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HORNER EXLW User Manual

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User Manual for
EXLW & XLW Prime
MAN1 256-20 .0 -EN_EXLW_XLWP_UM

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Summary of Contents for HORNER EXLW

  • Page 1 User Manual for EXLW & XLW Prime MAN1 256-20 .0 -EN_EXLW_XLWP_UM...
  • Page 2 Visual Map The datasheet is the first document to refer to for model-specific information related to EXLW/XLW Prime models for installation information. Find the documents via the Documentation Search page on the Horner website. Datasheet Manual Numbers EXLW Model 0...
  • Page 3 APG cannot assume responsibility or liability for actual use based on the examples and diagrams. It is the sole respons- ibility of the system designer utilizing the EXLW/XLW Prime OCS module to appropriately design the end system, to appropriately integrate the EXLW/XLW Prime OCS module and to make safety provisions for the end equipment as is usual and customary in industrial applications as defined in any codes or standards which apply.
  • Page 4 This manual explains how to use the EXLW/XLW Prime OCS. Copyright (C) 2020 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any lan- guage or computer language, in any form by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written permission of Horner APG, Inc.

  • Page 5: Table Of Contents

    Table of Cont ent s Safety and Compliance Intro to the EXLW & XLW Prime Visual Overview Where to find more information for the EXLW & XLW Prime Connectivity to the EXLW & XLW Prime Features of EXLW/XLW Prime OCS Mechanical Installation...
  • Page 6 Analog Inputs Analog Outputs High Speed I/O (HSC / PWM) Overview High Speed I/O Glossary High Speed Counter (HSC) Functions Frequency Totalize Pulse Width Measurement Period Measurement Quadrature HSC Functions Status Bits HSC Functions Register Maps High Speed Output Functions Stepper Function High Speed Output Functions Register Map HSC I/O Filtering...
  • Page 7 Modbus Addressing Table Firmware Updates Check for Current Firmware Revision Firmware Update Details Download Firmware Firmware Update Steps EXLW Rechargeable Battery Storing Register Contents Battery Life Lithium Battery Safety OCS Battery Charging Cycle Battery Charging Status Battery Status in System Registers Safety &...
  • Page 8 Connecting to the OCS Local Controller and Local I/O CsCAN Network USB Interfaces Basic Troubleshooting Technical Support Contacts Change Log...
  • Page 9 Safety and Compliance Page 9...

  • Page 10: Safety And Compliance

    Safety and Compliance Safety and Compliance Safety Warnings When found on the product, the following symbols specify: Warning: Consult user documentation. Warning: Electrical Shock Hazard. WARNING: EXPLOSION HAZARD – Substitution of components may impair suitability for Class I, Division 2. WARNING: EXPLOSION HAZARD –...
  • Page 11 Introduction to the EXLW & XLW Prime Page 11...

  • Page 12: Intro To The Exlw & Xlw Prime

    Intro to the EXLW & XLW Prime Intro to the EXLW & XLW Prime Visual Overview Where to find more information for the EXLW & XLW Prime Connectivity to the EXLW & XLW Prime Features of EXLW/XLW Prime OCS Visual Overview 1. Touchscreen 2.

  • Page 13: Where To Find More Information For The Exlw & Xlw Prime

    Intro to the EXLW & XLW Prime Where to find more information for the EXLW & XLW Prime Datasheets - The datasheets are the first documents to refer to for key information related to specific models. (A basic datasheet is provided in the box with the unit.)

  • Page 14: Features Of Exlw/Xlw Prime Ocs

    Intro to the EXLW & XLW Prime Features of EXLW/XLW Prime OCS The EXLW/XLW PRIME OCS are all-in-one industrial control devices. They combine control, user interface, I/O and networking into a single, integrated package. Unique features of the EXLW/XLW PRIME OCS include: Bright, 65,536 color graphical touch sensing LCD display in all models of EXLW/XLW PRIME.
  • Page 15 Mechanical Installation Page 15...

  • Page 16: Mechanical Installation

    3. Pass the unit through the panel. 4. Insert the each of the four (4) mounting clips into the slots in the EXLW & XLW Prime OCS case. One clip should be installed on each corner. Lightly tighten each screw so the clip is held in place.

  • Page 17: Mounting Orientation

    EXLW & XLW Prime OCS Mounting Clip EXLW & XLW Prime OCS Mounting Orientation NOTE: There are no orientation restrictions on the EXLW/XLW PRIME OCS. However, the above orientation provides for optimum readability of the screen and ease of use of the keypad.

  • Page 18: Dimensions

    Mechanical Installation Dimensions For installations requiring NEMA 4X liquid and dust protection, the panel cutout should be cut with a tolerance of +1mm/-0mm. Page 18 of 196...

  • Page 19: Installation Procedure

    1. Carefully locate an appropriate place to mount the EXLW/XLW PRIME. Be sure to leave enough room at the top of the unit for insertion and removal of the microSD™ card.

  • Page 20: Factors Affecting Panel Layout Design And Clearances

    Mechanical Installation Factors Affecting Panel Layout Design and Clearances WARNING: It is important to follow the requirements of the panel manufacture and to follow all applicable electrical codes and standards. The designer of a panel layout must assess the requirements of a particular system and to consider the following design factors.
  • Page 21 Mechanical Installation Panel Layout Design and Clearance Checklist The following list provides highlights of panel layout design factors: Meets the electrical code and applicable standards for proper grounding, etc.? Meets the panel manufacturer’s requirements for grounding, etc.? Is the panel box properly connected to earth ground? Is the panel door properly grounded? Has the appro- priate procedure been followed to properly ground the devices in the panel box and on the panel door? Are minimum clearance requirements met? Can the panel door be easily opened and closed? Is there adequate space between device bases as well as the sides of the panel and wiring ducts?
  • Page 22 Electrical Installation Page 22...

  • Page 23: Electrical Installation

    Ideally, a ground resistance measurement from equipment to earth ground is 0Ω. In reality it typically is higher. The US National Electrical Code (NEC) states the resistance to ground shall not exceed 25Ω. Horner Automation recom- mends less than 15Ω resistance from the equipment to ground. Resistance greater than 25Ω can cause undesir- able or harmful interference to the device.

  • Page 24: Primary Power Port

    Electrical Installation Primary Power Port NOTE: The Primary Power Range is 10VDC to 30VDC. Primary Power Port Pins Signal Description Ground Frame Ground Input Power Supply Ground Input Power Supply Voltage DC Input / Frame Solid/Stranded Wire: 12-24 awg (2.5-0.2mm) Strip length: 0.28”...
  • Page 25 System Settings and Adjustments Page 25...

