate and 1000+ is a heavy touch. These new features allow customizing the feel of the touch screen and can be used to add unique user interface fea- tures such as having different operations depending on the force of the touch. Page 148 of 196...
Page 149 Video Object Page 149...
Page 150 Video Object Video Object Video Object Overview Opening Video Object in Cscape Video Properties Configuration Video Object Performance Web Cameras Video Object Overview The Video Object feature allows two options for video type: Stream and Playback. T he Video Object trigger is used to start, stop, and pause video, and the System Register provides the status of the video object, which supports vari- ous resolutions and frames per second. Features and Specifications of Video Properties 4 channels supported through USB hub Streaming Channels 1 channel can be viewed at a time .mp4 .mov...
Page 151 Video Object Opening Video Object in Cscape NOTE: For Cscape 10 please refer to the Help File. In Cscape, select the XL4/XL4 Prime and model number by selecting Controller > Hardware Configuration from the toolbar. 1. Open the Graphics Editor by selecting the “T” button from the toolbar. 2. In the Graphics Editor, select the video button from the toolbar. 3. Click in the grid. Page 151 of 196...
Page 152 Video Object 4. Then double click on the icon in the middle to open the Video Properties dialog. Page 152 of 196...
Page 153 Video Object Video Properties Configuration Video Type There are two options for video type: Stream and Playback. Stream – This option can be selected to view live video from a web cam. Four channels are supported through the USB hub. Only one channel can be viewed at a time. Enter Channel Number directly or through registers in the Enter Channel No field. Playback – This option can be selected to view videos that are stored in Removable Media on the controller. Videos present in both A (microSD) and B (USB) drives are supported and can be viewed. Supported formats includ- ing .mp4, .mov, .mpg, and .wmv, can be played. Select Playback and enter video name in the Enter Target Path field either directly or through registers. For example: Test1.mp4 (from microSD) or B:\Test2.mp4 (from USB). Page 153 of 196...
Page 154 Video Object Control Trigger - The video control trigger is used to start, stop and pause video. Video trigger is done by bit level address- ing. The trigger reserves eight (8) bits and uses the first two (2) bits. NOTE: The least significant bit is Bit 1. High = Start Bit 1 Low = S top High = Pause Bit 2 Low = P lay System Register - The Video Control System Register provides the status of the Video Object. The status word is 16-bits and should be viewed in hexadecimal format. 0x0001 Video is currently playing 0x0002 Video is paused 0x00010 Channel number cannot be greater than 4 0x0020 File not present or corrupted 0x0040 Frame per second not supported or not c ompatible Page 154 of 196...
Page 155 Video Object Configuring Display Properties Resolution Options 320x240 (QVGA) Frames per Seconds 10, 15, 20, 24, 30 & MAX_FPS Video Object Performance 1. When Video Object is active, navigating to System Menu or any popup window, causes Video Object to be inactive. 2. Video Object can be made active in both Idle and Run modes. 3. If actual Frames Per Second of the configured video is different from the one that is configured in Cscape, few frames will be missed when video is played. Web Cameras If multiple web cameras are directly connected to the XL4/XL4 Prime, then only one web cam will be considered. If user needs to connect multiple web cams, USB hub needs to be used. A maximum of four channels (web cameras) are supported. Page 155 of 196...
Page 156 Removable Media Page 156...
Page 157 Using the Removable Media Manager Log Data View and Capture Screens Removable Media Object Function Blocks in Cscape Filenames System Registers used with RM All Horner OCS Prime O CS models provide a Removable Media slot, labeled Memory Card, which supports stand- ard 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. microSD Cards When the microSD card format was introduced, it was originally called TransFlash. Cards labeled either microSD or TransFlash, with up to 32GB of flash memory, are compatible with the Horner OCS Prime O CS Memory Card slot.
Page 158 Removable Media microSD File System The microSD Memory Card 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 Horner OCS Prime O CS and can write files that can be read by the Horner OCS Prime O CS. However, the Horner OCS Prime O CS 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 eight (8) characters, followed by an optional dot, and an optional extension with up to three (3) characters. Directories and sub-directories can be nested up to 16 levels deep as long as each pathname string does not exceed 147 characters. Using the Removable Media Manager The Removable Media Manager is an interactive Horner OCS Prime O CS screen that performs the following func- tions: a. Display number of total and free K bytes b. Browse file and directory lists c. ...
