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HORNER APG XL10 PRIME OCS User Manual

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EXL10/XL10 PRIME OCS
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HE-EXV1E0
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User Manual for
MAN1029-010-EN_EXL10_XL10P_UM
XL10
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  • Page 1 MAN1029-10-EN_EXL10_XL10P_UM User Manual for EXL10/XL10 PRIME OCS MAN1029-010-EN_EXL10_XL10P_UM XL10 XL10 PRIME North America Europe North America Europe HE-EXV1E0 HEXT505C100 HE-XPV1E0 HEXP505C100 HE-EXV1E2 HEXT505C112 HE-XPV1E2 HEXP505C112 HE-EXV1E3 HEXT505C113 HE-XPV1E3 HEXP505C113 HE-EXV1E4 HEXT505C114 HE-XPV1E4 HEXP505C114 HE-EXV1E5 HEXT505C115 HE-XPV1E5 HEXP505C115 HE-EXV1E6 HEXT505C116 HE-XPV1E6...

  • Page 2: Preface

    PREFACE This manual explains how to use the EXL10/XL10 PRIME 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...

  • Page 3: Limited Warranty And Limitation Of Liability

    NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS EXL10/XL10 PRIME OCS module. THIS WARRANTY SHALL NOT APPLY TO THIS EXL10/XL10 PRIME OCS module OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE.

  • Page 4: Visual Map Of Key Chapters

    VISUAL MAP OF KEY CHAPTERS FIRST STEP of ANY TASK: DATASHEET Each EXL10/XL10 PRIME 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/XL10 PRIME OCS models for specific installation information.

  • Page 5: Table Of Contents

    Grounding ..........................11 Compliance ..........................11 CHAPTER 2: INTRODUCTION ......................12 Visual Overview of EXL10/XL10 PRIME OCS ................12 Connectivity to the EXL10/XL10 PRIME OCS................14 Features of EXL10/XL10 PRIME OCS ..................15 Accessories ..........................16 Useful Documents and References ................... 16 CHAPTER 3: MECHANICAL INSTALLATION ..................
  • Page 6 Touch screen calibration ...................... 47 CHAPTER 6: REGISTERS ........................48 Register Definitions ........................48 Useful %S and %SR registers ..................... 48 Register Map for EXL10/XL10 PRIME OCS I/O ................57 Resource Limits ......................... 58 CHAPTER 7: CSCAPE CONFIGURATION ....................59 Overview ........................... 59 Cscape Status Bar ........................
  • Page 7 MAN1029-10-EN_EXL10_XL10P_UM CHAPTER 11: CAN COMMUNICATIONS ..................... 111 11.1 Overview ..........................111 11.2 Port Description ........................111 11.3 CAN Port Wiring ........................112 11.4 Cscape Programming via CAN ....................112 11.5 Ladder-Controlled CAN Communication ................112 11.6 Using CAN for I/O Expansion (Network I/O) ................112 CHAPTER 12: ETHERNET COMMUNICATION ...................
  • Page 8 Steps for Firmware Update ....................185 CHAPTER 24: TROUBLESHOOTING / TECHNICAL SUPPORT ............186 24.1 Connecting to the EXL10/XL10 PRIME OCS ................. 186 24.2 Local Controller and Local I/O ..................... 188 J u l y 6 , 2 0 2 2...
  • Page 9 MAN1029-10-EN_EXL10_XL10P_UM 24.3 CsCAN Network ........................189 24.4 Removable Media - Basic Troubleshooting ................. 190 24.5 USB Interfaces ........................190 24.6 Technical Support Contacts ....................190 CHANGE LOG ............................191 INDEX ..............................192 J u l y 6 , 2 0 2 2 P a g e 9 | 195...

  • Page 10: Chapter 1: Safety / Compliance

    MAN1029-10-EN_EXL10_XL10P_UM CHAPTER 1: SAFETY / COMPLIANCE Safety Warnings and Guidelines When found on the product, the following symbols specify: Warning: Electrical Shock Hazard. Warning: Consult user documentation. 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

    MAN1029-10-EN_EXL10_XL10P_UM 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

    MAN1029-10-EN_EXL10_XL10P_UM CHAPTER 2: INTRODUCTION Visual Overview of EXL10/XL10 PRIME OCS Figure 2.1 – Overview of the EXL10/XL10 PRIME J u l y 6 , 2 0 2 2 P a g e 12 | 195...
  • Page 13 MAN1316 Model 6 MAN1190 MAN1317 User Manual -This manual provides general information that is common to EXL10/XL10 PRIME OCS models and can be downloaded from our web. Visit the Horner website to obtain user documentation and updates. North America https://hornerautomation.com Europe http://www.hornerautomation.eu...

