HORNER EXLW PRIME Series User manual

User Manual for
EXLW/XLW PRIME OCS
MAN1256-05-EN_EXLW_XLWP_UM
XLW
XLW PRIME
North America
Europe
North America
Europe
HE-XLWE0
HEXT381C110
HE-XPLWEO
HEXP381C100
HE-XLWE2
HEXT381C112
HE-XPLWE2
HEXP381C112
HE-XLWE3
HEXT381C113
HE-XPLWE3
HEXP381C113
HE-XLWE4
HEXT381C114
HE-XPLWE4
HEXP381C114
HE-XLWE5
HEXT381C115
HE-XPLWE5
HEXP381C115
HE-XLWE6
HEXT381C116
HE-XPLWE6
HEXP381C116

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PREFACE
This manual explains how to use the EXLW/XLW PRIME OCS.
Copyright© 2020 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All
rights reserved. No part of this publication may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any 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.
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]
Web: http://www.hornerautomation.com
Email: [e-mail]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Web: http://www.hornerautomation.eu
Email: [e-mail]

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LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the EXLW/XLW 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 EXLW/XLW PRIME OCS module.
THIS WARRANTY SHALL NOT APPLY TO THIS EXLW/XLW 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 FOR WHOM THE EXLW/XLW 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
diskettes 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 EXLW/XLW PRIME OCS module to
appropriately design the end system, to appropriately integrate the EXLW/XLW PRIME OCS
module and to make safety provisions for the end equipment as is usual and customary in
industrial applications as defined in any codes or standards which apply.
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 CHAPTERS
FIRST STEP of ANY TASK: DATASHEET
Each EXLW/XLW PRIME OCS unit is sent with a datasheet in the box. The datasheets are the first
document to refer to for model-specific information related to EXLW/XLW PRIME OCS models for
installation information. To obtain datasheets and user manuals, Horner website.
North America: https://hornerautomation.com Europe: hornerautomation.eu
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety /
Compliance
Mechanical
Installation
System Settings
Modbus
Communications
Introduction
Registers
Electrical Installation
Cscape Configuration
Back-up Battery
General I/O
Maintenance
High Speed I/O
Troubleshooting
Serial
Communications
CAN Communications
Ethernet
Communications
Downloadable
Communication
Options
User Interface
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 CHAPTERS ....................................................................................................................4
TABLE OF CONTENTS...............................................................................................................................5
CHAPTER 1: SAFETY AND 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 EXLW/XLW PRIME ................................................................................. 12
2.2 Connectivity to the EXLW/XLW PRIME OCS.........................................................................14
2.3 Features of EXLW/XLW PRIME OCS....................................................................................... 15
2.4 Required and Suggested 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 EXLW/XLW PRIME Dimensions and Panel Cut-Out............................................................20
3.5 Installation Procedure................................................................................................................ 21
CHAPTER 4: ELECTRICAL INSTALLATION ......................................................................................24
4.1 Grounding Definition .................................................................................................................24
4.2 Ground Specifications ...............................................................................................................24
4.3 How to Test for Good Ground .................................................................................................25
4.4 Primary Power Port................................................................................................................... 26
CHAPTER 5: SYSTEM SETTINGS AND ADJUSTMENTS ................................................................ 27
5.1 System Menu - Overview.......................................................................................................... 27
5.2 System Menu –Navigation and Editing.................................................................................28
5.3 System Menu –Details ..............................................................................................................30
5.4 View Status................................................................................................................................... 31
5.5 View Diags.................................................................................................................................... 32
5.6 View Battery Status................................................................................................................... 33
5.7 View Protocols ............................................................................................................................35
5.8 Set Fkeys Mode...........................................................................................................................36
5.9 Set Serial Ports........................................................................................................................... 37
5.10 Set Beeper................................................................................................................................40
5.11 Set Screen..................................................................................................................................... 41
5.12 Removable Media ...................................................................................................................42
5.13 Fail –Safe System ......................................................................................................................43
5.14 AutoRun....................................................................................................................................44
5.15 AutoLoad ..................................................................................................................................45

