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HORNER APG EXL10 OCS User Manual

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User Manual for EXL10 OCS
MAN1029-08-EN_EXL10_UserManual
HE-EXV1E0 / HEXT505C100
HE-EXV1E2 / HEXT505C112
HE-EXV1E3 / HEXT505C113
HE-EXV1E4 / HEXT505C114
HE-EXV1E5 / HEXT505C115
HE- EXV1E6 / HEXT505C116

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  • Page 1 User Manual for EXL10 OCS MAN1029-08-EN_EXL10_UserManual HE-EXV1E0 / HEXT505C100 HE-EXV1E2 / HEXT505C112 HE-EXV1E3 / HEXT505C113 HE-EXV1E4 / HEXT505C114 HE-EXV1E5 / HEXT505C115 HE- EXV1E6 / HEXT505C116...

  • Page 2: Preface

    PREFACE This manual explains how to use the EXL10 OCS. Copyright© 2013 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written permission of Horner APG, Inc.

  • Page 3: Limited Warranty And Limitation Of Liability

    OTHER PERSON TO ASSUME FOR HE-APG, ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS EXL10 OCS module. THIS WARRANTY SHALL NOT APPLY TO THIS EXL10 OCS module OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. HE-APG MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE-APG.

  • Page 4: Visual Map Of Key Chapters

    VISUAL MAP OF KEY CHAPTERS FIRST STEP of ANY TASK: DATASHEET Each EXL10 OCS unit is sent with a datasheet in the box. The datasheets are the first documents to refer to for model-specific information related to EXL10 OCS models for specific installation information.

  • Page 5: Table Of Contents

    Grounding ..........................11 Compliance ..........................11 CHAPTER 2: INTRODUCTION ......................12 Visual Overview of EXL10 OCS ....................12 Connectivity to the EXL10 OCS ....................14 Features of EXL10 OCS ....................... 15 Accessories ..........................16 Useful Documents and References ................... 16 Opening Cscape Help File ......................
  • Page 6 Touch screen calibration ....................... 46 CHAPTER 6: REGISTERS ........................47 Register Definitions ........................47 Useful %S and %SR registers ..................... 47 Register Map for EXL10 OCS I/O ....................55 Resource Limits .......................... 56 CHAPTER 7: CSCAPE CONFIGURATION ....................57 Overview ............................ 57 Cscape Status Bar ........................
  • Page 7 MAN1029-08-EN_EXL10_UserManual CHAPTER 11: CAN COMMUNICATIONS ..................... 109 11.1 Overview ..........................109 11.2 Port Description ........................109 11.3 CAN Port Wiring ........................110 11.4 Cscape Programming via CAN ....................110 11.5 Ladder-Controlled CAN Communication ................. 110 11.6 Using CAN for I/O Expansion (Network I/O)................110 CHAPTER 12: ETHERNET COMMUNICATION ..................
  • Page 8 Steps for Firmware Update ....................176 22.5 Backup Battery Replacement....................177 CHAPTER 23: TROUBLESHOOTING / TECHNICAL SUPPORT ............. 179 23.1 Connecting to the EXL10 OCS ....................179 23.2 Local Controller and Local I/O....................181 23.3 CsCAN Network ........................182 A p r i l 2 4...
  • Page 9 MAN1029-08-EN_EXL10_UserManual 23.4 Removable Media - Basic Troubleshooting ................. 183 23.5 Technical Support Contacts ....................183 CHANGE LOG ............................184 MAIN INDEX ............................185 INDEX OF FIGURES AND TABLES ......................189 A p r i l 2 4 , 2 0 2 0 P a g e 9 | 191...

  • Page 10: Chapter 1: Safety / Compliance

    MAN1029-08-EN_EXL10_UserManual CHAPTER 1: SAFETY / COMPLIANCE Safety Warnings and Guidelines When found on the product, the following symbols specify: Warning: Consult user documentation. Warning: Electrical Shock Hazard. WARNING – EXPLOSION HAZARD – Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth) ground before making any other connections.

  • Page 11: Grounding

    MAN1029-08-EN_EXL10_UserManual a. All applicable codes and standards need to be followed in the installation of this product. b. For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG or larger. Adhere to the following safety precautions whenever any type of connection is made to the module. a.

  • Page 12: Chapter 2: Introduction

    MAN1029-08-EN_EXL10_UserManual CHAPTER 2: INTRODUCTION Visual Overview of EXL10 OCS Figure 2.1 – Overview of the EXL10 A p r i l 2 4 , 2 0 2 0 P a g e 12 | 191...
  • Page 13 Datasheet - The datasheet is the first document to refer to for key information related to specific EXL10 OCS models. The datasheets for all EXL10 OCS models are available on the Horner websites. Datasheets contain pin-outs, jumper settings and other model specific information.

  • Page 14: Connectivity To The Exl10 Ocs

    MAN1029-08-EN_EXL10_UserManual Connectivity to the EXL10 OCS The EXL10 OCS has excellent capabilities for connecting to a variety of devices. The diagram below shows some examples of devices that can be used with the EXL10 OCS. Other OCS Devices Other OCS Devices...

  • Page 15: Features Of Exl10 Ocs

    MAN1029-08-EN_EXL10_UserManual Features of EXL10 OCS The EXL10 OCS are all-in-one industrial control devices. They combine control, user interface, I/O and networking into a single, integrated package. Unique features of the EXL10 OCS include: Bright, 65,536 color graphical touch sensing LCD display in all models of EXL10.

  • Page 16: Accessories

    MAN1029-08-EN_EXL10_UserManual Accessories Please visit the Horner Control Accessories website for communication, programming, and I/O accessories. North America http://hornerautomation.com/product-category/home/control-accessories/ Europe http://horner-apg.com/en/products.aspx Useful Documents and References Visit our website to obtain user documentation, supplemental documents, certificates, and other documentation. North America https://hornerautomation.com Europe http://www.hornerautomation.eu Opening Cscape Help File...

  • Page 17: Chapter 3: Mechanical Installation

    EXL10 OCS. 1. Remove all connectors from the EXL10 OCS unit. 2. Make sure the gasket is installed on the EXL10 OCS and is free from dust and debris. Check that the corners of the gasket are secure.

  • Page 18: Mounting Orientation

    3.3.2 Figure 3.3 – Orientation of EXL10 OCS NOTE: There are no orientation restrictions on the EXL10 OCS. However, the above orientation provides for optimum readability of the screen and ease of use of the keypad. A p r i l 2 4...

  • Page 19: Panel Cut-Out & Dimensions

    Panel Cut-Out & Dimensions For installations requiring NEMA 4X liquid and dust protection the panel cutout should be cut with a tolerance of +1mm /-0mm.. Figure 3.4 – EXL10 OCS Dimensions A p r i l 2 4 , 2 0 2 0...

  • Page 20: Factors Affecting Panel Layout Design And Clearances

    3.5.4 Orientation When panel-mounted, there are no orientation restrictions on the EXL10 OCS. A p r i l 2 4 , 2 0 2 0...
  • Page 21 3.5.5 Noise Consider the impact on the panel layout design and clearance requirements if noise suppression devices are needed. Be sure to maintain an adequate distance between the EXL10 OCS and noisy devices such as relays, motor starters, etc. For details on output protection, especially when using contactors, solenoids, etc., see MAN0962.