  • Page 14: Connectivity To The Exl10/Xl10 Prime Ocs

    MAN1029-10-EN_EXL10_XL10P_UM Connectivity to the EXL10/XL10 PRIME OCS The EXL10/XL10 PRIME 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/XL10 PRIME OCS. Other OCS Devices...

  • Page 15: Features Of Exl10/Xl10 Prime Ocs

    PWM outputs and relays (depending upon the EXL10/XL10 PRIME OCS model used). Advanced high speed I/O capabilities Cscape programming software that allows all aspects of the EXL10/XL10 PRIME OCS to be programmed and configured from one integrated application. Optional communication add-on modules Two onboard Ethernet ports (10/100Mbps) for Cscape programming and application defined communication, with Auto MDI/MDI-X.

  • Page 16: Accessories

    MAN1029-10-EN_EXL10_XL10P_UM 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 J u l y 6 , 2 0 2 2...

  • Page 17: Chapter 3: Mechanical Installation

    3. Pass the unit through the panel. 4. Insert each of the ten (10) mounting clips into the slots in the EXL10/XL10 PRIME OCS case. One clip should be installed on each corner. Lightly tighten each screw so the clip is held in place.

  • Page 18: Mounting Orientation

    3.3.2 Figure 3.3 – Orientation of EXL10/XL10 PRIME OCS NOTE: There are no orientation restrictions on the EXL10/XL10 PRIME OCS. However, the above orientation provides for optimum readability of the screen and ease of use of the keypad. J u l y 6 , 2 0 2 2...

  • Page 19: Exl10/Xl10 Prime Dimensions

    MAN1029-10-EN_EXL10_XL10P_UM EXL10/XL10 PRIME Dimensions Figure 3.4 – EXL10/XL10 PRIME OCS Dimensions J u l y 6 , 2 0 2 2 P a g e 19 | 195...

  • Page 20: Installation Procedure

    MAN1029-10-EN_EXL10_XL10P_UM Installation Procedure • The EXL10/XL10 PRIME utilizes a clip installation method to ensure a robust and watertight seal to the enclosure. Please follow the steps below for the proper installation and operation of the unit. • This equipment is suitable for Class I, Division 2, Groups A, B, C and D or non-hazardous locations only.

  • Page 21: Factors Affecting Panel Layout Design And Clearances

    3.6.4 Orientation When panel-mounted, there are no orientation restrictions on the EXL10/XL10 PRIME OCS. J u l y 6 , 2 0 2 2...
  • Page 22 3.6.5 Noise Consider the impact on the panel layout design and clearance requirements if noise suppression devices are needed. Be sure to maintain an adequate distance between the EXL10/XL10 PRIME OCS and noisy devices such as relays, motor starters, etc.

  • Page 23: Chapter 4: Electrical Installation

    NOTE: The datasheets are the first documents to refer to for model-specific information related to EXL10/XL10 PRIME 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 24: How To Test For Good Ground

    MAN1029-10-EN_EXL10_XL10P_UM 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 25: Primary Power Port

    MAN1029-10-EN_EXL10_XL10P_UM Primary Power Port NOTE: The Primary Power Range is 10VDC to 30VDC. 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). •...

  • Page 26: Chapter 5: System Settings And Adjustments

    MAN1029-10-EN_EXL10_XL10P_UM CHAPTER 5: SYSTEM SETTINGS AND ADJUSTMENTS System Menu - Overview The EXL10/XL10 PRIME 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.

  • Page 27: System Menu - Navigation And Editing

    MAN1029-10-EN_EXL10_XL10P_UM System Menu – Navigation and Editing As mentioned above, the System Menu is started by pressing the System key on the EXL10/XL10 PRIME. 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 28 MAN1029-10-EN_EXL10_XL10P_UM 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/XL10 PRIME System Menu Map MAC ID2: Dflt Pgm Port MJ1-232 00:E0:C4:04:C0:35 Figure 5.1 MJ2 RS485 Bias IP2:...