  • Page 26: System Settings And Adjustments

    OCS LED Indicator Lights The EXLW/XLW Prime has a built-in System Menu, which lets the user view System Settings and makes adjust- ments. 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

    System Menu – Navigation and Editing As mentioned above, the System Menu is started by pressing the System key on the EXLW/XLW 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: System Menu Map

    System Settings and Adjustments System Menu Map Page 28 of 196...

  • Page 29: Set Networks

    System Settings and Adjustments Set Networks This sub menu allows setting for the CAN and Ethernet network to be viewed or changed. Yes = CAN1 connected to a CAN network and functioning properly No = Not ready to communicate on CAN network CAN ID 1 to 253 = This node’s CsCAN Network ID;...

  • Page 30: View Status & Diags

    View Status & Diags View Status The View Status Sub-Menu displays up to 19 System Settings. Only the Mode System Setting is editable. XW1yz = Model number of this EXLW/XLW PRIME OCS unit Model: 1yz = indicates the installed I/O module...
  • Page 31 System Settings and Adjustments View Diags The View Diags Sub-Menu displays up to 11 System Diagnostics, none of which are editable. The first two System Diagnostics are critical. If any of them indicate a Fault condition, the OCS will not enter or remain in Run mode, and the problem must be investigated and corrected.

  • Page 32: View Battery Status, I/O Slots & Protocols

    System Settings and Adjustments View Battery Status, I/O Slots & Protocols View Battery Status See also: "EXLW Rechargeable Battery" on page 183 The View Battery Status displays the following information. Waiting The charging system is waiting for voltages and temperatures to stabilize.
  • Page 33 System Settings and Adjustments View I/O Slots The View I/O Slots Sub-Menu displays three System Settings, all of which are not editable. Internal to the OCS, there is a CPU board, and up to two installed modules. Model 0 has no installed I/O or COM modules.
  • Page 34 System Settings and Adjustments View Protocols The View Protocols Sub-Menu displays three System Settings, none of which are editable. As mentioned in Downloadable Serial Communication Protocols section, both the MJ1 (Port 1) and MJ2 (Port 2) serial ports support downloadable protocols. To assign a downloadable protocol to an OCS serial port, select the Protocol Config item in Cscape’s Program menu and then setup a protocol for Port 1 or Port 2 (or both).

  • Page 35: Set Fkeys Mode, Serial Ports, Ethernet, Time/Date, Beeper & Screen

    System Settings and Adjustments Set Fkeys Mode, Serial Ports, Ethernet, Time/Date, Beeper & Screen Set Fkeys Mode The Set Fkeys Sub-Menu displays two System Settings, both of which are editable. Momentary = %K1-5 bits go On & Off as F1-F5 are pressed & released Fkeys Toggle = %K1-5 bits toggle each time F1-F4 are pressed Yes = Reset and all clear system functions enabled...
  • Page 36 System Settings and Adjustments Set Serial Ports The Set Serial Ports Sub-Menu displays three System Settings, all of which are editable, and one optional item. For the Dflt Pgm Port System setting, only MJ1-232 can be selected, unless a Modem (XMC) COM module is installed. MJ1-232 = MJ1 RS232 port is the default programming port Dflt Pgm Port Modem = Modem COM module is the default programming port...
  • Page 37 System Settings and Adjustments 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. Clock and Time Setting Terms Coordinated Universal Abbreviated to UTC, Coordinated Universal Time is the primary time standard by Time (UTC) which the world regulates clocks and time.
  • Page 38 System Settings and Adjustments To Set Time Zone: The Time Zone setting is an hourly offset from UTC time. If using the Time Zone setting, set it first, then set the local time. UTC time will be automatically set based on the time zone and local time settings. If using NTP: NTP utilizes UTC time, therefore when using NTP, the appropriate hourly offset from UTC time must entered into the time zone setting.
  • Page 39 System Settings and Adjustments Set Beeper The Set Beeper Sub-Menu displays one System Setting, which is editable. Yes (default) = Enables beeper Beeper Enable No = Disables beeper (does NOT affect ladder access) Page 39 of 196...
  • Page 40 System Settings and Adjustments Set Screen The Set Screen Sub-Menu displays four System Settings, all of which are editable. Yes = Enable screen saver Saver enable No (default) = Disable screen saver 5 - 1200 = Amount of time in minutes to expire with NO touch activity before activating screen Timeout (min) saver (black screen) Off (default) = Disable popup status...

  • Page 41: Removable Media

    System Settings and Adjustments Removable Media The Removable Media Sub-Menu displays the Removable Media Manager. After selecting Removable Media from the Main Menu, one of four Sub-Menu screens will appear: If a directory name is highlighted, pressing Enter will switch to that directory showing its files and sub-directories. In a sub-directory, highlighting ..

  • Page 42: Fail - Safe System

    System Settings and Adjustments 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, Elec- tromagnetic Interference, event.
  • Page 43 System Settings and Adjustments Enable AutoRun “Enable AutoRun” displays the following options which can be selected: No = OCS will be in IDLE mode after AutoLoad or Automatic Restore. Enable AutoRun Yes = OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore. Page 43 of 196...
  • Page 44 System Settings and Adjustments Enable AutoLoad “Enable AutoLoad” displays the following options which can be selected: No = Does not load AUTOLOAD.PGM automatically when application program is absent or cor- Enable rupted. Yes = Loads AUTOLOAD.PGM file automatically from RM when application program is absent or AutoLoad corrupted.

  • Page 45: Clone Unit

    System Settings and Adjustments 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 "Removable Media" on page 157for details on using RM.
  • Page 46 System Settings and Adjustments After confirmation, the OCS will create two new files in the root directory of the Removable Media Drive as shown below: AUTOLOAD.PGM Application file CLONE.DAT File having all unit settings and register values from battery-backed RAM Page 46 of 196...
  • Page 47 System Settings and Adjustments Load Clone Selecting “Clone Unit” menu will open the following menu screen. Select “Load Clone” (one of the virtual buttons beneath the screen). NOTE: For security enabled files, Load Clone asks for password validation before loading the application. Page 47 of 196...

  • Page 48: Webmi License Details

    License details page displays the information about the WebMI license. Please refer to MAN1036 for the WebMI Manual. Find the user manual via the Documentation Search page on the Horner website. The information can also be viewed from Cscape using the following %SR registers: %SR209.3 WebMI server status %SR209.4...