  • Page 22: Chapter 4: Electrical Installation

    ELECTRICAL INSTALLATION NOTE: The datasheets are the first documents to refer to for model-specific information related to EXL10 OCS models such as pin-outs, jumper settings, and other key installation information. Visit the Horner websites to obtain datasheets, user documentation, and updates.

  • Page 23: How To Test For Good Ground

    MAN1029-08-EN_EXL10_UserManual How to Test for Good Ground In order to test ground resistance, a Ground Resistance Tester must be used. A typical Ground Resistance Meter Kit contains a meter, two or three wire leads, and two ground rods. Instructions are supplied for either a two-point or three-point ground test.

  • Page 24: Primary Power Port

    MAN1029-08-EN_EXL10_UserManual Primary Power Port Table 4.1 – Primary Power Port Pins Signal Description Frame Ground Input power supply ground +24V Input power supply positive voltage Power Connector Power Up: Connect to Earth Ground. Apply 10 – 30VDC. Screen lights up. Torque Rating: 4.5 - 7 in-lbs 10-30 VDC (0.50 –...

  • Page 25: Chapter 5: System Settings And Adjustments

    MAN1029-08-EN_EXL10_UserManual CHAPTER 5: SYSTEM SETTINGS AND ADJUSTMENTS System Menu - Overview The EXL10 has a built-in System Menu, which lets the user view System Settings and makes adjustments. To start the System Menu, press the SYSTEM key (or set %SR3 to 1), which will display the Main Menu. Then use the ...

  • Page 26: System Menu - Navigation And Editing

    MAN1029-08-EN_EXL10_UserManual System Menu – Navigation and Editing As mentioned above, the System Menu is started by pressing the System key on the EXL10. Next press ESC to exit the System Menu or use  and  to select an item and press Enter to display the item’s Sub- Menu.
  • Page 27 MAN1029-08-EN_EXL10_UserManual Sub-Menus Sub-Menus CAN Ok? CAN ID: CAN Baud: 125KB Fkeys: Momentary SYS-Fn enable: MAC ID: 00:E0:C4:04:C7:35 ( Use ↑↓ to adjust ) 192.168.254.128 NetM: 255.255.255.0 GatW1 0.0.0.0 EXL10 System Menu Map MAC ID2: Dflt Pgm Port MJ1-232 00:E0:C4:04:C0:35 Figure 5.1 MJ2 RS485 Bias IP2: 192.168.254.127...

  • Page 28: Set Networks

    MAN1029-08-EN_EXL10_UserManual License Details Set Networks Server/ Users/ Pages/Data Points/ Exp. Date/User This sub menu allows setting for the CAN and Ethernet network to be viewed or changed. Logged In Yes= CAN1 connected to a CAN network and functioning properly CAN Ok? No= Not ready to communicate on CAN network CAN ID 1 to 253 = This node’s CsCAN Network ID;...

  • Page 29: View Status

    0.1 to 999.9= Average number of mS for each ladder scan OCS Net Use % 0.0 to 100.0 = CAN network bandwidth % used by this EXL10 OCS node All Net Use % 0.0 to 100.0 = CAN network bandwidth % used by all nodes...

  • Page 30: 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 either of these indicate a Fault condition, the EXL10 OCS will not enter or remain in Run mode, and the problem must be investigated and corrected.

  • Page 31: View Battery Status

    MAN1029-08-EN_EXL10_UserManual View Battery Status The View Battery Status displays the following information. Waiting The charging system is waiting for voltages and temperatures to stabilize. Battery Charging The battery is charging. Battery Full Shows at the end of a charge cycle. Remains in this state until the battery is steadily discharging.

  • Page 32: View I/O Slots

    The View I/O Slots Sub-Menu displays three System Settings, none of which may be edited. Internal to the EXL10 OCS, there is a CPU board, and up to two installed modules. Model 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.

  • Page 33: View Protocols

    Both the MJ1/MJ2 (Port 1) and MJ3 (Port 2) serial ports support downloadable protocols. To assign a downloadable protocol to an EXL10 OCS serial port, select the Protocol Config item in Cscape’s Program menu and then set up a protocol for Port 1 or Port 2 (or both).

  • Page 34: Set Fkeys Mode

    MAN1029-08-EN_EXL10_UserManual Set Fkeys Mode The Set Fkeys Sub-Menu displays two System Settings, both of which may be edited. 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 = Reset and all clear system functions enabled SYS_Fn enable No = Reset and all clear system functions disabled...

  • Page 35: Set Serial Ports

    MAN1029-08-EN_EXL10_UserManual 5.10 Set Serial Ports The Set Serial Ports Sub-Menu displays three System Settings, all of which may be edited, and one optional item. For the Dflt Pgm Port System setting, only MJ1-232 can be selected, unless a Modem (XMC) COM module is installed.

  • Page 36: Set Time/Date

    MAN1029-08-EN_EXL10_UserManual 5.11 Set Time/Date The following instructions are to set and display the real-time clock in the controller. More details can be found in the Help File in Cscape. Table 5.2 - Clock and Time Setting Terms Coordinated Universal Time (UTC) Abbreviated to UTC, Coordinated Universal Time is the primary time standard by which the world regulates clocks and time.
  • Page 37 MAN1029-08-EN_EXL10_UserManual 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.

  • Page 38: Set Beeper

    MAN1029-08-EN_EXL10_UserManual 5.12 Set Beeper The Set Beeper Sub-Menu displays one System Setting, which may be edited. Yes (default) = Enables beeper Beeper enable No = Disables beeper (does NOT affect ladder access) A p r i l 2 4 , 2 0 2 0 P a g e 38 | 191...

  • Page 39: Set Screen

    MAN1029-08-EN_EXL10_UserManual 5.13 Set Screen The Set Screen Sub-Menu displays four System Settings, all of which may be edited. = Enable screen saver Saver enable No (default) = Disable screen saver 5 - 1200 = Amount of time in minutes to expire with NO touch activity Timeout (min) before activating screen saver (black screen) Off (default) = Disable popup status...

  • Page 40: Removable Media

    MAN1029-08-EN_EXL10_UserManual 5.14 Removable Media The Removable Media Sub-Menu displays the Removable Media Manager. Having selected Removable Media from the Main Menu, one of four Sub-Menu screens will appear: Media Directory No Card = No microSD card has been installed in the Memory slot Media Directory Initializing = microSD card is installed, but it is still initializing...

  • Page 41: Fail - Safe System

    MAN1029-08-EN_EXL10_UserManual 5.15 Fail – Safe System The Fail-Safe System is a set of features that allow an application to continue running in the event of certain types of "soft" failures. These "soft" failures include: • Battery power loss • Battery-Backed Register RAM or Application Flash corruption due to, for example, an excessive EMI event.

  • Page 42: Enable Autorun And Autoload

    MAN1029-08-EN_EXL10_UserManual 5.16 Enable AutoRun and AutoLoad “Enable AutoRun” displays the following options which can be selected: No = OCS will be in IDLE mode after AutoLoad or Automatic Restore. Enable AutoRun Yes = OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore.

  • Page 43: Clone Unit

    MAN1029-08-EN_EXL10_UserManual 5.17 Clone Unit ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” application program and unit settings stored in Battery backed RAM of an OCS into the RM. Refer to the Removable Media Chapter for more details on using RM.

  • Page 44: Load Clone

    MAN1029-08-EN_EXL10_UserManual 5.18 Load Clone Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone”. NOTE: For security enabled files, Load Clone asks for password validation before loading the application. A p r i l 2 4 , 2 0 2 0 P a g e 44 | 191...

