HORNER EXLW User manual
User Manual for
EXLW & XLW Prime
MAN1256-20.0-EN_EXLW_XLWP_UM
Visual Map
The datasheet is the first document to refer to for model-specific information related to EXLW/XLW Prime models for
installation information. Find the documents via the Documentation Search page on the Horner website.
Datasheet Manual Numbers
EXLW Model 0
XLW Prime Model 0
MAN1257
MAN1338
EXLW Model 2
XLW Prime Model 2
MAN1258
MAN1333
EXLW Model 3
XLW Prime Model 3
MAN1259
MAN1334
EXLW Model 4
XLW Prime Model 4
MAN1260
MAN1335
EXLW Model 5
XLW Prime Model 5
MAN1261
MAN1336
EXLW Model 6
XLW Prime Model 6
MAN1262
MAN1337
Visual Map
Quick Start Installation Programming Troubleshooting
"Safety and Compliance" on
page10
"Mechanical Installation"
on page16
"System Settings and Adjust-
ments" on page26
"Fail-Safe System" on
page167
"Intro to the EXLW &XLW
Prime" on page12
"Electrical Installation" on
page23
"Removable Media" on
page157 "Clone Unit" on page163
"Serial Communications"
on page116
"General I/O Configuration" on
page72
"Firmware Updates" on
page179
"CAN Communications"
on page120
"High Speed I/O (HSC / PWM)
" on page94
"Modbus Communications"
on page175
"Protocol Configuration "
on page129 "User Interface" on page140 "EXLW Rechargeable Bat-
tery" on page183
"Ethernet Com-
munications" on page123
"System Register Tables" on
page51
"Prime OCS Prime Battery"
on page189
"Cscape Configuration" on
page61 "Troubleshooting" on
page192
"Video Object" on page150
LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the EXLW/XLW Prime 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 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 respons-
ibility of the system designer utilizing the EXLW/XLW Prime OCS module to appropriately design the end system, to
appropriately integrate the EXLW/XLW Prime OCS module and to make safety provisions for the end equipment as is
usual and customary in industrial applications as defined in any codes or standards which apply.
NOTE: The programming examples shown in this manual are for illustrative purposes only. Proper machine
operation is the sole responsibility of the system integrator.
PREFACE
This manual explains how to use the EXLW/XLW Prime OCS.
Copyright (C) 2020 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights reserved. No part
of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any lan-
guage or computer language, in any form by any means, electronic, mechanical, magnetic, optical, chemical, manual or
otherwise, without the prior agreement and written permission of Horner APG, Inc.
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, and CsCAN are trademarks of Horner APG. Ethernet is a trademark of Xerox
Corporation®.
microSD®and CompactFlash are registered trademarks of SanDisk Corporation®.
Published with Madcap Flare®.
North America
Tel: (+) (317) 916-4274
Fax: (+) (317) 639-4279
Web: http://www.hornerautomation.com
Email: [email protected]
Europe
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Web: http://hornerautomation.eu
Email: [email protected]
Table of Contents
Safety and Compliance 10
Intro to the EXLW &XLW Prime 12
Visual Overview 12
Where to find more information for the EXLW & XLW Prime 13
Connectivity to the EXLW & XLW Prime 13
Features of EXLW/XLW Prime OCS 14
Mechanical Installation 16
Mounting Requirements 16
Mounting Orientation 17
EXLW &XLW Prime OCS Mounting Clip 17
EXLW &XLW Prime OCS Mounting Orientation 17
Dimensions 18
Installation Procedure 19
Factors Affecting Panel Layout Design and Clearances 20
Electrical Installation 23
Ground Specifications 23
How to Test for Good Ground 23
Primary Power Port 24
System Settings and Adjustments 26
OCS LED Indicator Lights 26
System Menu – Navigation and Editing 27
System Menu Map 28
Set Networks 29
View Status & Diags 30
View Battery Status, I/O Slots &Protocols 32
Set Fkeys Mode, Serial Ports, Ethernet, Time/Date, Beeper &Screen 35
Removable Media 41
Fail – Safe System 42
Clone Unit 45
WebMI License Details 48
Touch Screen Calibration 49
System Register Tables 51
Register Definitions 51
%S Registers 52
%SR Registers 53
Cscape Configuration 61
Cscape Status Bar 61
Establishing Communications 62
Communicating via MJ1 Serial Port 67
Communicating via On Board Ethernet Port 68
Cscape Configuration 70
General I/O Configuration 72
Built-in Digital and Analog I/O Overview 72
Removing the Horner OCS Back Cover 73
Digital / HSC Input Configuration 74
Digital / PWM Output Configuration 78
Solid State Digital Outputs 78
