HORNER XL Series User manual

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Horner Rechargeable Battery Operation Manual
XL and RCC series controllers running 15.20 Firmware and Later
Table of Contents
1. Overview of Rechargeable Battery Function........................................................................................1
2. Battery Life ...................................................................................................................................................1
3. Lithium Battery Safety..............................................................................................................................2
4. OCS Battery Charging Cycle....................................................................................................................2
5. Battery Charging Status ...........................................................................................................................3
6. Battery Status in System Registers...................................................................................................... 4
7. Battery Operation...................................................................................................................................... 4
8. Fail-Safe System .........................................................................................................................................5
9. Popup Status and Recovery:....................................................................................................................5
10. Check Battery Procedure. ........................................................................................................................7
11. Battery Replacement for XL series units. ........................................................................................... 8
12. RCC Units..................................................................................................................................................... 8
11. Battery Warning..........................................................................................................................................9
12. Technical Support.......................................................................................................................................9
1. Overview of Rechargeable Battery Function
The OCS Controllers with rechargeable batteries maintain register data in high-speed RAM when
connected to DC power. When DC power is switched off or lost, critical circuits switch over and
run on battery power for around 100mS. During this time register and other retentive data is
saved to FLASH memory. After this time the real-time clock continues to run on the battery at a
very low power level. The battery is designed to maintain the real-time clock for a year or more in
the powered-down state. When powered, the OCS controller recharges the battery as necessary.
Recharging the battery can take up to 8 to 40 hours depending on temperature and the state of
charge.
Rechargeable Lithium Battery Table
Controller
Horner Part Number
Battery Description
HE-RCC1410
BAT00028F
3.7V LI-RECH 340mAH 4.5x40x24mm Bare Cell LF
HE-RCC2414
BAT00028F
3.7V LI-RECH 340mAH 4.5x40x24mm Bare Cell LF
HE-RCC8842
BAT00028F
3.7V LI-RECH 340mAH 4.5x40x24mm Bare Cell LF
XL4
BAT00019
3.7V LI ION Rechargeable 800mAH 14500 AA
XL7
BAT00019
3.7V LI ION Rechargeable 800mAH 14500 AA
EXL6
BAT00019
3.7V LI ION Rechargeable 800mAH 14500 AA
EXL10
BAT00019
3.7 V LI ION Rechargeable 800mAH 14500 AA
2. Battery Life
The battery is designed to last 300 full charges to 1000 partial charges or 7 to 10 years. Because
typical operation does not drain the battery, the 1000 charge cycles should never be reached, and
the 7 to 10-year aging of the battery would limit its useful life. The battery is designed to be
replaced.

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3. Lithium Battery Safety
Many of the publicized battery issues are a result of using multiple batteries or flexible battery
pack. The OCS uses a small single cell in a metal enclosure, and the battery is UL recognized and
comes from quality suppliers. The OCS has safety circuitry built into the charging IC and
additional external protection including fusing. These circuits were closely evaluated by UL and
Horner engineering for use in hazardous environments.
4. OCS Battery Charging Cycle
There are various charging states that are executed based on battery temperature, level of
battery charge, and self-test results. The battery temperature can be determined by checking the
CPU temperature in the controller System Menu: View Battery Status or by monitoring System
Register %SR195.
The battery temperature is equal to the CPU temperature minus 30°C.
Refer to Table 1 for charge states and definitions.
1. When power is applied to the OCS, the unit always goes to State 11; Waiting, for the first
two minutes.
2. After two minutes have expired, the OCS wil begin charging the battery based on battery
temperature. In this step, charging will ensue even if the battery is already fully charged.
In this step charging does not ensue if the battery temperature is outside of the
acceptable hot or cold 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 volts under state 2, Hot Charging; 4.1 volts is maintained
until Normal or Cold Charging can be executed.
Note: If the battery voltage is too low, less than 2.5 volts, or if the battery is missing, charging is
suspended. In this condition, the OCS unit fails self-test. Diagnostics will show a battery
warning. %SR55.13 will be ON.
Note: If the battery is not missing and the voltage is 2.5 volts or greater but will not fully charge in
8 to 40 hours, the charge cycle is suspended for 5 minutes and then tried again.
Note: Because the OCS is designed to maintain the Real Time Clock for a year or more in a powered
down state, this translates as; the battery requires up to 8 to 40 hours of recharging time in a
year.

