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HORNER APG EXL10 PRIME OCS, User Manual

The HORNER APG EXL10 PRIME OCS is a cutting-edge device that combines advanced features with user-friendly interface. Ensure seamless operation by referring to the comprehensive User Manual available for free download on our website. Enhance your experience with this exceptional product at manualshive.com, the one-stop destination for all your manual needs.

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MAN1029-10-EN_EXL10_XL10P_UM

 

J u l y   6 ,   2 0 2 2  

 

 

 

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21.8  Backup Battery Replacement 

 
The XL10 has an advanced battery system. It uses a rechargeable lithium battery. The battery powers the 
real time clock when power is removed. To store registers, the battery continues to power the OCS for 
less than a second after external power is removed. In this time the registers and other retentive data is 
saved to internal flash memory. This battery will need eight (8) hours of charging to last approximately 
two years when powered off.   
 

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.  

 
 

WARNING: DO NOT USE IF BATTERY IS LEAKING OR HAS BEEN DAMAGED.  
 
WARNING: LITHIUM BATTERIES MAY EXPLODE OR CATCH FIRE IF MISTREATED.  
DO NOT RECHARGE, DISASSEMBLE, HEAT ABOVE 100° C (212° F) INCINERATE, OR PUNCTURE. 
 
WARNING: EXPLOSION HAZARD 

–

 BATTERIES MUST BE ONLY BE CHANGED IN A AREA KNOWN TO BE 

NON-HAZARDOUS.  
 
WARNING: Disposal of lithium batteries must be done in accordance with federal, state, and local 
regulations. Be sure to consult with the appropriate regulatory agencies 

before 

disposing batteries. In 

addition, do not recharge, disassemble, heat or incinerate lithium batteries. 
 
WARNING:  Do not make substitutions for the battery. Be sure to only use the authorized part number 
to replace the battery. 

 

 
 
 
 

 

Summary of Contents for EXL10 PRIME OCS

Page 1: ..._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 HEXP505C116 ...

Page 2: ...described in this document or media is also copyrighted material subject to the terms and conditions of the Horner Software License Agreement Information in this document is subject to change without notice and does not represent a commitment on the part of Horner APG Cscape SmartStack SmartStix SmartRail SmartMod and CsCAN are trademarks of Horner APG Ethernet is a trademark of Xerox Corporation ...

Page 3: ...XL10 XL10 PRIME OCS module IS ORIGINALLY INSTALLED THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES In no event whether as a result of breach of contract warranty tort including negligence or otherwise shall HE APG or its suppliers be liable of any special consequential incidental or penal damages including but not limited to loss of profit or revenues loss of ...

Page 4: ...manuals and user documentation visit a Horner website North America https hornerautomation com Europe http www hornerautomation eu QUICK START INSTALLATION PROGRAMMING TROUBLESHOOTING Safety Compliance Mechanical Installation System Settings Modbus Communications Introduction Electrical Installation Registers Back up Battery Cscape Configuration Maintenance General I O Troubleshooting High Speed I...

Page 5: ...CHANICAL INSTALLATION 17 3 1 Overview 17 3 2 Mounting Requirements 17 3 3 Mounting Orientation 18 3 4 EXL10 XL10 PRIME Dimensions 19 3 5 Installation Procedure 20 3 6 Factors Affecting Panel Layout Design and Clearances 21 CHAPTER 4 ELECTRICAL INSTALLATION 23 4 1 Grounding Definition 23 4 2 Ground Specifications 23 4 3 How to Test for Good Ground 24 4 4 Primary Power Port 25 CHAPTER 5 SYSTEM SETTI...

Page 6: ...n 72 7 9 Scaling Analog Inputs 73 CHAPTER 8 GENERAL I O 75 8 1 Overview 75 8 2 Removing the EXL10 XL10 PRIME OCS I O Cover 75 8 3 Model and I O Overview 78 8 4 Solid State Digital Outputs 78 8 5 Relay Outputs 80 8 6 Digital Inputs 81 8 7 Analog Inputs 82 8 8 Universal Analog Inputs 83 8 9 Analog Outputs 84 CHAPTER 9 HIGH SPEED I O HSC PWM 85 9 1 Overview 85 9 2 Glossary 86 9 3 High Speed Counter H...

Page 7: ...guration 122 13 4 Device List and Device Configuration 124 13 5 Scan List 125 13 6 Data Mapping Configuration Scan List Entry 126 CHAPTER 14 USER INTERFACE 128 14 1 Overview 128 14 2 Screen Specifications 128 14 2 Displaying and Entering Data 128 14 3 Alpha Numeric Keypad 129 14 4 Screen Navigation 131 14 5 Ladder Based Screen Navigation 132 14 6 Beeper Acknowledgement 132 14 7 Touch Slip Sensitiv...

Page 8: ...NE UNIT 158 18 1 Overview 158 18 2 Clone 158 18 3 Load Clone 161 CHAPTER 19 FAIL SAFE SYSTEM 163 19 1 Overview 163 19 2 Settings 164 19 3 AutoLoad 168 19 4 AutoRun 170 CHAPTER 20 MODBUS COMMUNICATIONS 171 20 1 Modbus Overview 171 20 2 Modbus Slave Overview 171 20 3 Modbus Master Overview 172 20 4 Modbus Addressing Table for EXL10 XL10 PRIME Units 173 CHAPTER 21 BACK UP BATTERY 174 21 1 Overview 17...

Page 9: ... 10 EN_EXL10_XL10P_UM J u l y 6 2 0 2 2 P a g e 9 195 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 ...

Page 10: ...isk of fire and shock hazards WARNING In the event of repeated failure do not replace the fuse again as a repeated failure indicates a defective condition that will not clear by replacing the fuse WARNING EXPLOSION HAZARD Substitution of components may impair suitability for Class I Division 2 WARNING The USB parts are for operational maintenance only Do not leave permanently connected unless area...

Page 11: ... connect to the circuit to be monitored d Route power wires in a safe manner in accordance with good practice and local codes e Wear proper personal protective equipment including safety glasses and insulated gloves when making connections to power circuits f Ensure hands shoes and floors are dry before making any connection to a power line g Make sure the unit is turned OFF before making connecti...

Page 12: ...MAN1029 10 EN_EXL10_XL10P_UM J u l y 6 2 0 2 2 P a g e 12 195 CHAPTER 2 INTRODUCTION 2 1 Visual Overview of EXL10 XL10 PRIME OCS Figure 2 1 Overview of the EXL10 XL10 PRIME ...

Page 13: ...l 4 MAN1188 MAN1315 Model 5 MAN1189 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 2 1 2 Four main types of information are covered in thi...

Page 14: ... that can be used with the EXL10 XL10 PRIME OCS Figure 2 2 Visual Overview of Types of Devices that can be connected to EXL10 XL10 PRIME OCS CAN Serial I O XL10 XL10 PRIME OCS Other OCS Devices Drives PLCs Bar Code Readers Printers SCADA OPC Servers Serial I O Sensors Indicators Alarms Encoders Pumps Relays Solenoids Other OCS Devices Smart Stix I O RCX116 I O Base OPC Server Ethernet Cscape OPC S...

Page 15: ...s Removable media for 32GB of storage of programs data logging or screen captures CsCAN networking port for communication with remote I O other controllers or PCs High speed USB port for communication with PCs and programming of controller Configurable serial protocols for communication to drives PLCs or other serial peripherals Full featured built in I O including high resolution analog thermocou...

Page 16: ...d I O accessories North America http hornerautomation com product category home control accessories Europe http horner apg com en products aspx 2 5 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 ...

Page 17: ...anical installation of the unit 3 2 Mounting Requirements 3 2 1 Mounting Procedures Installed in a Panel Door Figure 3 1 Panel Mounting of an EXL10 XL10 PRIME Series OCS Once the panel design has been completed using the criteria and suggestions in the following sections use the following steps to panel mount the EXL10 XL10 PRIME OCS 1 Remove all connectors from the EXL10 XL10 PRIME OCS unit 2 Mak...

Page 18: ... EXL10 XL10 PRIME OCS with Mounting Clips 3 3 2 EXL10 XL10 PRIME OCS Mounting Orientation 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 Slots for mounting clips ...

Page 19: ...MAN1029 10 EN_EXL10_XL10P_UM J u l y 6 2 0 2 2 P a g e 19 195 3 4 EXL10 XL10 PRIME Dimensions Figure 3 4 EXL10 XL10 PRIME OCS Dimensions ...