Page 159 The Horner OCS Prime O CS File System uses bitmap files with the .BMP extension or JPEG files with the .JPG extension to store Horner OCS Prime O CS graphic screen captures. To view a captured Horner OCS Prime O CS screen, use the Removable Media Manager to find and highlight the desired .BMP or .JPG file, and then press Enter. To capture an Horner OCS Prime O CS screen, turning on the assigned Screen Capture Control Register will cap- ture the current Horner OCS Prime O CS graphics screen and write it to the microSD card using the assigned Screen Capture Filename. Before capturing an Horner OCS Prime O CS screen, Cscape must first be used to assign a Screen Capture Con- trol 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.
Page 160 Removable Media Function Blocks in Cscape NOTE: For detailed information regarding RM function blocks and parameters, refer to the Help File in Cscape Soft- ware. Refer to ‘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: a. microSD when filename is prefixed with ‘A:’ or nothing b. USB A flash drive when filename is prefixed with ‘B:’ Allows reading o f a comma-separated value file from the microSD interface into the c ontroller Read RM csv register space. Allows writing o f a comma-separated value file to the microSD interface from the controller Write RM csv register space. Rename RM Allows renaming a file on the RM card. The data in the file is not changed. Delete RM csv Allows deleting a file on the RM card Copy RM csv Allows copying a ...
Page 161 Removable Media Filenames The RM function blocks support the flash with a 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. Filename Special Symbols Symbol Description Example Substitutes t he current 2-digit year 2015 = 15 Substitutes t he current month with a 2-digit code March = 03 Substitutes t he current day 22nd = 22 Substitutes t he current hour in 24-hour format 5 ...
Page 162 Clone Unit Page 162...
Page 163 Clone Unit Clone Unit Make Clone Load Clone ‘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 to the f or 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. Make Clone The user needs to perform the following to Clone: Step 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: Page 163 of 196...
Page 164 Clone Unit Step 2: Selecting “Make Clone” will open the following menu screen. NOTE: Free/Total – displays number of free and total bytes in Removable Media. 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: Make/Create clone can also be triggered by setting %SR164.9 bit to “1” from Ladder program or graphics. Once the operation is completed, this bit is made zero by the firmware. When Make Clone operation is triggered by this SR bit, it does not ask the user for confirmation for making clone. The success / failure of the operation is also not noti- fied 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. Refer to to the Fail-Safe System Chapter. Page 164 of 196...
Page 165 Clone Unit 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: Step 1: Select “Clone Unit” from main System Menu of OCS as shown below: Step 2: Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”. NOTE: For security enabled files, Load clone asks for password validation before loading the application. Load Clone can also be triggered by setting %SR164.10 bit to “1” from Ladder program or graphics. Once the oper- ation 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 165 of 196...
Page 166 Fail-Safe System Page 166...
Page 167 Fail-Safe System Fail-Safe System Fail-Safe System Settings Backup / Restore Data AutoLoad AutoRun For the XL Series 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, Elec- tromagnetic Interference, event. For the XL Prime Series 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: Retentive Register or Application flash corruption due to, for example, an excessive EMI, Electromagnetic Interference, event. Fail-Safe System The Fail-Safe System has the following capabilities: a. ...
Page 168 Fail-Safe System Settings To use the Fail-Safe feature,the following steps are required: 1. From Cscape, create AUTOLOAD.PGM for the application program using ‘Export to Removable Media’. 2. Place the Removable Media with AUTOLOAD.PGM in the device. 3. Set the ‘Enable AutoLoad’ option in the device to YES. 4. Set the ‘Enable AutoRun’ option to YES if the controller needs to be placed in RUN mode automatically after automatic restore of data or AutoLoad operation. 5. Backup the current battery-backed RAM Register contents in onboard flash memory using System Menu options. Backup / Restore Data Selecting this option brings up a screen having four operations: Backup OCS Data. Restore OCS Data. Clear Backup Data. Exit 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. ...
Page 169 Fail-Safe System 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 1) a backup has been previously created and 2) on power-up the battery-backed RAM registers fail their check. The following steps are required: 1. Place the controller in IDLE mode. 2. Copy data from onboard flash memory to OCS battery-backed RAM 3. Reset the Contoller. 4. Put the controller in RUN mode if the AutoRun setting is ‘Yes’, or else it will remain in IDLE mode. %SR164.3 is set to 1 only when an automatic restore operation is performed, not on a manual one. This bit is reset to the value of “0” 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 0 when backed up data is erased. Exit: Goes back to the previous screen. Page 169 of 196...
