HORNER APG RCC Series User manual

User Manual
for RCC Series Controllers
RCC972
RCC1410
RCC8842

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PREFACE
This manual explains how to use the RCC Controller.
Copyright© 2017 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 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.
Ethernet™ is a trademark of Xerox Corporation.
microSD™ and CompactFlash are registered trademarks of SanDisk Corporation.
For user manual updates, contact Technical Support:
North America:
Tel: (+) 1-877-665-5666
Fax: (+) [phone]
Website: https://hornerautomation.com
Email: [e-mail]
Europe:
Tel: (+) 353-21-4321-266
Fax: (+) 353-21-4321-826
Website: https://www.hornerautomation.eu
Email: [e-mail]

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LIMITED WARRANTYAND LIMITATION OF LIABILITY
Horner APG, LLC, ("HE-APG") warrants to the original purchaser that the RCC controller 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 RCC module. THIS WARRANTY SHALL NOT APPLY TO THIS RCC 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 RCC
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
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
responsibility of the system designer utilizing the RCC controller module to appropriately
design the end system, to appropriately integrate the RCC controller 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.

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VISUAL MAP OF KEY CHAPTERS
FIRST STEP of ANY TASK: DATASHEET
Each RCC unit is sent with a datasheet in the box. The datasheet is the first document to
refer to for model-specific information related to RCC models such as pin-outs, jumper
settings, and other key installation information. To obtain updates to datasheets, manuals
and user documentation, visit a Horner website
North America https://hornerautomation.com
Europe https://www.hornerautomation.eu
QUICK START
INSTALLATION
PROGRAMMING
TROUBLESHOOTING
Safety / Compliance
Safety / Compliance
Safety / Compliance
Safety / Compliance
Introduction
Introduction
Introduction
Introduction
Mechanical
Installation
Serial
Communications
Fail / Safe
Electrical
Installation
CAN
Communications
Maintenance
Ethernet
Communications
Modbus
Communication
Downloadable
Communication
Protocols
Troubleshooting
Removable Media
General I/O
Cscape
Configuration
Registers

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TABLE OF CONTENTS
PREFACE .....................................................................................................................................................2
LIMITED WARRANTYAND LIMITATION OF LIABILITY.........................................................................3
ABOUT PROGRAMMING EXAMPLES.......................................................................................................3
VISUAL MAP OF KEY CHAPTERS............................................................................................................4
TABLE OF CONTENTS...............................................................................................................................5
CHAPTER 1: SAFETY / COMPLIANCE .................................................................................................. 8
1.1 Safety Warnings and Guidelines............................................................................................... 8
1.2 Grounding....................................................................................................................................... 9
1.3 Compliance .................................................................................................................................... 9
CHAPTER 2: INTRODUCTION..................................................................................................................10
2.1 General Overview of a 972, 1410, or 8842 RCC Unit ..........................................................10
2.2 Where to Find Information about the RCC.............................................................................. 11
2.3 Four main types of information are covered in this manual .............................................. 11
2.4 Features of RCC............................................................................................................................ 11
CHAPTER 3: MECHANICAL INSTALLATION...................................................................................... 12
3.1 Overview........................................................................................................................................ 12
3.2 RCC Dimensions........................................................................................................................... 12
3.2 RCC Installation ........................................................................................................................... 13
CHAPTER 4: ELECTRICAL INSTALLATION .......................................................................................15
4.1 Grounding Definition .................................................................................................................. 15
4.2 Ground Specifications................................................................................................................ 15
4.3 How to Test for Good Ground ..................................................................................................16
4.4 RCC972 Power Writing .............................................................................................................. 17
4.5 RCC1410 Power Writing.............................................................................................................. 17
4.6 RCC8842 Power Writing ...........................................................................................................18
CHAPTER 5: REGISTERS........................................................................................................................19
5.1 Register Definitions ....................................................................................................................19
5.2 Useful %S and %SR registers.................................................................................................20
5.3 Resource Limits..........................................................................................................................29
5.4 Register Map for RCC Series ...................................................................................................30
CHAPTER 6: CSCAPE CONFIGURATION ............................................................................................ 31
6.1 Overview........................................................................................................................................ 31
6.2 Cscape Status Bar....................................................................................................................... 31
6.3 Establishing Communications ................................................................................................. 32
6.4 Hardware Configuration............................................................................................................41
6.5 Scaling Analog Inputs................................................................................................................44
CHAPTER 7: GENERAL I/O...................................................................................................................46
7.1 Overview.......................................................................................................................................46
7.2 Solid-State Digital Outputs ......................................................................................................46
7.3 Digital Inputs................................................................................................................................47
7.4 Analog Inputs ..............................................................................................................................48
7.5 Analog Outputs...........................................................................................................................48