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5. Battery Charging Status
Viewed in the System Menu under “View Battery Status” or read as a numeric value in %SR196.
The battery temperature, Tb, is equal to the CPU temperature minus 30°C: Tb = CPU° - 30°C.
Table 1 –Charging State Table
State -
%SR196
Name
Description
Additional Information
0
Final Charge to 4.2V
The battery is fully charged
Next step, State 12 –Wait
Discharging
1
Normal Charging
Battery is fast charging
Tb: 11-45°C
@100mA to 4200mV
Up to 8 hrs charge time
2
Hot Charging
Battery is slow charging
Tb: 45-60°C
@20mA to 4100mV
Up to 40 hrs charge time
3
Battery Won’t Charge
Battery has not completed charging in
8/40 hours
Charging is suspended for 5
minutes and then tried again.
4
Battery Too Hot
Not Charging
Tb: > 60°C
Charging cycle resumes when
battery 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 fully charged to 4.1V
in Hot Charging mode.
4.1V is maintained until Normal or
Cold charging can execute.
10
Error: Voltage Too
Low
The battery voltage was too low at
power up. It will not attempt to charge
until the next power cycle. Make sure
a proper battery is installed.
%SR55.13 = ON
11
Waiting
The unit has powered up and is
waiting 2 minutes before attempting
to charge.
After 2 minutes, charging begins
even if the battery is fully
charged.
12
Wait Discharging
The battery has been charged and the
system is waiting for the voltage to
drop before charging again.
Charging resumes when battery
voltage has dropped below
4000mV.

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6. Battery Status in System Registers
Table 2 –Battery Status
%SR55.13
ON if battery is missing or if voltage is below 2.5V
%SR195
CPU temperature in °C
%SR196
Charge State; Refer to Table 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 unit, it will be in the ‘Waiting’ state, which means it is not charging,
%SR196 = 11.
7. Battery Operation
NOTE: In RCC, XL4, XL7, EXL6, and EXL10 controllers, the program downloaded from Cscape is
NOT battery backed. The program is stored in non-volatile FLASH memory at the time of
download. The battery plays no part in program retention.
The OCS controllers with rechargeable batteries write register data to high-speed RAM when
connected to DC power. When power to the OCS is switched off or lost, critical circuits switch
over and run on battery power for around a 100mS. During this time, register and other retentive
data is saved to FLASH memory. The clock continues to run on the battery at a much lower
power. The battery is designed to last over a year in this state. Once power is restored to the
OCS, under normal conditions, the battery will be recharged in up to 8 or 40 hours. Depending on
battery level, the charging state may last only a few minutes. Eight (8) to 40 hours is the
maximum amount of time to recharge a good battery. Normal Charging can take up to 8 hours.
Cold or Hot charging can take up to 40 hours to fully recharge the battery.
If a battery is bad, missing, or insufficiently charged, this compromises the ability of the controller
to write the register set to FLASH memory on power down. In this case, register data would
revert to previously saved data after a power cycle. This condition might be seen as the registers
being cleared to zero. This would be because zero was the data at the time of the last successful
save. If there is a battery issue at OCS power-down, the data set from the last successful save is
loaded at power-up.

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8. Fail-Safe System
It is highly recommended to enable the OCS Fail-Safe System for the retention of register data in
the event of battery failure. Please refer to the controller user manual for a complete description
of how the Fail-Safe System works and how to enable it. The Fail-Safe System can be enabled
from the controller System Menu: Fail-Safe System or from %SR System Registers.
In short, here are the steps to follow to enable the Fail-Safe System.
1. Enable Autorun –if desired.
2. Enable Autoload - if desired (requires microSD to be installed).
3. Perform a Backup
NOTE: It is important to follow these steps in the proper order. Do the Backup last.
9. Popup Status and Recovery:
In Firmware 15.20 Popup Status related to register data save status is optional.
If the application is such that retaining register data is not important, if the unit just has to run, then
it might be desirable to leave Pop-up Status messaging disabled. This will allow the unit to boot
normally and go into RUN mode without operator intervention even if there were a problem saving
register data at the last power-down.
If it is important to know at controller power-up that saving of register data had failed at the last
power-down, then it might be desirable to enable Popup status on the OCS. The retention of Job
setpoint data or PID tuning parameters are examples of why Popup status might be desired if a
register save failure occurs. Popup Status messaging is enabled in the System Menu: Set Screen:
Popup Status. How the Fail-Safe system is used or not used will dictate if operator intervention is
required at power-up in the event of a register save failure.
•If Pop-up status is enabled and Autorun is enabled in the Fail-Safe System, there is a delay to
allow the operator time to stop the unit from going into RUN mode. After a 30 seconds
timeout, the unit continues to boot and goes into RUN mode.
•If Pop-up status is enabled and Autorun is disabled, operator intervention is required for the
OCS controller to go into RUN mode.
•If a Backup has been made in the Fail-Safe feature, and if a register save failure occurs at
power-down, the OCS unit will load register data from the Backup when the unit boots up.
Periodic Backups can be made from program logic by writing to %SR164.
See details for %SR164 in the OCS user manual or Cscape help file.
If a register backup issue is detected and the warning screen is displayed the battery should be
checked. The battery most likely needs to be recharged or possibly needs to be replaced.
See the Battery Check procedure in Section 10.

