HORNER APG XL10 PRIME OCS User manual

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User Manual for
EXL10/XL10 PRIME OCS
MAN1029-010-EN_EXL10_XL10P_UM
XL10
XL10 PRIME
North America
Europe
North America
Europe
HE-EXV1E0
HEXT505C100
HE-XPV1E0
HEXP505C100
HE-EXV1E2
HEXT505C112
HE-XPV1E2
HEXP505C112
HE-EXV1E3
HEXT505C113
HE-XPV1E3
HEXP505C113
HE-EXV1E4
HEXT505C114
HE-XPV1E4
HEXP505C114
HE-EXV1E5
HEXT505C115
HE-XPV1E5
HEXP505C115
HE-EXV1E6
HEXT505C116
HE-XPV1E6
HEXP505C116

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PREFACE
This manual explains how to use the EXL10/XL10 PRIME OCS.
Copyright© 2013 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights
reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language or computer language, in any form by any means, electronic,
mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written
permission of Horner APG, Inc.
All software described in this document or media is also copyrighted material subject to the terms and
conditions of the Horner Software License Agreement.
Information in this document is subject to change without notice and does not represent a commitment
on the part of Horner APG.
Cscape, SmartStack, SmartStix, SmartRail, SmartMod, and CsCAN are trademarks of Horner APG.
Ethernet™ is a trademark of Xerox Corporation.
microSD™ and CompactFlash are registered trademarks of SanDisk Corporation.
For user manual updates, please visit our website:
North America:
Tel: (+) [phone]
Fax: (+) [phone]
Website: https://hornerautomation.com
Email: [e-mail]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Website: http://www.hornerautomation.eu
Email: technical.sup[email protected]m

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LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the EXL10/XL10 PRIME (HE-
XW/HEXT391) OCS module manufactured by HE-APG is free from defects in material and workmanship
under normal use and service. The obligation of HE-APG under this warranty shall be limited to the repair
or exchange of any part or parts which may prove defective under normal use and service within two (2)
years from the date of manufacture or eighteen (18) months from the date of installation by the original
purchaser whichever occurs first, such defect to be disclosed to the satisfaction of HE-APG after
examination by HE-APG of the allegedly defective part or parts. THIS WARRANTY IS EXPRESSLY IN LIEU OF
ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE-APG NEITHER ASSUMES,
NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HE-APG, ANY OTHER LIABILITY IN CONNECTION
WITH THE SALE OF THIS EXL10/XL10 PRIME OCS module. THIS WARRANTY SHALL NOT APPLY TO THIS
EXL10/XL10 PRIME OCS module OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT,
NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. HE-APG MAKES NO WARRANTY WHATSOEVER IN
RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE-APG. THE TERM "ORIGINAL PURCHASER", AS
USED IN THIS WARRANTY, SHALL BE DEEMED TO MEAN THAT PERSON FORWHOM THE EXL10/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 use of the products or any associated equipment,
damage to associated equipment, cost of capital, cost of substitute products, facilities, services or
replacement power, down time costs, or claims of original purchaser's customers for such damages.
To obtain warranty service, return the product to your distributor with a description of the problem,
proof of purchase, postpaid, insured and in a suitable package.
ABOUT PROGRAMMING EXAMPLES
Any example programs and program segments in this manual or provided on accompanying media are
included solely for illustrative purposes. Due to the many variables and requirements associated with any
particular installation, Horner APG cannot assume responsibility or liability for actual use based on the
examples and diagrams. It is the sole responsibility of the system designer utilizing the EXL10/XL10 PRIME
OCS module to appropriately design the end system, to appropriately integrate the EXL10/XL10 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.
NOTE: The programming examples shown in this manual are for illustrative purposes only.
Proper machine operation is the sole responsibility of the system integrator.

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VISUAL MAP OF KEY CHAPTERS
FIRST STEP of ANY TASK: DATASHEET
Each EXL10/XL10 PRIME OCS unit is sent with a datasheet in the box. The datasheets are the first
documents to refer to for model-specific information related to EXL10/XL10 PRIME OCS models for
specific installation information. To obtain updates to datasheets, 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/O
Serial Communications
CAN Communications
Ethernet
Communications
Downloadable
Communications
User Interface
Audio Object
Video Object
Removable Media
Clone Unit
Fail-Safe System