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Chapter 8: BACK-UP BATTERY ........................................................................................................49
8.1 Overview.......................................................................................................................................49
8.2 Storing Register Contents........................................................................................................49
8.3 Battery Life..................................................................................................................................49
8.4 Lithium Battery Safety..............................................................................................................49
8.6 Battery Charging Status...........................................................................................................50
8.7 Battery Charging State.............................................................................................................50
8.8 Battery Status in System Registers.......................................................................................50
CHAPTER 9: SERIAL COMMUNICATIONS.........................................................................................52
9.1 Overview.......................................................................................................................................52
9.2 MJ1 Serial Port Pinout...............................................................................................................52
9.3. RCC972 MJ1 Pins ....................................................................................................................52
9.4 RCC1410 MJ1 and MJ2 Pins ......................................................................................................53
9.5 RCC8842 MJ1 and MJ2 Pins....................................................................................................53
9.3 Cscape Programming via Serial Port ....................................................................................54
9.4 Ladder-Controlled Serial Communication............................................................................54
CHAPTER 10: CAN COMMUNICATIONS .............................................................................................55
10.1 Overview.......................................................................................................................................55
10.2 Port Description......................................................................................................................55
10.3 RCC972 CAN Port Wiring......................................................................................................56
10.4 RCC1410 CAN Port Wiring....................................................................................................56
10.5 RCC8842 CAN Port Wiring................................................................................................... 57
10.4 Cscape Programming via CAN ............................................................................................ 57
10.5 Ladder-Controlled CAN Communication .......................................................................... 57
10.6 Using CAN for I/O Expansion (Network I/O).................................................................... 57
CHAPTER 11: ETHERNET COMMUNICATION.....................................................................................58
11.1 Ethernet Overview .....................................................................................................................58
11.2 MAC Address ...............................................................................................................................58
11.3 Ethernet Module Protocols and Features ............................................................................59
11.4 Ethernet System Requirements..........................................................................................59
11.5 Ethernet Module Specifications..............................................................................................59
11.6 Ethernet Module Configuration ..............................................................................................60
11.7 Ethernet Configuration –IP Parameters ..............................................................................63
11.8 Ethernet Module Protocol Configuration.............................................................................63
CHAPTER 12: DOWNLOADABLE COMMUNICATION PROTOCOLS..............................................64
12.1 Overview.......................................................................................................................................64
12.2 Protocol Config...........................................................................................................................66
11.3 Network Configuration..............................................................................................................67
12.4 Device List and Device Configuration ...............................................................................69
12.5 Scan List .................................................................................................................................... 71
12.6 Data Mapping Configuration (Scan List Entry) ............................................................... 72
CHAPTER 13: REMOVABLE MEDIA.....................................................................................................74
13.1 Overview.......................................................................................................................................74
13.2 microSD Cards ............................................................................................................................74
13.3 microSD File System..................................................................................................................74
13.4 Using Removable Media to Log Data.................................................................................75
13.5 Using Removable Media to Load and Save Applications.................................................. 75
13.6 Removable Media (RM) Function Blocks in Cscape........................................................75
13.7 Filenames used with the Removable Media (RM) Function Blocks ................................76

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13.8 System Registers used with RM.......................................................................................... 77
CHAPTER 14: FAIL-SAFE SYSTEM......................................................................................................78
14.1 Overview.......................................................................................................................................78
14.2 Settings.....................................................................................................................................78
14.3 Backup / Restore Data ..........................................................................................................79
14.4 AutoLoad...................................................................................................................................81
14.5 AutoRun....................................................................................................................................83
CHAPTER 15: MAINTENANCE ..............................................................................................................84
15.1 Firmware Updates......................................................................................................................84
15.2 Backup Battery........................................................................................................................84
CHAPTER 16: MODBUS COMMUNICATIONS.....................................................................................86
16.1 Modbus Overview.......................................................................................................................86
16.2 Modbus Slave Overview........................................................................................................86
16.3 Modbus Master Overview .....................................................................................................87
16.4 Modbus Addressing Table for RCC Units..........................................................................88
CHAPTER 17: TROUBLESHOOTING / TECHNICAL SUPPORT.......................................................89
17.1 LED - Normal Functionality......................................................................................................89
17.2 LED Load Program/Firmware Functionality........................................................................89
17.3 Switch - Normal Functionality.................................................................................................90
17.4 LED –Diagnostic Functionality............................................................................................90
17.5 Connecting to the RCC............................................................................................................... 91
17.7 CsCAN Network ..........................................................................................................................93
17.8 Removable Media - Basic Troubleshooting......................................................................94
17.9 Technical Support Contacts ....................................................................................................94
INDEX............................................................................................................................................................95
CHANGE LOG..............................................................................................................................................97

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CHAPTER 1: SAFETY / COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
a. All applicable codes and standards need to be followed in the installation of this product.
b. For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG
or larger.
.
.
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 –EXPLOSION HAZARD –Substitution of components may impair suitability for Class
I, Division 2.
WARNING - The USB parts are for operational maintenance only. Do not leave permanently
connected unless area is known to be non-hazardous.
WARNING –EXPLOSION HAZARD - BATTERIES MUST NOT BE CHANGED.
WARNING –BATTERY MAY EXPLODE IF MISTREATED. DO NOT RECHARGE, DISSASSEMBLE, OR
DISPOSE IN FIRE.
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.

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Adhere to the following safety precautions whenever any type of connection is made to the
module.
a. Connect the green safety (earth) ground first before making any other connections.
b. When connecting to electric circuits or pulse-initiating equipment, open their related
breakers. Do not make connections to live power lines.
c. Make connections to the module first; then connect to the circuit to be monitored.
d. Route power wires in a safe manner in accordance with good practice and local codes.
e. Wear proper personal protective equipment including safety glasses and insulated
gloves when making connections to power circuits.
f. Ensure hands, shoes, and floors are dry before making any connection to a power line.
g. Make sure the unit is turned OFF before making connection to terminals. Make sure all
circuits are de-energized before making connections.
h. Before each use, inspect all cables for breaks or cracks in the insulation. Replace
immediately if defective.
1.2 Grounding
Grounding is covered in various chapters within this manual.
1.3 Compliance
To check for compliance and updates, visit the Horner website.
North America https://hornerautomation.com
Europe https://www.hornerautomation.eu

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CHAPTER 2: INTRODUCTION
2.1 General Overview of a 972, 1410, or 8842 RCC Unit
I/O
Connectors
Recessed
Buttons
-Run/Stop
-Load
RJ-45 Ports
LED Lights
-Run
-OK
-PWR
I/O
Connectors
Figure 02.1 –Overview of the RCC