Page 20: ...he unit for insertion and removal of the microSD card 2 Carefully cut the host panel per the diagram creating a 216mm x 288 5mm 0 1 mm opening into which the EXL10 XL10 PRIME may be installed If the opening is too large water may leak into the enclosure potentially damaging the unit If the opening is too small the OCS may not fit through the hole without damage 3 Remove any burrs and or sharp edge...

Page 21: ...ng Panel Box The panel box must be properly connected to earth ground to provide a good common ground reference Panel Door Tie a low impedance ground strap between the panel box and the panel door to ensure that they have the same ground reference 3 6 3 Temperature Ventilation Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient temperature range ...

Page 22: ...ut 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 appropriate procedure been followed to properly ground the devices in the panel box and on the panel door Are minimum clearance requirements met Can...

Page 23: ...ection between a circuit or piece of equipment and the earth Grounds are fundamentally used to protect an application from harmful interference causing either physical damage such as by lightning or voltage transients or from circuit disruption often caused by radio frequency interference RFI Grounding is also for the safety of the user 4 2 Ground Specifications Ideally a ground resistance measure...

Page 24: ...ce 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 Figure 4 1 Two Point Ground Connection Test METAL WATER PIPE OR OTHER GOOD GROUND GROUND ROD GROUND DISCONNECTED FROM SERVICE GROUND RESISTANCE METER ...

Page 25: ... 0 2mm Strip length 0 28 7mm Torque Terminal Hold Down Screws 4 5 7 in lbs 0 50 0 78 N m DC is internally connected to I O V but is isolated from CAN V A Class 2 power supply must be used POWER UP 1 OPTION Attach ferrite core with a minimum of two turns of the DC and DC signals from the DC supply that is powering the controllers 2 Connect to earth ground 3 Apply recommended power ...

Page 26: ... 1 which will display the Main Menu Then use the and Up Arrow or Down Arrow keys to select a Main Menu item and press Enter Return Arrow to display the item s Sub Menu Table 5 1 OCS LEDs RUN OFF indicates OCS is in IDLE STOP mode Flashing indicates DO IO mode or RUN with no ladder program ON indicates ladder code running OK OFF indicates one or more self tests failed ON indicates all self tests pa...

Page 27: ... edit the highlighted System Setting If Enter is pressed the System Setting s value will be highlighted indicating that it is ready to be modified When modifying a System Setting s value use either the arrow keys or the numeric keys or the appropriate touch screen icons to select a new value The arrow keys are used to edit System Settings that have just a few possible values Each time the arrow ke...

Page 28: ...ze 16 Firmware Rev 14 10 FPGA Rev 0 3 InitRD Rev 1 06 OS Ver 2 6 35 43 Self Test OK Logic Error Ok User Program Ok User Graphics Ok W Dog Trips 2 Net Errors 0 Network State Ok Network ID Ok Dup Net ID Ok Clock Error Ok I O System Ok Battery Ok Slot 1 I O Xex06 Slot 2 I O Empty Slot 3 I O ETN300 MJ1 None Loaded MJ2 None Loaded COM None Loaded MJ3 None Loaded Fkeys Momentary SYS Fn enable Yes Use to...

Page 29: ...N network 500kB 500kBd CAN network 1MB 1 MBd CAN network MAC ID Displays the Ethernet MAC ID of the unit IP Displays the Ethernet IP address of the unit NetM Displays the Ethernet net mask of the unit GatWy Displays the Ethernet gateway of the unit NOTE The IP address Net Mask and Gateway can be changed from the System Menu This is designed for commissioning or temporary field changes The actual p...

Page 30: ...E OCS node All Net Use 0 0 to 100 0 CAN network bandwidth used by all nodes Ladder Size x Number of bytes in application ladder program Config Size x Number of bytes in application I O configuration Graphics Size x Number of bytes in application graphic screens String Size x Number of bytes in application string table Bitmap Size x Number of bytes in application bitmaps Text Tbl Size x Number of b...

Page 31: ...ME OCS can still enter and remain in Run mode but the problem should be investigated and corrected User Graphics Ok Application graphics objects loaded successfully Fault Application graphics objects not loaded or load failed W Dog Trips 0 Watchdog timer has not tripped since the last power up x Number of times watchdog timer has tripped Net Errors 0 No CAN network bus off errors have occurred x N...

Page 32: ...attery Status The View Battery Status displays the following information Waiting The charging system is waiting for voltages and temperatures to stabilize Battery Charging The battery is charging Battery Full Shows at the end of a charge cycle Remains in this state until the battery is steadily discharging Battery Discharging The battery is steadily discharging ...

Page 33: ...No I O module installed but an I O module is configured Slot 1 I O XExyy yy I O module installed but no I O module configured Slot 1 I O XExyy yy I O module installed but another I O module configured Slot 1 I O XExyy yy I O module installed and configured properly Depending on the COM module that is installed and the COM module that has been configured by Cscape one of the following six System Se...

Page 34: ...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 In the View Protocols Sub Menu the currently downloaded protocol if any and its version number are displayed for each of MJ1 MJ2 COM board and MJ3 ...

Page 35: ... Sub Menu displays two System Settings both of which may be edited Fkeys Momentary K1 5 bits go On Off as F1 F5 are pressed released Toggle K1 5 bits toggle each time F1 F4 are pressed SYS_Fn enable Yes Reset and all clear system functions enabled No Reset and all clear system functions disabled ...

Page 36: ...em setting only MJ1 232 can be selected unless a Modem XMC COM module is installed Dflt Pgm Port MJ1 232 MJ1 RS232 port is the default programming port Modem Modem COM module is the default programming port MJ2 RS485 Bias No MJ2 RS485 bias resistors are not switched in Yes MJ2 RS485 bias resistors are switched in MJ3 RS485 Bias No MJ3 R5485 bias resistors are not switched in Yes MJ3 R5485 bias res...

Page 37: ...le latency data networks Daylight Saving Time Time as adjusted to achieve longer evening daylight especially in summer by setting the clocks an hour ahead of the standard time Apply Daylight Saving DST Daylight Saving Time DST is the practice of setting the clocks forward one hour from standard time during the summer months and back again in the fall in order to make better use of natural daylight...

Page 38: ...gic can be written to accomplish an automatic switchover using system register SR211 In program logic move a 1 INT into SR211 to enable Daylight Saving Time Move a 0 INT into SR211 to disable Daylight Saving Time Trigger the move to SR211 based on a compare function to the RTC date according to daylight saving practices in your desired region To Set Local Time The Set Time Date sub menu displays t...

Page 39: ..._XL10P_UM J u l y 6 2 0 2 2 P a g e 39 195 5 12 Set Beeper The Set Beeper Sub Menu displays one System Setting which may be edited Beeper enable Yes default Enables beeper No Disables beeper does NOT affect ladder access ...

Page 40: ...able screen saver Timeout min 5 1200 Amount of time in minutes to expire with NO touch activity before activating screen saver black screen Popup Status Off default Disable popup status Warning Display popup status only if controller status changes to NOT Ok or NOT Run mode On Display popup status on any controller status change Update Time ms 2 50 Maximum amount of time to allow for graphics upda...

Page 41: ... highlighting dot dot and pressing Enter will move up one directory Media Directory No Card Media Directory Dir Empty Media Directory Initializing No microSD card has been installed in the Memory slot microSD card is installed but it is still initializing microSD card is installed and initialized but contains no files Shows size of highlighted file or shows DIR if directory is highlighted Shows th...

Page 42: ...ication Flash corruption due to for example an excessive EMI Electromagnetic Interference event Selecting Fail Safe System menu will open the following menu screen Selecting Backup Restore Data displays the following screen in Backup Copies Battery Backed RAM contents on to the onboard flash memory of the OCS Restore Copies the backed up data from onboard flash memory to the battery backed RAM Cle...

Page 43: ...mode after AutoLoad or Automatic Restore Yes OCS will automatically be placed into RUN mode after AutoLoad or Automatic Restore Enable AutoLoad displays the following options which can be selected Enable AutoLoad No Does not load AUTOLOAD PGM automatically when application program is absent or corrupted Yes Loads AUTOLOAD PGM file automatically from RM when application program is absent or corrupt...

Page 44: ...nt OCS same model This feature can be used when Replacing an OCS by another unit of the same model Duplicating or clone units without a PC Clone Selecting Clone Unit menu will open the following menu screen NOTE Free Total displays number of free and total bytes in Removable Media Selecting Make Clone brings up the confirmation screen Upon confirmation the OCS will create two new files in the root...