  • Page 29: Set Networks

    MAN1029-10-EN_EXL10_XL10P_UM 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 30: View Status

    0.0 = EXL10/XL10 PRIME OCS is not in Run mode Scan Rate(mS) 0.1 to 999.9= Average number of mS for each ladder scan 0.0 to 100.0 = CAN network bandwidth % used by this EXL10/XL10 PRIME OCS OCS Net Use % node All Net Use % 0.0 to 100.0 = CAN network bandwidth % used by all nodes...

  • Page 31: View Diags

    Fault = Ladder program or I/O configuration not loaded or load failed The last nine System Diagnostics are informational. If any of these indicate a warning condition, the EXL10/XL10 PRIME OCS can still enter and remain in Run mode, but the problem should be investigated and corrected.

  • Page 32: View Battery Status

    MAN1029-10-EN_EXL10_XL10P_UM Ok = Backup battery operating properly Battery Warning = Backup battery needs to be replaced 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.

  • Page 33: 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/XL10 PRIME 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 34: 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/XL10 PRIME 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 35: Set Fkeys Mode

    MAN1029-10-EN_EXL10_XL10P_UM 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 36: Set Serial Ports

    MAN1029-10-EN_EXL10_XL10P_UM 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 37: Set Time/Date

    MAN1029-10-EN_EXL10_XL10P_UM 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 38 MAN1029-10-EN_EXL10_XL10P_UM 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 39: Set Beeper

    MAN1029-10-EN_EXL10_XL10P_UM 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) J u l y 6 , 2 0 2 2 P a g e 39 | 195...

  • Page 40: Set Screen

    MAN1029-10-EN_EXL10_XL10P_UM 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 41: Removable Media

    MAN1029-10-EN_EXL10_XL10P_UM 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 42: Fail - Safe System

    MAN1029-10-EN_EXL10_XL10P_UM 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, Electromagnetic Interference, event.

  • Page 43: Enable Autorun And Autoload

    MAN1029-10-EN_EXL10_XL10P_UM 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 44: Clone Unit

    MAN1029-10-EN_EXL10_XL10P_UM 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 45: Load Clone

    MAN1029-10-EN_EXL10_XL10P_UM 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. J u l y 6 , 2 0 2 2 P a g e 45 | 195...

  • Page 46: Webmi License Details

    MAN1029-10-EN_EXL10_XL10P_UM 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 %SR209.9 to SR209.16 Number of Users...

  • Page 47: Touch Screen Calibration

    MAN1029-10-EN_EXL10_XL10P_UM 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 48: Chapter 6: Registers

    REGISTERS Register Definitions When programming the EXL10/XL10 PRIME 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.
  • Page 49 MAN1029-10-EN_EXL10_XL10P_UM 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 50 MAN1029-10-EN_EXL10_XL10P_UM 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 51 MAN1029-10-EN_EXL10_XL10P_UM 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 52 MAN1029-10-EN_EXL10_XL10P_UM 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 53 MAN1029-10-EN_EXL10_XL10P_UM 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 54 MAN1029-10-EN_EXL10_XL10P_UM 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 55 MAN1029-10-EN_EXL10_XL10P_UM 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 56 MAN1029-10-EN_EXL10_XL10P_UM Table 6.3 – %SR Registers – Master %SR Table Program Display Min-Max Register Default I/O Name Description (Read/Write) (Read/Write) Values (XLE/XLT, X2, X4, & X7 use %SR101 & %SR108-112 for WebMI License Details) Expiration Date of WebMI License, license detail.

  • Page 57: Register Map For Exl10/Xl10 Prime Ocs I/O

    MAN1029-10-EN_EXL10_XL10P_UM Register Map for EXL10/XL10 PRIME OCS I/O Table 6.4 – I/O Register Map Description Registers no I/O 102 I/O 103 I/O 104 I/O 105 I/O 106 I/O %I1-%I12 Unused Digital Inputs %I13-%I16 Unused Reserved Digital Inputs Reserved %I17-%I24 Unused...

  • Page 58: Resource Limits

    MAN1029-10-EN_EXL10_XL10P_UM Table 6.5 – PWM Function Registers Map Register Stepper %AQ1 Start Frequency HSC1 PWM1 Duty Cycle (32-bit) %AQ2 Preset Value Run Frequency %AQ3 HSC2 Accel Count PWM2 Duty Cycle (32-bit) Preset Value (32-bit) %AQ4 %AQ5 PWM Prescale Run Count (32-bit) (32-bit) %AQ6...