Relay Outputs 79
Digital Output Configuration 80
Analog Inputs 83
Analog Outputs 92
High Speed I/O (HSC / PWM) 94
Overview 94
High Speed I/O Glossary 95
High Speed Counter (HSC) Functions 96
Frequency 96
Totalize 96
Pulse Width Measurement 98
Period Measurement 99
Quadrature 100
HSC Functions 101
Status Bits 102
HSC Functions Register Maps 103
High Speed Output Functions 107
Stepper Function 109
High Speed Output Functions Register Map 110
HSC I/O Filtering 113
Serial Communications 116
Port Descriptions 116
Wiring 116
Dip Switches 117
RS485 Termination 117
RS485 Biasing 117
Cscape Programming via Serial Port 118
Ladder-Controlled Serial Communication 118
Configuration via Mini-B USB 118
CAN Communications 120
Port Description 120
CAN1 Port Wiring 120
Cscape Programming via CAN 121
Ladder-Controlled CAN Communication 121
Using CAN for I/O Expansion (Network I/O) 121
Ethernet Communications 123
Ethernet Module Protocols and Features 123
Ethernet Module Specifications 124
Ethernet Module Configuration 124
Ethernet Configuration – IP Parameters 127
Ethernet Module Protocol Configuration 127
Protocol Configuration 129
Overview 129
Protocol Device Driver Selection 130
Network Configuration 131
Device List and Device Configuration 133
Scan List 135
User Interface 140
Screen Specifications 140
Displaying and Entering Data 141
Alpha-Numeric Keypad 142
Screen Navigation 143
Ladder-Based Screen Navigation 144
Beeper Acknowledgement 144
Touch (Slip) Sensitivity 144
Alarms 145
Removable Media 146
Screen Saver 147
Screen Brightness 147
Touch Screen Pressure 148
Video Object 150
Video Object Overview 150
Opening Video Object in Cscape 151
Video Properties Configuration 153
Video Object Performance 155
Web Cameras 155
Removable Media 157
microSD Cards 157
Using the Removable Media Manager 158
Log Data 158
View and Capture Screens 159
Removable Media Object 159
Function Blocks in Cscape 160
Filenames 161
System Registers used with RM 161
Clone Unit 163
Make Clone 163
Load Clone 165
Fail-Safe System 167
For the XL Series 167
For the XL Prime Series 167
Fail-Safe System 167
Settings 168
Backup / Restore Data 168
AutoLoad 171
AutoRun 173
Modbus Communications 175
Modbus Slave Overview 175
Modbus Master Overview 176
Modbus Addressing Table 177
Firmware Updates 179
Check for Current Firmware Revision 179
Firmware Update Details 180
Download Firmware 180
Firmware Update Steps 181
EXLW Rechargeable Battery 183
Storing Register Contents 183
Battery Life 183
Lithium Battery Safety 183
OCS Battery Charging Cycle 184
Battery Charging Status 185
Battery Status in System Registers 186
Safety & the Rechargeable Backup Battery 186
Steps to Replace the Rechargeable Battery 187
Prime OCS Prime Battery 189
Prime OCS Battery &Safety 189
Replacing the Prime OCS Battery 190
Troubleshooting 192
Safety and
Compliance
Page 9
Safety and Compliance
Safety and Compliance
Safety Warnings
When found on the product, the following symbols specify:
Warning: Consult user documentation. Warning: Electrical Shock Hazard.
WARNING: EXPLOSION HAZARD – Substitution of components may impair suitability for Class I, Division 2.
WARNING: EXPLOSION HAZARD – 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: 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.
NOTE: All applicable codes and standards need to be followed in the installation of this product.
NOTE: For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG or larger.
NOTE:See the "Electrical Installation" on page23 for more details.
Safety Precautions
Adhere to the following safety precautions whenever any type of connection is made to the module:
lConnect the green safety (earth) ground first before making any other connections.
lWhen connecting to electric circuits or pulse-initiating equipment, open their related breakers. Do not make
connections to live power lines.
lMake connections to the module first; then connect to the circuit to be monitored.
lRoute power wires in a safe manner in accordance with good practice and local codes.
lWear proper personal protective equipment including safety glasses and insulated gloves when making con-
nections to power circuits.
lEnsure hands, shoes, and floors are dry before making any connection to a power line.
lMake sure the unit is turned OFF before making connection to terminals. Make sure all circuits are de-ener-
gized before making connections.
lBefore each use, inspect all cables for breaks or cracks in the insulation. Replace immediately if defective.