  • Page 45: Webmi License Details

    MAN1029-08-EN_EXL10_UserManual 5.19 WebMI License Details License details page displays the information about the WebMI license. Refer to MAN1036 for the WebMI Manual. The information can also be viewed from Cscape using the following %SR registers: %SR209.3 WebMI server status %SR209.4 WebMI user logged in status %SR209.8 to SR209.16 Number of Users...

  • Page 46: Touch Screen Calibration

    MAN1029-08-EN_EXL10_UserManual 5.20 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 the 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 Figure 5.3 should appear.

  • Page 47: Chapter 6: Registers

    REGISTERS Register Definitions When programming the EXL10 OCS, data is stored in memory that is segmented into different types. This memory in the controller is referred to as registers. Different groups of registers are defined as either bits or words (16 bits). Multiple registers can usually be used to handle larger storage requirements. For example, 16 single-bit registers can be used to store a word, or two 16-bit registers can be used to store a 32-bit value.
  • Page 48 MAN1029-08-EN_EXL10_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Min-Max Register Default I/O Name Description (Read/Write) (Read/Write) Values User Screen Number %SR1 USER_SCR 0 to 1023 Read/Write Read/Write *Excludes RCC Units Alarm Screen Number (0=none) %SR2 ALRM_SCR 0 to 1023 Read Only Read Only...
  • Page 49 MAN1029-08-EN_EXL10_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Min-Max Register Default I/O Name Description (Read/Write) (Read/Write) Values %SR11-12 Ladder Size (32-Bit DINT) Read Only Read Only User Text Screen Size (32-Bit DINT) %SR13-14 Read Only Read Only *Excludes RCC Units System Text Screen Size (32-Bit DINT) %SR15-16...
  • Page 50 MAN1029-08-EN_EXL10_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Min-Max Register Default I/O Name Description (Read/Write) (Read/Write) Values %SR40 FPGA Image Rev Number ( / 10) Read Only Read Only Vertical Pixel Count %SR41 Read Only Read Only *Excludes RCC Units Horizontal Pixel Count %SR42...
  • Page 51 MAN1029-08-EN_EXL10_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Min-Max Register Default I/O Name Description (Read/Write) (Read/Write) Values Soft Key 1 = 34 Soft Key 2 = 35 Soft Key 3 = 36 Soft Key 4 = 37 Soft Key 5 = 38 Soft Key 6 = 39 Soft Key 7 = 40...
  • Page 52 MAN1029-08-EN_EXL10_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Min-Max Register Default I/O Name Description (Read/Write) (Read/Write) Values %SR152 RS-485 Termination Read / Write Read / Write MJ2 Termination Enable %SR152.1 Read / Write Read / Write *Excludes RCC972 MJ3 Termination Enable *XL+ Only...
  • Page 53 MAN1029-08-EN_EXL10_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Min-Max Register Default I/O Name Description (Read/Write) (Read/Write) Values *RCC Units Only %SR165-166 Reserved Screen Update Time, Default= 5 %SR167 2 to 50 Read/Write Read/Write *X4 & X7 Only – Default = 10 %SR168-170 Reserved %SR171...
  • Page 54 MAN1029-08-EN_EXL10_UserManual Table 6.3 – %SR Registers – Master %SR Table Program Display Min-Max Register Default I/O Name Description (Read/Write) (Read/Write) Values %SR193.9 TRUE if error in temporary program Read Only Read Only Battery Charge Temp Low %SR194 Read Only Read Only *XL+ Only –...

  • Page 55: Register Map For Exl10 Ocs I/O

    (XLE/XLT, X2, X4, & X7 use %SR101 & %SR108-112 for WebMI License Details) For additional information on system bits and registers, refer to the online help found in Cscape. Register Map for EXL10 OCS I/O Table 6.4 – I/O Register Map Description...

  • Page 56: Resource Limits

    MAN1029-08-EN_EXL10_UserManual Table 6.5 – PWM Function Registers Map Register Stepper %AQ1 HSC1 Start Frequency PWM1 Duty Cycle (32-bit) Preset Value %AQ2 Run Frequency %AQ3 HSC2 Accel Count PWM2 Duty Cycle (32-bit) Preset Value (32-bit) %AQ4 %AQ5 PWM Prescale Run Count %AQ6 (32-bit) (32-bit)

  • Page 57: Chapter 7: Cscape Configuration

    Please see the on-line help provided with Cscape for additional details. Cscape Status Bar When the EXL10 OCS is connected to a PC using Cscape software a Status Bar appears at the bottom of the screen. The Cscape Status Bar can be used to determine if communications have been established between the EXL10 OCS and the Cscape program.

  • Page 58: Establishing Communications

    MAN1029-08-EN_EXL10_UserManual Establishing Communications The EXL10 OCS can communicate with Cscape using USB to USB, USB to serial adapters, serial port communications via MJ1 Port and MJ3 Port, Ethernet, onboard Ethernet Ports, 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.
  • Page 59 MAN1029-08-EN_EXL10_UserManual The PC will detect a new device has been plugged into the USB port. Now that the EXL10 is plugged in, go to Cscape → Controller → Connection Wizard. If you are just opening Cscape, Connection Wizard usually opens by default. Select USB and click Next >>.
  • Page 60 MAN1029-08-EN_EXL10_UserManual 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 connecting via USB. Figure 7.3 –...
  • Page 61 MAN1029-08-EN_EXL10_UserManual 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. Figure 7.4 – Cscape: Alternative Connection Method Screenshot Figure 7.5 – Add Target Screenshot in Cscape NOTE: The following fields, Target Name, Connection Medium, Connected Device, and Connection Settings, need to be filled for communication configuration if Cscape Connection Wizard was not used.
  • Page 62 MAN1029-08-EN_EXL10_UserManual Table 7.1 – Communication Configuration Dialog Target Name Name for connection. This is not a mandatory column to be filled, by default Cscape will populate ‘Default1’ in edit box. Connection Medium Com Port Select this option to communicate over serial communication with the device. The port number can be configured here.
  • Page 63 ID and do not require the ID to be configured. To check or change the ID on the EXL10 OCS, press the System Menu key. The first item in the menu is Set Networks. Pressing Enter allows the ID of the unit to be viewed or modified.
  • Page 64 MAN1029-08-EN_EXL10_UserManual 15.3.1 Communicating via MJ1 or MJ3 Serial Ports Start by configuring Cscape to use the correct communications port. This can be done using the Tools → Options → Communication Port dialog in Cscape. 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.
  • Page 65 MAN1029-08-EN_EXL10_UserManual 15.3.2 Communicating via Onboard Ethernet Port From Cscape go to Controller → Hardware Configuration and do auto configuration for the connected controller, click on Config of Ethernet → 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.

  • Page 66: Configuration

    2. If the EXL10 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 EXL10 OCS is not connected press the Config button to the right of the top of the unit. This allows the base CPU to be selected.

  • Page 67: Digital / Hsc Input Configuration

    The High-Speed Counters group box contains all of the windows that are used for configuring the 4 available high-speed counters on the EXL10 OCS. In configuring a counter, the user needs to set the type, mode, and counts per rev.

  • Page 68: Digital / Pwm Output Configuration

    MAN1029-08-EN_EXL10_UserManual Digital / PWM Output Configuration The following figure illustrates the Digital / PWM Output Configuration dialog. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 7.8 – Digital / PWM Output Configuration Dialog The Q1 and Q2 group boxes allow the user to specify the operation of the multi-function outputs.