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5.16 Clone Overview .......................................................................................................................46
5.17 Load Clone ...................................................................................................................................47
5.18 License Details ........................................................................................................................48
5.19 Touch Calibration Screen .....................................................................................................49
CHAPTER 6: REGISTERS.......................................................................................................................50
6.1 Register Definitions ...................................................................................................................50
6.2 Useful %S and %SR registers.................................................................................................. 51
6.3 Register Map for EXLW/XLW PRIME OCS I/O .....................................................................59
6.4 Resource Limits..........................................................................................................................60
CHAPTER 7: CSCAPE CONFIGURATION ............................................................................................61
7.1 Overview........................................................................................................................................ 61
7.2 Cscape Status Bar....................................................................................................................... 61
7.3 Establishing Communications .................................................................................................62
7.4 Configuration ..............................................................................................................................70
7.5 Digital / HSC Input Configuration........................................................................................... 72
7.6 Digital / PWM Output Configuration...................................................................................... 73
7.7 Analog Input Configuration .....................................................................................................74
7.8 Analog Output Configuration.................................................................................................. 75
CHAPTER 8: GENERAL I/O................................................................................................................... 76
8.1 Overview....................................................................................................................................... 76
8.2 Removing the EXLW/XLW PRIME OCS I/O Cover .............................................................. 76
8.3 Model and I/O Overview ...........................................................................................................78
8.4 Solid-State Digital Outputs ......................................................................................................79
8.5 Relay Outputs..............................................................................................................................80
8.6 Digital Inputs.................................................................................................................................81
8.7 Analog Inputs ..............................................................................................................................82
8.8 Universal Analog Inputs Model 5............................................................................................82
8.9 Universal Analog Inputs Model 6 Universal Analog Inputs.............................................83
8.10 Analog Outputs .......................................................................................................................84
CHAPTER 9: HIGH SPEED I/O..............................................................................................................85
9.1 Overview.......................................................................................................................................85
9.2 Glossary ........................................................................................................................................86
9.3 High Speed Counter (HSC) Functions ...................................................................................87
9.4 Frequency ....................................................................................................................................87
9.5 Totalize .........................................................................................................................................87
9.6 Pulse Width Measurement .......................................................................................................89
9.7 Period Measurement .................................................................................................................90
9.8 Quadrature.................................................................................................................................... 91
9.9 Register Match............................................................................................................................92
9.10 HSC Functions .........................................................................................................................93
9.11 Status Bits....................................................................................................................................94
9.12 HSC Functions Register Map ...............................................................................................95
9.13 High Speed Output Functions..............................................................................................98
9.14 High-Speed Output Functions Register Map...................................................................102
9.15 PWM Examples .......................................................................................................................103
9.16 STP Examples........................................................................................................................ 104
9.17 HSC I/O Filtering....................................................................................................................... 105
CHAPTER 10: SERIAL COMMUNICATIONS ..................................................................................... 108
10.1 Overview..................................................................................................................................... 108

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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
CHAPTER 11: CAN Communications ....................................................................................................111
11.1 Overview........................................................................................................................................ 111
11.2 Port Description........................................................................................................................... 111
11.3 CAN Port Wiring...........................................................................................................................111
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: ETHERENET COMMUNICATION .................................................................................113
12.1 Ethernet Overview .....................................................................................................................113
12.2 Ethernet Module Protocols and Features ............................................................................113
12.3 Ethernet System Requirements .............................................................................................114
12.4 Ethernet Module Specifications..........................................................................................114
12.5 Ethernet Module Configuration ..........................................................................................115
12.6 Ethernet Configuration –IP Parameters ..........................................................................119
12.7 Ethernet Module Protocol Configuration .............................................................................119
CHAPTER 13: DOWNLOADABLE COMMUNICATION PROTOCOLS.............................................120
13.1 Overview......................................................................................................................................120
13.2 Protocol Config..........................................................................................................................122
13.3 Network Configuration.............................................................................................................123
13.4 Device List and Device Configuration ..............................................................................125
13.5 Scan List ......................................................................................................................................126
13.6 Data Mapping Configuration (Scan List Entry) ..............................................................127
CHAPTER 14: USER INTERFACE.........................................................................................................129
14.1 Overview......................................................................................................................................129
14.2 Screen Specifications ...........................................................................................................129
14.2 Displaying and Entering Data .............................................................................................130
14.3 Alpha-numeric Keypad..........................................................................................................131
14.4 Screen Navigation .................................................................................................................133
14.5 Ladder Based Screen Navigation ......................................................................................134
14.6 Beeper Acknowledgement ..................................................................................................135
14.7 Touch (Slip) Sensitivity ........................................................................................................135
14.8 Alarms ......................................................................................................................................136
14.9 Removable Media ..................................................................................................................138
14.10 Screen Saver.......................................................................................................................... 140
14.11 Screen Brightness ................................................................................................................ 140
14.12 Touch Screen Pressure.........................................................................................................141
CHAPTER 15: VIDEO OBJECT for EXLW/XLW PRIME..................................................................143
15.1 Video Object Overview.............................................................................................................143
15.2 Opening Video Object in Cscape....................................................................................... 144
15.3 Video Properties: Video Type.................................................................................................147
15.4 Video Properties: Control................................................................................................... 148
15.5 Configuring Display Properties ......................................................................................... 149