Page 45: ...J u l y 6 2 0 2 2 P a g e 45 195 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 ...

Page 46: ...n 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 SR218 Number of Webpages SR219 Number of Data Points SR220 220 Expiry Date of WebMI License ...

Page 47: ...ation 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 Thereafter use a plastic tip stylus and follow the dialog instructions For best results in screen calibration use a stylus with a plastic tip When the crosshair appears touch the center of the crosshair as exactly as possible and release A small should appear and will move...

Page 48: ...reens on a unit which has the ability to display a screen If the bit is SET the screen is displayed I Digital Input Single bit input registers Typically an external switch is connected to the registers K Key Bit Single bit flags used to give the programmer direct access to any front panel keys appearing on a unit M Retentive Bit Retentive single bit registers Q Digital Output Single bit output reg...

Page 49: ...lf Test Results Read Only Read Only SR4 1 Self Test Results BIOS Error Read Only Read Only SR4 2 Self Test Results Engine Error Read Only Read Only SR4 3 Self Test Results Ladder Error Read Only Read Only SR4 4 Self Test Results RAM Error Read Only Read Only SR4 5 Self Test Results Duplicate ID Error Read Only Read Only SR4 6 Self Test Results Bad ID Error Read Only Read Only SR4 7 Self Test Resul...

Page 50: ...ad Only SR27 Network Configuration Table CRC Read Only Read Only SR28 Security Data Table CRC Read Only Read Only SR29 NET_ID Network ID Read Only Read Write CsCAN Mode 1 to 253 DeviceNet Mode 0 to 63 CANOpen Mode 1 to 127 SR30 Network Baud Rate 0 125KB 1 250kB 2 5000KB 3 1MB 4 50K 0 to 4 Read Only Read Write SR31 Network Required 0 Network not required 1 Network required 2 Network optimized 3 Net...

Page 51: ...me Clock Hour 0 to 23 Read Only Read Only SR47 RTC_DATE Real Time Clock Date 1 to 31 Read Only Read Only SR48 RTC_MON Real Time Clock Month 1 to 12 Read Only Read Only SR49 RTC_YEAR Real Time Clock Year 1996 to 2095 Read Only Read Only SR50 RTC_DAY Real Time Clock Day 1 Sunday 1 to 7 Read Only Read Only SR51 Network Error Count Read Only Read Only SR52 Watchdog Tripped Error Count Read Only Read O...

Page 52: ...Only SR61 NUM_IDS Number of CsCAN Network IDs Read Only Read Only SR62 100 Reserved SR101 3 WebMI License Details WebMI server status XLEe XLTe X2 X4 X7 only Read Only Read Only SR101 4 WebMI License Details WebMI user logged in status XLEe XLTe X2 X4 X7 only Read Only Read Only SR101 8 101 16 WebMI License Details Number of users XLEe XLTe X2 X4 X7 only Read Only Read Only SR102 107 Reserved SR10...

Page 53: ...N Sets Enable AutoRun to Yes or No Read Write Read Write SR164 6 EN_AUTO_LD Enable AUTOLOAD Sets Enable AutoLoad to Yes or Not Read Write Read Write SR164 7 STRT_BCKUP Start Backup trigger bit Setting TRUE starts backup of all register data Read Write Read Write SR164 8 CLR_BACKUP Clear Backup trigger bit Setting TRUE clears backup of all register data if a backup was done previously Read Write Re...

Page 54: ...ad Only SR183 SYS_BEEP Beep on Keypress Enable 0 Disabled 1 Enabled 0 to 1 Read Write Read Write SR184 USER_BEEP Internal Beeper 0 OFF 1 ON 0 to 1 Read Write Read Write SR185 Screen Saver Enabled 0 Disabled 1 Enabled NOTE See SR57 16 0 to 1 Read Only Read Only SR186 Screen Saver Time in minutes delay 5 to 1200 Read Only Read Only SR187 NET_USE Network Usage Avg 0 to 1000 Read Only Read Only SR188 ...

Page 55: ...nly Read Only SR199 Reserved SR200 InitRD Version 100 Read Only Read Only SR201 205 Linux Kernel version ASCII 10 characters Read Only Read Only SR206 208 Reserved SR209 3 WebMI Server Status Bit 3 is ON if server running Read Only Read Only SR209 4 WebMI User Logged in Status Bit 4 is ON if 1 or more users logged in Read Only Read Only SR209 9 209 16 Number of Users Shows in upper byte in decimal...

Page 56: ...ad Write Display Read Write XLE XLT X2 X4 X7 use SR101 SR108 112 for WebMI License Details SR220 222 Expiration Date of WebMI License license detail XLE XLT X2 X4 X7 use SR101 SR108 112 for WebMI License Details Read Only Read Only NOTE Not every OCS supports every SR For additional information on system bits and registers refer to the online help found in Cscape ...

Page 57: ...igital Outputs Q13 Q16 Unused Reserved Digital Outputs Reserved Q17 Q20 Unused Link HSC Table Q21 Q24 Unused Reserved AI1 AI4 Unused Analog Inputs AI1 AI2 for Analog Input Channels AI3 AI4 Unused Mirror of first four analog channels AI33 AI38 Unused Analog Inputs for all 6 channels AQ1 AQ8 Unused PWM Table Below AQ9 AQ10 Unused Analog Outputs Unused These registers can be used as general purpose r...

Page 58: ...r Quad 2 Acc AI11 12 HSC4 function Accumulator AQ1 2 HSC1 Preset AQ3 4 HSC2 Preset Q17 Clear HSC1 Clear Quad 1 Q18 Clear HSC2 Set Quad 1 Q19 Clear HSC3 Clear Quad 2 Q20 Clear HSC4 Set Quad 2 6 4 Resource Limits Table 6 7 Resource Limits Resource Value Resource Value S 13 Ethernet CsCAN Ping EGD SRTP Modbus TCP Master Downloadable Protocol Slave Ethernet IP FTP or HTTP 10MBd or 100MBd SR 448 CsCAN ...

Page 59: ...tus of the pass through Connector Local xx indicates the Network ID of the OCS to which the Cscape program is physically connected through its serial port It can serve as a pass through device to other nodes on the network Target yy R indicates the Network ID of the device with which the Cscape program is exchanging data NOTE The Local unit and Target unit can be the same unit or they can be separ...

Page 60: ...t on the OCS only on select models to an open USB port on the PC A cable for doing this is included in the HE XCK and HE CPK programming kits The OCS will install as a device once plugged in Drivers for it are normally found automatically by the Windows operating system as long as an Internet connection is established Otherwise the drivers may be loaded from the HE XEC Ethernet Utility HTTP Web Se...

Page 61: ...1 195 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: ...necting for the first time we suggest connecting via USB Figure 7 3 Cscape Connection Wizard Screenshots If Controller USB COM Port is not present in the dropdown list the Windows operating system has not yet recognized the OCS as an installed device Be sure the installation process is complete and that the correct drivers are installed The Connection Wizard must be completely closed and reopened ...

Page 63: ...e 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 Table 7 1 below explains the information needed in each field ...

Page 64: ...face Select this option to communicate over CAN This option requires additional hardware to be installed with the PC to be able to do so Select the type of hardware installed from the dropdown Installed Modem Select this option to communicate to the device through the internal modem of the computer Cscape will automatically detect the internal modem attached with PC and list in the attached drop d...

Page 65: ...he Target ID allows directing communications to a particular unit when multiple units are connected via a CsCAN network Units without CsCAN network ports respond to any network ID and do not require the ID to be configured To check or change the ID on the EXL10 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 ...

Page 66: ...pport files Europe https www hornerautomation eu support Next connect the PC s serial port to the port labeled MJ1 MJ2 or MJ3 on the EXL10 XL10 PRIME If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above If the controller is not communicating it may be required to set the target ID of the controller in Cscape o...

Page 67: ...u item Once running or power cycled the configuration will come from the Cscape configuration stored in the unit In Module configuration dialog go to IP Address field enter unused IP Address and configure unused registers in Register field then click OK Screen shot for the same as follows Figure 7 6 LAN1 Configuration Screen Download the configuration in to Controller Connect LAN cable to the Cont...