  • Page 69: Analog Input Configuration

    MAN1029-08-EN_EXL10_UserManual Analog Input Configuration The following figure illustrates the Analog Input Configuration dialog of a Model 2. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 7.9 – Analog Input Configuration Dialog The Channel x drop down windows allow the user to specify the mode for each analog input to operate.

  • Page 70: Analog Output Configuration

    MAN1029-08-EN_EXL10_UserManual Analog Output Configuration The following figure illustrates the Analog Output Configuration dialog. To open the I/O configuration dialogs, select Controller → Hardware Configuration → Local I/O → Config (top button) → Module Setup. Figure 7.10 – Analog Output Configuration Dialog The Output value on Stop group box contains items that allow the user to specify how the analog output channels behave when the controller is stopped.

  • Page 71: Scaling Analog Inputs

    MAN1029-08-EN_EXL10_UserManual Scaling Analog Inputs To access the Advanced Math Scaling function, select Tools → Project Toolbox. This will open a side bar, and then select Advanced Math → Scale. Figure 7.11 –Scaling Analog Inputs A p r i l 2 4 , 2 0 2 0 P a g e 71 | 191...
  • Page 72 MAN1029-08-EN_EXL10_UserManual 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. With the analog channel set to the 4-20mA range, the raw analog input value, which is in INT format ranges from 0-32,000 for 4mA-20mA.

  • Page 73: Chapter 8: General I/O

    To remove the I/O cover of the EXL10 OCS, remove the four (4) Phillips screws from the I/O back. It may help to place the EXL10 OCS unit face down on a clean work surface. Once the four screws are removed the I/O cover can be lifted straight off.
  • Page 74 MAN1029-08-EN_EXL10_UserManual A p r i l 2 4 , 2 0 2 0 P a g e 74 | 191...
  • Page 75 MAN1029-08-EN_EXL10_UserManual Figure 8.2 – EXL10 I/O Cover Removed (sample I/O board) Once the back is removed the jumper selection can be changed. The jumper settings are documented on each data sheet using a diagram such as Figure 8.3 below and a description of the jumper settings. Figure 8.3 –...

  • Page 76: Model And I/O Overview

    NOTE: The digital outputs used on the EXL10 OCS are “sourcing” outputs. This means the output applies a positive voltage to the output pin when turned ON. When turned off, the output applies approximately zero volts with respect to the I/O ground.
  • Page 77 The digital outputs in the EXL10 OCS are typically controlled via %Q bits in the register mapping. Some of the outputs are designed for high-speed applications and can be used for PWM or frequency output applications.

  • Page 78: Relay Outputs

    Relay outputs are designed to switch loads that typically have high voltage or current requirements or require the isolation that relays provide. NOTE: The design of the EXL10 OCS does not require external coil power for the relays to function. The relays will activate anytime the EXL10 OCS is powered.

  • Page 79: Digital Inputs

    NOTE: Refer to the datasheet for EXL10 OCS model being used for details on jumper settings. NOTE: The digital inputs on the EXL10 OCS are designed for low voltage DC inputs. The inputs are designed to support both positive and negative input modes. The mode is set by a jumper setting and a configuration parameter in Cscape.

  • Page 80: Analog Inputs

    MAN1029-08-EN_EXL10_UserManual Analog Inputs NOTE: See the datasheet for the EXL10 OCS model being used for jumper settings and see the appropriate page in this manual (see Index) for details on how to use Cscape to configure the digital filtering. The analog inputs on the EXL10 OCS allow voltage or current measurement from a variety of devices. The voltage or current mode is set though jumpers on the unit and settings in Cscape.

  • Page 81: Universal Analog Inputs

    Universal Analog Inputs NOTE: See the data sheet for the EXL10 OCS model being used for jumper settings and see the appropriate pages in this manual (see Index) for details on how to use Cscape to configure the digital filtering.

  • Page 82: Analog Outputs

    Torque Rating—2 in-lbs (0.2 N-m). Analog Outputs NOTE: Refer to the datasheet for EXL10 OCS model being used for details on jumper settings. The analog outputs on EXL10 OCS devices provide high resolution voltage or current outputs. The voltage or current selection is controlled with jumpers and configuration settings in Cscape.

  • Page 83: Chapter 9: High Speed I/O (Hsc / Pwm)

    HIGH SPEED I/O (HSC / PWM) Overview In addition to the compliment of simple analog and digital I/O, several of the EXL10 OCS I/O modules support High Speed Counting (HSC) I/O functions and may also support Pulse Width Modulation (PWM) Output functions (non-relay modules).

  • Page 84: Glossary

    MAN1029-08-EN_EXL10_UserManual Glossary Table 9.1 – Glossary of High Speed I/O Terms Accumulator Register used to accumulate or store up a sum or count of many items or events. A special function to zero out the value in a specific register. (Not used with Frequency Clear or Period Measurement.) Disable...

  • Page 85: High-Speed Counter (Hsc) Functions

    MAN1029-08-EN_EXL10_UserManual High-Speed Counter (HSC) Functions The EXL10 supports either two or four very high speed, configurable counters. There are four dedicated inputs that can be configures to a number of different options. each of the counters can run in one of five modes.
  • Page 86 MAN1029-08-EN_EXL10_UserManual 9.3.2 Totalize In totalize mode, the accumulator is simply incremented or decremented each time the input transitions in a specific direction. The totalizer supports the following modes: Internal This mode ties the input to the counter to an internal 10MHz or 1MHz clock.
  • Page 87 MAN1029-08-EN_EXL10_UserManual NOTE: Counter triggers off the rising edge of the signal. Rising Edge Signal Falling Edge Signal Three different options are available to reset the current count. They are: • Configured reset value When configuring the Totalize function, a value may be specified under the Counts per Rev column.
  • Page 88 MAN1029-08-EN_EXL10_UserManual 9.3.3 Pulse Width Measurement In pulse width measurement mode, the high-speed input can measure the width of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode the Disable and Latch special functions are allowed.
  • Page 89 MAN1029-08-EN_EXL10_UserManual 9.3.4 Period Measurement In period measurement mode, the high-speed input can measure the period of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode the Disable and Latch special functions are allowed.
  • Page 90 MAN1029-08-EN_EXL10_UserManual 9.3.5 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 typically used for reporting the value of an encoder.
  • Page 91 MAN1029-08-EN_EXL10_UserManual 9.3.6 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.
  • Page 92 MAN1029-08-EN_EXL10_UserManual 9.3.7 HSC Functions The high-speed input on the EXL10 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). Also, they can be set as an “overflow interrupt” or “underflow interrupt” meaning that they will occur when either the Overflow or Underflow, input has been activated.

  • Page 93: Hsc Functions Register Map

    MAN1029-08-EN_EXL10_UserManual HSC Functions Register Map The register assignments for the high-speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below. Table 9.3 –...
  • Page 94 MAN1029-08-EN_EXL10_UserManual NOTE: Four Count Mode requires FPGA update. Table 9.4 – HSC Functions Register Map for 4 HSC Configuration Register Frequency Pulse Totalize %AI401-402 Accumulator - Counter 1 %AI403-404 Latch Value – Counter 1 %AI405-406 Accumulator – Counter 2 %AI407-408 Latch Value –...
  • Page 95 MAN1029-08-EN_EXL10_UserManual %Q1650 Preload – Counter 4 %Q1651 Clear – Counter 4 %Q1652 Disable – Counter 4 %Q1653 Direction – C4 %Q1654 Output Reset – Counter 4 %Q1655 Preload Disable – Counter 4 %Q1656 Latch Disable – Counter 4 %Q1657-1664 Reserved %I1601 Overflow Flag –...