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The following flowchart describes the operation when Popup Status is enabled.

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10. Check Battery Procedure.
The following procedure should be used to determine the battery condition.
•Within the first two minutes after power up, while the unit is in state 11, Waiting (%SR196),
check the battery voltage from the System Menu or %SR198.
oWhen charging, the voltage reading is affected by the charging circuit and therefore
will not be an accurate read. Check battery voltage in a non-charging state.
•A battery may be considered low at less than 4.0 volts. But this is not an indication of a bad
battery.
oAny low battery should be given time to charge before deciding if it is bad or not.
oIn general, let the OCS charge the battery overnight or at least for a few hours, cycle
power to the controller, and check the battery voltage during the Waiting state.
•There are 5 charging states, which are based on battery temperature. (not ambient)
oNot Charging = below 0°C
Cold Charging = 0-10°C - charge current = 20mA (Charges to 4.2 volts)
Normal Charging = 11-45°C - charge current = 100mA (Charges to 4.2 volts)
Hot Charging = 46-60°C - charge current = 20mA (Charges to 4.1V)
Not Charging = greater than 60°C
oThe battery temperature can be gauged by taking the CPU temperature and
subtracting 30°C.
▪Example, in battery status, CPU temperature shows 73°C. The battery
temperature is 43°C and the charging state would be state 1, Normal
Charging.
•When charging in state 2 (Hot Charging) or state 5 (Cold Charging) the current is lower and
so will take much longer to charge. (See %SR196 for state).
oStates 2 or 5 can take up to 40 hours to fully charge a battery, depending on its level
at the beginning of charging.
oState 1, Normal Charging can take up to 8 hours to fully charge a battery, depending
on its level at the beginning of charging.
oIf a battery is only slightly low or close to fully charged, it may only take a few
minutes to fully charge the battery.
•If a battery is completely dead, the battery status from System Menu or %SR198 will still
show around 3.2 to 3.5 volts. This is not the battery, but the supporting circuitry voltage.
oIf the battery if very low or dead, the OCS will fail self-test and show a ‘Battery:
Warning’ in diagnostics. %SR55.13 will be set ON.
o3.2 to 3.5 volts is very low. In this case it would be a good idea to remove the battery
and check it with a volt meter.
▪If the battery shows 1 volt or less, it is dead and should be replaced.
▪If the battery measures greater than 1 volt, let it charge for a few hours
and see if there is improvement or not by checking the voltage while the
OCS is in a non-charging state such as the first two minutes after
powering up the unit.

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11. Battery Replacement for XL series units.
This covers units with Lithium ION batteries including XL4e, XL7e, EXL6, and EXL10:
1. Make sure there is a backup of your register data. Using the Clone feature is an easy
option (requires micro SD). You may also upload the program and registers using Cscape.
2. Remove power from the unit.
3. Follow directions in the user manual for replacing the battery.
4. Apply power and restore program and registers if necessary.
5. Allow the unit to remain powered near room temperature (10-35°C) for 6 to 8 hours. This
will ensure the battery is fully charged properly for the first time.
6. Once the battery is charged, test the battery function by removing power and re-applying.
Registers and clock function should be retained and there be no error messages on power
up.
(On first power-up after replacing a battery, it is normal for the unit to fail the self-test
and popup the Register Backup Issue Detected message. After the battery has been given
time to charge, on subsequent power-ups the messages should go away, and the unit
should pass self-tests).
7. Once charged, the battery management system will maintain the battery at optimal charge
depending on use and temperature.
12. RCC Units
All the RCC OCS models, EXCEPT for the RCC972, use a lithium-ion battery. This battery powers
the real time clock, registers, and data memory when power is removed. Under normal conditions,
the battery should last seven years. Higher operating temperatures or variations in batteries may
reduce this time.
NOTE: The battery is adhered to the unit and not replaceable.
NOTE: The RCC972 does not have a backup battery.
If the battery fails in an RCC unit, please contact your supplier and arrange for the unit to be sent
in on RMA for repair. Do not attempt to disassemble the unit as the lithium battery may explode
or catch fire if mishandled.

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11. Battery Warning
Please refer User Manual for proper handling of the rechargeable lithium battery.
WARNING: Lithium Batteries may explode or catch fire if mistreated.
Do not recharge, disassemble, heat above 100⁰C (212⁰F) incinerate, or puncture.
12. Technical Support
North America:
Tel: [phone]
Fax: [phone]
Web: https://hornerautomation.com
Email: techspp[email protected]
Europe:
Tel: [phone]
Fax: [phone]
Web: http://www.horner-apg.com
Email: [e-mail]