Page 68: ...pe of EXL10 XL10 PRIME OCS is selected the model drop down box will provide the EXL10 XL10 PRIME OCS model numbers from which to choose from 6 Once the EXL10 XL10 PRIME OCS CPU is selected press OK to exit the dialog and configure the I O that is present in the first slot 7 The I O configure dialog Specifically the Module Setup tab provides four 4 buttons to configure all of the I O Go through eac...

Page 69: ...sitive logic or active low Negative logic It is important that this setting match what the jumper settings are on the hardware The High Speed Counters group box contains all of the windows that are used for configuring the 4 available high speed counters on the EXL10 XL10 PRIME OCS In configuring a counter the user needs to set the type mode and counts per rev The type drop down includes the follo...

Page 70: ... The PWM State On Controller Stop group box contains items that allow the user to specify how the PWM outputs behave when the controller is stopped These items can either hold their value or default to some value when the controller is stopped NOTE The PWM outputs are set to the OFF state at power up and during program download and remain in that state until the unit is placed in RUN The Output St...

Page 71: ...ilable 0 10V 0 20mA 4 20mA On Model 5 and Model 6 I O other options on channels are outlined below Table 7 2 Analog In for Models 5 6 Model 5 Model 6 Channels 1 2 Channels 1 6 0 10V 0 10V 0 20mA 0 20mA 4 20mA 4 20mA 100mV Disable PT100 DIN RTD 1 20 C 0 60mV Type J Thermocouple 1 20 C PT100 DIN RTD 1 10 C Type K Thermocouple 1 20 C PT1000 DIN RTD 1 10 C Type N Thermocouple 1 20 C Type J Thermocoupl...

Page 72: ...p 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 The outputs can either hold their value or default to a value when the controller is stopped The Output Mode group box allows the user to select the operating modes for each of the ...

Page 73: ... J u l y 6 2 0 2 2 P a g e 73 195 7 9 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 ...

Page 74: ... format ranges from 0 32 000 for 4mA 20mA Use the Scale function to obtain an Integer pressure reading using the 0 32000 raw input range and the sensor s 0 2000psi output range Example 2 If readings with fractions are required the raw Integer input value must first be translated in REAL or Floating Point format The Cscape INT to REAL Conversion function may be used to convert the raw input value f...

Page 75: ...es referencing register mapping 8 2 Removing the EXL10 XL10 PRIME OCS I O Cover Some I O configurations require jumper settings to be changed in the EXL10 XL10 PRIME OCS unit Examples of these settings are setting positive or negative logic on digital inputs or setting current or voltage on analog inputs Each EXL10 XL10 PRIME OCS I O jumper is set to a factory default Refer to the EXL10 XL10 PRIME...

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: ...ion of the jumper settings Figure 8 3 Example Jumper Diagram To re install the cover place the I O cover back on the unit Place the screw back into the hole and turn the screw slowly counter clockwise until it clicks into the threads This prevents the screw from being cross threaded Now turn the screw clock wise until the cover is firmly secured Repeat this process for all four 4 screws Ensure not...

Page 78: ...e found on the data sheets attached at the end of the manual Descriptions and applications of the different type of I O can be found below up to 6mA V In mA V RTD TC and 4mA V Out 8 4 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 the EXL10 XL10 ...

Page 79: ...r high speed applications and can be used for PWM or frequency output applications Please see the data sheet and the chapter on High Speed I O for additional information When the controller is stopped the operation of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state By default digital outputs turn off For ...

Page 80: ...e Rating Products containing relays often have total current limits based on the ambient temperature of the application Please see the product data sheet for current temperature de rating information for relays Fusing External fusing is generally required to protect the relays devices and wiring from shorts or overloads 001XLE015 0V ON J1 12 24VDC R2 C2 R3 C3 R6 C6 R4 C4 R5 C5 R1 C1 H4 H2 H3 LOAD ...

Page 81: ...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 The mode is set by a jumper setting and a configuration parameter in Cscape All the inputs on the unit must be configured to the same mode Figure 8 6 Positive and Negative Inputs In positive logic mode a positive voltag...

Page 82: ...downside to digital filtering is the inputs will respond more slowly to sudden changes in the actual input 8 7 1 Thermistor Option for Special Orders NOTE The standard unit does NOT support thermistor Thermistor support is a factory option for Models 2 3 and 4 only Model 2 can support a two channel and four channel thermistor Models 3 4 support the two channel thermistor only Please refer to the T...

Page 83: ...figuration parameter in Cscape Like the standard analog inputs these inputs have a digital filter that can be used to filter electrical noise that may be unavoidable in some installations The downside to digital filtering is the inputs will respond more slowly to sudden changes in the actual input The Universal Analog Inputs on the Model 6 I O board are unique from other Horner X series input outp...

Page 84: ...10 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 NOTE Each channel can be separately configured for voltage or current mode When the controller is stopped the operation of each output is co...

Page 85: ...n availability refer to the associated model s Specification Installation sheet Digital DC Input Output sections The OCS contains a Field Programmable Gate Array FPGA which is an integrated configurable circuit that allows the EXL10 XL10 PRIME to be programmed to have either two high speed counters or four high speed counters The EXL10 XL10 PRIME ships with two high speed counters but a customer c...

Page 86: ...re bits A latch has a data input a clock input and an output When the clock input is active data on the input is latched or stored and transferred to the output register either immediately or when the clock input goes inactive The output retains its value until the clock goes active again Marker Input into the OCS that indicates a particular position Typically an encoder has a marker output that r...

Page 87: ... may be consumed The measurement values are provided to ladder in a AI register Refer to the Registers chapter for more details 12 3 1 Frequency In frequency mode the frequency of the input signal is written to the accumulator in terms of Hertz cycles second When using frequency mode four update selections are provided which specify the width of the sample window NOTE Selecting a shorter sample wi...

Page 88: ...his decrements the accumulator when the input is enabled NOTE Two inputs can be assigned Either input can cause the counter to decrement The second input can also be disabled Up Down Input 1 Up Input 2 Down In this mode Input 1 assigned to any of the four inputs increments the counter while Input 2 also assigned to any of the 4 inputs decrements the counter Clk Dir Input 1 Clk Input 2 Dir This mod...

Page 89: ...reset signals specify the type as Totalize Reset NOTE The corresponding Totalize HSC must be previously configured before this option is available The direct digital reset controls are edge sensitive with the edge polarity configurable Maximum direct digital reset latency is 100μs The totalize function also supports an option which compares the current accumulator value with a supplied Preset Valu...

Page 90: ... last sampled value In this mode the Disable and Latch special functions are allowed Refer to the HSC Glossary for a description of these functions Width High 1μs Counts In this sub mode the accumulator value will contain the number of 1μs counts the pulse is high Width Low 1μs Counts In this sub mode the accumulator value will contain the number of 1μs counts the pulse is low Figures 9 1 9 2 Puls...

Page 91: ...Refer to the HSC Glossary for a description of these functions Period Rising Edges 1μs Counts In this sub mode the period of the input signal is reported in one 1 μs units The period measurement will start on the rising edge of the input Period Falling Edges 1μs Counts In this sub mode the period of the input signal is reported in one 1 μs units The period measurement will start on the falling edg...

Page 92: ... form it uses or try both modes to determine if the encoder counts up when expected Figures 9 5 Quadrature Using the above waveforms and a HSC input configuration of Quadrature 1 leads 2 count up the accumulator will count up when 1 is rising and 2 is low 1 is high and 2 is rising 1 is falling and 2 is high and when 1 is low and 2 is falling This results in 4 counts per revolution So in order to d...

Page 93: ...or counters 1 and 2 3 The High Speed Outputs are Q1 for Counter 1 and Q2 for Counter 2 They operate as high speed outputs independent of the controller scan rate when configured as HSC Output in the Digital Out PWM configuration in Cscape 4 The High Speed Output state reflects in the status register High Speed Out e g I1603 for Counter 1 the update speed of the status bit is scan rate dependent 5 ...

Page 94: ...ore if the marker is enabled and Assigned Q is selected then both the Disable and the Disable Marker bits need to be set high in order to disable the high speed input If the Marker is set for one of the inputs then the input will need to be High in order to use any of the Disable Clear Preload or Latch functions 9 3 8 Status Bits There are three status bits I registers for each high speed counter ...