Page 170 Fail-Safe System The OCS follows the following sequence in execution of Automatic Restore: AutoLoad Page 170 of 196...
Page 171 Fail-Safe System AutoLoad This System Menu option allows 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: When there is no application program in the OCS and a valid AUTOLOAD.PGM is available in the removable media of the device. 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. %SR164.6 can be set to enable AutoLoad feature. Page 171 of 196...
Page 172 Fail-Safe System The OCS follows the following sequence in execution of AutoLoad: Page 172 of 196...
Page 173 Fail-Safe System 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 dis- played. 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. Page 173 of 196...
Page 174 Modbus Communications Page 174...
Page 175 Modbus Communications Modbus Communications Modbus Slave Overview Modbus Master Overview Modbus Addressing Table NOTE: For complete Modbus instructions, please refer to the Help file in Cscape. Modbus (serial) is a popular, de-facto standard protocol that allows industrial devices from multiple manufacturers to easily share data in real-time. For Modbus serial communications, the EXL6/XL6 Prime c an act as either a Master or a Slave. Modbus protocol (serial) allows for one master and multiple slaves. The master always initiates the conversation by sending a request to a particular slave. Only the addressed slave will send a response when the request is com- pleted. Should the slave be unable to complete the request, it returns the appropriate error response. Should the slave be unable to respond, the master’s timeout timer expires to provide an indication of No Response. Modbus Slave Overview For complete Modbus Slave instructions, please refer to the Help file in Cscape.
Page 176 Modbus Master Function Block—This is for serial only. This is an advanced feature that should only be used in rare occasions. Protocol Config—The Protocol Config is configured in the Hardware Configuration dialog box in Cscape (serial). Refer to the Modbus Addressing section. This is the preferred method in most applications. After the protocol has been selected from the dropdown menu, the Network, Devices, and Scan List become avail- able. The Protocol Config is configured on three different levels: Network—Parameters, such as the polling rate of the data scan, are specified along with timeout values, retry, and re-acquisition settings. Serial configuration, baud rate, parity, etc. are also set here. Devices—For every slave to be polled, configuration details are added in the Devices dialog box. This includes Slave ID (serial). Under Device Type, the Modbus addressing style matching that specified in the slave’s user documentation may be selected. For instance, some slaves specify Modbus addresses (i.e. 40,001), and others specify offsets (i.e. 0000). Hex or Decimal—Some specify addresses in hex, and others in decimal. By allowing the user to select the Modbus addressing style for each slave on the network, minimal address conversion is required. Also, if the slave is another Horner product (i.e. another OCS), the “Native Addressing” option can be selected (i.e. %R1, %M17, etc.), and this skips the conversion to Modbus style alto- gether. Scan List—This is where the specific Modbus addresses to be read/written from/to each slave are specified. Up to 32 words of data can be read at the same time. NOTE: Once configuration has been completed on the Network and Devices level, Modbus data can be directly read/written from graphics objects in the Cscape screen editor. This is available even if the Modbus register is not listed on the scan list. Page 176 of 196...
Page 177 Modbus Communications Modbus Addressing Table To access EXL6/XL6 Prime r egisters, a Modbus Master must be configured with the appropriate register type and offset. This is usually accomplished with one of two methods: Method 1: The first method uses Traditional Modbus References, in which the high digit represents the register type, and the lower digits represent the register offset (starting with Register 1 for each type). Since only four register types can be represented in this manner, EXL6/XL6 Prime M odbus Function Blocks pack several EXL6/XL6 Prime r egister types into each Modbus register type. Starting addresses of each EXL6/XL6 Prime register type are shown in the Traditional Modbus Reference column of the Mobus Table. Method 2: The second method requires the Modbus Master to be configured with a specific Modbus Command and Modbus Offset. The supported Modbus commands and the associated offsets are also illustrated in Modbus Table. EXL6 / XL6 Prime Modbus Master Mapping Trad. Modbus Refer- Expanded Modbus Maximum Modbus Command Modbus Off- ence Ref.
Page 178 Rechargeable Battery for XL Series Page 178...
