HORNER SmartStack HE800JCM100 User manual

HE800JCM100
SmartStack Engine
Interface Module
First Edition
08 June 2001
MAN0460-01

MAN0460-01 08 JUNE 2001 PAGE 3
PREFACE
This manual explains how to use the Horner APG SmartStackEngine Interface Module.
Copyright (C) 2001, Horner APG, LLC, Inc., 640 North Sherman Drive Indianapolis, Indiana 46201. All
rights reserved. No part of this publication can 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, LLC.
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, LLC.
Cscape, SmartStack, and Cscan are trademarks of Horner APG.
For user manual updates, contact Horner Advanced Products Group,
Technical Support Division, at [phone] or visit our website at
www.heapg.com.

PAGE 408 JUNE 2001 MAN0460-01
LIMITED WARRANTY AND LIMITATION OF LIABILITY
Horner APG. ("HE-APG") warrants to the original purchaser that SmartStackEngine Interface Module
manufactured by HE 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 SmartStackEngine Interface Module.
THIS WARRANTY SHALL NOT APPLY TO THIS SmartStackEngine Interface 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 SmartStackEngine
Interface 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 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 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 SmartStackEngine Interface Module to
appropriately design the end system, to appropriately integrate the SmartStackEngine Interface
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.

MAN0460-01 08 JUNE 2001 PAGE 5
TABLE OF CONTENTS
PREFACE ...............................................................................................................................................3
ABOUT PROGRAMMING EXAMPLES....................................................................................................4
TABLE OF CONTENTS...........................................................................................................................5
CHAPTER 1: INTRODUCTION...............................................................................................................7
1.1 Scope........................................................................................................................................7
1.2 Hardware Description ................................................................................................................7
1.2.1 Primary Serial Port..............................................................................................................8
1.2.2 PLC Interface......................................................................................................................8
1.2.3 Secondary Serial Port.........................................................................................................8
1.3 Specifications ............................................................................................................................8
CHAPTER 2: INSTALLATION.................................................................................................................9
2.1 Module Placement.....................................................................................................................9
2.2 Ports and Pin-outs ...................................................................................................................10
2.3 Installing and Removing a SmartStack Module (Shown with the OCS) .....................................11
2.4 Configuration Procedures Using Cscape Software ...................................................................12
2.4.1 Preliminary Configuration Procedures ...............................................................................12
2.4.2 Configuration of JCM100 Module......................................................................................14
CHAPTER 3: FUNCTIONALITY OVERVIEW.........................................................................................17
3.1 Overview .................................................................................................................................17
3.2 Register Mapping.....................................................................................................................17
APPENDIX A: SERIAL PORT WIRING.................................................................................................19
A.1.1 Primary Port Cable Pin-outs..............................................................................................19
A.2.1 Pin-out..............................................................................................................................20

PAGE 608 JUNE 2001 MAN0460-01
NOTES

MAN0460-01 08 JUNE 2001 PAGE 7
CHAPTER 1: INTRODUCTION
1.1 Scope
The supplement for the SmartStackEngine Interface Module provides information that is pertinent to
the setup and operation of the HE800JCM100 (JCM100) module.
Chapter One covers the features and hardware description of the JCM100 module. Installation
procedures are covered in Chapter Two. Chapter Three covers the functionality of the JCM100. Finally,
Appendix A covers the wiring of the serial ports.
Installation and configuration procedures that are common to all SmartStack Modules are contained
in the Control Station Hardware Manual (MAN0227).
1.2 Hardware Description
The JCM100 module utilizes state-of-the-art electronic components on a six-layer copper-clad printed
circuit board for electrically quiet operation. It uses the same hardware as the ASCII Basic module.
HE800ASC100). Two important precautions must be observed while handling the module:
WARNING
NEVER insert or remove the module into or out of the OCS/RCS unit while power is applied to the
backplane.
WARNING
ALWAYS observe reasonable static discharge precautions while handling the module. Touch a grounded
metal surface to discharge any static buildup before touching the module.