CE Compliance
To check for compliance and updates, visit our website.
North America https://hornerautomation.com/certifications
Europe https://www.hornerautomation.eu/support/certifications-2/
Page 10 of 196
Introduction to
the EXLW&
XLWPrime
Page 11
Intro to the EXLW &XLW Prime
Intro to the EXLW &XLW Prime
Visual Overview 12
Where to find more information for the EXLW & XLW Prime 13
Connectivity to the EXLW & XLW Prime 13
Features of EXLW/XLW Prime OCS 14
Visual Overview
1. Touchscreen
2. USB 2.0 “A”: Flash Drive
3. LAN Port
4. PWR: 10-30VDC In
5. CAN Port
6. MJ3: RS-232/485
7. Dip Switches
8. MJ1/MJ2: RJ45 Serial Port
9. microSD: Data Storage
10. USB mini “B”: Programming
NOTE: Use caution when connecting controllers to PCs via serial or USB. PCs, especially laptops may use “floating
power supplies” that are ungrounded. This could cause a damaging voltage potential between the laptop and con-
troller. Ensure the controller and laptop are grounded for maximum protection. Consider using a USB isolator due to
voltage potential differences as a preventative measure.
Page 12 of 196
Intro to the EXLW &XLW Prime
Where to find more information for the EXLW & XLW Prime
Datasheets - The datasheets are the first documents to refer to for key information related to specific models. (A
basic datasheet is provided in the box with the unit.)
Find the documents via the Documentation Search page on the Horner website.
Datasheet Manual Numbers
EXLW Model 0
XLW Prime Model 0
MAN1257
MAN1338
EXLW Model 2
XLW Prime Model 2
MAN1258
MAN1333
EXLW Model 3
XLW Prime Model 3
MAN1259
MAN1334
EXLW Model 4
XLW Prime Model 4
MAN1260
MAN1335
EXLW Model 5
XLW Prime Model 5
MAN1261
MAN1336
EXLW Model 6
XLW Prime Model 6
MAN1262
MAN1337
Connectivity to the EXLW & XLW Prime
Connectivity
CAN I/O USB Serial Ethernet
Other OCS Devices Sensors Flash Drive Other OCS Devices Cscape
SmartStix I/O Indicators Cscape Drives OPC Server
SmartBlock I/O Alarms PLCs Modbus TCPDevices
SmartRail I/O Encoders Printers
OPC Pumps SCADA
Relays OPC Server
Solenoids Portal
I/O Devices
SmartRail Devices
Page 13 of 196
Intro to the EXLW &XLW Prime
Features of EXLW/XLW Prime OCS
The EXLW/XLW PRIME OCS are all-in-one industrial control devices. They combine control, user interface, I/O and
networking into a single, integrated package. Unique features of the EXLW/XLW PRIME OCS include:
nBright, 65,536 color graphical touch sensing LCD display in all models of EXLW/XLW PRIME.
nDisplay of complex graphical objects including trends, gauges, meters and animations.
nVery high-performance graphic processing.
nAdvanced control capabilities including floating point, multiple auto-tuning PID loops and string handling cap-
abilities.
nRemovable media for 32GB of storage of programs, data logging or screen captures.
nCsCAN networking port for communication with remote I/O, other controllers or PCs.
nHigh speed USB port for communication with PCs and programming of controller.
nConfigurable serial protocols for communication to drives, PLCs, or other serial peripherals.
nFull featured, built-in I/O including high resolution analog, thermocouple, RTD, high-speed counters, PWM
outputs and relays (depending upon the EXLW/XLW PRIME OCS model used).
nAdvanced high speed I/O capabilities.
nCscape programming software that allows all aspects of the EXLW/XLW PRIME OCS to be programmed
and configured from one integrated application.
nOptional communication add-on modules.
nTwo on board Ethernet ports (10/100Mbps) for Cscape programming and application defined com-
munication, with Auto MDI/MDI-X.
Page 14 of 196
Mechanical
Installation
Page 15
Mechanical Installation
Mechanical Installation
Mounting Requirements 16
Mounting Orientation 17
Dimensions 18
Installation Procedure 19
Factors Affecting Panel Layout Design and Clearances 20
NOTE: The datasheet is the first document to refer to for model-specific information related to EXLW &XLW Prime
models such as pin-outs, jumper settings, and other key installation information. See the Documentation Search for
datasheets.
The mechanical installation greatly affects the operation, safety and appearance of the system. Information is
provided to mechanically install the unit such as cut-out sizes, mounting procedures, and other recommendations
for the proper mechanical installation of the unit.
