HORNER X Series User manual

MAN1138-03-EN-EU
Unit 1 Centrepoint, Centre Park Road, Cork, T12 H24E, Ireland. | (p) [phone] (f) [phone] | www.horner-apg.comg.comg.comg.comg.comg.comg.com
Please visit our website for a complete listing and to learn more about certified Horner Automation products.
This document is the property of Horner Automation Group, and is subject to change.
1 TECHNICAL SPECIFICATIONS
1.4 Control & Logic
Control Language
Support
Advanced ladder logic
Full IEC 61131-3 languages
Logic Program Size 256kB
Non-Retentive Memory 128kB
Internal Storage
Memory 16Mb
Total Program
Memory 2.5Mb
Logic Scan Rate 0.4ms/kB
%I (Digital Inputs) 1024
%Q (Digital Outputs) 1024
%AI (Analog Inputs) 256
%AQ (Analog
Outputs) 256
%M (Retentive Bits) 1024
%T (Temporary Bits) 1024
%R (Retentive Registers) 5000
%D (Display Bits) 250
%K (Key Bit) 4
%S (Status Bits) 16
%SR (System Registers) 192
1.3 Connectivity
Serial Ports 1 x RS232, 1 x RS485
485 Terminations On-board, software
controlled
USB mini-B Slave only
USB Programming
Support Yes
USB Type USB 2.0
CAN Hardware CAN 2.0
CAN Port Connector RJ45 (Red)
CAN Port Speeds
Support
125kB, 250kB, 500kB,
1Mb/sec.
CAN Port Termination On-board, software
controlled
CAN Protocols CsCAN
Removable Memory In
microSD (SDHC, SDXC
IN FAT32 format,
support for 32GB max.
Application Updates,
Datalogging, more)
1.2 User Interface
Display 4.3” 65k Color
Transmissive
Resolution 480 x 272 pixels
Backlight White LED
Backlight Lifetime 20,000 hrs to reach
50% brightness
Backlight Control Yes, software
controlled (ON/OFF)
User-Programmable
Screens/Pages 250
No. of Objects/Screens 30
Screen Memory 256kB
Keypad Slide Keys (Touch)
Tactile Feedback Optional Sound
Number of Keys Slide Keys (Touch)
X OCS MODEL: HE-X4
1.1 General
Primary Pwr.
Range 24VDC +/- 20%
Typical power
Backlight 100%
140mA @ 24VDC
170mA @ 19.2VDC
Power
Backlight Off
105mA @ 24VDC
135mA @ 19.2VDC
Inrush Current 30mA ˂1ms
Real Time Clock Battery backed;
lithium coin cell CR2450
Clock Accuracy +/- 90 Secs/Month
Relative Humidity 5 to 95% Non-condensing
Operating Temp. -10°C to +60°C
Storage Temp. -20°C to +70°C
Weight 360g
Mounting Clips 4 composite type
Housing Material Polycarbonate, UL rated
Panel Seal Silicone rubber
Packaging 100% Recyclable
paper fiber materials
Included in Box
Controller,
3 x I/0 connectors,
4 x mounting clips,
1 x power connector, Quick
Reference Guide
1.5 I/O Connections
Terminal Type Removable 3.5 m
color-coded
I/O Options None
Remote I/O Serial, CAN, Ethernet
1.6 Testing
Shock IEC 60068-2-27
Vibration IEC 60068-2-6
Washdown NEMA 4X
Certifications
(UL/CE)
USA: https://hornerauto-
mation.com/certifications/
Europe: http://www.
horner-apg.com/en/support/
certification.aspx
1.7 Inputs/Outputs Model Overview
MODEL R MODEL A
DC In 12 12
DC Out 2 12
Relays 6 –
HS In 4 4
HS Out 2 2
mA In/RTD 4 4
mA Out 2 2
There are four high-speed inputs of the total DC Inputs.
There are two high-speed outputs of the total DC outputs.
Model A supports sourcing outputs. Model R DC outputs are
sinking with integral pull up resistors.
page 1 of 7 technical specifications continued on next page...