  • Page 49: Touch Screen Calibration

    System Settings and Adjustments Touch Screen Calibration The touch screen is calibrated at the factory and rarely needs modification. However, if actual touch locations do not appear to correspond with responding objects on the display, field adjustment is available. Ensure SYS_fn Enable is set to YES in System Menu.
  • Page 50 System Registers Page 50...

  • Page 51: System Register Tables

    System Register Tables System Register Tables Register Definitions %S Registers %SR Registers here are two types of System Registers that may be used during programming. %S registers indicate the status of several system operations. %SR egisters indicate the state of many system operations and can be used to control them in several cases.

  • Page 52: S Registers

    System Register Tables %S Registers %S registers indicate system status as follows: Name Predefined Notes I/O Name First Scan FST_SCN On for 1 scan only each time the program is first run Network OK NET_OK If on, the Network is OK 10ms pulse T_10MS Cycling pulse that is high for 5ms and low for 5ms...

  • Page 53: Sr Registers

    System Register Tables %SR Registers %SR registers are special word-length registers that display and/or control system operations in the controller. Not all controllers support all defined system registers. Click on the name of the register to see more information on that register.
  • Page 54 System Register Tables %SR6 Average Scan Rate ms ( / 10) Read Only Read Only %SR7 Minimum Scan Rate ms ( / 10) Read Only Read Only %SR8 Maximum Scan Rate ms ( / 10) Read Only Read Only %SR9 Current Touch Pressure TCH_PRESSURE 0 to 3000 Read Only Read Only...
  • Page 55 System Register Tables %SR43 Keypad Type Read Only Read Only %SR44 Real-Time-Clock Second RTC_SEC 0 to 59 Read Only Read Only %SR45 Real-Time-Clock Minute RTC_MIN 0 to 59 Read Only Read Only %SR46 Real-Time-Clock Hour RTC_HOUR 0 to 23 Read Only Read Only %SR47 Real-Time-Clock Date...
  • Page 56 System Register Tables %SR57 LCD Backlight Dimmer Register 0 to 255 Read Only Read Only 0-100 = 0% to 100% On 100-255 = 100% On %SR57.16 Temporarily disable Screen Saver Read/Write Read/Write %SR58 User LEDs USER_LEDS Read/Write Read/Write %SR59 Engine Build Number Read Only Read Only (Only last three numbers displayed)
  • Page 57 System Register Tables %SR164.10 LOAD_CLONE trigger bit – LOAD_CLONE Read/Write Read/Write Setting TRUE does a LOAD CLONE (if a media card is present that con- tains clone files) %SR164.11 Make Clone Fail MK_CLN_FL Read/Write Read/Write (This bit goes high when Make/Create Clone fails) %SR164.12 Load Clone Fail...
  • Page 58 System Register Tables EXTENDED SYSTEM REGISTERS %SR193 Online Change ONLINE_CHG %SR193.1 TRUE if 2 programs in target FLASH Read Only Read Only %SR193.2 TRUE to switch programs, FALSE when Read Only Read Only complete %SR193.3 TRUE if executing program is temporary Read Only Read Only test...
  • Page 59 System Register Tables Daylight Saving: NO = 0 (If daylight saving is enabled, one hour will be added to the local time). %SR212 UTC - Seconds Read Only Read Only %SR213 UTC - Minutes Read Only Read Only %SR214 UTC - Hours Read Only Read Only %SR215...
  • Page 60 Cscape Configuration Page 60...

  • Page 61: Cscape Configuration

    Cscape Status Bar When the EXLW/XLW 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 EXLW/XLW Prime OCS and the Cscape program.

  • Page 62: Establishing Communications

    The PC will detect a new device has been plugged into the USB port. Now that the EXLW/XLW Prime is plugged in, go to Cscape > Controller > Connection Wizard. If you are just opening Cscape, Connection Wizard usually opens by default.
  • Page 63 Cscape Configuration If the Connection Wizard does not pop up upon opening Cscape, then select Controller (in the Cscape tool bar) > Connection Wizard, choose your connection method. If you are connecting for the first time, we suggest con- necting via USB. If Controller USB COM Port is not present in the dropdown list, the Windows operating system has not yet recog- nized the OCS as an installed device.
  • Page 64 Cscape Configuration Page 64 of 196...
  • Page 65 User can select modem and telephone number for target controller. NOTE: Cscape will do necessary initialization for the selected internal modem. Select this option to communicate over USB. Now Horner devices and Horner USB to serial converters are recognized and can be specifically selected.
  • Page 66 Units without CsCAN network ports respond to any network ID and do not require the ID to be configured. To check or change the ID on the EXLW/XLW Prime OCS, press the System Menu key. The first item in the menu is Set Networks. Pressing Enter allows you to view or modify the ID of the unit.

  • Page 67: Communicating Via Mj1 Serial Port

    Connect the PC’s serial port or the USB-to-Serial adaptor to the port labeled MJ1 on the EXLW/XLW Prime. The instructions are similar to using a USB port, as shown above. In the Connection Wizard, select the “Serial” option.

  • Page 68: Communicating Via On Board Ethernet Port

    Cscape Configuration Communicating via On Board Ethernet Port From Cscape go to Controller > Hardware Configuration and do auto configuration for the connected controller, Click on Config of Ethernet and select Module Setup. The IP address, Net Mask, and Gateway of the controller may be temporarily set from the System Menu under the Set Networks menu item.
  • Page 69 Cscape Configuration In Module configuration dialog, go to IP Address field enter unused IP Address and configure unused registers in Register field & then click OK. Screen shot for the same as follows: Download the configuration in to Controller. Connect LAN cable to the Controller in default LAN Port. From Cscape go to Tools >...

  • Page 70: Cscape Configuration

    Base model, I/O, and any communication options. 3. If the EXLW/XLW 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 71 General I/O Configuration Page 71...

  • Page 72: General I/O Configuration

    Built-in Digital and Analog I/O Overview The Horner OCS is a compact unit that contains high density and very versatile I/O. Using the I/O properly requires wiring to the proper terminals, configuring jumpers inside the Horner OCS unit and configuring Cscape properly.

  • Page 73: Removing The Horner Ocs Back Cover

    To remove the back cover of the Horner OCS, remove the four (4) Phillips screws from the back of the unit. It may help to place the Horner OCS unit face down on a clean work surface. Once the four screws are removed the back cover can be lifted straight off.