  • Page 96: High Speed Output Functions

    MAN1029-08-EN_EXL10_UserManual 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. 9.5.1 Normal When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives that respective output.
  • Page 97 MAN1029-08-EN_EXL10_UserManual 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.
  • Page 98 MAN1029-08-EN_EXL10_UserManual 9.5.3 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. See details in the high-speed input section. 9.5.4 Stepper Function The EXL10 supports two stepper functions, one on each high-speed output when in two counter mode.
  • Page 99 MAN1029-08-EN_EXL10_UserManual The stepper provides two Boolean registers to provide stepper status: A high indication on this register indicates the stepper sequence can be started Ready/Done (i.e. not currently busy) and also when the move is completed. A high indication on this register indicates that one of the analog parameters specified above is invalid or the stepper action was aborted before the Error operation was complete.

  • Page 100: High Speed Output Functions Register Map

    MAN1029-08-EN_EXL10_UserManual High Speed Output Functions Register Map The register assignments for the high speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below. Table 9.8 –...
  • Page 101 MAN1029-08-EN_EXL10_UserManual PWM Examples Example 1 Duty Cycle Frequency To get a 50% Duty Cycle @ 10kHz Set %AQ421-422 = 16,000 Set %AQ423-424 = 10,000 waveform on PWM1: Example 2 Duty Cycle Frequency Set %AQ421-422 = 16,000 To get a 50% Duty Cycle on PW1 Set %AQ423-424 = 1,000 and 90 % Duty Cycle on PWM2 @ Set %AQ431-432 = 28,800...
  • Page 102 MAN1029-08-EN_EXL10_UserManual STP Examples Example 1 Start Accel Count Run Count Decel Count Frequency Frequency 10,000,000 Set %AQ423-4 = Set %AQ425-6 = Set %AQ427-8 = steps Set %AQ421 = Set %AQ422 = 1,000,000 8,000,000 1,0000,000 control 2500Hz 5000Hz (Steps) (Steps) (Steps) sequence When the Start Move bit is energized, the example starts at 2.5kHz and ramps up to 5kHz during the first 1,000,000 steps.

  • Page 103: Hsc I/O Filtering

    MAN1029-08-EN_EXL10_UserManual HSC I/O Filtering This feature is used to enable digital Filter for HSC Inputs. Selecting Digital In/HSC configuration opens 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 Frequency and Number of samples based on the frequency of the Input signal.
  • Page 104 MAN1029-08-EN_EXL10_UserManual equals the number of samples configured, the sample counter is reset. If 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. If the high-speed input state changes during the sample counting, the sample counter is reset to zero and the process starts over.
  • Page 105 MAN1029-08-EN_EXL10_UserManual Figure 3: Input signal before filtering Figure 4: Input signal after filtering This delay will be 4μs. A p r i l 2 4 , 2 0 2 0 P a g e 105 | 191...

  • Page 106: Chapter 10: Serial Communications

    SERIAL COMMUNICATIONS 10.1 Overview All EXL10 OCS models provide two independent serial ports, on the first 8-pin modular RJ45 connector, which is labeled MJ1/MJ2. The MJ1 serial port is RS232 while the MJ2 port is RS485. By default, MJ1 can be connected to the COM port of a PC running Cscape, for OCS programming.

  • Page 107: Rs485 Termination

    MAN1029-08-EN_EXL10_UserManual Figure 10.1 – Serial Port Wiring & Dip Switches 10.4 RS485 Termination Proper RS485 termination minimizes signal reflections and improves reliability. Both the MJ2 and MJ3 serial ports allow an internal termination resistor to be placed across pins 1 and 2 by DIP Switch Setting.

  • Page 108: Cscape Programming Via Serial Port

    10.6 Cscape Programming via Serial Port The EXL10 OCS MJ1 and MJ3 serial ports support CsCAN Programming Protocol. If a PC COM port is connected to the EXL10 OCS MJ1 or MJ3 serial port, Cscape can access the EXL10 OCS for programming and monitoring.

  • Page 109: Chapter 11: Can Communications

    11.2 Port Description The EXL10 OCS CAN ports implement the ISO 11898-2 physical layer and the CAN 2.0A data link layer standards. Also, since the CAN ports are powered by an internal isolated power supply, external CAN power is not required.

  • Page 110: Can Port Wiring

    The CAN1 port supports CsCAN Programming Protocol. If a PC has a CAN interface installed (via PCI card or USB), and the PC CAN port is connected to the EXL10 OCS CAN1 port, Cscape can access the EXL10 OCS for programming and monitoring.

  • Page 111: Chapter 12: Ethernet Communication

    Ethernet Global Data SRTP Slave (90-30 Service Service Request Transfer Protocol Request) CsCAN TCP Server Horner APG CsCAN over Ethernet (for Cscape to OCS programming) Modbus Slave Modbus over Ethernet Ethernet / IP ODVA CIP over Ethernet FTP (File Server)

  • Page 112: Ethernet Module Configuration

    MAN1029-08-EN_EXL10_UserManual 12.4 Ethernet Module Configuration NOTE: The following configuration is required for all applications regardless of the protocols used. Additional configuration procedures must be performed for each protocol used. To configure the Ethernet Module, use Cscape Programming Software to perform the following steps On the main Cscape screen, select the Controller →...
  • Page 113 MAN1029-08-EN_EXL10_UserManual Figure 12.2 – Ethernet Module Configuration 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 octets and they are always separated by decimal points.
  • Page 114 MAN1029-08-EN_EXL10_UserManual Table 12.3 - Ethernet Status Word Register Format High Byte Low Byte Link TCP Connections Status Values Status Bit(s) Status Indication Minimum Maximum Reserved Always 0 0 = Half Link Duplex (Auto-Negotiated) 1 = Full Duplex Duplex Link Speed (Auto-Negotiated) 0 = 10MHz 1 = 100MHz Receive State...

  • Page 115: Ethernet Configuration - Ip Parameters

    MAN1029-08-EN_EXL10_UserManual 12.5 Ethernet Configuration – IP Parameters For primary operation, the IP address, Net Mask, and Gateway should be set in the LAN config of the Cscape Hardware Configuration. There are options to get IP parameters from the LAN Config or to get parameters from registers.

  • Page 116: Chapter 13: Downloadable Communication Prot0Cols

    MAN1029-08-EN_EXL10_UserManual CHAPTER 13: DOWNLOADABLE COMMUNICATION PROT0COLS 13.1 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.
  • Page 117 MAN1029-08-EN_EXL10_UserManual These basic types are also subdivided into Read or Write operations. For polled operations, a Read operation only reads from a remote device. Likewise, 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.

  • Page 118: Protocol Config

    MAN1029-08-EN_EXL10_UserManual 13.2 Protocol Config After opening Cscape, choose Program → Protocol Config, and select the port drop-down box to select a protocol device driver. All protocol device drivers currently loaded in Cscape are displayed in the dropdown selection. Some OCS models can be limited in the number of ports or number of protocol device drivers that can be selected.

