HORNER HE-X4A User manual

User Manual
for X4 OCS
HE-X4A, HE-X4R
MAN1137-20-EN_X4_UM

LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the X4 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 war-
ranty shall be limited to the repair or exchange of any part or parts which may prove defective under normal use and ser-
vice 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 X4 OCS MODULE. THIS WARRANTY
SHALL NOT APPLY TO THIS 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 X4 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, post-
paid, insured, and in a suitable package.
ABOUT PROGRAMMING EXAMPLE
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 respons-
ibility of the system designer utilizing the X4 OCS module to appropriately design the end system, to appropriately integ-
rate the X4 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 X4 OCS.
Copyright© 2018 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 oth-
erwise, 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.
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: (+) [phone]
Fax: (+) [phone]
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 8
Warnings 8
FCC Compliance 8
Safety Precautions 8
Intro to the X4 11
Visual Overview 11
Where to find more information for the X4 OCS 12
Connectivity to the X4 12
Features of X4 OCS 13
Mechanical Installation 15
Mounting Overview 15
Mounting Procedures (Installed in a Panel Door) 15
Mounting Clip Locations 16
Dimensions 17
Installation Procedure 17
Factors Affecting Panel Layout Design and Clearances 18
Electrical Installation 21
Ground Specifications 21
How to Test for Good Ground 21
Primary Power Port 22
System Settings and Adjustments 24
OCS LED Indicator Lights 24
System Menu 25
Set Networks &Set Network Baud Rate 27
View Status & Diags 29
View Protocols 31
Set Keys, Serial Ports, Time/Date, Beeper & Screen 32
Removable Media 37
I/O Calibration 38
Fail – Safe System 39
Clone Unit 42
WebMI License Details 45
Touch Screen Calibration 46
System Register Tables 48
Register Definitions 48
%S Registers 49
%SR Registers 50
I/O Register Map for X4 OCS 57
X4 Resource Limits 57
PWM Function Registers Map 58
HSC Functions Registers Map 58
General I/O Configuration 60
Built-in Digital and Analog I/O Overview 60
Digital / HSC Input Configuration 61
Model R &Model A Digital Input J2 Wiring 61
Digital / PWM Output Configuration 66
Solid-State Digital Outputs 66
Model A & Model R Digital Output Wiring 66
Relay Outputs 67

Model R: Sinking and Sourcing Outputs 68
Digital Output Configuration 69
Analog Input Configuration 72
Analog Output Configuration 76
I/O Status and Calibration 79
High Speed I/O 83
High Speed Counter (HSC) Functions 84
Frequency 84
Totalize 85
Pulse 86
Period Measurement 86
Quadrature 87
High Speed Counter 90
HSC Register Map for Micro OCS 90
Pulse Width Modulation (PWM) Functions 91
HSC Pulse Output 94
Serial Communications 96
Port Descriptions 96
Wiring—MJ1/MJ2 Serial Ports 96
RS-485 Termination and Biasing 97
Cscape Programming via Serial Port 97
Ladder-Controlled Serial Communication 98
Configuration via Mini-B USB 98
CAN Communications 100
Overview 100
CAN Port Wiring 101
Cscape Programming via CAN 101
Ladder-Controlled CAN Communication 101
Using CAN for I/O Expansion (Network I/O) 101
CAN and Termination and Bias 101
Ethernet Communications 103
Ethernet Module Protocols and Features 103
Ethernet System Requirements 103
Ethernet Module Specifications 103
Ethernet Module Configuration 104
Ethernet Configuration – IP Parameters 107
Ethernet Module Protocol Configuration 107
Protocol Configuration 109
Overview 109
Protocol Device Driver Selection 110
Network Configuration 111
Device List and Device Configuration 113
Scan List 115
User Interface 120
Screen Specifications 120
Displaying and Entering Data 121
Numeric keypad 122
Screen Navigation 123
Ladder Based Screen Navigation 124
Touch (Slip) Sensitivity 124
Alarms 125
Removable Media 127
Screen Saver 128