Page 95: ...AQ411 412 Match2 Counter 2 AQ413 424 Reserved Q1601 Latch Counter 1 Q1602 Preload Counter 1 Q1603 Clear Counter 1 Q1604 Disable Counter 1 Q1605 Direction C 1 Q1606 Output Reset Counter 1 Q1607 Preload Disable Counter 1 Q1608 Latch Disable Counter 1 Q1609 Disable Marker C1 Q1610 Latch Marker C1 Q1611 Preload Marker C1 Q1612 Clear Marker C1 Q1613 1616 Reserved Q1617 Latch Counter 2 Q1618 Preload Cou...

Page 96: ...ad Counter 3 AQ415 416 Match1 Counter 3 AQ417 418 Match2 Counter 3 AQ419 420 Preload Counter 4 AQ421 422 Match1 Counter 4 AQ421 424 Match2 Counter 4 Q1601 Latch Counter 1 Q1602 Preload Counter 1 Q1603 Clear Counter 1 Q1604 Disable Counter 1 Q1605 Direction C1 Q1606 Output Reset Counter 1 Q1607 Preload Disable Counter 1 Q1608 Latch Disable Counter 1 Q1609 1616 Reserved Q1617 Latch Counter 2 Q1618 P...

Page 97: ...ble Counter 4 Q1657 1664 Reserved 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 I1609 Overflow flag Counter 3 I1610 Underflow flag Counter 3 I1611 High Speed Out 3 I1612 Reserved I1613 Overflow flag Counter 4 I1614 Underflow flag Counter 4 I1615 Hi...

Page 98: ... is a 32 bit value from 0 to 32 000 indicating the relative duty cycle of the output For example a value of 8000 would indicate a 25 duty cycle a value of 16 000 would indicate a 50 duty cycle The value zero 0 turns the output off and 32 000 turns the output on Frequency The Frequency is a 32 bit value indicating the output frequency in Hertz One over the frequency is the period Figure 9 6 Figure ...

Page 99: ...t circuitry The HE XHSQ generates 24V pulse outputs with a recommended max of 400kHz The HE XHSQ 5 generates 5V pulse outputs with a recommended max of 1 0MHz The add on HSQ and HSQ 5 module can be added to the 1E2 unit for HSC function 9 5 3 PWM Output Waveform Figure 9 8 PWM Output Waveform Table 9 5 PWM Output Waveform Table Rise Time 150ns Max Fall Time 150ns Max PWM Period Frequency 1 𝑃𝑒𝑟𝑖𝑜𝑑 ...

Page 100: ...e run frequency or an error is generated Run Frequency pulses per second Sets the frequency for the last cycle during the acceleration phase the consistent frequency during the run phase and the frequency of the first cycle during the deceleration mode The Run Frequency must be greater than 0 and must not exceed 5000Hz standard 400 000Hz HE XHSQ or 1MHz HE XHSQ 5 Acceleration Count Sets the number...

Page 101: ...he next start command if the error was corrected Table 9 7 Boolean Registers The stepper requires one discrete register to control the stepper action Setting this register starts the stepper cycle This register must remain set to complete the entire cycle Clearing this register before the cycle is complete aborts the step sequence and sets the error bit NOTE Setting the PLC mode to stop while the ...

Page 102: ...r 2 AQ433 434 PWM 2 Frequency Run Frequency Stepper 2 AQ435 436 Acceleration Count Stepper 2 AQ437 438 Run Count Stepper 2 AQ439 440 Deceleration Count Stepper 2 Q1 Start Move Bit Stepper 1 Q2 Start Move Bit Stepper 2 I1617 Ready Done Stepper 1 I1618 Error Stepper 1 I1619 Ready Done Stepper 2 I1620 Error Stepper 2 Table 9 9 PWM Functions Register Map Four Counter Register PWM Stepper AQ451 452 PWM...

Page 103: ...quency To get a 50 Duty Cycle on PW1 and 90 Duty Cycle on PWM2 1kHz waveform Set AQ421 422 16 000 Set AQ431 432 28 800 duty cycle 32000 0 9 Set AQ423 424 1 000 Set AQ433 434 1 000 Example 3 Duty Cycle Frequency To turn PWM 1 output ON all the time Set AQ421 422 32 000 Set AQ423 424 Any Value Example 4 Duty Cycle Frequency To turn PWM 1 output OFF all the time Set AQ421 422 0 Set AQ423 424 Any Valu...

Page 104: ...teps Finally during the last 1 000 000 steps it slows to a stop Example 3 Start Frequency Run Frequency Accel Count Run Count Decel Count 6 000 000 steps control sequence Set AQ421 50Hz Set AQ422 250Hz Set AQ423 4 150 000 Steps Set AQ425 6 5 500 000 Steps Set AQ427 8 350 000 Steps When the Start Move bit is energized the following example starts at 50Hz and ramps up to 250Hz during the first 150 0...

Page 105: ...User has to select Filter Frequency and Number of samples based on the frequency of the Input signal Filter Frequency To set the filter choose a value that is 4 Number of Samples Expected Max Hz on the high speed inputs Number of samples The input must be stable for this many samples before the HSC accumulator is affected by any change The state high or low of the high speed input is sampled with ...

Page 106: ...n Input signal is sampled for 4 samples and if the signal is stable for 4 samples i e 4μs then the signal is passed to Accumulator If the Input state is changed in between the sampling counts then the count is reset and the Input state is again checked for given number of samples Refer to Dotted lines in the Figure 2 after 2 samples the state of input signal changes to 1 so the counter is again st...

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

Page 108: ...rd data exchange protocols The second 8 pin modular RJ45 connector which is labeled MJ3 provides a multiplexed serial port which can be configured for either RS232 or RS485 MJ3 can be optionally set for OCS programming via the System Menu for connection to the COM port of a PC running Cscape 10 2 Port Descriptions The MJ1 serial port contains an RS232 interface with RTS CTS handshaking The MJ2 ser...

Page 109: ...ted 10 5 RS485 Biasing RS485 biasing passively asserts a line idle state when no device is actively transmitting which is useful for multi drop RS485 networking Both the MJ2 and MJ3 serial ports allow internal bias resistors to be switched in pulling Pin 1 up to 3 3V and pulling Pin 2 down to ground The Set Serial Ports item in the System Menu can be used to enable RS485 biasing Also an applicatio...

Page 110: ...odbus Slave Protocols In addition external modems can be connected and accessed using Init Dial and Answer Modem function blocks 10 8 Configuration via Mini B USB NOTE The unit must be connected via the mini USB port to the PC or laptop It is possible to load the program and monitor data via the Mini B USB To load via Mini B USB configure the communications port in Cscape as follows Select Tools f...

Page 111: ...l data with other OCS RCS controllers and to access remote Network I O devices SmartStix Smart Blocks and Smart Rail Modules The CAN1 port also supports pass through communications for programming multiple OCS controllers over the CsCAN network CAN1 port does not supply power to the network CAN2 port supports CsCAN CANopen J1939 and DeviceNet Master layer 3 as a selectable option one only 11 2 Por...

Page 112: ...N1 port network 11 5 Ladder Controlled CAN Communication Using Put and Get Network Words function blocks the CAN 1 port can exchange digital and analog global data with other EXL10 XL10 PRIME OCS or OCS RCS devices nodes attached to the CAN1 port network In addition Put and Get Network Heartbeat function blocks allow nodes on the CAN 1 port network to regularly announce their presence and to detec...

Page 113: ...thernet Module Protocols Features Protocol Feature Protocol Feature Description ICMP Ping Internet Control Message Protocol EGD 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 FTP File Server File Transfer Protoco...

Page 114: ...ons Table 12 2 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 Recommended CAT5 or better UTP Port Auto MDI MDI X Auto Crossover ...

Page 115: ...re to perform the following steps 1 On the main Cscape screen select the Controller Hardware Configuration sub menu to open the Hardware Configuration dialog Figure 12 1 2 If configuring a different OCS Model than the one shown in the Hardware Configuration dialog click on the topmost Config button select the desired OCS Model and then click OK Figure 12 1 Hardware Configuration Dialog 3 Click the...

Page 116: ...Class C IP Addresses in which case the low octet rightmost number is used to uniquely identify each node on the local network In this case the default Net Mask value of 255 255 255 0 should be used Gateway Enter the IP Address of a Gateway Server on the local network that allows for communication outside of the local network To prevent the Ethernet Module from communicating outside the local netwo...

Page 117: ...gister Enter an OCS Register reference such as R101 to indicate which 16 bit OCS register will have the Ethernet Firmware Version written to it The value stored in the Version Register is Ethernet Firmware Version 100 For example for Ethernet Firmware Version 4 30 the Version register will contain 430 Get Settings From Get settings from allows the programmer to configure either the IP Address Net ...

