HORNER RCC972 User manual

User Manual
for RCC Series Controllers
RCC972
RCC1410
RCC2414
RCC8842
MAN1078-07-EN_RCC_Series_UM

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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 General Overview of an RCC2414 Unit.................................................................................... 11
2.3 Connectivity to the RCC ............................................................................................................ 12
2.4 Features of RCC........................................................................................................................... 13
2.5 Useful Documents and References.........................................................................................14
2.6 Opening Cscape Help File..........................................................................................................14
CHAPTER 3: MECHANICAL INSTALLATION........................................................................................ 15
3.1 Overview........................................................................................................................................ 15
3.2 RCC Dimensions...........................................................................................................................15
3.2 RCC Installation ...........................................................................................................................16
CHAPTER 4: ELECTRICAL INSTALLATION .......................................................................................18
4.1 Grounding Definition ..................................................................................................................18
4.2 Ground Specifications................................................................................................................18
4.3 How to Test for Good Ground ..................................................................................................19
4.4 RCC972 Power Writing .............................................................................................................20
4.5 RCC1410 Power Writing.............................................................................................................20
4.6 RCC2414 Power Writing............................................................................................................. 21
4.7 RCC8842 Power Writing ........................................................................................................... 21
CHAPTER 5: SERIAL COMMUNICATIONS.........................................................................................56
5.1 Overview.......................................................................................................................................56
5.2 MJ1 Serial Port Pinout...............................................................................................................56
5.3 Cscape Programming via Serial Port ....................................................................................59
5.4 Ladder-Controlled Serial Communication............................................................................59
CHAPTER 6: CAN COMMUNICATIONS ...............................................................................................60
6.1 Overview.......................................................................................................................................60
6.2 Port Description..........................................................................................................................60
6.3 CAN Port Wiring...........................................................................................................................61
6.4 Cscape Programming via CAN................................................................................................63
6.5Ladder-Controlled CAN Communication ..............................................................................63
6.6 Using CAN for I/O Expansion (Network I/O)........................................................................63
CHAPTER 7: ETHERNET COMMUNICATION.......................................................................................64
7.1 Ethernet Overview .....................................................................................................................64

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7.2 MAC Address ...............................................................................................................................64
7.3 Ethernet Module Protocols and Features ............................................................................65
7.4 Ethernet System Requirements .............................................................................................65
7.5 Ethernet Module Specifications..............................................................................................65
7.6 Ethernet Module Configuration ..............................................................................................66
7.7 Ethernet Configuration –IP Parameters ..............................................................................69
7.8 Ethernet Module Protocol Configuration.............................................................................69
CHAPTER 8: DOWNLOADABLE COMMUNICATION PROTOCOLS...............................................70
8.1 Overview.......................................................................................................................................70
8.2 Protocol Config........................................................................................................................... 72
8.3 Network Configuration.............................................................................................................. 73
8.4 Device List and Device Configuration ...................................................................................75
8.5 Scan List ....................................................................................................................................... 77
8.6 Data Mapping Configuration (Scan List Entry)...................................................................78
CHAPTER 9: REMOVABLE MEDIA ......................................................................................................80
9.1 Overview.......................................................................................................................................80
9.2 microSD Cards ............................................................................................................................80
9.3 microSD File System..................................................................................................................80
9.4 Using Removable Media to Log Data......................................................................................81
9.5 Using Removable Media to Load and Save Applications...................................................81
9.6 Removable Media (RM) Function Blocks in Cscape ............................................................81
9.7 Filenames used with the Removable Media (RM) Function Blocks................................82
9.8 System Registers used with RM .............................................................................................83
CHAPTER 10: GENERAL I/O .................................................................................................................50
10.1 Overview.......................................................................................................................................50
10.2 Solid-State Digital Outputs...................................................................................................50
10.3 Digital Inputs............................................................................................................................. 51
10.4 Analog Inputs...........................................................................................................................52
10.5 Analog Outputs .......................................................................................................................52
CHAPTER 11: CSCAPE CONFIGURATION ...........................................................................................35
11.1 Overview....................................................................................................................................... 35
11.2 Cscape Status Bar......................................................................................................................35
11.3 Establishing Communications .................................................................................................36
11.4 Hardware Configuration...........................................................................................................45
11.5 Scaling Analog Inputs................................................................................................................48
Chapter 12: BACK-UP BATTERY ........................................................................................................53
12.1 Overview.......................................................................................................................................53
12.2 Storing Register Contents........................................................................................................53
12.3 Battery Life..................................................................................................................................53
12.4 Lithium Battery Safety..........................................................................................................53
12.6 Battery Charging Status .......................................................................................................54
12.7 Battery Charging State.............................................................................................................54
12.8 Battery Status in System Registers...................................................................................54
CHAPTER 13: REGISTERS ..................................................................................................................... 23
13.1 Register Definitions ................................................................................................................... 23
13.2 Useful %S and %SR registers.................................................................................................24
13.3 Resource Limits.......................................................................................................................... 33
13.4 Register Map for RCC Series ...............................................................................................34
CHAPTER 14: FAIL-SAFE SYSTEM......................................................................................................84