  • Page 59: Chapter 7: Cscape Configuration

    PRIME OCS unit. Please see the on-line help provided with Cscape for additional details. Cscape Status Bar When the EXL10/XL10 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 EXL10/XL10 PRIME OCS and the Cscape program.

  • Page 60: Establishing Communications

    MAN1029-10-EN_EXL10_XL10P_UM Establishing Communications The EXL10/XL10 PRIME 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 61 MAN1029-10-EN_EXL10_XL10P_UM The PC will detect a new device has been plugged into the USB port. Now that the EXL10/XL10 PRIME 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 62 MAN1029-10-EN_EXL10_XL10P_UM 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 63 MAN1029-10-EN_EXL10_XL10P_UM 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 64 MAN1029-10-EN_EXL10_XL10P_UM 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 65 ID and do not require the ID to be configured. To check or change the ID on the EXL10/XL10 PRIME 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 66 MAN1029-10-EN_EXL10_XL10P_UM 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 67 MAN1029-10-EN_EXL10_XL10P_UM 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 68: Configuration

    Base model, I/O and any communication options. 3. If the EXL10/XL10 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.

  • Page 69: 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/XL10 PRIME OCS. In configuring a counter, the user needs to set the type, mode, and counts per rev.

  • Page 70: Digital / Pwm Output Configuration

    MAN1029-10-EN_EXL10_XL10P_UM 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 71: Analog Input Configuration

    MAN1029-10-EN_EXL10_XL10P_UM 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 72: Analog Output Configuration

    MAN1029-10-EN_EXL10_XL10P_UM 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 73: Scaling Analog Inputs

    MAN1029-10-EN_EXL10_XL10P_UM 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 J u l y 6 , 2 0 2 2 P a g e 73 | 195...
  • Page 74 MAN1029-10-EN_EXL10_XL10P_UM 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 75: Chapter 8: General I/O

    To remove the I/O cover of the EXL10/XL10 PRIME OCS, remove the four (4) Phillips screws from the I/O back. It may help to place the EXL10/XL10 PRIME 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 76 MAN1029-10-EN_EXL10_XL10P_UM J u l y 6 , 2 0 2 2 P a g e 76 | 195...
  • Page 77 MAN1029-10-EN_EXL10_XL10P_UM Figure 8.2 – EXL10/XL10 PRIME 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. 001XLE005-R1 Figure 8.3 –...

  • Page 78: Model And I/O Overview

    Model 5 Model 6 Table 8.1 shows the different types of I/O included with the various EXL10/XL10 PRIME OCS models. Specific specifications, jumper settings and wiring diagrams can be found on the data sheets attached at the end of the manual. Descriptions and applications of the different type of I/O can be found below.
  • Page 79 The digital outputs in the EXL10/XL10 PRIME 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 80: 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/XL10 PRIME OCS does not require external coil power for the relays to function. The relays will activate anytime the EXL10/XL10 PRIME OCS is powered.

  • Page 81: Digital Inputs

    Cscape settings pages. Digital Inputs NOTE: Refer to the datasheet for EXL10/XL10 PRIME OCS model being used for details on jumper settings. NOTE: The digital inputs on the EXL10/XL10 PRIME OCS are designed for low voltage DC inputs. The inputs are designed to support both positive and negative input modes.

  • Page 82: Analog Inputs

    MAN1029-10-EN_EXL10_XL10P_UM Analog Inputs NOTE: See the datasheet for the EXL10/XL10 PRIME OCS model being used for jumper settings and see the appropriate page in this manual (see Index) for details on how to use Cscape to configure the digital filtering.

  • Page 83: Universal Analog Inputs

    Universal Analog Inputs NOTE: See the data sheet for the EXL10/XL10 PRIME 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 84: Analog Outputs

    Torque Rating—2 in-lbs (0.2 N-m). Analog Outputs NOTE: Refer to the datasheet for EXL10/XL10 PRIME OCS model being used for details on jumper settings. The analog outputs on EXL10/XL10 PRIME OCS devices provide high resolution voltage or current outputs. The voltage or current selection is controlled with jumpers and configuration settings in Cscape.

  • Page 85: 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/XL10 PRIME 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.