  • Page 74: Digital / Hsc Input Configuration

    General I/O Configuration Digital / HSC Input Configuration Horner controllers vary greatly on series and model numbers. Refer to the datasheets on the Document Search table on the Horner website. The inputs are designed to support both positive and negative input modes. For many models, the mode is set by a jumper setting and a configuration parameter in Cscape.
  • Page 75 General I/O Configuration Digital Input Configuration Home > Hardware Configuration [select Device Type/Model#] > Local I/O Tab > I/O / Config Button > Mod- ule Setup > Digital In/HSC Select Hardware Configuration from the Home menu and ensure that the correct Device Type and Model# are selec- ted.
  • Page 76 General I/O Configuration The Module Setup allows a user to configure four types of I/O. NOTE: Not all controllers offer all four types. Refer to the controller's datasheet on the using Horner's Documentation Search page. Page 76 of 196...
  • Page 77 The High-Speed Counters group box contains all the windows that are used to configure the four available high- speed counters on the Horner OCS. To configure a counter, the user needs to set the type, mode, and counts per rev.

  • Page 78: Digital / Pwm Output Configuration

    General I/O Configuration Digital / PWM Output Configuration Solid State Digital Outputs Solid-state digital outputs are generally used to activate lamps, low voltage solenoids, relays, and other low voltage and low current devices. NOTE: The digital outputs used on some controllers are sourcing outputs. This means the output applies a positive voltage to the output pin when turned ON.

  • Page 79: Relay Outputs

    Some protective measures need to be determined by an engineer. Below you will find recommendations that will work for many applications. If you have additional questions on protection from inductive load, consult an application engineer or Horner Technical Support. Details on devices that may protect outputs can be found in the Spark Quencher Datasheet, MAN0962, which is located on the website.

  • Page 80: Digital Output Configuration

    General I/O Configuration Digital Output Configuration Home > Hardware Configuration [select Device Type/Model#] > Local I/O Tab > I/O / Config Button > Mod- ule Setup > Digital Out/PWM Select Hardware Configuration from the Home menu and ensure that the correct Device Type and Model# are selec- ted.
  • Page 81 General I/O Configuration The Module Setup allows a user to configure four types of I/O. NOTE: Not all controllers offer all four types. Refer to the controller's datasheet the using Horner's Documentation Search page. Select Digital Out/PWM to open the Digital / PWM Output Configuration dialogue.
  • Page 82 General I/O Configuration The Q1 and Q2 group boxes allow the user to specify the operation of the multifunction outputs. PWM State On Controller Stop - Contains items that allow the user to specify how the PWM outputs behave when the controller is stopped.

  • Page 83: Analog Inputs

    General I/O Configuration Analog Inputs The analog inputs on the OCS allow voltage or current measurement from a variety of devices. The voltage or cur- rent mode is set though jumpers on the unit and settings in Cscape. Each channel can be separately configured for voltage or current mode.
  • Page 84 General I/O Configuration The Module Configuration screen will appear, select the Module Setup tab. See below. Page 84 of 196...
  • Page 85 General I/O Configuration The Module Setup allows a user to configure four types of I/O. NOTE: Not all controllers offer all four types. Refer to the controller's datasheet on the Horner website's Documentation Page for more information regarding specific models.
  • Page 86 General I/O Configuration Universal Analog Inputs Model 5 The universal analog inputs provide a high resolution, very flexible interface for a variety of analog inputs. These inputs include voltage, current, theremocouple, RTD, and millivolt. Each channel can be configured separately using jumpers and configuration settings in Cscape.
  • Page 87 General I/O Configuration Model 5 Universal Analog Input Configuration 1. Select Analog In to access the Analog Input Configuration menu. 2. Select any of the Analog input types from the drop-downs by clicking the down arrow beneath each cor- responding Channel, as seen below: 3.
  • Page 88 General I/O Configuration Table for Model 5 Universal Wiring J3 Connector for Universal Wiring TC (1+) or RTD (1+) or 100mV (1+) TC (1-) or RTD (1-) or 100mV (1-) TC (2+) or RTD (2+) or 100mV (2+) TC (2-) or RTD (2-) or 100mV (2-) 10V or 20mA OUT (1) 10V or 20mA OUT (2) Common...
  • Page 89 Universal Analog Inputs Model 6 The Universal Analog Inputs on the Model 6 IO board are unique from other Horner XL-series input/output cards in that they are configurable through the module configuration instead of having to change jumper settings in order to setup the input type.
  • Page 90 General I/O Configuration 3. Ensure the proper wiring is used for each of the 3 pins A , B, and C on the Universal Analog Inputs as seen in the reference image below: Scaling Analog Inputs & Examples To access the Advanced Math Scaling function, select Home > View > Project Toolbox. This will open a side bar, and then select Advanced Math >...
  • Page 91 General I/O Configuration Example 1 The Cscape Scale function, found in the Advanced Math functions, allows for very easy conversion of the raw input value into a meaningful reading. For example, a pressure transducer may be specified as a 4-20mA signal to signify a 0-2000 psi pressure reading.

  • Page 92: Analog Outputs

    Analog Outputs NOTE: Refer to the datasheet for details on jumper settings. The analog outputs on Horner OCS devices provide high resolution voltage or current outputs. The voltage or cur- rent selection is controlled with jumpers and configuration settings in Cscape.
  • Page 93 High Speed I/O (HSC & PWM) Page 93...

  • Page 94: High Speed I/O (Hsc / Pwm)

    OCS to be programmed to have either two high-speed counters or four high-speed counters. The OCS ships with two high-speed counters, but a customer can contact Horner Technical Support to receive a file that will configure the unit to have four. These modes are not supported simultaneously. Two counter mode supports Quad- rature mode and two stepper outputs, while four counter mode does not support Quadrature mode and supports only one stepper output.

  • Page 95: High Speed I/O Glossary

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

  • Page 96: High Speed Counter (Hsc) Functions

    High Speed I/O (HSC / PWM) High Speed Counter (HSC) Functions The supports two high speed, configurable counters. There are four dedicated inputs that can be configured to a number of different options. Each of the two counters can run in one of five modes. Those modes are Totalizer, Fre- quency Counter, Pulse Width Measurement, Period Measurement and Quadrature measurement.
  • Page 97 High Speed I/O (HSC / PWM) Three different options are available to reset the current count: a. Configured reset value - When configuring the Totalize function, a value may be specified under the Counts per Rev column. When the totalizer accumulator reaches this value - 1, the accumulator will reset to zero on the next count.