MODEL A BUILT-IN I/O: 12 DIGITAL IN, 12 DIGITAL OUT, 4 ANALOG IN/RTD IN, 2 ANALOG OUT
MODEL R BUILT-IN I/O: 12 DIGITAL IN, 6 RELAY OUT, 2 PWM OUT, 4 ANALOG IN/RTD IN, 2 ANALOG OUT

MAN1138-03-EN-EU
Unit 1 Centrepoint, Centre Park Road, Cork, T12 H24E, Ireland. | (p) [phone] (f) [phone] | www.horner-apg.comg.comg.comg.comg.comg.comg.com
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1.9 Relay Outputs: Model R
Outputs per
Module 6 Relay
Commons per
Module 6
Max. Output Cur-
rent per Relay
3A @ 60VAC, resistive
3A @ 30VDC, resistive
Max. Total Output
Current 5A continuous
Max. Output
Voltage
3A @ 60VAC, resistive
3A @ 30VDC, resistive
Max. Switched
Power 150W
Contact Isolation
to Ground 1000VAC
Max. Voltage Drop at
Related Current 0.5V
Expected Life (see
below derating
chart for detail)
No Load: 5,000,000
Rated Load: 100,000
Max. Switching
Rate
300 CPM at no load
20 CPM at rated load
Type Mechanical Contact
Response Time One update per ladder scan
plus 10 ms
1.12 Analog Inputs: Models R & A
Number of Channels 4
Input Ranges 0-20mA; 4-20mA;
PT100 RTD
RTD Temperature
Range
-58° to 392°F
(-50° to 200°C)
PT100 DIN
Nominal Resolution 12 Bits
Safe Input Voltage
Range
-0.5V to 12V,
protection up to 24V
Input Impedance
(clamped @ -0.5VDC
to 12VDC)
Current Mode: 100Ω
Nominal Resolution 12 Bits
%AI Full Scale 32,000
Max. Over Current 35mA
Max Error at 25˚C
(excluding Zero)
Adjusting Filtering may
Tighten
< 1.5%
Filtering
160 Hz Hash (noise)
Filter, 1-128 Scan Digital
Running Average Filter
1.8 Digital DC Inputs: Models R & A
Inputs per Module 12 Including 4 Config-
urable HSC Inputs
Commons per Module 1
Input Voltage Range 12VDC / 24VDC
Absolute Max.
Voltage 35VDC Max.
Input Impedance 10kΩ
Input Current: Positive
Logic
Negative
Logic
Upper Threshold
Lower Threshold
0.8mA
0.3mA
-1.6mA
-2.1mA
Max. Upper Threshold 8VDC
Min. Lower Threshold 3VDC
OFF to ON Response 0.1ms
ON to OFF Response 0.1ms
Number of Counters 4
Maximum Frequency 500kHz
Accumulator Size 32-bits each
Modes Supported
Totalizer, quadrature, pulse
measurement, frequency
measurement, set-point
controllled outputs
technical specifications continued...
1.13 Analog Outputs: Models R & A
Number of Channels 2
Output Ranges 4-20mA
Nominal Resolution 12 Bits
Update Rate Once per PLC scan
Max. Error at 25°C
(Exluding Zero) <1.5%
Maximum 20 mA
Load 500Ω
% AQ Full Scale 32,000
Protection Protect against miswire up
to 24VDC auto-recover
1.10 Digital DC Outputs, Sinking: Model R
Outputs per Module 2 (PWM or HSC)
Commons per Module 1
Type Sinking w/optional
10kΩpull-up
Absolute Max. Voltage 28VDC
Output Protection Short circuit
Max. Output per
Point: Sinking 500mA
Max. Voltage Drop at
Rated Current 0.25VDC
Max Inrush 650mA
OFF to ON Time 20μs
ON to OFF Time 10μs
PWM Out 65kHz
Rise Time 10μs
Fall Time 20μs
1.11 Digital DC Outputs,
Sourcing: Model A
Outputs per Module 12 Including 2 Config-
urable PWM Outputs
Commons per Module 2
Type Sourcing / 10kΩPull-
Down
Absolute Max. Voltage 28VDC
Output Protection Short circuit
Max. Output per
Point: Sourcing 2.4mA @ 24VDC
Max. Voltage Drop at
Rated Current 0.25VDC
Max Inrush 650mA
OFF to ON Time 1μs
ON to OFF Time 1μs
PWM Out 65kHz
Rise Time 150ns
Fall Time 150ns
page 2 of 7

MAN1138-03-EN-EU
Unit 1 Centrepoint, Centre Park Road, Cork, T12 H24E, Ireland. | (p) [phone] (f) [phone] | www.horner-apg.comg.comg.comg.comg.comg.comg.com
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2 CONTROLLER OVERVIEW
2.1 - Port Connectors
page 3 of 7
DC Input / Frame
Solid/Stranded wire; 12-24 awg (2.5-0.2mm). Strip length – 0.28” (7mm).
Torque rating: 4.5 – 7 in-lbs (0.50 – 0.78 Nm).
DC- is internally connected to I/O V-.