  • Page 86: Glossary

    MAN1029-10-EN_EXL10_XL10P_UM Glossary Table 9.1 – Glossary of High Speed I/O Terms Error! Bookmark not defined. 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 87: High-Speed Counter (Hsc) Functions

    MAN1029-10-EN_EXL10_XL10P_UM High-Speed Counter (HSC) Functions The EXL10/XL10 PRIME 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. Those modes are Totalizer, Frequency Counter, Pulse Width Measurement, Period Measurement and Quadrature measurement.
  • Page 88 MAN1029-10-EN_EXL10_XL10P_UM 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 89 MAN1029-10-EN_EXL10_XL10P_UM 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 90 MAN1029-10-EN_EXL10_XL10P_UM 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 91 MAN1029-10-EN_EXL10_XL10P_UM 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 92 MAN1029-10-EN_EXL10_XL10P_UM 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 93 MAN1029-10-EN_EXL10_XL10P_UM 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 94 MAN1029-10-EN_EXL10_XL10P_UM 9.3.7 HSC Functions The high-speed input on the EXL10/XL10 PRIME 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”...

  • Page 95: Hsc Functions Register Map

    MAN1029-10-EN_EXL10_XL10P_UM 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 96 MAN1029-10-EN_EXL10_XL10P_UM 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 97 MAN1029-10-EN_EXL10_XL10P_UM %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 98: High Speed Output Functions

    MAN1029-10-EN_EXL10_XL10P_UM 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 99 MAN1029-10-EN_EXL10_XL10P_UM 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 100 MAN1029-10-EN_EXL10_XL10P_UM 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/XL10 PRIME supports two stepper functions, one on each high-speed output when in two counter mode.
  • Page 101 MAN1029-10-EN_EXL10_XL10P_UM 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 102: High Speed Output Functions Register Map

    MAN1029-10-EN_EXL10_XL10P_UM 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 103 MAN1029-10-EN_EXL10_XL10P_UM 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 104 MAN1029-10-EN_EXL10_XL10P_UM 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 105: Hsc I/O Filtering

    MAN1029-10-EN_EXL10_XL10P_UM 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 106 MAN1029-10-EN_EXL10_XL10P_UM 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 107 MAN1029-10-EN_EXL10_XL10P_UM Figure 3: Input signal before filtering Figure 4: Input signal after filtering This delay will be 4μs. J u l y 6 , 2 0 2 2 P a g e 107 | 195...

  • Page 108: Chapter 10: Serial Communications

    SERIAL COMMUNICATIONS 10.1 Overview All EXL10/XL10 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 connected to the COM port of a PC running Cscape, for OCS programming. In addition, both MJ1 and MJ2 can be used for application-specific communication, using a variety of standard data exchange protocols.

  • Page 109: Rs485 Termination

    MAN1029-10-EN_EXL10_XL10P_UM 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 110: Cscape Programming Via Serial Port

    The EXL10/XL10 PRIME OCS MJ1 and MJ3 serial ports support CsCAN Programming Protocol. If a PC COM port is connected to the EXL10/XL10 PRIME OCS MJ1 or MJ3 serial port, Cscape can access the EXL10/XL10 PRIME OCS for programming and monitoring. Programming can also be done via the CAN port, USB A port or Ethernet.

  • Page 111: Chapter 11: Can Communications

    11.2 Port Description The EXL10/XL10 PRIME 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 112: 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/XL10 PRIME OCS CAN1 port, Cscape can access the EXL10/XL10 PRIME OCS for programming and monitoring.

  • Page 113: 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 114: Ethernet Module Specifications

    MAN1029-10-EN_EXL10_XL10P_UM 12.4 Ethernet Module Specifications Table 12.2 – Ethernet Module Specifications 10 BaseT Ethernet (10Mbps) Speeds 100 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 Crossover)

  • Page 115: Ethernet Module Configuration

    MAN1029-10-EN_EXL10_XL10P_UM 12.5 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 116 MAN1029-10-EN_EXL10_XL10P_UM 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 117 MAN1029-10-EN_EXL10_XL10P_UM 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 118: Ethernet Configuration - Ip Parameters

    MAN1029-10-EN_EXL10_XL10P_UM 12.6 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 119: Chapter 13: Downloadable Communication Prot0Cols

    MAN1029-10-EN_EXL10_XL10P_UM 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 120 MAN1029-10-EN_EXL10_XL10P_UM 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 121: Protocol Config