  • Page 98: Pulse Width Measurement

    High Speed I/O (HSC / PWM) Pulse Width Measurement In pulse width measurement mode, the high-speed input can measure the width of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode the Disable and Latch special functions are allowed.

  • Page 99: Period Measurement

    High Speed I/O (HSC / PWM) Period Measurement In period measurement mode, the high-speed input can measure the period of a pulse stream in one of two modes and provides a continuous indication of the last sampled value. In this mode, the Disable and Latch special func- tions are allowed.

  • Page 100: Quadrature

    High Speed I/O (HSC / PWM) Quadrature Quadrature mode uses two HSC inputs, any of the four HSC inputs can be assigned for this purpose. Quadrature mode works much like the totalizer except the accumulator will automatically increment or decrement based on the rotation phase of the two inputs.

  • Page 101: Hsc Functions

    High Speed I/O (HSC / PWM) Register Match Totalizer & Quadrature counter modes support a register match function. When the accumulator value matches either the Match 1 or Match 2 value configured in the corresponding %AQ registers, a high-speed output can Turn On, Turn Off, or Toggle.

  • Page 102: Status Bits

    High Speed I/O (HSC / PWM) Status Bits There are three status bits (%I registers for each high-speed counter): Overflow Flag: This status bit turns high when the Accumulator “overflows”, it moves from 4,294,967,295 (- 1 if Signed) to 0, this bit can be reset with the “Output Reset Bit”. See Table 9.4. Underflow Flag: This status bit turns high when the Accumulator “underflows”, it moves from 0 to 4,294,967,295 (-1 if Signed), this bit can also be reset with the “Output Reset Bit”.

  • Page 103: Hsc Functions Register Maps

    High Speed I/O (HSC / PWM) HSC Functions Register Maps The register assignments for the high-speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below. HSC Functions Register Map for 2 HSC Configuration Register Frequency...
  • Page 104 High Speed I/O (HSC / PWM) %I1601 Overflow Flag – Counter 1 %I1602 Underflow Flag – Counter 1 %I1603 High Speed Out 1 %I1604 Reserved %I1605 Overflow Flag – Counter 2 %I1606 Underflow Flag – Counter 2 %I1607 High Speed Out 2 %I1608 Reserved Page 104 of 196...
  • Page 105 High Speed I/O (HSC / PWM) HSC Functions Register Map for 4 HSC Configuration NOTE: Four Count Mode requires FPGA update. See "Overview" on page 94. Register Frequency Pulse Totalize %AI401-402 Accumulator - Counter 1 %AI403-404 Latch Value – Counter 1 %AI405-406 Accumulator –...
  • Page 106 High Speed I/O (HSC / PWM) %Q1633 Latch – Counter 3 %Q1634 Preload – Counter 3 %Q1635 Clear – Counter 3 %Q1636 Disable – Counter 3 %Q1637 Direction – C3 %Q1638 Output Reset – Counter 3 %Q1639 Preload Disable – Counter 3 %Q1640 Latch Disable –...

  • Page 107: High Speed Output Functions

    High Speed I/O (HSC / PWM) High Speed Output Functions On units that support high-speed output functions, two dedicated outputs are available that can be configured for one of four modes of operation. Those modes are Normal, PWM, HSC Match and Stepper. Normal When either Q1 or Q2 is configured for Normal operation, the digital output registers %Q1 and %Q2 drives that respective output.
  • Page 108 High Speed I/O (HSC / PWM) PWM Output Waveform PWM Output Waveform Table Rise Time 150ns Max Fall Time 150ns Max PWM Period Frequency = 1/Period High Speed Counter Match When either Q1 or Q2 is configured for HSC Output operation, their output state is based on a comparison between the counter accumulator and match registers.

  • Page 109: Stepper Function

    High Speed I/O (HSC / PWM) Stepper Function The OCS supports two stepper functions, one on each high-speed output when in two counter mode. In four counter mode, the OCS supports one stepper function The Stepper requires five parameters (%AQs) to be set for operation. These parameters may be set at run-time but are ‘latched’...

  • Page 110: High Speed Output Functions Register Map

    High Speed I/O (HSC / PWM) High Speed Output Functions Register Map The register assignments for the high speed I/O can be moved via a setting in Cscape. The values shown are the DEFAULT values and may not match the same starting point as the values shown below. PWM Functions Register Map, Two Counter Register Stepper...
  • Page 111 High Speed I/O (HSC / PWM) PWM Examples Example 1 Duty Cycle Frequency To get a 50% Duty Cycle @ 10kHz waveform Set %AQ421-422 = 16,000 Set %AQ423-424 = 10,000 on PWM1: Example 2 Duty Cycle Frequency Set %AQ421-422 = 16,000 To get a 50% Duty Cycle on PW1 and Set %AQ423-424 = 1,000 90 % Duty Cycle...
  • Page 112 High Speed I/O (HSC / PWM) STP Examples Start Example 1 Accel Count Run Count Decel Count Frequency Frequency Set %AQ423-4 = Set %AQ425-6 = Set %AQ427-8 = 10,000,000 steps Set %AQ421 = Set %AQ422 = 1,000,000 8,000,000 1,0000,000 control sequence 2500 (Hz) 5000 (Hz) (Steps)

  • Page 113: Hsc I/O Filtering

    High Speed I/O (HSC / PWM) HSC I/O Filtering This feature is used to enable digital Filter for HSC Inputs. Selecting Digital In/HSC configuration opens up the following dialog where in HSC I/O Filtering is available. Input signal is filtered based on the filter frequency and Number of samples selected. User has to select Filter Fre- quency and Number of samples based on the frequency of the Input signal.
  • Page 114 High Speed I/O (HSC / PWM) If user selects filter frequency as 1MHz and Number of samples as 4, then Input signal is sampled for 4 samples and if the signal is stable for 4 samples i.e. 4μs then the signal is passed to Accumulator. If the Input state is changed in between the sampling counts, then the count is reset, and the Input state is again checked for given number of samples.
  • Page 115 Serial Communications Page 115...

  • Page 116: Serial Communications

    Configuration via Mini-B USB All EXLW/XLW PRIME OCS models provide two independent serial ports, on the first 8-pin modular RJ45 con- nector, 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 117: Dip Switches

    Serial Communications Dip Switches The DIP switches are used to provide a built-in termination to both the MJ1, MJ2 & MJ3 ports if needed. The ter- mination for these ports should only be used if this deviced is located at either end of the multidrop/daisy-chained RS-485 network.