Mounting Requirements
Once the panel design has been completed using the criteria and suggestions in the following sections, use the fol-
lowing steps to panel mount the EXLW &XLW Prime OCS.
1. Remove all connectors from the EXLW &XLW Prime OCS unit.
2. Make sure the gasket is installed on the EXLW &XLW Prime OCS and is free from dust and debris. Check
that the corners of the gasket are secure.
3. Pass the unit through the panel.
4. Insert the each of the four (4) mounting clips into the slots in the EXLW &XLW Prime OCS case. One clip
should be installed on each corner. Lightly tighten each screw so the clip is held in place.
5. Tighten the screws on the clips such that the gasket is compressed against the panel. Recommended torque
is 4-8 in-lbs (0.45 – 0.90 N-m).
Page 16 of 196
Mechanical Installation
Mounting Orientation
EXLW &XLW Prime OCS Mounting Clip
EXLW &XLW Prime OCS Mounting Orientation
NOTE: There are no orientation restrictions on the EXLW/XLW PRIME OCS. However, the above orientation
provides for optimum readability of the screen and ease of use of the keypad.
Page 17 of 196
Mechanical Installation
Dimensions
For installations requiring NEMA 4X liquid and dust protection, the panel cutout should be cut with a tolerance of
+1mm/-0mm.
Page 18 of 196
Mechanical Installation
Installation Procedure
nThe EXLW/XLW PRIME utilizes a clip installation method to ensure a robust and watertight seal to the
enclosure. Please follow the steps below for the proper installation and operation of the unit.
nThis equipment is suitable for Class I, Division 2, Groups A, B, C and D or non-hazardous locations only.
nDigital outputs shall be supplied from the same source as the operator control station.
nJumpers on connector JP1 shall not be removed or replaced while the circuit is live unless the area is known
to be free of ignitable concentrations of flammable gases or vapors.
1. Carefully locate an appropriate place to mount the EXLW/XLW PRIME. Be sure to leave enough room at the
top of the unit for insertion and removal of the microSD™ card.
2. Carefully cut the host panel per the diagram, creating a 131.9mm x 175.0mm, with a +1mm/-0mm panel
cutout tolerance, opening into which the EXLW/XLW 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 edges and ensure the panel is not warped in the cutting process.
4. 4Remove all Removable Terminals from the EXLW/XLW PRIME. Insert the EXLW/XLW PRIME through the
panel cutout (from the front). The gasket must be between the host panel and the EXLW/XLW PRIME.
5. Install and tighten the four mounting clips (provided in the box) until the gasket forms a tight seal. NOTE: Max
torque is 0.8 to 1.13Nm, or 7 to 10 in-lbs.
6. Reinstall the EXLW/XLW PRIME I/O Removable Terminal Blocks. Connect communications cables to the
serial port, USB ports, Ethernet port, and CAN port as required.
Page 19 of 196
Mechanical Installation
Factors Affecting Panel Layout Design and Clearances
WARNING: It is important to follow the requirements of the panel manufacture and to follow all applicable electrical
codes and standards.
The designer of a panel layout must assess the requirements of a particular system and to consider the following
design factors.
Clearance / Adequate Space
Install devices to allow sufficient clearance to open and close the panel door.
Minimum Clearance Requirements for Panel Box and Door
Minimum Distance between base of device and sides of cabinet 2” (50.80mm)
Minimum Distance between base of device and wiring ducts 1.5” (38.10mm)
If more than one device installed in panel box (or on door):
Minimum Distance between bases of each device
4” (101.60mm) between bases of each
device
When door is closed:
Minimum distance between device and closed door
(Be sure to allow enough depth for the OCS.)
2” (50.80mm)
Grounding
Panel Box: The panel box must be properly connected to earth ground to provide a good common ground ref-
erence.
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.
WARNING: Be sure meet the ground requirements of the panel manufactuer and also meet applicable electrical
codes and standards.
Temperature / Ventilation
Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient tem-
perature range. Consider the impact on the design of the panel layout if operating at the extreme ends of the ambi-
ent temperature range. For example, if it is determined that a cooling device is required, allow adequate space and
clearances for the device in the panel box or on the panel door.
Noise
Consider the impact on the panel layout design and clearance requirements if noise suppression devices are
needed. Be sure to maintain an adequate distance between the OCS and noisy devices such as relays, motor
starters, etc.
Shock and Vibration
The OCS has been designed to operate in typical industrial environments that may inflict some shock and vibration
on the unit. For applications that may inflict excessive shock and vibration please use proper dampening techniques
or relocate the OCS to a location that minimizes shock and/or vibration.
Page 20 of 196
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