A Class 2 power supply must be used to meet UL requirements.
2.2 - Power Wiring
Primary Power Port Pins
PIN SIGNAL DESCRIPTION
1 Ground Frame Ground
2DC- Power Supply Common
3 DC+ Power Supply Voltage
wiring: I-O continued on next page...
1. Touch Screen
2. High Capacity microSD Slot
3. RS232/RS485 Serial Connector
4. CAN Port (via RJ45)
5. LAN Port
6. USB Mini-B Port
7. Analog I/O
8. DC Inputs
9. DC Outputs
10. DC Power
1
2
3 4 5 6
7
8
9
10
POSITION/PIN DIGITAL MODEL
1 Q1 Output 1 (PWM)
2 Q2 Output 2 (PWM)
3 Q3 Output 3
4 Q4 Output 4
5 V+ External V+
6 C Common
7 Q5 Output 5
8 Q6 Output 6
9 Q7 Output 7
10 Q8 Output 8
11 Q9 Output 9
12 Q10 Output 10
13 Q11 Output 11
14 Q12 Output 12
15 V+ External V 2 +
16 C Common
Q1 Q2 Q3 Q4 V+ CQ5 Q6 Q7 Q8 Q9 Q10 Q11 Q12 V+ C
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
Model A - Digital Out
J1 Wiring
POSITION/PIN DIGITAL MODEL
1 R1 Relay 1 N.O.
2 C1 Relay 1 C
3 R2 Relay 2 N.O.
4 C2 Relay 2 C
5 R3 Relay 3 N.O.
6 C3 Relay 3 C
7 R4 Relay 4 N.O.
8 C4 Relay 4 C
9 R5 Relay 5 N.O.
10 C5 Relay 5 C
11 R6 Relay 6 N.O.
12 C6 Relay 6 C
13 Q1 Output 1
14 Q2 Output 2
15 V+ External V+
16 C Common
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
L
N
L
N
L
N
L
N
L
N
L
N
230 VAC or 25 VDC
230 VAC or 25 VDC
230 VAC or 25 VDC
230 VAC or 25 VDC
230 VAC or 25 VDC
230 VAC or 25 VDC
R1 C1 R2 C2 R3 C3 R4 C4 R5 C5 R6 C6 Q1 Q2 V+ C
SINKING
SOURCING
NOTE: Internal 10kΩresistors
between: V+ and Q1; V+ and Q2
Model R - Relay and Digital Out
J1 Wiring
3 WIRING: INPUTS AND OUTPUTS
3.1 - Digital Output Wiring
3.2 - Model R - Outputs and Sinking/Sourcing

MAN1138-03-EN-EU
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wiring: I-O continued...
page 4 of 7
Positive Logic vs. Negative Logic Wiring
The OCS can be wired for positive logic inputs or negative.
0V
I1
0V
I1
12-24VDC
Positive Logic In Negative Logic In
Model R: Sinking Outputs
Model R: Sourcing Outputs
Model R Sinking and Sourcing Outputs
Sinking: Outputs can sink 500mA.
Sourcing: 2.4mA sourcing @ 24VDC
Q1
10kΩ
V+
C
Load
Q1
C
Load
POSITION/PIN DIGITAL MODEL
1 I1 Input 1
2 I2 Input 2
3 I3 Input 3
4 I4 Input 4
5 I5 Input 5
6 I6 Input 6
7 I7 Input 7
8 I8 Input 8
9 I9 Input 9 (HSC1)
10 I10 Input 10 (HSC2)
11 I11 Input 11 (HSC3)
12 I12 Input 12 (HSC4)
13 C Common
14 C Common
I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 I11 I12 C C
12-24
VDC
Model R & Model A - Digital Input
J2 Wiring
3.4 - RTD Wiring
Removing and Inserting Connectors:
Use a small screwdriver to gently pry up the connector.
Gently press on connector to snap into place.
Wiring Details:
Solid/Stranded wire; 12-24 awg (2.5-0.2mm).
Strip length – 0.28” (7mm)
Torque rating: 4.5 – 7 in-lbs (0.50 – 0.78 Nm).
wiring: I-O continued on next page...