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TABLE OF CONTENTS
PREFACE............................................................................................................................................2
LIMITED WARRANTY AND LIMITATION OF LIABILITY ...........................................................................3
ABOUT PROGRAMMING EXAMPLES ...................................................................................................3
VISUAL MAP OF KEY CHAPTERS..........................................................................................................4
TABLE OF CONTENTS..........................................................................................................................5
CHAPTER 1: SAFETY / COMPLIANCE ..................................................................................................10
1.1 Safety Warnings and Guidelines...............................................................................................10
1.2 Grounding .................................................................................................................................11
1.3 Compliance ...............................................................................................................................11
CHAPTER 2: INTRODUCTION .............................................................................................................12
2.1 Visual Overview of EXL10/XL10 PRIME OCS .............................................................................12
2.2 Connectivity to the EXL10/XL10 PRIME OCS.............................................................................14
2.3 Features of EXL10/XL10 PRIME OCS.........................................................................................15
2.4 Accessories................................................................................................................................16
2.5 Useful Documents and References...........................................................................................16
CHAPTER 3: MECHANICAL 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 SETTINGS AND ADJUSTMENTS ........................................................................26
5.1 System Menu - Overview..........................................................................................................26
5.2 System Menu –Navigation and Editing....................................................................................27
5.3 Set Networks.............................................................................................................................29
5.4 View Status ...............................................................................................................................30
5.5 View Diags.................................................................................................................................31
5.6 View Battery Status...................................................................................................................32
5.7 View I/O Slots............................................................................................................................33
5.8 View Protocols..........................................................................................................................34
5.9 Set Fkeys Mode.........................................................................................................................35
5.10 Set Serial Ports ......................................................................................................................36
5.11 Set Time/Date...........................................................................................................................37
5.12 Set Beeper.............................................................................................................................39
5.13 Set Screen .................................................................................................................................40
5.14 Removable Media .................................................................................................................41

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5.15 Fail –Safe System..................................................................................................................42
5.16 Enable AutoRun and AutoLoad .............................................................................................43
5.17 Clone Unit .................................................................................................................................44
5.18 Load Clone.............................................................................................................................45
5.19 WebMI License Details..........................................................................................................46
5.20 Touch screen calibration......................................................................................................47
CHAPTER 6: REGISTERS .....................................................................................................................48
6.1 Register Definitions...................................................................................................................48
6.2 Useful %S and %SR registers.....................................................................................................48
6.3 Register Map for EXL10/XL10 PRIME OCS I/O ..........................................................................57
6.4 Resource Limits.........................................................................................................................58
CHAPTER 7: CSCAPE CONFIGURATION..............................................................................................59
7.1 Overview...................................................................................................................................59
7.2 Cscape Status Bar......................................................................................................................59
7.3 Establishing Communications...................................................................................................60
7.4 Configuration............................................................................................................................68
7.5 Digital / HSC Input Configuration..............................................................................................69
7.6 Digital / PWM Output Configuration........................................................................................70
7.7 Analog Input Configuration.......................................................................................................71
7.8 Analog Output Configuration....................................................................................................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 (HSC) Functions .......................................................................................87
9.4 HSC Functions Register Map.....................................................................................................95
9.5 High Speed Output Functions...................................................................................................98
9.6 High Speed Output Functions Register Map...........................................................................102
9.7 HSC I/O Filtering......................................................................................................................105
CHAPTER 10: SERIAL COMMUNICATIONS .......................................................................................108
10.1 Overview.................................................................................................................................108
10.2 Port Descriptions.................................................................................................................108
10.3 Wiring and Dip Switches .....................................................................................................108
10.4 RS485 Termination..............................................................................................................109
10.5 RS485 Biasing ......................................................................................................................109
10.6 Cscape Programming via Serial Port ...................................................................................110
10.7 Ladder-Controlled Serial Communication...........................................................................110
10.8 Configuration via Mini-B USB..............................................................................................110