Page 118: ...owever any edits made from System Menu Set Networks is not retained through a power cycle After power cycle the unit reverts to the last downloaded Cscape LAN Config that was loaded into non volatile RAM at power down Cscape LAN Config Get Settings from Register When Get settings from is set to Register the IP parameters are retrieved from the OCS registers assigned in LAN Config Configured regist...

Page 119: ...some OCS models support multiple protocols on a single Ethernet port Once the protocol is selected for a specific port that port must be configured to match the bit transfer size and rate of the target device s This is configured under the Network Config menu which contains port specific information such as the basic serial port parameters i e baud rate stop bits parity retries etc In addition to ...

Page 120: ...nned sequentially to generate data transactions with the remote device This transaction scanning can be on a continual basis automatic or controlled from ladder logic manual once a complex connection is programmatically created i e dialup modem The specific transaction scanning mode is selected from the Network Config menu The following Horner Automation websites offer OCS Protocol Software Downlo...

Page 121: ...e 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 Once a protocol is selected the Network Devices and Data Scan List must be configured through corresponding dialogs accessible through the respective buttons Network Device and Scan List Figure 13 1 Protocol Config Dialog Three fields must be configu...

Page 122: ...95 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 ...

Page 123: ...mes a transaction is retried on a failed response Timeout Specifies the amount of time for a device to wait for a valid response Update Scan Automatic Update Interval Specifies the update interval at which all the mapped entries are executed Reacquire Time Specifies the amount of time to wait before attempting communications with an offline device Manual Trigger Specifies the binary register that ...

Page 124: ... 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 Typically the number of entries is limited to 64 devices Device Configuration This configuration is reached from the Device List when adding or modifying an existing device ...

Page 125: ...ach mapping entry transaction contains the source and destination registers the number of consecutive registers transferred the direction of the transfer and what triggers the transfer Typically the number of entries is limited to 512 NOTE The order of the Scan List is the order in which the transactions occur Sort functions are provided to change the order of the list Each entry also has an ident...

Page 126: ...nless 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 transaction scans to write each changed register When the OCS is placed in RUN mode the initial action for this mapping type is ...

Page 127: ... of the OCS This allows registers to be initialized locally before Writing to the target device register s Triggered Read A read transaction is triggered by a high level on a separately designated OCS binary trigger register Once the read transaction is complete or the device is offline the OCS trigger register is cleared by the OCS This update type can be used for occasion data accesses such as r...

Page 128: ... Data Figure 14 1 Example Screen Multiple objects are provided for displaying data such as virtual panel lights push buttons numeric value displays bar graphs meters graphs and animated bitmaps On the EXL10 XL10 PRIME these graphical objects through ladder manipulation of attribute bits can change color flash or change visibility to attract operator attention On objects that accept user input the ...

Page 129: ...wn in Figure 14 2 Once invoked the operator may touch the appropriate keys to enter a specific value When entering a value the alpha numeric keypad is in one of two modes new value or edit value New Value Mode Generally when the alpha numeric keypad is first invoked it is placed in new value mode Initially the alpha numeric keypad displays the current value with all the digits being highlighted On...

Page 130: ...lue Password Object When editing a password value the arrow keys and the keys are disabled Additionally overwrite mode is disabled When entering digits the pop up keypad hides the value by displaying alternately for each digit ASCII Object When editing an ASCII value an ASCII keypad is displayed as shown figure 13 2 The ASCII keypad has 3 modes numeric symbols and alpha In Alpha mode the Caps Lock...

Page 131: ...ying the object as one that causes a screen change shown below in Figure 14 3 Screen jumps can also be triggered on other keys or based on control logic for more advanced applications To allow the operator to change screens a screen jump object is generally used This object may be visually represented as a button responding to touch or remain invisible and logically tied to an OCS register An opti...

Page 132: ...t is de energized the screen remains until it is switched by the user or ladder Figure 14 4 Force and Switch Coils in Ladder Programming There is also a system register that can be used to for control based screen navigation SR1 can be read to determine the current screen or written to change the current screen Refer to the on line help in Cscape for more information on control based screen naviga...

Page 133: ...ns such as jog buttons where the operator is pushing a button for a period of time the amount of slip while holding a button pressed may exceed the default sensitivity To increase the amount of tolerable slip and prevent false releases of the button the EXL10 XL10 PRIME allows adjustment of the allowable slide up to 5x the default value To enable the touch slip sensitivity first an OCS data regist...

Page 134: ...n what the operator should expect The alarm object is generally used to enunciate alarms to the operator While the display characteristics of this object is configurable it is generally displayed as a button that changes colors to indicate the highest state of the alarm s in the alarm group it is monitoring The following indicates the priority of the alarm states and the default colors associated ...

Page 135: ...so indicates the current relative position The current state of the displayed alarm is indicated by its color and optionally by an abbreviated indicator after the date time stamp ALM ACK RTN The operator can acknowledge an alarm by selecting it from the list and touching the ACK button The operator can also clear an alarm if that function is enabled in the alarm object If not enabled the Clear but...

Page 136: ... is displayed as pop up removable media dialog similar to that shown in Figure 14 8 NOTE The removable media object can be configured to open the removable media viewer at a certain directory complete with restrictions on transversing back up the file path This may be used to restrict operator access to non critical files Figure 14 8 Removable media viewerError Bookmark not defined The currently s...

Page 137: ...are complete simply touch the Esc button to remove the pop up removable media viewer If the removable media is used in an application the removable media device requires changing by the operator and the application is attempting to write to the removable media when it is removed the screen designer should create objects that allow the operator to temporally halt access to the removable media This ...

Page 138: ...the backlight is otherwise ignored by the EXL10 XL10 PRIME Any additional touch activity is also ignored by the EXL10 XL10 PRIME for approximately one second thereafter It is possible for the application to temporarily disable the screen saver by generating a positive transition to SR57 16 coil only at a rate faster than the screen saver timeout value This may be desired while waiting for alarm ac...

Page 139: ...r this feature Minimum Firmware Version 15 xx or later Minimum OS Version 2 6 35 49 Minimum Cscape Version 9 80 SP1 Figure 14 10 Touch Force NOTE Touch creates contact between resistive circuit layers closing a switch With a unique change to the touch monitoring firmware user can measure the pressure being exerted on the touch screen This feature has been added in some Horner XL series controllers...

Page 140: ...nge of 0 to 3000 0 indicates no pressure and 3000 is the maximum amount of pressure that can be measured SR10 I O Name TCH_PRESSURE_TSH This register sets the pressure threshold to indicate a touch A value of 200 is typically the lightest touch 600 is moderate and 1000 is a heavy touch These new features allow customizing the feel of the touch screen and can be used to add unique user interface fe...

Page 141: ...ps Sampling Rate Supported 24000Hz to 44100Hz Audio Playback Only one audio file can be played at a time If multiple bits are simultaneously triggered only the least significant bit will be acted upon After completing playback the next least significant bit will be acted upon File Location Files must be present in Removable Media for playback and are NOT downloaded from Cscape 15 2 Audio Configura...

Page 142: ...egister gives the status of the audio files see table below Table 15 1 1st and 2nd Status Registers Bit Number Description 1st Status Register Bit 1 to Bit 8 Volume Control 0 100 Bit 9 Play Control 1 Pause 0 Play Bits 10 16 Not Used 2nd Status Register Bit 1 Cannot open ALSA Lib Bit 2 Cannot open MP3 Lib Bit 3 Audio output device cannot be setup Bit 4 Cannot open input Audio Stream Bit 5 Memory al...

Page 143: ... 143 195 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 ...

Page 144: ...nfigure 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 Only one audio file can be played at a time If multiple bits are simultaneously triggered only the least significant bit will be acted upon 3 Only MP3 and WAV formats are supported 4 256 audio files can be played ...

Page 145: ...rigger 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 Table 16 1 Features and Specifications of Video Properties Streaming Channels 4 channels supported through USB hub 1 channel can be viewed at a time Playback Formats mp4 mov mpg wmv Resolution 320x240 QVGA Frames per Seconds 10 15 20 ...

Page 146: ...re 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 1 Open the Graphics Editor by selecting the T button from the toolbar 2 In Graphic Editor select the video button from the toolbar 3 Then click on the grid ...

Page 147: ...MAN1029 10 EN_EXL10_XL10P_UM J u l y 6 2 0 2 2 P a g e 147 195 4 Double click on the icon in the middle to open the Video Properties dialog ...