    MAN1029-10-EN_EXL10_XL10P_UM 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 122: Network Configuration

    MAN1029-10-EN_EXL10_XL10P_UM 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. J u l y 6 , 2 0 2 2 P a g e 122 | 195...
  • Page 123 MAN1029-10-EN_EXL10_XL10P_UM 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 124: Device List And Device Configuration

    MAN1029-10-EN_EXL10_XL10P_UM 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 125: Scan List

    MAN1029-10-EN_EXL10_XL10P_UM 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 126: Data Mapping Configuration (Scan List Entry)

    MAN1029-10-EN_EXL10_XL10P_UM 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 127 MAN1029-10-EN_EXL10_XL10P_UM 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 128: Chapter 14: User Interface

    MAN1029-10-EN_EXL10_XL10P_UM CHAPTER 14: USER INTERFACE 14.1 Overview This chapter presents the user interface (or operator view) of the EXL10/XL10 PRIME and some of the model specific characteristics of the EXL10/XL10 PRIME as compared to the rest of the OCS line. This chapter does NOT cover building screens or using the Cscape graphics editor.

  • Page 129: Alpha-Numeric Keypad

    MAN1029-10-EN_EXL10_XL10P_UM 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 130 MAN1029-10-EN_EXL10_XL10P_UM 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 131: Screen Navigation

    MAN1029-10-EN_EXL10_XL10P_UM 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 132: Ladder Based Screen Navigation

    MAN1029-10-EN_EXL10_XL10P_UM 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 133: Touch (Slip) Sensitivity

    MAN1029-10-EN_EXL10_XL10P_UM 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/XL10 PRIME assumes touch has been released (equates to approximately a quarter inch of movement with a stylus).

  • Page 134: Alarms

    MAN1029-10-EN_EXL10_XL10P_UM 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 135 MAN1029-10-EN_EXL10_XL10P_UM 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 136: Removable Media

    MAN1029-10-EN_EXL10_XL10P_UM 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 137 MAN1029-10-EN_EXL10_XL10P_UM (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 138: Screen Saver

    MAN1029-10-EN_EXL10_XL10P_UM 14.10 Screen Saver The EXL10/XL10 PRIME screen backlight life is typically five (5) years when in continuous use. If the application does not require interaction with the EXL10/XL10 PRIME for long periods of time, the backlight life can be extended by using the screen saver function. When enabled through the System Menu, the backlight is shut off (screen goes black) after a specified time of no touch activity on the screen.

  • Page 139: Touch Screen Pressure

    MAN1029-10-EN_EXL10_XL10P_UM 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 140 MAN1029-10-EN_EXL10_XL10P_UM 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 141: Chapter 15: Audio Playback Configuration

    MAN1029-10-EN_EXL10_XL10P_UM 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 142: Audio Config Details

    MAN1029-10-EN_EXL10_XL10P_UM 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 143: Audio Files

    MAN1029-10-EN_EXL10_XL10P_UM 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. J u l y 6 , 2 0 2 2 P a g e 143 | 195...
  • Page 144 MAN1029-10-EN_EXL10_XL10P_UM 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 145: Chapter 16: Video Object

    MAN1029-10-EN_EXL10_XL10P_UM 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 146: Opening Video Object In Cscape

    MAN1029-10-EN_EXL10_XL10P_UM 16.2 Opening Video Object in Cscape NOTE: Video Object requires Firmware 14.03 or newer to use with the EXL10/XL10 PRIME devices. In Cscape, select the EXL10/XL10 PRIME and model number by selecting Controller → Hardware Configuration from the toolbar. Open the Graphics Editor by selecting the “T”...
  • Page 147 MAN1029-10-EN_EXL10_XL10P_UM Double click on the icon in the middle to open the Video Properties dialog. J u l y 6 , 2 0 2 2 P a g e 147 | 195...

  • Page 148: Video Properties: Video Type

    MAN1029-10-EN_EXL10_XL10P_UM 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 149: Video Properties: Control

    MAN1029-10-EN_EXL10_XL10P_UM 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 150: Configuring Display Properties

    MAN1029-10-EN_EXL10_XL10P_UM 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 151: Chapter 17: Removable Media

    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 EXL10/XL10 PRIME OCS memory card slot (larger sizes were not tested at time of publication).