Page 179 The following information pertains to the XL Series and RCC Series units. T his does NOT apply to the Prime Ser- ies. NOTE: For more details on the back-up battery, refer to the Battery Manual [MAN1142]. Storing Register Contents The OCS controllers with rechargeable batteries write register data to high speed RAM when connected to DC power. When this power is lost, critical circuits switch over and run on batter power for about 1/10 of a second. Dur- ing this time, register and other retentive data is saved away to flash memory. The clock continues to run on the bat- tery at a much lower power. The battery is designed to last well over a year in this state. Once power is restored, the battery recharges in eight (8) hours or less. Battery Life The battery is designed to last 300 full charges to 1000 partial charge cycles or 7 to 10 years. Because typical oper- ation does not drain the battery, the 1000 charge cycles should never be reached and the 7 to 10-year aging of the battery would limit its useful life. The battery is designed to be replaced. Lithium Battery Safety Many of the publicized battery issues are a result of using multiple batteries of flexible battery packs. The OCS uses a small, single cell in a metal enclosure. The battery is UL recognized and comes from quality suppliers. The OCS has safety circuitry built into the charging IC and additional external protection including fusing. These circuits were closely evaluated by UL and Horner engineering for use in hazardous environments. Page 179 of 196...
Page 180 EXL6 Rechargeable Battery OCS Battery Charging Cycle There are various charging states that are executed based on battery temperature, level of battery charge, and self- test results. The battery temperature can be determined by checking the CPU temperature in the controller System Menu >View Battery Status or by monitoring System Register %SR195. The battery temperature is equal to the CPU temperature minus 30°C. NOTE: Refer to "Battery Charging Status" on the next page for charge states and definitions. 1. When power is applied to the OCS, the unit always goes to State 11; Waiting, for the first two minutes. 2. After two minutes have expired, the OCS will begin charging the battery based on battery temperature. In this step, charging will ensue even if the battery is already fully charged. 3. In this step charging does not ensue if the battery temperature is outside of the acceptable hot or cold limits. 4. The battery is charged fully to 4.2 volts in the Normal Charging or Cold Charging states or to 4.1 volts in the Hot Charging state. 5. Once fully charged to 4.2 volts, state 0, the Wait Discharging state is executed, state 12. T he battery is allowed to discharge to 4.0 volts for however long that takes. Powering up the OCS will reset the charge cycle to step 1. 6. If the battery was charged to 4.1 volts under state 2, Hot Charging; 4.1 volts is maintained until Normal or Cold Charging can be executed. ...
Page 181 EXL6 Rechargeable Battery Battery Charging Status Viewed in the System Menu > View Battery Status or read as a numeric value in %SR196. The battery tem- perature, Tb, is equal to the CPU temperature minus 30°C: Tb = CPU° - 30°C. Charging State Table State - Name Description Additional Information %SR196 Final Charge Next step, State 12 – W ait Dis- The battery is fully c harged to 4.2V charging Normal Char- Battery is fast c harging @100mA to 4200mV Tb: 11-45°C Up to 8 hrs charge time ging Battery is slow ...
Page 182 EXL6 Rechargeable Battery Battery Status in System Registers NOTE: Registers NOT supported by the XL Prime controllers. Battery Status %SR55.13 ON if battery is missing or if voltage is b elow 2.5V %SR195 CPU temperature in °C %SR196 Charge State; Refer to Table 20.1 %SR197 Charging Current mA %SR198 Battery Voltage in mV IMPORTANT: The battery voltage shown in the System Menu and in %SR198 is ONLY valid if the battery is not in the Charging State. To check battery voltage, power cycle the controller and check the battery voltage within the first two minutes of power-up. In the first two minutes after power is applied to the unit, it will be in the ‘Waiting’ state, which means it is not charging, %SR196 = 11. Safety & the Rechargeable Backup Battery The EXL6 has an advanced battery system that uses a rechargeable lithium-ion 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 ...