Page 148: ...e Enter Channel Number directly or through registers in the Enter Channel No field Playback This option can be selected to view videos that are stored in Removable Media on the controller Videos present in both A microSD and B USB drives are supported and can be viewed Supported formats including mp4 mov mpg and wmv can be played Select Playback and enter video name in the Enter Target Path field ...

Page 149: ... bits and uses the first two 2 bits NOTE The least significant bit is Bit 1 Definitions are as follows Bit 1 High Start Low Stop Bit 2 High Pause Low Play System Register The Video Control System Register provides the status of the Video Object The status word is 16 bits and should be viewed in hexadecimal format The status definitions are as follows 0x0001 Video is currently playing 0x0002 Video ...

Page 150: ...ing to System Menu or any popup window causes Video Object to be inactive 2 Video Object can be made active in both Idle and Run modes 3 If actual Frames Per Second of the configured video is different from the one that is configured in Cscape few frames will be missed when video is played 16 7 Web Cameras If multiple web cameras are directly connected to the EXL10 XL10 PRIME then only one web cam...

Page 151: ...0 PRIME OCS power is On or Off To install a microSD card Align its 8 pin gold edge connector down facing the front of the EXL10 XL10 PRIME OCS unit then carefully push it all the way into the Memory slot Ensure that it clicks into place To remove the microSD card Push in on the top of the card gently to release the spring The card pops out for removal 17 3 microSD File System The microSD Memory sl...

Page 152: ...able Media Manager can be accessed via the System Menu or by using Cscape to place a Removable Media Manager object on an application graphics screen Figure 17 2 Removable Media Submenu 17 5 Using Removable Media to Log Data 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 w...

Page 153: ... reader by selecting the 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 To view a captured EXL10 XL10 PRIME OCS screen use the Removable Media Manager to find and highl...

Page 154: ... the Esc button to remove the pop up removable media viewer 17 9 Removable Media RM Function Blocks in Cscape NOTE For detailed information regarding RM function blocks and parameters refer to the help file in Cscape Software Refer USB Flash Media support for RM Functions for USB flash drive access details The following RM functional blocks are available in Cscape Software These function blocks wi...

Page 155: ...ovable Media RM Features Graphic Screen Editor a Trends The historic support feature in the trend object utilizes Removable Media b Removable Media This is a graphic object used to access files and functions pertaining to Removable Media c Recipes This is a graphic object that is used in conjunction with the recipe editor which is mentioned above 17 12 Removable Media RM Features Additional Config...

Page 156: ...eplaced by the OCS with current time and date information Table 17 2 Filename Special Symbols Symbol Description Example Y Substitutes the current 2 digit year 2015 15 M Substitutes the current month with a 2 digit code March 03 D Substitutes the current day 22nd 22 h Substitutes the current hour in 24 hour format 4 pm 16 m Substitutes the current minute 45 45 s Substitutes the current second 34 3...

Page 157: ...76 Free Space This 32 bit register shows the free space on the RM card in bytes SR178 Card Capacity This 32 bit register shows the total card capacity in kilobytes Table 17 4 System Registers used with RM Possible status values are shown in the table For additional status information consult the Cscape Help file Table 17 5 RM Status Values 0 RM interface OK 1 Card present but unknown format 2 No c...

Page 158: ... in using RM It can then be used to clone a different OCS same model This feature can be used for Replacing an OCS by another unit of the same model Duplicating or clone units without a PC 18 2 Clone User needs to perform the following to Clone 1 The Clone Unit can be accessed by going to the System Menu of the OCS A new menu Clone Unit has been added at the end of the main System Menu as shown be...

Page 159: ...Selecting Make Clone brings up the screen below for the user Figure 18 3 Clone Unit Confirm Screen After confirmation the OCS will create two new files in the root directory of the Removable Media Drive as shown below AUTOLOAD PGM Application file CLONE DAT File having all unit settings and register values from battery backed RAM Figure 18 4 Clone Unit Files NOTE Make Create clone operation automa...

Page 160: ...on is completed this bit is made zero by the firmware When Make clone operation is triggered by this SR bit it does not ask the user for confirmation for making clone The success failure of the operation is also not notified on screen to the user In case of failure of Make Clone operation SR164 11 bit is set to 1 by the firmware and never reset NOTE Backup of registers in flash memory is not perfo...

Page 161: ...o the battery backed RAM Regardless of AutoLoad settings and then resets the OCS for the settings to take effect User needs to perform the following to Load Clone 1 Select Clone Unit from main System Menu of OCS as shown below Figure 18 6 System Menu 2 Selecting Clone Unit menu will open the following menu screen Select Load Clone Figure 18 7 Clone Unit Menu after Cloning ...

Page 162: ...OTE For security enabled files Load clone asks for password validation before loading the application Load clone can also be triggered by setting SR164 10 bit to 1 from Ladder program or graphics Once the operation is completed this bit is made zero by the firmware When Load clone operation is triggered by this SR bit it does not ask the user for confirmation for loading clone The success failure ...

Page 163: ...es These soft failures include Retentive Register or Application flash corruption due to for example an excessive EMI Electromagnetic Interference event The Fail Safe System has the following capabilities Manually backup the current Retentive Register Settings into flash memory Manually restore Register Settings from the values previously backed up in flash memory to battery backed RAM Detect corr...

Page 164: ...re of data or AutoLoad operation 5 Backup the current battery backed RAM Register contents in onboard flash memory using System Menu options Backup Restore Data Selecting this option brings up a screen having four operations Backup OCS Data Restore OCS Data Clear Backup Data Exit Figure 19 2 Backup Restore Data Backup OCS Data When initiated this will allow the user to manually copy battery backed...

Page 165: ...ill be followed for restoring data The controller will be placed in IDLE mode Data will be copied from onboard flash memory to OCS battery backed RAM The controller will reset The controller will be put in RUN mode if the AutoRun setting is Yes else it will remain in IDLE mode Figure 19 4 Restore OCS Data SR164 3 is set to the value of 1 only when an automatic restore operation is performed not on...

Page 166: ... 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: ... Restore Figure 19 6 Flow Chart for Automatic Restore OCS Power Cycle Battery Backed RAM Registers check failed Backup exists Controller placed in IDLE mode Data copied from Onboard FLASH to OCS Battery backed RAM Controller Resets AutoRun Enabled OCS put in RUN Mode OCS put in IDLE Mode NO YES YES NO Application Program erased ...

Page 168: ...hen the program residing in onboard memory is corrupted and a valid AUTOLOAD PGM is available in the removable media of the device AutoLoad can be manually initiated when the SYS F3 key is pressed OCS can be in any of the following mode Idle Run DOIO This also requires a valid AUTOLOAD PGM to be present in the removable media of the device When the AutoLoad setting is not enabled set to NO OCS wil...

Page 169: ...19 8 Flow Chart for AutoLoad Power up OCS Application Program absent or Application Program corrupted AutoLoad Enabled AUTOLOAD PGM present in the RM of the device AutoLoad initiated OCS put in IDLE mode AutoLoad run sequence failed with reasons for failure NO NO YES YES AutoRun Enabled OCS put in RUN Mode OCS put in IDLE Mode NO YES ...

Page 170: ... 5 can be set by putting the system into RUN mode automatically once an AutoLoad has been performed or an Automatic Restore has occurred If for any reason the AutoLoad Run Loading the AUTOLOAD PGM automatically and OCS put in RUN mode sequence does not succeed a pop up message box saying AUTO LOAD RUN SEQUENCE FAILED will be displayed It will also show the reason for its failure On acknowledging t...

Page 171: ...be unable to complete the request it returns the appropriate error response Should the slave be unable to respond the master s timeout timer expires to provide an indication of No Response 20 2 Modbus Slave Overview For complete Modbus Slave instructions please refer to the Help file in Cscape The Modbus slave function block when used with the appropriate Modem and or Open function blocks allows t...

Page 172: ... For every slave to be polled configuration details are added in the Devices dialog box This includes Slave ID serial Under Device Type the Modbus addressing style matching that specified in the slave s user documentation may be selected For instance some slaves specify Modbus addresses i e 40 001 and others specify offsets i e 0000 o Hex or Decimal Some specify addresses in hex and others in deci...