  • Page 152: Using The Removable Media Manager

    Using Read and Write Removable Media function blocks, an application ladder program can read and write EXL10/XL10 PRIME 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 153: Using Removable Media To Load And Save Applications

    Export to Removable Media item on the Cscape File menu. 17.7 Using Removable Media to View and Capture Screens The EXL10/XL10 PRIME OCS File System uses bitmap files with the .BMP extension or JPEG files with the .JPG extension to store EXL10/XL10 PRIME OCS graphic screen captures.

  • Page 154: Configuration Of A Removable Media

    MAN1029-10-EN_EXL10_XL10P_UM 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 155: Removable Media (Rm) Features-Program Features

    MAN1029-10-EN_EXL10_XL10P_UM 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 156: Filenames Used With The Removable Media (Rm) Function Blocks

    MAN1029-10-EN_EXL10_XL10P_UM 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 157: System Registers Used With Rm

    MAN1029-10-EN_EXL10_XL10P_UM 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 158: Chapter 18: Clone Unit

    MAN1029-10-EN_EXL10_XL10P_UM 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 159 MAN1029-10-EN_EXL10_XL10P_UM 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 160 MAN1029-10-EN_EXL10_XL10P_UM 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 161: Load Clone

    MAN1029-10-EN_EXL10_XL10P_UM 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 162 MAN1029-10-EN_EXL10_XL10P_UM 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 163: Chapter 19: Fail - Safe System

    MAN1029-10-EN_EXL10_XL10P_UM CHAPTER 19: FAIL – SAFE SYSTEM 19.1 Overview For the EXL10 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: •...

  • Page 164: Settings

    MAN1029-10-EN_EXL10_XL10P_UM 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 165 MAN1029-10-EN_EXL10_XL10P_UM 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 166 MAN1029-10-EN_EXL10_XL10P_UM 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 167 MAN1029-10-EN_EXL10_XL10P_UM 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 168: Autoload

    MAN1029-10-EN_EXL10_XL10P_UM 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 169 MAN1029-10-EN_EXL10_XL10P_UM 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 170: Autorun

    MAN1029-10-EN_EXL10_XL10P_UM 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 171: Chapter 20: Modbus Communications

    MAN1029-10-EN_EXL10_XL10P_UM 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/XL10 PRIME can act as either a Master or a Slave.

  • Page 172: Modbus Master Overview

    MAN1029-10-EN_EXL10_XL10P_UM 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/XL10 PRIME 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 173: Modbus Addressing Table For Exl10/Xl10 Prime Units

    MAN1029-10-EN_EXL10_XL10P_UM 20.4 Modbus Addressing Table for EXL10/XL10 PRIME Units To access EXL10/XL10 PRIME 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 174: Chapter 21: Back-Up Battery

    MAN1029-10-EN_EXL10_XL10P_UM CHAPTER 21: BACK-UP BATTERY The following information pertains to the XL and RCC OCS units running 14.24 firmware and newer. This does NOT apply to the Prime Series. Please refer to the next chapter for information on the Prime Series backup battery.

  • Page 175: Ocs Battery Charging Cycle

    MAN1029-10-EN_EXL10_XL10P_UM 21.5 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.

  • Page 176: Battery Charging Status

    MAN1029-10-EN_EXL10_XL10P_UM 21.6 Battery Charging Status Viewed in the System Menu under “View Battery Status” or read as a numeric value in %SR196. The battery temperature, Tb, is equal to the CPU temperature minus 30°C: Tb = CPU° - 30°C. Table 21.1 – Charging State Table State - Name Description...

  • Page 177: Battery Status In System Registers

    MAN1029-10-EN_EXL10_XL10P_UM 21.7 Battery Status in System Registers NOTE: Registers NOT supported by the XL Prime controllers. Table 21.2 – Battery Status %SR55.13 ON if battery is missing or if voltage is below 2.5V %SR195 CPU temperature in °C %SR196 Charge State; Refer to Table 21.1 %SR197 Charging Current mA %SR198...

  • Page 178: Backup Battery Replacement

    NOTE: For the registers to be retentive the battery only needs to be charged and present at power down. The EXL10/XL10 PRIME 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 179 MAN1029-10-EN_EXL10_XL10P_UM Below are the steps to replace the lithium-ion battery, part no. BAT00019, 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 XL10 OCS unit including I/O power. Unplug I/O connections.
  • Page 180 MAN1029-10-EN_EXL10_XL10P_UM J u l y 6 , 2 0 2 2 P a g e 180 | 195...