Screen Brightness 128
Removable Media 130
microSD Cards 130
Using the Removable Media Manager 131
Log Data 131
View and Capture Screens 132
Removable Media Object 132
Function Blocks in Cscape 133
Filenames 134
System Registers used with RM 134
Clone Unit 136
Make Clone 136
Load Clone 138
Fail-Safe System 140
For the XL & X Series 140
For the XL Prime Series 140
Fail-Safe System 140
Settings 141
Backup / Restore Data 141
AutoLoad 144
AutoRun 146
Micro OCS Communications 148
Modbus Slave Overview 148
Modbus Master Overview 149
Modbus Addressing Table 150
Firmware Updates 152
Check for Current Firmware Revision 152
Firmware Update Details 153
Download Firmware 153
Firmware Update Steps 153
Firmware Update via microSD card 154
Method 1 154
Method 2 155
Replacing the Backup Battery 157
Steps to Replace the Battery 157
Troubleshooting 159
Connecting to the OCS 159
Local Controller and Local I/O 160
CsCAN Network 161
USB Interfaces 161
Basic Troubleshooting 162
Technical Support Contacts 162
X4 Change Log 163

Safety and
Compliance
Page 7

Safety and Compliance
Safety and Compliance
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.
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 a repeated failure indicates a defective con-
dition that will not clear by replacing the fuse.
5. Only qualified electrical personnel familiar with the construction and operation of this equipment and the haz-
ards 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 res-
ult 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 page21 for more details.
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 oper-
ation.
Safety Precautions
Adhere to the following safety precautions whenever any type of connection is made to the module:
ll 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 safe manner in accordance with good practice and local codes.
6. Wear proper personal protective equipment including safety glasses and insulated gloves when making con-
nections 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.
Page 8 of 163

Safety and Compliance
12. 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
controller. Ensure the controller and laptop are grounded for maximum protection. Consider using a USB isol-
ator due to voltage potential differences as a preventative measure.
Page 9 of 163

Intro to the X4
Page 10

Intro to the X4
Intro to the X4
Visual Overview 11
Where to find more information for the X4 OCS 12
Connectivity to the X4 12
Features of X4 OCS 13
Visual Overview
Touch Screen - Press upper right corner to bring out the function keys and SYSTEM key
to access the Main Menu.
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
Page 11 of 163

Intro to the X4
Where to find more information for the X4 OCS
Datasheet - The datasheet is 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 MAN1138 via the Documentation Search page on the Horner
website.
NOTE: For the Voltage Units, refer to MAN1409 for the HE-X4R-V20 or MAN1410 for the HE-X4R-42.
Connectivity to the X4
Connectivity
CAN I/O USB Serial Ethernet
Other OCS Devices Sensors Cscape Other OCS Devices Cscape
SmartStix I/O Indicators Drives OPC Server
SmartBlock I/O Alarms PLCs Modbus TCPDevices
SmartRail I/O Encoders Printers
OPC Pumps SCADA
Relays OPC Server
Solenoids Portal
I/O Devices
Page 12 of 163

Intro to the X4
Features of X4 OCS
The X4 OCSs 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 X4 OCS include the following:
nSmall, sleek profile saves space and resources.
nPhysical Specifications
nmm: 96 tall x 125 wide x 331 deep
nin: 3.79 tall x 4.92 wide x 1.22 deep
nweight: 360g
nBright color touch display
nDisplay of complex graphical objects including trends, gauges, meters and animations
nAdvanced control capabilities including floating point, multiple auto-tuning PID loops and string handling cap-
abilities
nIntuitive interface
nRemovable media for storage of programs, data logging, or screen captures
nCsCAN networking port for communication with remote I/O, other controllers or PCs
nCscape programming software that allows all aspects of the X4 to be programmed and configured from one
integrated application
nFail – Safe System which allows an application to continue running in the event of “Soft” failures such as (Bat-
tery power loss or Battery Backed register RAM / Application flash corruption)
nClone Unit allows the user to “clone” the OCS. This feature “clones” application program and unit settings
stored in Battery backed RAM of an OCS. It can then be used to clone a different OCS (but must be the exact
same model).
nSuited for most applications across a diverse range of industries.
Page 13 of 163