PAGE 808 JUNE 2001 MAN0460-01
1.2.1 Primary Serial Port
The PRIMARY port located on the front of the JCM100 Module incorporates a 9-pin D-type connector for
standard cable interface (See Appendix A for wiring diagrams).
There are two LEDs (Light Emitting Diodes) located on the end of the module. They are labeled
according to the RS-232 signal name to which they are connected. The GREEN LED illuminates
whenever data is transmitted from the module, and the RED LED illuminates whenever data is received
by the module.
1.2.2 PLC Interface
Proprietary circuitry is used in the interface between the JCM100 Module and the OCS/RCS. This
circuitry provides up to 128 WORDS (sixty-four 16-bit %AI input and sixty-four 16-bit %AQ output) for
both the OCS/RCS and the JCM100. Circuitry and software are provided in the firmware to insure data
integrity on both sides.
1.2.3 Secondary Serial Port
The JCM100 Module is equipped with a secondary serial port. This port is multiplexed between RS-232
and RS-485. The pin-outs/connections for both ports are shown in Appendix A. By default, the JCM100
module uses the RS-232 port (Port 1) for communication with an Engine Control Module. The JCM100
does not use the RS-485 port.
The module also has two LED’s located on the module’s front panel behind the plastic window (on the
end of the module) for each auxiliary port. They are labeled according to the RS-232 or RS-485 signal
name to which they are connected. The GREEN LED illuminates whenever data is transmitted from the
Engine Interface MODULE while the RED LED illuminates whenever data is received by the Engine
Interface MODULE.
1.3 Specifications
Table 1.1 – JCM100 Specifications
Number of
communication ports 3 ports
(Two RS-232 ports),
(Currently not used – reserved for
future use: One RS-485/422 port)
Status LEDs RXD/TXD for all ports
Required Power
(Steady State) 34.0mA @ 5VDC CE Pending
Required Power (Inrush) 89.6mA @ 5VDC in 10µSUL Pending
Relative Humidity 5 to 95% Non-condensing Terminal Type 9-Pin D-Subs
Operating Temperature 0°to 60°Celsius Weight 9.5 oz. (270 g)

MAN0460-01 08 JUNE 2001 PAGE 9
CHAPTER 2: INSTALLATION
2.1 Module Placement
The JCM100 is one of the many SmartStack Option Modules that are available for use in the Operator
Control Station (OCS100/OCS200) and the Remote Control Station (RCS210). Compact and easy to
install, up to four Smart Stack Modules can be placed into each device. Although Chapter Two contains
pertinent installation information for the JCM100, consult the Control Station Hardware User Manual
(MAN0227) for complete details covering panel box requirements and other key installation issues
pertaining to SmartStack Option Modules, OCS, and RCS devices.
RCS
Figure 2.2 - RCS in Panel Box
(Shown with Four SmartStack Modules)
OCS
Figure 2.1 - Back View of OCS
(Shown with Four SmartStack Modules)
Caution: Do not install more than four SmartStack Modules per OCS or RCS. Improper
operation or damage to the OCS, RCS, and SmartStack Modules could result.

PAGE 10 08 JUNE 2001 MAN0460-01
2.2 Ports and Pin-outs
The PRIMARY or programming port (Labeled as P0 on the module) follows the RS-232 standard. This
port is only used for firmware upgrades.
The SECONDARY port is RS-232 (Labeled as P1 on the module). This port (P1) is used for the
connection to an Engine Control Module.
Table 2.1 – Port 0/1 Pin-out
JCM100
Direction Pin Port 0/1
Output 1DCD (Data Carrier Detect)
Output 2RXD (Receive Data)
Input 3TXD (Transmit Data)
Input 4DTR (Data Terminal Ready)
GND 5Signal Ground
Output 6DSR (Data Set Ready)
Input 7CTS (Clear to Send)
Output 8RTS (Request to Send)
Output 9RI (Ring Indicate)
Note: For ports 0 and 1, the signal names reflect the
EIA RS232 signal names for a DCE device.
The names do not necessarily reflect the
signal direction with respect to the JCM100
module.
P1
1
5
P0
P2
5
1
5
1
6 9 9 6 9 6
P2 P1 P0
OCS Bottom View – Shows
Corresponding I/O Pin
Figure 2.3 – Close-up of Port Connectors Figure 2.4 – Port Connectors