  • Page 118: Cscape Programming Via Serial Port

    It is possible to download or upload and use the data monitoring functions once connected. NOTE: It is advisable to use an isolated USB cable between the PC or laptop and the EXLW/XLW PRIME when third party devices are connected to the EXLW/XLW PRIME to avoid damage to the PC or laptop and/or the EXLW/XLW PRIME.
  • Page 119 Communications Page 119...

  • Page 120: Can Communications

    Cscape Programming via CAN Ladder-Controlled CAN Communication Using CAN for I/O Expansion (Network I/O) NOTE: For additional CAN information, refer to the CAN Networks manual, MAN0799 (MAN0799) using Horner's Documentation Search page. OCS models provide A CAN network port, which is implemented with 5-pin connectors. The CAN port allows the OCS to exchange global data with other OCS controllers and to access remote Network I/O devices (SmartStix, Smart Blocks and Smart Rail Modules).

  • Page 121: Cscape Programming Via Can

    CAN Communications Cscape Programming via CAN The CAN port supports CsCAN Programming Protocol. If a PC has a CAN interface installed (via PCI card or USB), and the PC CAN port is connected to the OCS CAN port, Cscape can access the OCS for programming and mon- itoring.
  • Page 122 Ethernet Communication Page 122...

  • Page 123: Ethernet Communications

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

  • Page 124: Ethernet Module Specifications

    Ethernet Communications Ethernet Module Specifications Speeds 10 BaseT Ethernet (10Mbps) 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) Ethernet Module Configuration NOTE: The following configuration is required for all applications regardless of the protocols used.
  • Page 125 Ethernet Communications 3. Click the Config button to the right of the LAN1 for LAN 1 or LAN2 for LAN 2, revealing the Ethernet Module Configuration dialog. 4. Configure the Ethernet Module parameters as follows: IP Address: Enter the static IP Address for the Ethernet Module being configured. NOTE: IP Addresses are entered as four numbers, each ranging from 0 to 255.
  • Page 126 Ethernet Communications Ethernet Status Word Register Format High Byte Low Byte Bit 16 Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Link TCP Connections...

  • Page 127: Ethernet Configuration - Ip Parameters

    Ethernet Communications Ethernet Configuration – IP Parameters For primary operation, the IP address, Net Mask, and Gateway should be set in the LAN config of the Cscape Hard- ware Configuration. There are options to get IP parameters from the LAN Config or to get parameters from registers.
  • Page 128 Downloadable Protocols Page 128...

  • Page 129: Protocol Configuration

    Protocol Configuration Protocol Configuration Overview Protocol Device Driver Selection Network Configuration Device List and Device Configuration Scan List Overview Through loadable protocol device drivers, certain models of the OCS family can provide the ability to exchange data with remote devices such as variable-frequency drives, PLCs and remote I/O devices. This feature greatly expands the OCS ’s control capability with negligible effect on the OCS ’s ladder scan time.

  • Page 130: Protocol Device Driver Selection

    Protocol Configuration These basic types are also subdivided into read or write operations. For polled operations, a Read operation only reads from a remote device. 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 131: Network Configuration

    Protocol Configuration Network Configuration Network Configuration provides the required parameters to configure the network. Each protocol is different and may not require the entire Network Config field. Please refer to the table below for the options in the Network Config field.
  • Page 132 Protocol Configuration Network Protocols Baud Rate, Data Bits, These field define the bit level transfer over the serial port. Stop Bits, Parity None – No handshake lines are used Multidrop Full – Rx remains active while Tx is occurring. Handshake Multidrop Half –...

  • Page 133: Device List And Device Configuration

    Protocol Configuration Device List and Device Configuration Device List This configuration list is reached from the Device button on the Protocol Config screen and provides a list of the con- figured devices on the Network. Devices must be created and exist in this list before corresponding Scan List entries can be created for this device.
  • Page 134 Protocol Configuration Device Configuration This configuration is reached from the device list when adding or modifying an existing device. While each protocol is somewhat different and can contain protocol specific field, all protocols typically support at least: Device Name - Specifies a tag name for this device. This tag name is used in the Data Mapping con- figuration to identify this device.

  • Page 135: Scan List

    Protocol Configuration Scan List This configuration list is reached 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 136 Protocol Configuration Menu Edit > Copy All - Copies Scan List to clipboard in a tab delimited format suitable for pasting into an applic- ation like Microsoft Excel. Edit > Paste - Loads Scan List from clipboard. Pasted items are added to the scan list even if they are duplic- ates.
  • Page 137 Protocol Configuration Data Mapping Configuration (Scan List Entry) Target Device Name - Selects the target device (by tag name) to use for this transaction. Only those device entries previously created from the Device Config menu are available. Device Register - Specifies the target device’s register to use for this transaction. This designation is target- specific.
  • Page 138 Protocol Configuration types, only the local register(s) that change in value are written. More specifically, only one write trans- action occurs per scan per mapping entry for the register or consecutive sub-group of local registers that changed in value. Depending on the protocol, the number of points written with that write trans- action are limited either to one or the number of consecutive points that changed value.
  • Page 139 User Interface Page 139...

  • Page 140: User Interface

    Touch Screen Pressure This chapter presents the user interface (or operator view) of the EXLW/XLW Prime and some of the model specific characteristics of the EXLW/XLW Prime as compared to the rest of the OCS line. This chapter does NOT cover building screens or using the CSCAPE graphics editor.

  • Page 141: Displaying And Entering Data

    Multiple objects are provided for displaying data such as virtual panel lights, push buttons, numeric value displays, bar graphs, meters, graphs and animated bitmaps. On the EXLW/XLW Prime , these graphical objects (through lad- der manipulation of attribute bits) can change color, flash, or change visibility to attract operator attention.

  • Page 142: Alpha-Numeric Keypad

    User Interface Alpha-Numeric Keypad To allow entry of a specific number or text, several of the input objects invoke a pop-up alpha-numeric keypad when the object is touched. An example of the alpha-numeric keypad invoked from a numeric input object is shown below.

  • Page 143: Screen Navigation

    User Interface Since the alpha-numeric keypad services several different graphical objects, certain keys on the alpha-numeric keypad may be disabled (grayed) when the keypad is invoked for certain objects. The following describes the alpha-numeric keypad variation based on object. Alpha-Numeric Keypad Variations Numeric When editing a numeric value, the [+/-] or the [.] key are disabled (grayed) if the object is NOT con- Object...