Page 173: ...ster type are shown in the Traditional Modbus Reference column of the Table 20 1 Method 2 The second method requires the Modbus Master to be configured with a specific Modbus Command and Modbus Offset Table 20 1 Modbus Master Mapping EXL10 XL10 PRIME Reference Maximum Range Trad Modbus Ref 5 Digits Expanded Modbus Ref 6 Digits Modbus Commands Modbus Offset I1 2048 10001 010001 Read Input Status 2 ...

Page 174: ...10 of a second During this time register and other retentive data is saved away to flash memory The clock continues to run on the battery at a much lower power The battery is designed to last well over a year in this state Once power is restored the battery recharges in eight 8 hours or less 21 3 Battery Life The battery is designed to last 300 full charges to 1000 partial charge cycles or 7 to 10...

Page 175: ...limits 3 The battery is charged fully to 4 2 volts in the Normal Charging or Cold Charging states or to 4 1 volts in the Hot Charging state 4 Once fully charged to 4 2 volts state 0 the Wait Discharging state is executed state 12 The battery is allowed to discharge to 4 0 volts for however long that takes Powering up the OCS will reset the charge cycle to step 1 5 If the battery was charged to 4 1...

Page 176: ...ry temperature falls to 60 C or less 5 Cold Charging Battery is slow charging Tb 0 10 C 20mA to 4200mV Up to 40hrs charge time 6 Battery Too Cold Not Charging Tb 0 C Charging cycle resumes when battery temperature climbs to 0 C or greater 7 Error No Battery No battery was detected at power up It will not attempt to charge until the next power cycle SR55 13 ON 8 Final Charge to 4 1V The battery has...

Page 177: ... SR196 Charge State Refer to Table 21 1 SR197 Charging Current mA SR198 Battery Voltage in mV IMPORTANT The battery voltage shown in the System Menu and in SR198 is ONLY valid if the battery is not in the Charging State To check battery voltage power cycle the controller and check the battery voltage within the first two minutes of power up In the first two minutes after power is applied to the un...

Page 178: ...0 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 WARNING DO NOT USE IF BATTERY IS LEAKING OR HAS BEEN DAMAGED WARNING LITHIUM BATTERIES MAY EXPLODE OR CATCH FIRE IF MISTREATED DO NOT RECHARGE DISASSEMBLE HEAT ABOVE 100 C 212 F INCINERATE OR PUNCTURE WARNING EXPLOSION HAZARD BATTERIES ...

Page 179: ...into the guideposts If an insert came off be sure to slide it back into the cover before replacing 10 This unit has self tapping screws Once the screws are aligned gently turn the screw counterclockwise until it clicks Then turn the screw clockwise until screw is seated 11 Once the larger back panel is replaced gently replace the I O circuit board by aligning the edges with the guideposts Align th...

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: ...ed that it be replaced as preventative maintenance NOTE Use only the proper battery type listed NOTE Use only the proper battery type listed WARNING DO NOT USE IF BATTERY IS LEAKING OR HAS BEEN DAMAGED WARNING LITHIUM BATTERIES MAY EXPLODE OR CATCH FIRE IF MISTREATED DO NOT RECHARGE DISASSEMBLE HEAT ABOVE 100 C 212 F INCINERATE OR PUNCTURE WARNING EXPLOSION HAZARD BATTERIES MUST BE ONLY BE CHANGED...

Page 182: ...ect all power from the XL10 Prime unit including I O power 3 On the back of the XL10 Prime model slide off the battery plate cover 4 Connect the new battery into the adjacent connector first and then remove the old battery 5 Dispose of the old battery properly see the above warning on disposal regulations 6 Slide battery plate cover back on the unit 7 Apply power to the unit Check that the battery...

Page 183: ...ck for Current Firmware Revision To check the firmware revision on a controller open System Menu View Status Warning Firmware updates should only be performed when the equipment being controlled by the XL10 XL10 PRIME OCS is in a safe non operational state Communication or hardware failures during the firmware update process can cause the controller to behave erratically resulting in injury or equ...

Page 184: ...d to be unzipped and placed in the root of the drive for them to function properly Method B RS232 Serial Connection Serial firmware updates are done from Cscape software to the controller s primary serial port MJ1 in most cases STEP ONE In North America visit https hornerautomation com Then click Support Downloads Controller Firmware and download the most recent firmware set with the correct commu...

Page 185: ...stall Bootloader button and then press Yes NOTE DO NOT press the Install Firmware option This has the potential to create a scenario where the unit will not boot up If this is pressed by mistake contact Tech Support for the recovery procedure e When Operation Completed appears press OK f Power cycle the OCS controller and wait for it to boot up g Press SYSTEM key select View Status and press the E...

Page 186: ...established to the local controller Local No Port Cscape is unable to access the COM port of the PC This could mean that Cscape is configured for a COM port that is not present or that another program has control of the COM port Only one Cscape window can access a port at a time Subsequent instances of Cscape opened will indicate No Port Local No Com Cscape has accessed a PC COM port but is not co...

Page 187: ...PG offers a USB to serial adapter Part numbers HE XCK and HE CPK 24 1 2 Connecting Troubleshooting Checklist 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 Communications 3 Be sure that the USB cable is connected between the PC and the controller Check Windows Device Manager to ensure that the USB dri...

Page 188: ... Check diagnostics to ensure controller passed self tests View Diags in System Menu or in Cscape click Controller Diagnostics 3 Check data sheets to ensure proper wiring 4 Ensure that hardware jumpers and software configuration for I O match 5 Check data sheets for voltage and current limits 6 Take ladder out of the picture From Cscape set controller to Do I O mode In this mode inputs can be monit...

Page 189: ...esistors should be placed across the CAN_HI and CAN_LO terminals 5 Measure the resistance between CAN_HI and CAN_LO If the network is properly wired and terminated there should be around 60Ω 6 Check for duplicate node ID s 7 Keep proper wires together One twisted pair is for V and V and the other twisted pair is used for CAN_HI and CAN_LO 8 Make sure the baud rate is the same for all controllers o...

Page 190: ...s cannot be guaranteed Larger USB devices such as hard drives etc should only be attached and removed when the OCS is powered down The resets are caused by short sharp current spikes when devices are added or removed from the OCS these spikes can exceed the USB specification but are usually very short and mostly do not cause problems Some devices however draw a longer larger current as they power ...

Page 191: ...ated Install Procedure Firmware Updates Audio Chapter Throughout Cscape Config Analog In Table 7 2 Firmware Update 8 16 2021 9 4845 Updated WebMI register 4802 WebMI Max of connections 6482 Updated Install Procedure 6319 USB Interfaces 6442 Battery Charging Cycle SR Table Ethernet Overview Install Procedure USB Interfaces Battery Status in SR 1 10 2021 10 6987 Added XL10 Prime Added Backup Battery...

Page 192: ...via Mini B USB 109 Configured reset value 88 Configuring Video Properties 148 Count 97 99 Csape Program Via Serial Port 109 Cscape 15 33 34 56 59 65 67 75 78 80 81 82 83 84 107 109 111 131 152 153 186 187 188 Alternative Connection Method Screenshot 63 Analog In Configuration 71 Analog Out Configuration 72 Configuration Procedures 68 Digita In HSC Configuration 69 Digital Out PWM Configuration 70 ...

Page 193: ...ress 115 Jumpers Example 76 Ladder control 88 LIMITED WARRANTY 3 Lithium Battery Safety 174 Load Clone 45 161 Loop Power Requirements 83 Maintenance 183 Make Clone 158 Manual Index 13 MECHANICAL INSTALLATION 17 microSD Cards 151 Installing Removing 151 microSD System 151 Minimum Clearance Requirements for Panel Box and Door 21 Modbus Addressing Table for XL10 Units 173 Modbus Master Mapping 173 Mo...

Page 194: ...ate 78 80 Storing Register Contents 174 Sub Menus 26 System Menu Details 47 Navigate Edit 27 System Menu Map 28 SYSTEM SETTINGS AND ADJUSTMENTS 26 Sytem Menu Overview 26 target ID 66 Target ID 65 66 target indicator 66 67 Target indicator 65 Technical Support 2 80 190 Contacts 190 Testing for Good Ground 24 Thermistor Option 81 totalize 87 Totalize 87 Touch Screen Pressure 138 Tranzorb 81 Triggere...

Page 195: ...MAN1029 10 EN_EXL10_XL10P_UM J u l y 6 2 0 2 2 P a g e 195 195 View Status 30 Visual Overview 12 Where to Find Information 13 XL4 PRIME BACK UP BATTERY 181 ...

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