MAN0460-01 08 JUNE 2001 PAGE 11
2.3 Installing and Removing a SmartStack Module (Shown with the OCS)
The following section describes how to install and remove a SmartStack Module.
a. Installing SmartStack Modules
1. Hook the tabs. Each SmartStack Module has two tabs that fit into slots located on the OCS. (The
slots on the OCS are located on the back cover.)
2. Press the SmartStack Module into the locked position, making sure to align the SmartStack Module
fasteners with the SmartStack receptacles on the OCS.
b. Removing SmartStack Modules
1. Using a flathead screwdriver, pry up the end of the SmartStack Module (opposite of tabs) and swing
the module out.
2. Lift out the tabs of the module.
SmartStack Tab
OCS Back Cover
Mating Pins
Fastener
Figure 2.5 – Installing a SmartStack

Module in an OCS.
Caution: To function properly and avoid possible damage, do not install more than four
Smart Stack Modules per OCS or RCS.

PAGE 12 08 JUNE 2001 MAN0460-01
2.4 Configuration Procedures Using Cscape Software
2.4.1 Preliminary Configuration Procedures
The SmartStack configuration is accomplished through the Configure Controller Type Dialog.
1. From the Main Menu, select Controller|Configure for the following dialog:
Note: Ensure that the proper controller is selected. If it is not selected, double-click on the box and
select the desired controller from the pull-down menu. Press the OK button.
If the OCS/RCS has one or more SmartStackModules already installed, the user can use AutoConfig to
determine and set the I/O automatically. If the controller is not physically attached to Cscape or its
SmartStackModules are not available, use the manual configuration.
Figure 2.6 – Configure Controller Type Dialog

MAN0460-01 08 JUNE 2001 PAGE 13
The user can choose to do the following:
a. Add a SmartStack I/O Module
1. To place a SmartStack I/O module into an empty slot, ADD the module. From the CONFIGURE I/O
Dialog, click on the Config button to the right of the desired module or double-click on the empty slot.
Either method invokes the SmartStack Module Selection Dialog:
2. Use the mouse to select the type of module desired. The JCM100 is a specialty module. Select
the Other tab. Select the desired module
Note: Because the JCM100 uses the same hardware as the ASC100, select the ASC100
module) and click the OK button.
b. Delete a SmartStack Module
If the desired SmartStack slot shows a module already installed, the module can be deleted.
1. Right-click on the picture of the configured slot. A floating menu appears.
2. From the menu, click on DELETE MODULE.
Figure 2.7 – Add I/O Module Screen
(“Other” selections are shown.)
Caution: To function properly and avoid possible damage, do not install more than four
Smart Stack Modules per OCS or RCS.

PAGE 14 08 JUNE 2001 MAN0460-01
c. Select a Different SmartStack Module
If the desired SmartStack slot shows a module already installed, the module can be replaced with a
different module.
1. Right-click on the picture of the configured slot. A floating menu appears.
2. From the menu, click on 1. REPLACE MODULE. This invokes the SmartStack Module Selection Dialog.
3. Use the mouse to select the desired module and then click OK.
2.4.2 Configuration of JCM100 Module
The screen now depicts that the appropriate controller has been selected. It also depicts that the
ASC100 has been selected, although the actual module selected is JCM100. Again, the JCM100
uses the same hardware as the ASC100.
The desired module is ready to be configured.
1. Double-click on the picture of the module or click on the Config button just to the right of the picture.
Figure 2.8 – Configure I/O Screen