Page 183 EXL6 Rechargeable Battery Steps to Replace the Rechargeable Battery Below are the steps to replace the lithium-ion battery, part no. BAT0019, available from Horner APG. 1. Make sure the user program and any data stored in retentive memory is backed up. 2. Disconnect all power from the XL6 OCS unit including I/O power. Unplug I/O connections. 3. Using a small Phillips screwdriver, remove the I/O back panel, which is the smaller back panel, by turning four (4) corner screws counterclockwise. 4. Carefully lift off the I/O back panel. Be aware that a small insert may come loose from the back cover. It can be inserted when back panel is replaced. 5. After the I/O back panel is removed, carefully rock the I/O circuit board until released from the unit and lift straight up from the unit. Set carefully to the side. 6. Remove the larger back cover by turning four (4) corner screws counterclockwise. Once again, an insert may come loose from this cover. 7. Remove the Lithium battery carefully. 8. Insert new battery by aligning the positive (+) end of the battery with the positive (+) sign on the board. 9. Replace the larger back panel by carefully aligning the four (4) screws into the guideposts. If an insert came off, be sure to slide it back into the cover before replacing. 10. This unit has self-tapping screws. Once the screws are aligned, gently turn the screw counterclockwise until it “clicks”. Then turn the screw clockwise until screw is seated. 11. Once the larger back panel is replaced, gently replace the I/O circuit board by aligning the edges with the guideposts. Align the XL Bus Connector, and then gently press on the I/O circuit board until it is seated. If an ...
Page 184 Prime Series Backup Battery Page 184...
Page 185 Prime OCS Prime Battery Prime OCS Prime Battery Prime OCS Battery & Safety Replacing the Prime OCS Battery Prime OCS Battery & Safety NOTE: This does not include the XL Series, only the Prime Series. The Prime OCS has an improved memory architecture that does not require a battery for program or register reten- tion. The onboard lithium coin-cell battery runs the real time clock and is user replaceable with an expected life- time of seven (7) to ten (10) years. Environmental conditions, including extreme temperatures and humidity, can affect battery life. If the battery older than seven (7) to ten (10) years old, it is recommended that it be replaced as preventative maintenance. NOTE: Use only the proper battery type listed. NOTE: Use only the proper battery type listed. ...
Page 186 Prime OCS Prime Battery Replacing the Prime OCS Battery The Prime OCS uses a lithium coin-type battery with part no. HE-BAT013, with harness and connector available from Horner APG. WARNING: Replacing the battery is a delicate procedure. If unsure about the procedure, please contact Horner Tech Support via Horner Contact Us . Below are the steps to replace the battery: 1. Make sure the user program and any data stored in retentive memory is backed up.
Page 187 Firmware Update Page 187...
Page 188 Firmware Updates Firmware Updates Check for Current Firmware Revision Firmware Update Details Download Firmware Firmware Update Steps The EXL6/XL6 Prime O CS products contain field updatable firmware to allow new features to be added to the product. 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 OCS is in a safe, non-operational state. Communication or hardware failures during the firmware update pro- cess can cause the controller to behave erratically resulting in injury or equipment damage.
Page 189 There are two methods for updating firmware. The method used depends on the type of controller being updated. Method A: Removable Media Method – The controller firmware is updated by a bootloader, using a microSD card or USB Flash drive (not through the Cscape Firmware Update Wizard). To update or change firmware: 1. Download desired Firmware set from the Horner APG website. (Verify CsCAN or CANopen com- munications.) 2. Save Firmware files to microSD card or USB, these are the removable media devices. 3. Update the firmware through the controller’s Firmware Update function NOTE: F iles from the Horner website come as a .ZIP file which need to be unzipped and placed in the root of the drive for them to function properly. Method B: RS232 Serial Connection – Serial firmware updates are done from Cscape software to the controller’s primary serial port, MJ1 in most cases. Download Firmware In North America, visit https://hornerautomation.com. Then click Support > Downloads > Controller Firmware and download the most recent firmware set with the correct communication protocol.
Page 190 Firmware Updates Firmware Update Steps Update firmware in an EXL6/XL6 PRIME by completing the following steps: 1. Unzip all files from downloaded .zip file (see above) onto removable media. 2. Plug removable media into a powered-up controller. 3. Touch the upper-right-hand screen corner to slide out the control panel. 4. Press and hold the SYSTEM key until the Boot Installer screen appears. Select System upgrade option. Boot Installer screen appears. Press and hold the SYSTEM key until system recovery screen appears. Select System upgrade option. Boot Installer screen will appear. 5. Press the Install Bootloader button and then press Yes. 6. When Operation Completed appears, press OK. 7. Power-cycle the controller and wait for it to boot up. 8. Touch the upper-right-hand screen corner to slide out the control panel. 9. Press SYSTEM key, select View Status and press the Enter button. 10. If any of the version numbers are incorrect, verify the correct files were copied to the removable media device and repeat the steps above. For more Firmware Update information refer to the Firmware Update Manual, MAN1011, which can be found on the Horner website. NOTE: User must register and be logged into website in order to download this manual. Page 190 of 196...