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CHAPTER 11: CAN COMMUNICATIONS.............................................................................................111
11.1 Overview.................................................................................................................................111
11.2 Port Description......................................................................................................................111
11.3 CAN Port Wiring......................................................................................................................112
11.4 Cscape Programming via CAN.................................................................................................112
11.5 Ladder-Controlled CAN Communication ................................................................................112
11.6 Using CAN for I/O Expansion (Network I/O)...........................................................................112
CHAPTER 12: ETHERNET COMMUNICATION ...................................................................................113
12.1 Ethernet Overview..................................................................................................................113
12.2 Ethernet Module Protocols and Features ..............................................................................113
12.3 Ethernet System Requirements..............................................................................................113
12.4 Ethernet Module Specifications..........................................................................................114
12.5 Ethernet Module Configuration..........................................................................................115
12.6 Ethernet Configuration –IP Parameters.............................................................................118
12.7 Ethernet Module Protocol Configuration...............................................................................118
CHAPTER 13: DOWNLOADABLE COMMUNICATION PROT0COLS....................................................119
13.1 Overview.................................................................................................................................119
13.2 Protocol Config .......................................................................................................................121
13.3 Network Configuration ...........................................................................................................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) Sensitivity ........................................................................................................133
14.8 Alarms .................................................................................................................................134
14.9 Removable Media ...............................................................................................................136
14.10 Screen Saver........................................................................................................................138
14.11 Screen Brightness................................................................................................................138
14.12 Touch Screen Pressure........................................................................................................139
CHAPTER 15: AUDIO PLAYBACK CONFIGURATION ..........................................................................141
15.1 Audio Overview.......................................................................................................................141
15.2 Audio Configuration in Cscape............................................................................................141
15.3 Audio Config Details................................................................................................................142
15.4 Audio Files...........................................................................................................................143
CHAPTER 16: VIDEO OBJECT ............................................................................................................145
16.1 Video Object Overview...........................................................................................................145
16.2 Opening Video Object in Cscape.........................................................................................146
16.3 Video Properties: Video Type..............................................................................................148
16.4 Video Properties: Control....................................................................................................149
16.5 Configuring Display Properties............................................................................................150
16.6 Video Object Performance..................................................................................................150

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16.7 Web Cameras..........................................................................................................................150
CHAPTER 17: REMOVABLE MEDIA ...................................................................................................151
17.1 Overview.................................................................................................................................151
17.2 microSD Cards.........................................................................................................................151
17.3 microSD File System................................................................................................................151
17.4 Using the Removable Media Manager................................................................................152
17.5 Using Removable Media to Log Data......................................................................................152
17.6 Using Removable Media to Load and Save Applications........................................................153
17.7 Using Removable Media to View and Capture Screens..........................................................153
17.8 Configuration of a Removable Media .................................................................................154
17.9 Removable Media (RM) Function Blocks in Cscape................................................................154
17.10 Removable Media (RM) Features—Program Features.......................................................155
17.11 Removable Media (RM) Features—Graphic/Screen Editor................................................155
17.12 Removable Media (RM) Features—Additional Configuration............................................155
17.13 Filenames used with the Removable Media (RM) Function Blocks....................................156
17.14 System Registers used with RM ..........................................................................................157
CHAPTER 18: CLONE 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.................................................................................................................................174
21.2 Storing Register Contents .......................................................................................................174
21.3 Battery Life..............................................................................................................................174
21.4 Lithium Battery Safety.........................................................................................................174
21.5 OCS Battery Charging Cycle.................................................................................................175
21.6 Battery Charging Status.......................................................................................................176
21.7 Battery Status in System Registers .........................................................................................177
21.8 Backup Battery Replacement..............................................................................................178
CHAPTER 22: XL10 PRIME BACK UP BATTERY .......................................................................................181
CHAPTER 23: MAINTENANCE..........................................................................................................183
23.1 Firmware Updates ..................................................................................................................183
23.2 How to Check for Current Firmware Revision.....................................................................183
23.3 Firmware Update Files ........................................................................................................184
23.4 Steps for Firmware Update.................................................................................................185
CHAPTER 24: TROUBLESHOOTING / TECHNICAL SUPPORT............................................................186
24.1 Connecting to the EXL10/XL10 PRIME OCS.........................................................................186
24.2 Local Controller and Local I/O.............................................................................................188

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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

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CHAPTER 1: SAFETY / COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
Warning: Consult user documentation.
Warning: Electrical Shock Hazard.
WARNING –EXPLOSION HAZARD –Do not disconnect equipment unless power has been switched off
or the area is known to be non-hazardous
WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth) ground
before making any other connections.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly recommended to
fuse the voltage measurement inputs. Be sure to locate fuses as close to the source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk of fire and
shock hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated failure
indicates a defective condition that will not clear by replacing the fuse.
WARNING –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 is known to be non-hazardous
WARNING –EXPLOSION HAZARD - BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE
NON-HAZARDOUS
WARNING: Battery May Explode If Mistreated. Do Not Recharge, Disassemble or Dispose Of In Fire
WARNING: Only qualified electrical personnel familiar with the construction and operation of this
equipment and the hazards involved should install, adjust, operate, or service this equipment. Read
and understand this manual and other applicable manuals in their entirety before proceeding. Failure
to observe this precaution could result in severe bodily injury or loss of life.