MAN0460-01 08 JUNE 2001 PAGE 15
The following screen appears:
Use the Default of 64 %AIs and 64 %AQs.
For Cscape configuration purposes, check the box labeled, Force Startup Mode 0 to force the module
into Startup Mode 0 during the next power-up.
3. Select I/O Map for a summary of the I/O devoted to the module and where within the PLC register
space the I/O is. The following screen appears:
Figure 2.9 – Module Configuration Screen
Figure 2.10 – I/O Screen

PAGE 16 08 JUNE 2001 MAN0460-01
NOTES

MAN0460-01 08 JUNE 2001 PAGE 17
CHAPTER 3: FUNCTIONALITY OVERVIEW
3.1 Overview
The HE800JCM100 module is an interface between an Engine Control Module, which uses the SAE
J1587 protocol, and the OCS/RCS Programmable Logic Controller. The JCM100 listens to the J1587 link
and provides the selective J1587 data in %AI registers devoted to the module. The values presented in
the %AI registers are merely raw data coming from the J1587 link.
The JCM100 supports single data character PIDs 1 through 127 and double data character PIDs 128
through 191. It also supports the diagnostic PIDs and SIDs within PID 194 (when it is transmitted directly,
as well as when it is sectioned using PID 192). Refer to SAE J1587 specifications for details on the PIDs
such as Bit Resolution, Update Period, etc. JCM100 provides the PID values as Analog Inputs in the %AI
registers in the OCS. Each PID is provided in a separate %AI register, so in case of single character
PIDs, the data is put in the lower byte of %AI register and the higher byte is set to 0. The PID values are
provided as Raw Values and may be scaled in the ladder program running in the OCS. The JCM100
does not currently support ‘On Request’ parameters.
NOTE: It is assumed that the user is familiar with the specifics of the SAE J1587 protocol specification.
The J1587 specification is beyond the scope of this manual.
3.2 Register Mapping
The JCM100 module uses 64 %AI registers, and 64 %AQ registers.
The register mapping is as follows: %AI1 – 45 èAre used for regular PID values
%AI46 – 53 èAre used for diagnostic PID values (Under PID194)
%AI54 – 60 èAre used for diagnostic SID values (Under PID194)
%AI61 – 64 èDiagnostic Data, not mapped to any PID
The default map for the PIDs is given in Table 3.1. This map may be altered at run time by following
procedure:
1. Enter the regular PIDs (PID 1 to 191) that you are interested in, into registers AQ1 through AQ45.
One PID value for each register.
2. Enter the diagnostic PIDs – REGULAR or EXPANSION - (PIDs within PID 194) that you are
interested in, in to registers AQ46 through AQ53.
3. Enter the diagnostic SIDs – (SIDs within PID 194) that you are interested in, into registers AQ54 –
AQ60.
4. AQ64 is the ‘control register’. Enter a non-zero value in AQ64. When the firmware in the JCM100
receives a non-zero value in the control register, it goes into a Pause state, in which the it waits for
the control register to be Reset again.
5. Enter ‘0’ in the Control Register. After the control register is reset to 0, the firmware reads AQ
registers 1 through 60 and maps the PIDs to the corresponding AI registers. You do not need to
restart the module; the mapping immediately takes effect.
NOTE: The register numbers in the above explanation are described as if the register base for the
JCM100 module were at %AQ1 and %AI1. However the register base could be at a higher value, so
those register numbers would be adjusted accordingly with respect to the register base.