3.3 - Digital Inputs
PIN 4 x 2 -Wire RTD
Connections
1 AI1
2 RTD1+
3 AI2
4 RTD2+
5 AI3
6 RTD3+/AQ1
7 AI4
8 RTD4+/AQ2
9 Common
RTD
AI1 R1+ AI2 R2+ AI3 R3+
AQ1 AI4 R4+
AQ2 C
RTD
RTD
RTD
RTD: 4 x 2-Wire RTD Connection
J3 Wiring
RTD: 4 x 3 -Wire RTD Connection
J3 Wiring
PIN 4 x 3 -Wire RTD
Connections
1 AI1
2 RTD1+
3 AI2
4 RTD2+
5 AI3
6 RTD3+/AQ1
7 AI4
8 RTD4+/AQ2
9 Common
RTD
AI1 R1+ AI2 R2+ AI3 R3+
AQ1 AI4 R4+
AQ2 C
RTD
RTD
RTD
If AQ1 is used, RTD3 is unavailable.
If AQ2 is used, RTD4 is unavailable.

MAN1138-03-EN-EU
Unit 1 Centrepoint, Centre Park Road, Cork, T12 H24E, Ireland. | (p) [phone] (f) [phone] | www.horner-apg.comg.comg.comg.comg.comg.comg.com
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wiring: I-O continued... 4 COMMUNICATIONS
CAN Pin Assignments
PIN SIGNAL
8 No Connection
7 Ground
6 Shield
5 No Connection
4 No Connection
3 Ground
2 CAN Data Low
1 CAN Data High
CAN
Modular jack
(8 posn RJ45)
4.1 - CAN Communications
The CAN port is provided via the single 8-position modular jack labeled
“CAN”. It may be used to communicate with other OCS products using
Horner’s CsCAN protocol. Additionally, remote expansion I/O such as
SmartRail, SmartBlock, and SmartStix may be implemented using the
CsCAN protocol.
Termination for the CAN port may be enabled from the System Menu or
System Register. This should only occur if the X4 is at either end of the
CAN network. Only the two devices on either end of the CAN network
should be terminated.
page 5 of 7
I/O STATUS AND CALIBRATION
This controller supports field calibration for higher accuracy.
Refer to the X4 User Manual [MAN1137] for full details.
MJ1 & MJ2 PINS
PIN SIGNAL DIRECTION
8TXD OUT
7RXD IN
6 0V Common
5+5V @
60 mA OUT
4RTS OUT
3CTS IN
2RX-/TX- IN/OUT
1RX+/TX+ IN/OUT
4.2 - Serial Communications
MJ1: RS-232
w/full handshaking
MJ2: RS-485
half-duplex
RS-485 termination
and biasing via
System Menu or
System Register
X4 User Manual [MAN1137]
The User Manual includes extensive information on:
• Built-in I/O
• I/O Status and Calibration
• Common %S & %SR Registers
• HSC/PWM/Totalizer/Quadrature & Accumulator Registers
• Resource Limits
3.5 - 4-20mA Wiring
4 x 4-20mA Input / 4-20mA Output
J3 Wiring
PIN 4-20mA Input/
Output
1 AI1
2 RTD1+
3 AI2
4 RTD2+
5 AI3
6 RTD3+/AQ1
7 AI4
8 RTD4+/AQ2
9 Common
AI1 R1+ AI2 R2+ AI3 R3+
AQ1 AI4 R4+
AQ2 C
+ 20mA -
+ 20mA -
LOOP PWR
communications continued on next page...
PIN 2 x 3 -Wire RTD
Connections
1 AI1
2 RTD1+
3 AI2
4 RTD2+
5 AI3
6 RTD3+/AQ1
7 AI4
8 RTD4+/AQ2
9 Common
RTD: 2 x 3-Wire RTD Connection
& 2 x 4-20mA Output-J3 Wiring
RTD
AI1 R1+ AI2 R2+ AI3 R3+
AQ1 AI4 R4+
AQ2 C
RTD
+ 20mA -
+ 20mA -

MAN1138-03-EN-EU
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page 6 of 7
5.1 - Built-in I/O (Model R & Model A)
Both X4 models feature built-in I/O. The I/O is mapped into OCS
Register space, in three separate areas – Digital/Analog I/O, High-Speed
Counter I/O, and High-speed Output I/O. Digital and analog I/O location
is fixed starting at 1, but the high-speed counter and high-speed output
references may be mapped to any open register location. For more
details on using the high-speed counter and high-speed outputs, see
the X4 OCS User’s Manual (MAN1137).
5 BUILT-IN I/O
FIXED
ADDRESS
DIGITAL/ANALOG
I/O FUNCTION MODEL R MODEL A
%I Digital Inputs 1-12 1-12
Reserved 13-32 13-32
%Q Digital Outputs 1-6 1-12
Reserved 7-16 13-16
%AI Analog Inputs 1-4 1-4
Reserved 5-12 5-12
%AQ Analog Outputs 1-2 1-2
Reserved 3-6 3-6
6 BATTERY
The X4 uses a replaceable non-rechargeable 3V lithium coin-cell
battery (CR2450) to run the Real-Time Clock and to maintain the
retained register values. This battery is designed to maintain the clock
and memory for 7-10 years. Please reference MAN1137 for instructions
on how to replace the battery.