  • Page 181: Chapter 22: Xl10 Prime Back Up Battery

    MAN1029-10-EN_EXL10_XL10P_UM CHAPTER 22: XL10 PRIME BACK UP BATTERY NOTE: For XL series controller battery information (not the Prime series) please refer to the chapter above. The XL10 Prime has an improved memory architecture that does not require a battery for program or register retention.
  • Page 182 MAN1029-10-EN_EXL10_XL10P_UM The XL10 Prime OCS uses a lithium coin-type battery with part no. BAT00013, with harness and connector available from Horner APG. Below are the steps to replace the battery: 1. Make sure the user program and any data stored in retentive memory is backed up.

  • Page 183: Chapter 23: Maintenance

    MAINTENANCE 23.1 Firmware Updates The EXL10/XL10 PRIME 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 184: 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 185: Steps For Firmware Update

    MAN1029-10-EN_EXL10_XL10P_UM 23.4 Steps for Firmware Update Update firmware in an EXL10/XL10 PRIME 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 186: Chapter 24: Troubleshooting / Technical Support

    CHAPTER 24: TROUBLESHOOTING / TECHNICAL SUPPORT 24.1 Connecting to the EXL10/XL10 PRIME 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 187 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 188: Local Controller And Local I/O

    MAN1029-10-EN_EXL10_XL10P_UM 24.2 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 189: Cscan Network

    1. Use the proper Belden wire type or equivalent for the network as specified in MAN0799. 2. The EXL10/XL10 PRIME OCS does not provide 24VDC to the network. An external voltage source must be used for other devices such as SmartStix I/O.

  • Page 190: Removable Media - Basic Troubleshooting

    MAN1029-10-EN_EXL10_XL10P_UM 24.4 Removable Media - Basic Troubleshooting Description Action EXL10/XL10 PRIME OCS does not The media card should be formatted with the EXL10/XL10 PRIME read media card. OCS. Make sure the project file is saved as a .pgm file and not a .csp EXL10/XL10 PRIME OCS will not file.

  • Page 191: Change Log

    #6987 – Added XL10 Prime Throughout Added Backup Battery for XL10 Prime XL10 Prime Battery #6429 – Revised Register Map 6.3 Register Map for EXL10/XL10 PRIME OCS J u l y 6 , 2 0 2 2 P a g e 191 | 195...

  • Page 192: Index

    MAN1029-10-EN_EXL10_XL10P_UM INDEX %Q bits, 78 Count, 97, 99 Accessories, 16 Csape Program accumulator, 86, 87, 89, 91 Via Serial Port, 109 Add Target Screenshot in Cscape, 63 Cscape, 15, 33, 34, 56, 59, 65, 67, 75, 78, 80, 81, Alpha-Numeric Keypad, 128 82, 83, 84, 107, 109, 111, 131, 152, 153, 186, Analog Input Configuration Screen, 82 187, 188...
  • Page 193 MAN1029-10-EN_EXL10_XL10P_UM Ethernet Module Protocols & Features, 112 Manual Index, 13 Ethernet Module Protocols and Features, 112 MECHANICAL INSTALLATION, 17 Ethernet Module Specifications, 112 microSD Cards, 151 Ethernet System Requirements, 112 Installing / Removing, 151 XL10 I/O Cover Removed (sample I/O board) microSD System, 151 Photograph, 76 Minimum Clearance Requirements for Panel Box...
  • Page 194 MAN1029-10-EN_EXL10_XL10P_UM Definitions, 48 System Menu Map, 28 I/O, 57 SYSTEM SETTINGS AND ADJUSTMENTS, 26 Resource Limits, 58 Sytem Menu Relay Outputs, 79 Overview, 26 Removable Media, 41 target ID, 66 Files Names, 156 Target ID, 65, 66 Function Blocks, 154 target indicator, 66, 67 Graphic/Screen Editor, 155 Target indicator, 65...
  • Page 195 MAN1029-10-EN_EXL10_XL10P_UM View Status, 30 Where to Find Information, 13 Visual Overview, 12 XL4 PRIME BACK UP BATTERY, 181 J u l y 6 , 2 0 2 2 P a g e 195 | 195...

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