  • Page 119: Network Configuration

    MAN1029-08-EN_EXL10_UserManual 13.3 Network Configuration Network Configuration provides the required parameters to configure the network. Each protocol is different and may not require all the Network Config field. Please refer to the table below for the options in the Network Config field. A p r i l 2 4 , 2 0 2 0 P a g e 119 | 191...
  • Page 120 MAN1029-08-EN_EXL10_UserManual Table 13.1 – Network Protocols Baud Rate, Data Bits, Stop Bits, These field define the bit level transfer over the serial port. Parity None – No handshake lines are used Handshake Multidrop Full – Rx remains active while Tx is occurring. Multidrop Half –...

  • Page 121: Device List And Device Configuration

    MAN1029-08-EN_EXL10_UserManual 13.4 Device List and Device Configuration Device List The Device List is reached from the Device button on the Protocol Config screen and provides a list of the configured devices on the Network. Devices must be created and exist in this list before corresponding Scan List entries can be created for this device.

  • Page 122: Scan List

    MAN1029-08-EN_EXL10_UserManual 13.5 Scan List This can be accessed from the Scan List button on the Protocol Config screen or the Mapping button on the Device List screen and provides a Scan List of the Data Mapping entries. To transfer data between the OCS and remote target, a Scan List must be created that defines each transaction.

  • Page 123: Data Mapping Configuration (Scan List Entry)

    MAN1029-08-EN_EXL10_UserManual 13.6 Data Mapping Configuration (Scan List Entry) Update Type This field specifies the direction and what triggers the transfer of data between the OCS and target device for a mapping entry. Polled Read On every transaction scan, a read-only target device register(s) transaction occurs. Polled Read/Write On every transaction scan, a read target device register transaction occurs unless a local register value has changed.
  • Page 124 MAN1029-08-EN_EXL10_UserManual Polled Read/Write/Init On every transaction scan, a read target device register transaction occurs unless a local register value has changed. The write transaction only updates those local registers that have changed in value. If several non-consecutive local registers (contained in a single mapping entry) change value between transaction scans, it takes several consecutive scans to write each changed register.

  • Page 125: Chapter 14: User Interface

    MAN1029-08-EN_EXL10_UserManual CHAPTER 14: USER INTERFACE 14.1 Overview This chapter presents the user interface (or operator view) of the EXL10 and some of the model specific characteristics of the EXL10 as compared to the rest of the OCS line. This chapter does NOT cover building screens or using the Cscape graphics editor.
  • Page 126 MAN1029-08-EN_EXL10_UserManual A p r i l 2 4 , 2 0 2 0 P a g e 126 | 191...

  • Page 127: Alpha-Numeric Keypad

    MAN1029-08-EN_EXL10_UserManual 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.
  • Page 128 MAN1029-08-EN_EXL10_UserManual 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 disappears.

  • Page 129: Screen Navigation

    MAN1029-08-EN_EXL10_UserManual 14.4 Screen Navigation To allow the operator to change screens, a screen jump object is generally used. This object may be visually represented as a 3-D button (responding to touch) or remain invisible and logically tied to an OCS register.

  • Page 130: Ladder Based Screen Navigation

    MAN1029-08-EN_EXL10_UserManual 14.5 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.

  • Page 131: Touch (Slip) Sensitivity

    MAN1029-08-EN_EXL10_UserManual 14.7 Touch (Slip) Sensitivity Touch slip sensitivity is preset to meet most applications; however, adjustment is available to reduce the sensitivity for touch release. That is, once a graphical object (button) is touched and held by a finger, the default touch slip sensitivity allows for a slight slip of the finger on the graphical object before the EXL10 assumes touch has been released (equates to approximately a quarter inch of movement with a stylus).

  • Page 132: Alarms

    MAN1029-08-EN_EXL10_UserManual 14.8 Alarms Alarm presentation to the operator is highly configurable and beyond the scope of this document to describe fully. For more information refer to the graphics editor help file. This section presents a typical configuration thereby providing an introductory description on what the operator should expect. The alarm object is generally used to enunciate alarms to the operator.
  • Page 133 MAN1029-08-EN_EXL10_UserManual Alarm Viewer To view, acknowledge and/or clear alarms, the operator must access the alarm viewer. This is accomplished by touching an (enabled) alarm object. When accessed, the alarm viewer is displayed as pop-up alarm viewer dialog similar to that shown in Figure 14.6. Figure 14.6 –...

  • Page 134: Removable Media

    MAN1029-08-EN_EXL10_UserManual 14.9 Removable Media The removable media object is generally used to inform the operator on the current state of the removable media device and allow access to its file structure. The removable media object is displayed as a button that changes colors to indicate the current state of the removable media device. The following indicates the device states and the default colors associated with these states.
  • Page 135 MAN1029-08-EN_EXL10_UserManual (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) 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.

  • Page 136: Screen Saver

    MAN1029-08-EN_EXL10_UserManual 14.10 Screen Saver The EXL10 screen backlight life is typically five (5) years when in continuous use. If the application does not require interaction with the EXL10 for long periods of time, the backlight life can be extended by using the screen saver function.

  • Page 137: Touch Screen Pressure

    MAN1029-08-EN_EXL10_UserManual 14.12 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. The following are required for this feature: Minimum Firmware Version: 15.xx or later Minimum OS Version: 2.6.35.49 Minimum Cscape Version: 9.80 SP1...
  • Page 138 MAN1029-08-EN_EXL10_UserManual 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. 0 indicates no pressure and 3000 is the maximum amount of pressure that can be measured.

  • Page 139: Chapter 15: Audio Playback Configuration

    MAN1029-08-EN_EXL10_UserManual CHAPTER 15: AUDIO PLAYBACK CONFIGURATION 15.1 Audio Overview Audio Files Specifications Formats Supported .MP3 & .WAV Audio Channel Type Supported Stereo # of Files Supported 256 Audio Files can be configured 64kbps, 128kbps (recommended), 192kbps, 256kbps, Bit Rates Supported 1411kbps .MP3 Format Bit Rate Range 96 to 320kbps...

  • Page 140: Audio Config Details

    MAN1029-08-EN_EXL10_UserManual The following dialog will open. Figure 15.1 - Audio Config Dialog 15.3 Audio Config Details Triggers – Set the trigger bit high to play the audio file. NOTE: The bit needs to be left on to continue playing. The bit will be set to low after the file is finished laying. Status –...

  • Page 141: Audio Files

    MAN1029-08-EN_EXL10_UserManual 15.4 Audio Files Index – Index of all the audio files will be assigned automatically when audio files are added. Audio Target Path – This gives information about the path of the audio file, audio filename, and format of the audio files added to the list. A p r i l 2 4 , 2 0 2 0 P a g e 141 | 191...
  • Page 142 MAN1029-08-EN_EXL10_UserManual Add – Selecting this button display the following window, where an audio filename with full path needs to be configure. The Modify and Delete button are also available in the Audio Config dialog. IMPORTANT: 1. Audio files are not downloaded from Cscape; they must be present 2.

  • Page 143: Chapter 16: Video Object

    MAN1029-08-EN_EXL10_UserManual CHAPTER 16: VIDEO OBJECT 16.1 Video Object Overview The Video Object feature allows two options for video type: Stream and Playback. The Video Object trigger is used to start, stop, and pause video, and the System Register provides the status of the video object, which supports various resolutions and frames per second.