PAGE 18 08 JUNE 2001 MAN0460-01
Table 3.1 – Default Register Map
AI Register PID Description
1 85 Cruise Control Switch Status
2 84 Vehicle Speed
3 91 Percent Throttle
4 92 Percent Engine Load
5 93 Output Torque
6 94 Fuel Delivery Pressure
7 100 Engine Oil Pressure
8 102 Turbo Boost Pressure
9 108 Barometric Pressure
10 110 Coolant Temperature
11 111 Coolant Level
12 168 Battery Voltage
13 172 Air Inlet Temperature
14 173 Exhaust Gas Temperature
15 174 Fuel Temperature
16 175 Engine Oil Temperature
17 183 Fuel Rate
18 190 Engine Speed
19 98 Engine Oil Level
20 44 Atten./Wrn Indicator Lamp Status
21-45 N/A Not mapped to PID
46 Diag PID - 94
(REGULAR or EXPANSION) Fuel Delivery Pressure (if regular PID)
47 Diag PID - 100
(REGULAR or EXPANSION) Engine Oil Pressure (if regular PID)
48 Diag PID - 102
(REGULAR or EXPANSION) Boost Pressure (if regular PID)
49 Diag PID - 110
(REGULAR or EXPANSION) Engine Coolant Temperature (if regular PID)
50 Diag PID - 111
(REGULAR or EXPANSION) Coolant Level (if regular PID)
51 Diag PID - 172
(REGULAR or EXPANSION) Air Inlet Temperature (if regular PID)
52 Diag PID - 174
(REGULAR or EXPANSION) Fuel Temperature (if regular PID)
53 Diag PID - 175
(REGULAR or EXPANSION) Engine Oil Temperature (if regular PID)
54 Diag. SID – 1 Injector #1 response time
55 Diag. SID – 2 Injector #2 response time
56 Diag. SID – 3 Injector #3 response time
57 Diag. SID – 4 Injector #4 response time
58 Diag. SID – 5 Injector #5 response time
59 Diag. SID – 6 Injector #6 response time
60 Open (SID) Not originally mapped to any SID
61 N/A N/A
62 N/A Processed Messages Index
63 N/A Stuffing Messages index
64 N/A Reset Counter

MAN0460-01 08 JUNE 2001 PAGE 19
APPENDIX A: SERIAL PORT WIRING
A.1 Primary Port Wiring
The JCM100 Module features two serial ports. The PRIMARY or programming port (Labeled as P0 on
the module) follows the RS-232 standard. This port is only used for firmware upgrades.
The SECONDARY port is RS-232 (Labeled as P1 on the module). This port (P1) is used for the
connection to an Engine Control Module.
The PRIMARY port is typically connected to an IBM compatible personal computer. In this manual, all
cable diagrams feature pin-outs are labeled according to function rather than the EIA standard. In the
table below, the JCM100 Module's RS-232 pin-out is listed, with the designation used in the wiring
diagrams of this manual. Also listed is the direction of the signal.
Table A.1 – Primary Port
Pin # Signal Name Direction
1(DCD) Always High Output
2(TXD) Transmit Data Output
3(RXD) Receive Data Input
4No Connection N/A
5(GND) Signal Ground N/A
6(DSR) Always High Output
7(CTS) Clear To Send Input
8(RTS) Request To Send Output
9(RI) Always High Output
A.1.1 Primary Port Cable Pin-outs.
The following pin-outs show connections to the JCM100 Module's primary RS-232 port. These pin-outs
are typical and do not represent all possible connections.
Figure A.1 – PC with 9-pin RS232 Port

PAGE 20 08 JUNE 2001 MAN0460-01
A.2 Auxiliary Port Wiring
A.2.1 Pin-out
The Auxiliary serial port (P1) can be made point-to-point over a distance of 50 feet.
In this manual, all cable diagrams feature pin-outs are labeled according to function rather than the EIA
standard. In the table below, the JCM100 Module's P1 pin-out is listed with the designation used in the
wiring diagrams of this manual. Also listed is the direction of the signal.
Table A.2 – Port 0/1 Pin-out
JCM100
Direction Pin Port 0/1
Output 1DCD (Data Carrier Detect)
Output 2RXD (Receive Data)
Input 3TXD (Transmit Data)
Input 4DTR (Data Terminal Ready)
GND 5Signal Ground
Output 6DSR (Data Set Ready)
Input 7CTS (Clear to Send)
Output 8RTS (Request to Send)
Output 9RI (Ring Indicate)
Note: For Ports 0 and 1, the signal names reflect the
EIA RS232 signal names for a DCE device.
The names do not necessarily reflect the
signal direction with respect to the JCM100
module.
Figure A.2 – PC with 25-pin RS232 Port