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15.6 Video Object Performance................................................................................................. 149
15.7 Web Cameras............................................................................................................................. 149
CHAPTER 16: REMOVABLE MEDIA................................................................................................... 150
16.1 Overview..................................................................................................................................... 150
16.2 Removable microSD Cards................................................................................................. 150
16.3 File System for microSD cards............................................................................................151
16.4 Using the Removable Media Manager ...............................................................................151
16.5 Using Removable Media to Log Data................................................................................152
16.6 Using Removable Media to Load and Save Applications.............................................152
16.7 Using Removable Media to View and Capture Screens...................................................153
16.8 Configuration of a Removable Media ...............................................................................153
16.9 Removable Media (RM) Function Blocks in Cscape...................................................... 154
16.10 Removable Media (RM) Features—Program Features ................................................. 154
16.11 Removable Media (RM) Features—Graphic/Screen Editor ......................................... 154
16.12 Removable Media (RM) Features—Additional Configuration ......................................155
16.13 Filenames used with the Removable Media (RM) Function Blocks ...........................155
16.14 System Registers used with RM.........................................................................................156
CHAPTER 17: CLONE UNIT ..................................................................................................................157
17.1 Overview......................................................................................................................................157
17.2 Clone.............................................................................................................................................157
17.3 Load Clone ...................................................................................................................................161
CHAPTER 18: FAIL –SAFE SYSTEM ..................................................................................................163
18.1 Overview......................................................................................................................................163
18.2 Settings................................................................................................................................... 164
18.3 Backup / Restore Data ........................................................................................................ 164
18.4 Backup OCS Data...................................................................................................................165
18.5 Restore OCS Data................................................................................................................. 166
18.6 Clear Backup Data.................................................................................................................167
18.7 AutoLoad ................................................................................................................................ 169
18.8 AutoRun....................................................................................................................................171
CHAPTER 19: CLONE UNIT ..................................................................................................................172
19.1 Overview......................................................................................................................................172
19.2 Clone.........................................................................................................................................172
19.3 Load Clone ..............................................................................................................................176
CHAPTER 20: MODBUS COMMUNICATIONS ..................................................................................178
20.1 Modbus Overview ..................................................................................................................178
20.2 Modbus Slave Overview.......................................................................................................178
20.3 Modbus Master Overview ....................................................................................................179
20.4 Modbus Addressing Table for EXLW/XLW PRIME Units ............................................. 180
CHAPTER 21: XLW BACK-UP BATTERY.............................................................................................181
21.1 Overview.......................................................................................................................................181
21.2 Storing Register Contents........................................................................................................181
21.3 Battery Life..................................................................................................................................181
21.4 Lithium Battery Safety..........................................................................................................181
21.5 OCS Battery Charging Cycle...............................................................................................182
21.6 Battery Charging Status ......................................................................................................183
21.7 Battery Status in System Registers..................................................................................... 184
21.7 Replacing the Rechargeable Backup Battery.................................................................... 185
CHAPTER 22:XLW PRIME BACK UP BATTERY..................................................................................187

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CHAPTER 23: MAINTENANCE ........................................................................................................... 189
23.1 Firmware Updates.................................................................................................................... 189
23.2 How to Check for Current Firmware Revision............................................................... 189
23.3 Updating Firmware Details................................................................................................. 190
23.4 Steps for updating the firmware: .......................................................................................191
CHAPTER 24: TROUBLESHOOTING / TECHNICAL SUPPORT .......................................................192
24.1 Connecting to the EXLW/XLW PRIME OCS .....................................................................192
24.2 Local Controller and Local I/O .......................................................................................... 194
24.3 CsCAN Network......................................................................................................................195
24.4 Removable Media - Basic Troubleshooting.................................................................... 196
24.5 Technical Support Contacts............................................................................................... 196
CHANGE LOG.............................................................................................................................................197
MAIN INDEX .............................................................................................................................................. 198

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CHAPTER 1: SAFETY AND 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.