Horner XL Prime OCS PLC HMI Controllers
The Horner XL Prime Series is a family of all-in-one OCS (Operator Control Station) controllers combining PLC logic, a colour operator interface, industrial communications, data logging and optional built-in I/O in a single compact unit. The range extends from the compact XL4 Prime through to the large-format XL15 Prime, allowing a common control platform to be used across machines and process systems of very different sizes.
XL Prime builds on Horner's established XL architecture with a faster processor, 2 MB logic program capacity, onboard mass storage and a modern non-volatile memory system. PLC logic, HMI graphics, I/O and communications are developed in Horner Cscape, reducing the need to engineer and maintain separate PLC and HMI projects.
Why Use a Horner XL Prime OCS?
A conventional automation system may require a PLC, separate HMI, I/O modules and communication hardware. XL Prime integrates these functions into one industrial controller. This can reduce panel space, wiring and component count while providing one software environment for the complete control application.
The series is particularly useful where an operator interface is required at the machine together with local control and I/O. Multiple screen sizes and I/O configurations make it possible to select a controller around the application rather than designing the application around a fixed controller format.
XL Prime Model Range
The XL Prime family includes XL4 Prime, XL6 Prime, XLW Prime, XL7 Prime, XL10W Prime, XL10 Prime and XL15 Prime. Display formats range from compact 4-inch units to a 15-inch XGA touchscreen, with widescreen versions available where additional horizontal display area is useful for process graphics, trends and machine visualisation.
- XL4 Prime – compact 4-inch OCS for smaller machines and control panels.
- XL6 Prime – 6-inch VGA controller with integrated physical keys.
- XLW Prime – widescreen 800 × 480 interface in the XL Prime platform.
- XL7 Prime – 7-inch 800 × 480 OCS with expanded communications and physical keys.
- XL10W Prime – 10-inch widescreen 1024 × 600 operator interface.
- XL10 Prime – 10-inch controller with 640 × 480 display and physical keys.
- XL15 Prime – large 15-inch 1024 × 768 OCS for applications requiring extensive operator graphics.
Flexible Built-In and Remote I/O
XL Prime controllers are available with several built-in I/O options. Depending on the selected model, these can include DC digital inputs and outputs, relay outputs, analogue inputs and analogue outputs. Higher-specification analogue options support signal types including voltage, current, thermocouple, millivolt and RTD, making the platform suitable for both machine control and process instrumentation.
Where additional or distributed I/O is required, XL Prime supports Horner remote I/O systems. This allows sensors and actuators to be located away from the main controller and provides a practical expansion path for larger machines, pumping systems and distributed process applications.
Industrial Communications and Networking
XL Prime provides Ethernet, serial and CAN networking for connection to variable speed drives, instrumentation, remote I/O, supervisory systems and other industrial equipment. Supported technologies include Modbus TCP, Modbus RTU, EtherNet/IP, BACnet, CANopen, J1939 and CsCAN, depending on the model, configuration and protocol requirements.
XL4 Prime, XL6 Prime and XLW Prime provide one Ethernet and one CAN port, while XL7 Prime, XL10W Prime, XL10 Prime and XL15 Prime provide two Ethernet and two CAN ports. This additional connectivity can be useful where separate plant and machine networks or multiple CAN-based devices are required.
Data Logging, Storage and Remote Access
XL Prime includes onboard non-volatile storage together with removable microSD and USB mass-storage support. Applications can use this capacity for recipes, alarm history, production information and process data. Ethernet functions include WebMI, email, FTP server and NTP time synchronisation, subject to the controller configuration and application requirements.
Programming With Horner Cscape
XL Prime is programmed using Horner Cscape. PLC logic, touchscreen graphics, I/O configuration, alarms, data handling and communications are developed within the same engineering environment. A single integrated project can simplify commissioning, backups, fault finding and future machine modifications compared with maintaining separate PLC and HMI software packages.
Key Features of the Horner XL Prime Series
- All-in-one PLC, HMI, networking and I/O architecture
- Fast 0.02 ms/kB logic scan rate
- 2 MB logic program capacity
- 50,000 word program-variable capacity
- Colour touchscreen displays from compact to 15-inch formats
- Multiple built-in digital, relay and analogue I/O configurations
- Support for Horner remote I/O systems
- Ethernet, serial RS-232/RS-485 and CAN communications
- microSD and USB removable mass storage
- 8 GB onboard program storage and non-volatile variable memory
- Integrated PLC and HMI development using Horner Cscape
- 10–30 VDC supply and IP65 front-panel environmental rating
Typical XL Prime Applications
- OEM machinery and machine automation
- Pump and pumping station control
- Water and wastewater treatment
- HVAC and building services
- Conveyors and material handling systems
- Packaging and production machinery
- Food and beverage processing
- Agricultural and irrigation automation
- Process monitoring, data logging and control
- Industrial plant and factory automation
Frequently Asked Questions
What is a Horner XL Prime OCS?
An XL Prime OCS combines the functions of a PLC and operator touchscreen with industrial networking, data storage and optional built-in I/O. The controller and HMI are programmed together in Horner Cscape.
Which Horner XL Prime model should I choose?
Selection is mainly determined by the required screen size and format, built-in I/O, communications and available panel space. Compact machines may suit an XL4 Prime, while applications requiring larger process graphics or more network connectivity may be better suited to XL7, XL10W, XL10 or XL15 Prime.
Can XL Prime connect directly to variable speed drives and instrumentation?
Yes. XL Prime supports widely used industrial Ethernet, serial and CAN protocols, allowing it to communicate with drives, energy meters, transmitters, remote I/O and other automation devices where compatible protocols are available.
Can an XL Prime controller log process data?
Yes. XL Prime provides onboard storage plus microSD and USB mass-storage support, allowing applications to record alarms, process values, production information and other data configured within the Cscape application.
Is XL Prime suitable for new applications?
Yes. Horner positions XL Prime as a current all-in-one OCS platform and recommends XL Prime or Canvas for many new applications where older XL products are now considered mature.
Horner XL Prime OCS Support in New Zealand
Advanced Motor Control Ltd supports Horner OCS products in New Zealand, including XL Prime controller selection, I/O configuration, communications and Cscape application support. Contact us to discuss the screen size, I/O and networking requirements for your machine or process.