Mechanical
Installation
Page 14

Mechanical Installation
Mechanical Installation
Mounting Overview 15
Mounting Procedures (Installed in a Panel Door) 15
Mounting Clip Locations 16
Dimensions 17
Installation Procedure 17
Factors Affecting Panel Layout Design and Clearances 18
NOTE: Refer to the datasheet for X4 [MAN1138] via the Document Search for more details. For the Voltage Units,
refer to MAN1409 for the HE-X4R-V20 or MAN1410 for the HE-X4R-42.
Mounting Overview
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 Procedures (Installed in a Panel Door)
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 X4 OCS.
NOTE: Unit comes with composite clips, which are tested for typical wash down, shock, and vibration. If metal
mounting clips are needed, they can be ordered at the Horner Automation website.
1. Carefully locate an appropriate place to mount the X4. Be sure to leave enough room at the top of the unit for
insertion. Remove the microSD card to prevent damage to the panel edge.
2. Carefully cut the host panel per the measurements found in the datasheet MAN1131. Dimensions can also
be found below in the Panel Cutout section. 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 dam-
age. NOTE:For the Voltage Units, refer to MAN1409 for the HE-X4R-V20 or MAN1410 for the HE-X4R-42.
3. Remove any burrs and/or shape edges and ensure the panel is not warped in the cutting process.
4. Make sure the gasket is installed on the X4 OCS and is free from dust and debris. Check that the corners of
the gasket are secure.
5. Pass the unit through the panel.
6. Insert each of the four (4) mounting clips into the slots in the X4 OCS case. One composite plastic clip should
be installed on each corner. Lightly tighten each screw so the clip is held in place.
Clip Description Part Number
Composite Plastic Clip 400B178-R2.0
Metal Clip HE500ACC604
7. Tighten the screws on the clips such that the gasket is compressed against the panel. Recommended torque
is 2-3 in-lbs (0.23 – 0.34 Nm). If metal mounting clips are used in place of the plastic composite mounting
clips, the recommended torque is 4-8 in-lbs (0.45-0.90 Nm).
8. Connect communications cables to the serial port, USB ports, and CAN port as required.
Page 15 of 163

Mechanical Installation
Mounting Clip Locations
X4 OCS Mounting Orientation
NOTE—For panel or DIN rail mounting: The orientation shown above provides for optimum readability of the
screen and ease of use of the keypad.
Page 16 of 163

Mechanical Installation
Dimensions
For installations requiring NEMA 4X liquid and dust protection, the panel cutout should be cut with a tolerance of
+0.5mm / -0mm.
Installation Procedure
lThis equipment is panel mounted and is meant to be installed in an enclosure suitable for the environment,
such that the back of the equipment is only accessible with the use of a tool.
lThis equipment is suitable for use in Class I, Division 2, Groups A, B, C and D; Class II, Division 2 Groups F
and G; and Class III Hazardous Locations or Non-Hazardous Locations only.
lThe X4 utilizes a clip installation method to ensure a robust and watertight seal to the enclosure. 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, creating a 90.5mm x 119.5mm with a tolerance of +/-0.5mm
opening into which the X4 is to 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 dam-
age.
3. Remove any burrs/sharp edges and ensure the panel is not warped in the cutting process.
4. Install and tighten the four mounting clips (provided in the box) until the gasket forms a tight seal. For stand-
ard composite mounting clips (included with product). NOTE: Torque rating is 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.
Page 17 of 163

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)
Page 18 of 163

Mechanical Installation
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.
Panel Layout Design and Clearance Checklist
The following list provides highlights of panel layout design factors:
nMeets the electrical code and applicable standards for proper grounding, etc.?
nMeets the panel manufacturer’s requirements for grounding, etc.?
nIs the panel box properly connected to earth ground? Is the panel door properly grounded? Has the appro-
priate procedure been followed to properly ground the devices in the panel box and on the panel door?
nAre minimum clearance requirements met? Can the panel door be easily opened and closed? Is there
adequate space between device bases as well as the sides of the panel and wiring ducts?
nIs the panel box deep enough to accommodate the controller?
nIs there adequate ventilation? Is the ambient temperature range maintained? Are cooling or heating devices
required?
nAre noise suppression devices or isolation transformers required? Is there adequate distance between the
base of the controller and noisy devices such as relays or motor starters? Ensure that power and signal wires
are not routed in the same conduit.
nAre there other requirements that impact the particular system, which need to be considered?
Page 19 of 163

Electrical
Installation
Page 20