  • Page 144: Opening Video Object In Cscape

    MAN1029-08-EN_EXL10_UserManual 16.2 Opening Video Object in Cscape NOTE: Video Object requires Firmware 14.03 or newer to use with the EXL10 devices. In Cscape, select the EXL10 and model number by selecting Controller → Hardware Configuration from the toolbar. Open the Graphics Editor by selecting the “T” button from the toolbar. In Graphic Editor, select the video button from the toolbar.
  • Page 145 MAN1029-08-EN_EXL10_UserManual Double click on the icon in the middle to open the Video Properties dialog. A p r i l 2 4 , 2 0 2 0 P a g e 145 | 191...

  • Page 146: Video Properties: Video Type

    MAN1029-08-EN_EXL10_UserManual 16.3 Video Properties: Video Type Figure 16.1 – Configuring 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.

  • Page 147: Video Properties: Control

    MAN1029-08-EN_EXL10_UserManual 16.4 Video Properties: Control Figure 16.2 – Configuring Control Trigger The Video Properties: The video control trigger is used to start, stop and pause video. Video trigger is done by bit level addressing. The trigger reserves eight (8) bits and uses the first two (2) bits.

  • Page 148: Configuring Display Properties

    MAN1029-08-EN_EXL10_UserManual 0x0040 Frame per second not supported or not compatible 16.5 Configuring Display Properties Figure 16.3 – Configuring Display Properties Resolution Options 320x240 (QVGA) Frames per Seconds 10, 15, 20, 24, 30 & MAX_FPS 16.6 Video Object Performance 1. When Video Object is active, navigating to System Menu or any popup window, causes Video Object to be inactive.

  • Page 149: Chapter 17: Removable Media

    EXL10 OCS power is On or Off. To install a microSD card: Align its 8-pin gold edge connector down, facing the front of the EXL10 OCS unit; then carefully push it all the way into the Memory slot. Ensure that it clicks into place.

  • Page 150: Using The Removable Media Manager

    Using Read and Write Removable Media function blocks, an application ladder program can read and write EXL10 OCS register data in the form of comma-delimited files, with a .CSV extension. These files are compatible with standard database and spreadsheet PC programs. In addition, an application ladder program can use Rename and Delete Removable Media function blocks to rename and delete files.

  • Page 151: Using Removable Media To Load And Save Applications

    17.6 Using Removable Media to Load and Save Applications A special file type, with a .PGM extension, is used to store EXL10 OCS application programs on microSD. To load an application from microSD to the EXL10 OCS, use the Removable Media Manager (open the Removable Media Manager in the System Menu) to find and highlight the desired .PGM file, and then...

  • Page 152: Configuration Of A Removable Media

    MAN1029-08-EN_EXL10_UserManual 17.8 Configuration of a Removable Media The configuration of the Removable Media Object that loads the Removable Media Viewer defines what buttons are enabled and available to the user. (Enter) button performs certain operations based on the selected file’s type: - change display to parent directory <DIR>...

  • Page 153: Removable Media (Rm) Features-Program Features

    MAN1029-08-EN_EXL10_UserManual 17.10 Removable Media (RM) Features—Program Features a. Datalog Configuration—This feature allows the controller to periodically log register values to Removable Media. The register data is stored in .csv (comma separated value) format, which is compatible with 3 party PC applications, such as Microsoft Excel. b.

  • Page 154: Filenames Used With The Removable Media (Rm) Function Blocks

    MAN1029-08-EN_EXL10_UserManual 17.13 Filenames used with the Removable Media (RM) Function Blocks The RM function blocks support the flash memory with a DOS/Windows standard FAT-16 file system. All names must be limited to the “8.3” format where the filename contains eight characters a period then a three-character extension.

  • Page 155: System Registers Used With Rm

    MAN1029-08-EN_EXL10_UserManual 17.14 System Registers used with RM %SR174 Removable Write a 1 to %SR174 to prohibit read/write access to the removable Media Protect media card. Write a zero (0) to allow access. %SR175 Status This shows the current status of the RM interface %SR176 Free Space This 32-bit register shows the free space on the RM card in bytes %SR178 Card Capacity...

  • Page 156: Chapter 18: Clone Unit

    MAN1029-08-EN_EXL10_UserManual CHAPTER 18: CLONE UNIT 18.1 Overview ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” application program and unit settings stored in battery-backed RAM of an OCS into the RM. Refer to the Removable Media chapter for details in using RM.
  • Page 157 MAN1029-08-EN_EXL10_UserManual 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: Figure 18.3 –...
  • Page 158 MAN1029-08-EN_EXL10_UserManual 3. Once the cloning is successful, OCS gives a message as below: Figure 18.5 – Cloning Status Make/Create clone can also be triggered by setting %SR164.9 bit to “1” from Ladder program or graphics. Once the operation is completed, 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.

  • Page 159: Load Clone

    MAN1029-08-EN_EXL10_UserManual 18.3 Load Clone This option loads the application, all unit settings and register values from Removable media to the battery-backed RAM (Regardless of AutoLoad settings) and then resets the OCS for the settings to take effect. User needs to perform the following to Load Clone: 1.
  • Page 160 MAN1029-08-EN_EXL10_UserManual 3. User needs to confirm Load Clone as shown below: Figure 18.8 – Load Clone Confirm Screen 4. After confirmation, all unit settings and register values will be loaded from Removable Media to the battery-backed RAM (Regardless of AutoLoad settings) and then OCS resets for the settings to take effect.

  • Page 161: Chapter 19: Fail - Safe System

    MAN1029-08-EN_EXL10_UserManual CHAPTER 19: FAIL – SAFE SYSTEM 19.1 Overview The Fail-Safe System is a set of features that allow an application to continue running in the event of certain types of "soft" failures. These "soft" failures include: Battery power loss Battery-backed register RAM or Application Flash corruption due to, for example, an excessive EMI event.

  • Page 162: Settings

    MAN1029-08-EN_EXL10_UserManual 19.2 Settings To use the fail – safe feature, the user needs to do the following: 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.
  • Page 163 MAN1029-08-EN_EXL10_UserManual Figure 19.3 – Backup Registers Restore OCS Data: When initiated, this will allow the user to manually copy the backed-up data from the onboard flash memory to the battery-backed RAM. A restore operation will be automatically initiated if a backup has been previously created and on power- up the battery-backed RAM registers fail their check.
  • Page 164 MAN1029-08-EN_EXL10_UserManual Clear Backup Data: When initiated, the backup data will be erased from the onboard flash memory and no backup will exist. %SR164.4 and %SR164.3 is reset to the value of “0” when backed up data is erased. Figure 19.5 – Clear Backup Data Exit: Goes back to the previous screen.
  • Page 165 MAN1029-08-EN_EXL10_UserManual The OCS follows the following sequence in execution of Automatic Restore: OCS Power Cycle Battery Backed RAM Registers check failed Backup exists? Controller placed in Application IDLE mode Program erased Data copied from Onboard FLASH to OCS Battery backed Controller Resets AutoRun OCS put in IDLE...

  • Page 166: Autoload

    MAN1029-08-EN_EXL10_UserManual 19.3 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.
  • Page 167 MAN1029-08-EN_EXL10_UserManual The OCS follows the following sequence in execution of AutoLoad: Power up OCS Application Program absent Application Program corrupted AutoLoad OCS put in IDLE mode Enabled? AutoLoad run sequence AUTOLOAD.PGM present in failed (with reasons for the RM of the device ? failure) AutoLoad initiated.

  • Page 168: Autorun

    MAN1029-08-EN_EXL10_UserManual 19.4 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.

  • Page 169: Chapter 20: Modbus Communications

    MAN1029-08-EN_EXL10_UserManual CHAPTER 20: MODBUS COMMUNICATIONS 20.1 Modbus Overview 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 EXL10 can act as either a Master or a Slave.