  • Page 144: Ladder-Based Screen Navigation

    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 EXLW/XLW Prime assumes touch been released (equates to approximately a quarter inch of movement with a stylus).

  • Page 145: Alarms

    User Interface Alarms Alarm presentation to the operator is highly configurable and beyond the scope of this document to describe fully. For more information, refer to the Graphics Editor help file in Cscape. This section presents a typical configuration thereby providing an introductory description on what the operator should expect. The alarm object is generally used to enunciate alarms to the operator.

  • Page 146: Removable Media

    User Interface Removable Media The Removable Media Object is generally used to inform the operator on the current state of the removable media device and allow access to its file structure. The Removable Media Object is displayed as a button that changes col- ors to indicate the current state of the removable media device.

  • Page 147: Screen Saver

    Screen Saver The EXLW/XLW Prime screen backlight life is typically five (5) years when in continuous use. If the application does not require interaction with the EXLW/XLW Prime for long periods of time, the backlight life can be extended by using the screen saver function.

  • Page 148: Touch Screen Pressure

    With a unique change to the touch monitoring firmware user can measure the pressure being exerted on the touch screen. This feature has been added in some Horner XL series controllers. This allows the OCS programmer to be notified of the touch pressure and it can configure the pressure required to accept a touch event.
  • Page 149 Video Object Page 149...

  • Page 150: Video Object

    Video Object Video Object Video Object Overview Opening Video Object in Cscape Video Properties Configuration Video Object Performance Web Cameras Video Object Overview The Video Object feature allows two options for video type: Stream and Playback. 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 vari- ous resolutions and frames per second.

  • Page 151: Opening Video Object In Cscape

    Video Object Opening Video Object in Cscape NOTE: For Cscape 10 please refer to the Help File. In Cscape, select the XL4/XL4 Prime and model number by selecting Controller > Hardware Configuration from the toolbar. 1. Open the Graphics Editor by selecting the “T” button from the toolbar. 2.
  • Page 152 Video Object 4. Then double click on the icon in the middle to open the Video Properties dialog. Page 152 of 196...

  • Page 153: Video Properties Configuration

    Video Object Video Properties Configuration Video Type There are two options for video type: Stream and Playback. Stream – This option can be selected to view live video from a web cam. Four channels are supported through the USB hub. Only one channel can be viewed at a time. Enter Channel Number directly or through registers in the Enter Channel No field.
  • Page 154 Video Object Control Trigger - The video control trigger is used to start, stop and pause video. Video trigger is done by bit level address- ing. The trigger reserves eight (8) bits and uses the first two (2) bits. NOTE: The least significant bit is Bit 1. High = Start Bit 1 Low = Stop...

  • Page 155: Video Object Performance

    Video Object Configuring Display Properties Resolution Options 320x240 (QVGA) Frames per Seconds 10, 15, 20, 24, 30 & MAX_FPS Video Object Performance 1. When Video Object is active, navigating to System Menu or any popup window, causes Video Object to be inactive.
  • Page 156 Removable Media Page 156...

  • Page 157: 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 Horner OCS Prime OCS Memory Card slot. The Memory Card slot is equipped with a “push-in, push-out” connector and a microSD card can be safely inserted into the Memory Card slot whether the Horner OCS Prime OCS power is On or Off.

  • Page 158: Using The Removable Media Manager

    The microSD Memory Card slot uses the PC-compatible FAT32 File System. This means that a PC, with a microSD-compatible card reader, can read files that have been written by the Horner OCS Prime OCS and can write files that can be read by the Horner OCS Prime OCS.

  • Page 159: View And Capture Screens

    Removable Media View and Capture Screens The Horner OCS Prime OCS File System uses bitmap files with the .BMP extension or JPEG files with the .JPG extension to store Horner OCS Prime OCS graphic screen captures. To view a captured Horner OCS Prime OCS screen, use the Removable Media Manager to find and highlight the desired .BMP or .JPG file, and then press Enter.

  • Page 160: Function Blocks In Cscape

    Removable Media Function Blocks in Cscape NOTE: For detailed information regarding RM function blocks and parameters, refer to the Help File in Cscape Soft- ware. Refer to ‘USB flash Media support for RM Functions’ for USB flash drive access details. The following RM functional blocks are available in Cscape Software.

  • Page 161: Filenames

    Removable Media Filenames The RM function blocks support the flash with a Windows standard FAT-16 file system. All names must be limited to the “8.3” format where the filename contains eight characters a period then a three-character extension. The entire filename including any path must be less than or equal to 147 characters. When creating filenames and directories, it is sometimes desirable to include parts of the current date or time.
  • Page 162 Clone Unit Page 162...

  • Page 163: Clone Unit

    Clone Unit Clone Unit Make Clone Load Clone ‘Clone Unit’ feature allows the user to “clone” the OCS of the exact same model. This feature “clones” application program and unit settings stored in battery-backed RAM of an OCS into the RM. Refer to the for details in using RM. It can then be used to clone a different OCS (exact same model).
  • Page 164 Clone Unit Step 2: Selecting “Make Clone” will open the following menu screen. NOTE: Free/Total – displays number of free and total bytes in Removable Media. Make/Create Clone option enables user to duplicate / Clone application file, all unit settings and all register values from battery-backed RAM.

  • Page 165: Load Clone

    Clone Unit Load Clone This option loads the application, all unit settings and register values from Removable media to the battery-backed RAM (Regardless of AutoLoad settings) and then resets the OCS for the settings to take effect. User needs to perform the following to Load Clone: Step 1: Select “Clone Unit”...
  • Page 166 Fail-Safe System Page 166...

  • Page 167: Fail-Safe System

    Fail-Safe System Fail-Safe System Fail-Safe System Settings Backup / Restore Data AutoLoad AutoRun For the XL Series The Fail-Safe System is a set of features that allow an application to continue running in the event of certain types of "soft" failures. These "soft" failures include: Battery power loss Battery-Backed Register RAM or Application flash corruption due to, for example, an excessive EMI, Elec- tromagnetic Interference, event.

  • Page 168: Settings

    Fail-Safe System Settings To use the Fail-Safe feature,the following steps are required: 1. From Cscape, create AUTOLOAD.PGM for the application program using ‘Export to Removable Media’. 2. Place the Removable Media with AUTOLOAD.PGM in the device. 3. Set the ‘Enable AutoLoad’ option in the device to YES. 4.
  • Page 169 Fail-Safe System Restore OCS Data When initiated, this will allow the user to manually copy the backed-up data from the onboard flash to the battery- backed RAM. A restore operation will be automatically initiated if 1) a backup has been previously created and 2) on power-up the battery-backed RAM registers fail their check.
  • Page 170 Fail-Safe System The OCS follows the following sequence in execution of Automatic Restore: AutoLoad Page 170 of 196...