7 DIMENSIONS & INSTALLATION
4.92” (125mm)
3.79”
(96mm)
1.22” (31mm)
Panel Cutout
3.58”
(91mm)
4.675” (118.75mm)
7.2 - Installation Procedure
The X4 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.
1. Carefully locate an appropriate place to mount the X4. 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 on Page 1, creating a
91mm x 118.75mm +/-0.1mm opening into which the X4 is to be
installed. If the opening is too large, water may leak into the
enclosure,potentiallydamaging the unit. If the opening is toosmall,
the OCS may not fit through the hole without damage.
3. Removeanyburrs/sharpedgesandensurethepanelisnotwarpedin
the cutting process.
4. Install and tighten the four mounting clips (provided in the box)
untilthegasketformsatightseal.Forstandardcompositemountingclips
(included with product), use a torque rating of 2-3 in-lbs (0.23-0.34
Nm). For optional metal mounting clips, use a torque rating of 4-8
in-lbs (0.45-0.90 Nm).
5. Connect communications cables to the serial port, USB ports, and
CAN port as required.
4.3 - Ethernet Communications
Link
Indicator
Activity
Indicator
10/100 Ethernet port with automatic MDI-X (crossover detection)
is provided via the single 8-position modular jack lableled “LAN”.
Several features are available for use over Ethernet, such as WebMI,
Modbus TCP/IP, Ethernet/IP, SMTP (E-mail), and more.
Ethernet configuration is done via the Cscape Hardware
Configuration, though temporary Ethernet configuration may be done
through the System Menu directly on the X4.
For more information on the Ethernet, available features and
protocols, refer to the Ethernet Supplement document (SUP0740).
communications continued...
6.1 - Battery Maintenance
7.1 - X4 Dimensions

MAN1138-03-EN-EU
Unit 1 Centrepoint, Centre Park Road, Cork, T12 H24E, Ireland. | (p) [phone] (f) [phone] | www.horner-apg.comg.comg.comg.comg.comg.comg.com
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page 7 of 7
8.1 - WARNINGS
1. To avoid the risk of electric shock or burns, always connect the safety (or earth) ground
before making any other connections.
2. 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.
3. Replace fuse with the same type and rating to provide protection against risk of fire and
shock hazards.
4. In the event of repeated failure, do NOT replace the fuse again as repeated failure indicates
a defective condition that will NOT clear by replacing the fuse.
5. Only qualified electrical personnel familiar with the construction and operation of this
equipmentand the hazardsinvolvedshouldinstall,adjust,operate, orservicethis 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.
6. If the equipment is used in a manner not specified by Horner APG, the protection
provided by the equipment may be impared.
8.2 - FCC COMPLIANCE
This device complies with Part 15 of the FCC Rules. Operation is subject to the following
two conditions:
1. This device may not cause harmful interference
2. This device must accept any interference received, including interference that may
cause undesired operation
8.3 - PRECAUTIONS
All applicable codes and standards need to be followed in the installation of this product.
Adhere to the following safety precautions whenever any type of connection is made to the
module:
1. Connect the safety (earth) ground on the power connector first before making any
other connections.
2. When connecting to the electric circuits or pulse-initiating equipment, open their
related breakers.
3. Do NOT make connection to live power lines.
4. Make connections to the module first; then connect to the circuit to be monitored.
5. Route power wires in a save manner in accordance with good practice and local
codes.
6. Wearproperpersonalprotectiveequipmentincludingsafetyglassesandinsulatedgloves
when making connections to power circuits.
7. Ensure hands, shoes, and floor are dry before making any connection to a power line.
8. Make sure the unit is turned OFF before making connection to terminals.
9. Make sure all circuits are de-energized before making connections.
10. Before each use, inspect all cables for breaks or cracks in the insulation. Replace
immediately if defective.
11. Use copper conductors in Field Wiring only, 60/75˚C.
8 SAFETY 9 PART NUMBER
GLOBAL MODEL NUMBERS
HE-X4
R relay and solid state outputs
A solid state output
model
10 CONTACT INFORMATION
For assistance and manual updates, contact Technical Support at the
following locations:
North America Europe
[phone] (+) 353-21-4321-266
www.hornerautomation.com www.horner-apg.com
[e-mail] [e-mail]
9.1 - Part Number Builder
10.1 - Technical Support