Page 191 Troubleshooting & Tech Support Page 191...
Page 192 Target: Communication i s not established to the target controller. Check node ID of controller and s et Target to #(?) match. Make sure local connection is established. Serial Port – MJ1 Programming 1. Controller must be powered up. 2. Ensure that the correct COM port is selected in Cscape. Tools > Applications Settings > Com- munications. 3. Ensure that a cable with proper pinout is being used between PC and controller port MJ1. 4. 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. 5. Successful communications with USB-to-serial adapters vary. If in doubt, Horner APG offers a USB to serial adapter: part number HE-CPK. Page 192 of 196...
Page 193 Troubleshooting USB Port - Mini B Programming 1. Controller must be powered up. 2. Ensure that the correct COM port is selected in Cscape.Tools > Applications Settings > Com- munications. 3. Be sure that the USB cable is connected between the PC and the controller. Check Windows Device Man- ager to ensure that the USB driver is properly installed and to verity the port number. ETN Port Programming 1. Controller must be powered up. 2. Ensure that the correct IP address is given in the Ethernet field and correct Mode is selected, in Cscape: Tools > Applications Settings > Communications. 3. Ensure that an Ethernet connection has been established by pinging the controller from the Windows DOS prompt. Local Controller and Local I/O The System Menu provides the following status indications that are useful for troubleshooting and system main- tenance. To view the System Menu, press the System key.
Page 194 CsCAN Network For complete information on setting up a CsCAN network, refer to CAN Networks manual (MAN0799) by using Horner's Documentation Search page. Network status, node ID, errors, and baud rate in the controller System Menu are all in reference to the CsCAN net- work. These indications can provide performance feedback on the CsCAN network and can also be used to aid in troubleshooting. CsCAN Network Troubleshooting Checklist 1. Use the proper Belden wire type or equivalent for the network as specified in the CAN Networks Manual, MAN0799. 2. The Horner O CS does not provide 24VDC to the network. An external voltage source must be used for other devices such as SmartStix I/O. 3. Check voltage at both ends of the network to ensure that voltage meets specifications of attached devices. 4. Proper termination is required. Use 121Ω (or 120Ω) resistors at each end of the network. T he resistors should be placed across the CAN_HI and CAN_LO terminals. 5. Measure the resistance between CAN_HI and CAN_LO. If the network is properly wired and terminated, there should be around 60Ω. 6. Check for duplicate node ID’s. 7. Keep proper wires together. One twisted pair is for V+ and V- and the other twisted pair is used for CAN_HI and CAN_LO. 8. Make sure the baud rate is the same for all controllers on the network. 9. Assure shields are connected at one end of each segment—they are not continuous through the network.
Page 195 The media card should be formatted with the controller. read media card. OCS will not Make s ure the project file is saved as a .pgm file and not a .csp file. In a ddition, the file must be download pro- .pgm. The file's I/O configuration must match the controller c onfiguration for it to download. ject f ile. Technical Support Contacts For manual updates and assistance, contact Technical Support at the following locations: North America: Tel: (317) 916-4274 Fax: (317) 639-4279 Website: https://hornerautomation.com Email: techsppt@heapg.com Europe: Tel: (+) 353-21-4321-266 Fax: (+353)-21-4321826 Website: https://www.hornerautomation.eu Email: technical.support@horner-apg.com Page 195 of 196...
Page 196 Change Log Change Log Date Rev # Description of Revision Location in Doc 1. Files Needed 1. Added steps to download files to Cscape. 2. Cscape Install 2. Cscape Install Step 3. Firmware Install 3. Firmware Install Step 3/6/2020 4. Through out 4. Added new information from New Cscape Helpfile. 5. Rearranged Rev1. 5. Throughout 6. Added updated Cscape screenshots. 6. Throughout 3/12/2020 Reorder Chapters (Mantis 3029) Throughout Changed Table 2 with updated RTD/TC formula for Model 6. ( Rev R10- Analog In (Cscape 4/24/2020 10-01 was named per a website saving i ssue. N o change in User Config) Table 7.2 Manual.) #4845 – Updated WebMI register System Register Table #4802 – WebMI – Max # of connections...

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