  • Page 171: Autoload

    Fail-Safe System AutoLoad This System Menu option allows the user to specify whether the OCS automatically loads the application AUTOLOAD.PGM located in Removable Media. When the AutoLoad setting is enabled (set to YES), it can either be manually initiated or automatically initiated at power-up.
  • Page 172 Fail-Safe System The OCS follows the following sequence in execution of AutoLoad: Page 172 of 196...

  • Page 173: Autorun

    Fail-Safe System AutoRun This System Menu option, when enabled (YES), allows the user to automatically place the OCS into RUN mode after the AutoLoad operation or automatic Restore Data operation. When the AutoRun setting is disabled (NO), the OCS remains in the IDLE mode after a Restore Data or AutoLoad operation.
  • Page 174 Modbus Communications Page 174...

  • Page 175: Modbus Communications

    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 EXLW/XLW Prime can act as either a Master or a Slave.

  • Page 176: 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 EXLW/XLW Prime to allow the user to specify the data to be read/written from/to the slaves.

  • Page 177: Modbus Addressing Table

    Modbus Communications Modbus Addressing Table To access EXLW/XLW 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 178 Firmware Update Page 178...

  • Page 179: Firmware Updates

    Download Firmware Firmware Update Steps The EXLW/XLW Prime OCS products contain field updatable firmware to allow new features to be added to the product. Firmware updates should only be performed when a new feature or correction is required. WARNING: Firmware updates should only be performed when the equipment being controlled by the OCS is in a safe, non-operational state.

  • Page 180: Firmware Update Details

    2. Save Firmware files to microSD card or USB, these are the removable media devices. 3. Update the firmware through the controller’s Firmware Update function NOTE: Files from the Horner website come as a .ZIP file which need to be unzipped and placed in the root of the drive for them to function properly.

  • Page 181: Firmware Update Steps

    For more Firmware Update information refer to the Firmware Update Manual, MAN1011, which can be found on the Horner website. NOTE: User must register and be logged into website in order to download this manual. Page 181 of 196...
  • Page 182 Rechargeable Battery for XL Series Page 182...

  • Page 183: Exlw Rechargeable Battery

    Steps to Replace the Rechargeable Battery The EXLW has an advanced battery system that uses a rechargeable lithium-ion battery. The battery powers the real time clock when power is removed, and it is needed for register data retention. Does not include the XLW Prime.

  • Page 184: Ocs Battery Charging Cycle

    EXLW Rechargeable Battery OCS Battery Charging Cycle There are various charging states that are executed based on battery temperature, level of battery charge, and self- test results. The battery temperature can be determined by checking the CPU temperature in the controller System Menu >View Battery Status or by monitoring System Register %SR195.

  • Page 185: Battery Charging Status

    EXLW Rechargeable Battery Battery Charging Status Viewed in the System Menu > View Battery Status or read as a numeric value in %SR196. The battery tem- perature, Tb, is equal to the CPU temperature minus 30°C: Tb = CPU° - 30°C.

  • Page 186: Battery Status In System Registers

    Safety & the Rechargeable Backup Battery The EXLW has an advanced battery system that uses a rechargeable lithium-ion battery. The battery powers the real time clock when power is removed. To store registers, the battery continues to power the OCS for less than a second after external power is removed.

  • Page 187: Steps To Replace The Rechargeable Battery

    EXLW Rechargeable Battery Steps to Replace the Rechargeable Battery Below are the steps to replace the lithium-ion battery, part no. BAT0019, available from Horner APG. 1. Make sure the user program and any data stored in retentive memory is backed up.
  • Page 188 Prime Series Backup Battery Page 188...

  • Page 189: Prime Ocs Prime Battery

    Prime OCS Prime Battery Prime OCS Prime Battery Prime OCS Battery & Safety Replacing the Prime OCS Battery Prime OCS Battery & Safety NOTE: This does not include the XL Series, only the Prime Series. The Prime OCS has an improved memory architecture that does not require a battery for program or register reten- tion.

  • Page 190: Replacing The Prime Ocs Battery

    The Prime OCS uses a lithium coin-type battery with part no. HE-BAT013, with harness and connector available from Horner APG. WARNING: Replacing the battery is a delicate procedure. If unsure about the procedure, please contact Horner Tech Support via Horner Contact Us Below are the steps to replace the battery: 1.
  • Page 191 Troubleshooting & Tech Support Page 191...

  • Page 192: Troubleshooting

    4. Check that a Loaded Protocol or ladder is not actively using MJ1. Taking the controller out of Run Mode from the System Menu on the controller will make MJ1 available to Cscape. 5. Successful communications with USB-to-serial adapters vary. If in doubt, Horner APG offers a USB to serial adapter: part number HE-CPK.

  • Page 193: Local Controller And Local I/O

    Troubleshooting USB Port - Mini B Programming 1. Controller must be powered up. 2. Ensure that the correct COM port is selected in Cscape.Tools > Applications Settings > Com- munications. 3. Be sure that the USB cable is connected between the PC and the controller. Check Windows Device Man- ager to ensure that the USB driver is properly installed and to verity the port number.

  • Page 194: Cscan Network

    Manual, MAN0799. 2. The Horner OCS does not provide 24VDC to the network. An external voltage source must be used for other devices such as SmartStix I/O. 3. Check voltage at both ends of the network to ensure that voltage meets specifications of attached devices.

  • Page 195: Basic Troubleshooting

    Technical Support Contacts For manual updates and assistance, contact Technical Support at the following locations: North America: Tel: (317) 916-4274 Fax: (317) 639-4279 Website: https://hornerautomation.com Email: techsppt@heapg.com Europe: Tel: (+) 353-21-4321-266 Fax: (+353)-21-4321826 Website: https://www.hornerautomation.eu Email: technical.support@horner-apg.com Page 195 of 196...

  • Page 196: Change Log

    Battery Status in SR Throughout #6986 – AddedXLW Prime XLW Prime Battery 11/10/2021 Added Backup Battery forXLW Prime Register Map for EXLW/XLW #6429 – Updated Register Map PRIME OCS I/O #8470 - Convert to Madcap Flare Output Throughout 12-12-22 #8982 - Updated Prime Battery info...

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