  • Page 170: Modbus Master Overview

    MAN1029-08-EN_EXL10_UserManual 20.3 Modbus Master Overview For complete Modbus Master instructions, please refer to the Help file in Cscape. When acting as a Modbus master, there are two primary mechanisms used by the EXL10 to allow the user to specify the data to be read/written from/to the slaves. Modbus Master Function Block—This is for serial only.

  • Page 171: Modbus Addressing Table For Exl10 Units

    MAN1029-08-EN_EXL10_UserManual 20.4 Modbus Addressing Table for EXL10 Units To access EXL10 registers, 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).

  • Page 172: Chapter 21: Back-Up Battery

    MAN1029-08-EN_EXL10_UserManual CHAPTER 21: BACK-UP BATTERY The following information pertains to the XL and RCC OCS units running 14.24 firmware and newer. NOTE: For more details on the back-up battery, refer to the Battery Manual [MAN1142]. 21.1 Overview The EXL10 has an advanced battery system that uses a rechargeable lithium-ion battery. The battery powers the real time clock when power is removed and is needed for register data retention.

  • Page 173: Battery Charging Cycle

    MAN1029-08-EN_EXL10_UserManual 21.5 Battery Charging Cycle 1. The battery is charged at unit power up. The first two minutes after boot there is a wait period before charging begins. 2. In all charge cycles, battery is charge fully to 4.2V (4200mV). 3.

  • Page 174: Chapter 22: Maintenance

    MAINTENANCE 22.1 Firmware Updates The EXL10 OCS products contain field updatable firmware to allow new features to be added to the product at a later time. Firmware updates should only be performed when a new feature or correction is required.

  • Page 175: Firmware Update Files

    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 communications.) 2) Save Firmware files to microSD card or USB, these are the removable media devices.

  • Page 176: Steps For Firmware Update

    MAN1029-08-EN_EXL10_UserManual 22.4 Steps for Firmware Update Update firmware in an EXL10 by completing the following steps: a. Unzip all files from downloaded .zip file (Step One, p.1) onto removable media. b. Plug the removable media into a powered-up OCS controller. c.

  • Page 177: Backup Battery Replacement

    NOTE: For the registers to be retentive the battery only needs to be charged and present at power down. The EXL10 OCS uses a lithium ion battery available from Horner Automation: part no. BAT00019. NOTE: Do not use an alkaline AA battery, only the proper battery type listed.
  • Page 178 1. Make sure the user program and any data stored in retentive memory is backed up. 2. Disconnect all power from the EXL10 OCS unit including I/O power. Unplug I/O connections. 3. Using a small Philips screwdriver, remove the I/O back panel, which is the smaller back panel, by turning four (4) corner screws counterclockwise.

  • Page 179: Chapter 23: Troubleshooting / Technical Support

    CHAPTER 23: TROUBLESHOOTING / TECHNICAL SUPPORT 23.1 Connecting to the EXL10 OCS Cscape connects to the local controller automatically when the serial connection is made. The status bar below shows an example of a successful connection. This status bar is located in the bottom right hand corner of the Cscape window.
  • Page 180 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 numbers HE-XCK and HE-CPK.

  • Page 181: Local Controller And Local I/O

    MAN1029-08-EN_EXL10_UserManual 23.2 Local Controller and Local I/O The System Menu provides the following status indications that are useful for troubleshooting and system maintenance. - Self-test results, diagnostics. - RUN and OK status - Network status and usage - Average logic scan rate - Application memory usage - Loaded firmware versions - Loaded protocols...

  • Page 182: Cscan Network

    1. Use the proper Belden wire type or equivalent for the network as specified in MAN0799. 2. The EXL10 OCS does not provide 24VDC to the network. An external voltage source must be used for other devices such as SmartStix I/O.

  • Page 183: Removable Media - Basic Troubleshooting

    23.4 Removable Media - Basic Troubleshooting Description Action EXL10 OCS does not read media The media card should be formatted with the EXL10 OCS. card. Make sure the project file is saved as a .pgm file and not a .csp EXL10 OCS will not download file.

  • Page 184: Change Log

    MAN1029-08-EN_EXL10_UserManual CHANGE LOG Change Log Date Rev # Description of Revision Location in Doc 5/6/2020 Updated Firmware Update Steps per new Firmware Updates Firmware Update Manual. (Mantis 2209) Updated Audio Chapter. (Mantis 2588) Audio Chapter Rearranged Chapter Order. (Mantis 3029) Throughout Updated Model 6 and RTC/TC Formula.

  • Page 185: Main Index

    MAN1029-08-EN_EXL10_UserManual MAIN INDEX %Q bits, 75 Configuration of a Removable Media, 149 Accessories, 15 Configuration via Mini-B USB, 106 accumulator, 83, 84, 86, 88 Configured reset value, 85 Add Target Screenshot in Cscape, 60 Configuring Video Properties, 143 Alpha-Numeric Keypad, 124 Count, 94, 96 Analog Input Configuration Screen, 79 Csape Program...
  • Page 186 EXL10 OCS Mounting Clip, 17 Modbus Master Mapping, 168 EXL10 OCS Mounting Orientation, 17 Modbus Master Overview, 167 EXL10 OCS with Mounting Clips, 17 Modbus Overview, 166 Fail – Safe System, 40 Modbus Slave Overview, 166 Fail Safe System Overview, 158...
  • Page 187 MAN1029-08-EN_EXL10_UserManual Frequency Formula, 96 sourcing, 74, 77 Registers, 98 stepper, 81, 96, 97 Quadrature, 66, 83, 88 stop state, 75, 77 References / Useful documents, 15 Storing Register Contents, 169 register mapping, 72, 75 Sub-Menus, 24 registers, 46 System Menu Registers Details, 45 %S / %SR, 46...
  • Page 188 MAN1029-08-EN_EXL10_UserManual Using Removable Media to View and Capture View Diags, 29 Screens, 148 View I/O Slots, 31 Video Object View Protocols, 32 Playback, 143 View Status, 28 Stream, 143 Visual Overview, 11 View Battery Status, 30 Where to Find Information, 12 A p r i l 2 4 , 2 0 2 0 P a g e 188 | 191...

  • Page 189: Index Of Figures And Tables

    Figure 02.2 – Visual Overview of Types of Devices that can be connected to EXL10, 14 Figure 03.1 – Panel Mounting of an EXL10 Series OCS, 17 Figure 03.2 – EXL10 OCS with Mounting Clips, 18 Figure 03.3 – Orientation of EXL10 OCS, 18 Figure 03.4 –...
  • Page 190 Table 05.2 Clock and Time Setting Terms, 36 Table 05.3 – System Registers for UTC (Coordinated Universal Time), 36 Table 06.1 - Types of Registers found in the EXL10 OCS, 47 Table 06.2 – Common %S Register Definitions, 47 Table 06.3 - %SR Registers, 48 Table 06.4 –...
  • Page 191 MAN1029-08-EN_EXL10_UserManual Table 09.10 – PWM Examples, 100 Table 09.11 – STP Examples, 101 Table 12.1—Ethernet Module Protocols & Features, 110 Table 12.2 – Ethernet Module Specifications, 110 Table 12.3 - Ethernet Status Word Register Format, 113 Table 13.1 - Network Protocols, 119 Table 15.1 - 1st and 2nd Status Registers, 138 Table 17.1 –...

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