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14.1 Overview.......................................................................................................................................84
14.2 Settings.....................................................................................................................................84
14.3 Backup / Restore Data ..........................................................................................................85
14.4 AutoLoad..................................................................................................................................87
14.5 AutoRun....................................................................................................................................89
CHAPTER 15: MAINTENANCE ..............................................................................................................90
15.1 Firmware Updates......................................................................................................................90
15.2 Backup Battery........................................................................................................................90
CHAPTER 16: MODBUS COMMUNICATIONS.....................................................................................92
16.1 Modbus Overview.......................................................................................................................92
16.2 Modbus Slave Overview........................................................................................................92
16.3 Modbus Master Overview .....................................................................................................93
16.4 Opening Cscape Help File................................................... Error! Bookmark not defined.
16.5 Modbus Addressing Table for RCC Units..........................................................................94
CHAPTER 17: TROUBLESHOOTING / TECHNICAL SUPPORT.......................................................95
17.1 LED - Normal Functionality......................................................................................................95
17.2 LED Load Program/Firmware Functionality........................................................................95
17.3 Switch - Normal Functionality.................................................................................................96
17.4 LED –Diagnostic Functionality............................................................................................96
17.5 Connecting to the RCC.............................................................................................................. 97
17.7 CsCAN Network ..........................................................................................................................99
17.8 Removable Media - Basic Troubleshooting.................................................................... 100
17.9 Technical Support Contacts .................................................................................................. 100
MAIN INDEX ................................................................................................................................................101
CHANGE LOG.............................................................................................................................................103

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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 –Consult user documentation.
Warning –Electrical Shock Hazard.
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

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2.2 General Overview of an RCC2414 Unit
USB 2.0 Port
mini-B USB port
LAN ports
NOTE: See USB precaution in datasheet
2.2.1 Where to Find Information about the RCC
a) Datasheet - The datasheet is the first document to refer to for key information
related to specific RCC models. The datasheets are available on the Horner website
and contain pin-outs and other model specific information.
Table 2.1 –Datasheets for RCC Models
RCC Model
Datasheet
RCC972
MAN0970
RCC1410
MAN1034
RCC2414
MAN1033
RCC8842
MAN1073
b) User Manual -This manual provides general information that is common to RCC models
and can be downloaded from our website to obtain user documentation and updates.
North America https://hornerautomation.com
Europe https://www.hornerautomation.eu
2.2.2 Four main types of information are covered in this manual
a) Safety and installation guidelines / instructions (Mechanical and Electrical)
b) Descriptions of hardware features (Serial ports, Removable Media, Communication
Options, etc.)
c) Configuration and use of the RCC
d) Maintenance and support

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2.2.3 Manual Index
Major topics of interest may be found in the Index towards the end of this manual.
2.3 Connectivity to the RCC
The RCC has excellent capabilities for connecting to a variety of devices. The diagram below
shows some examples of devices that can be used with the RCC.
Figure 02.2—Visual Overview of Connectivity of the RCC OCS
CAN
Serial
I/O
RCC
Other Control
Devices
Drives
PLCs
Bar Code Readers
Printers
SCADA
OPC Servers
Serial I/O
Sensors
Indicators
Alarms
Encoders
Pumps
Relays
Solenoids
Other OCS Devices
Smart Stix I/O
Smart Block I/O
Smart Rail I/O
Ethernet
Cscape
OPC Server
Modbus TCP
Devices
PLCs
SCADA
Portal
I/O Devices

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2.4 Features of RCC
The RCC are industrial control devices with built in I/O. They combine control, I/O, and
networking into a single, integrated package.
Unique features of the RCC include:
- Advanced control capabilities including floating point, multiple auto-tuning PID loops,
and string handling capabilities
- Removable media for storage of programs, data logging, and on-site updating
- CsCAN networking for communication with remote I/O, other controllers, or PCs
- Configurable serial protocols for communication to drives, PLCs, or other serial
peripherals
- Advanced high speed I/O capabilities
- Cscape programming software that allows all aspects of the RCC to be programmed
and configured from one integrated application
- On board Ethernet port (10/100Mbps) for Cscape programming and application defined
communication, with Auto MDI/MDI-X
- WebMI and Push capabilities for access from the Internet
- Small, compact, din-rail mountable logic controller with flexible built in I/O

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2.5 Useful Documents and References
Visit our website to obtain user documentation, supplemental documents, certificates, and
other documentation.
North America https://hornerautomation.com
Europe https://www.hornerautomation.eu
2.6 Opening Cscape Help File
After opening the Cscape Help file, either use the Contest, Index or Search tabs to located
information. The Cscape Help file has more information than the scope of this user manual.
Select “Index” tab.

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CHAPTER 3: MECHANICAL INSTALLATION
NOTE: The datasheet is the first document to refer to for information related to RCC models
such as pin-outs, I/O and general specification, and other key installation information. Visit the
Horner websites to obtain datasheets, user documentation, and updates.
3.1 Overview
The mechanical installation greatly affects the operation, safety, and appearance of the system.
Information is provided to mechanically install the unit such as cutout sizes, mounting
procedures and other recommendations for the proper mechanical installation of the unit.
3.2 RCC Dimensions
Figure 3.1 –RCC Dimensions

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3.2 RCC Installation
These RCC modules are suitable for use in the Class I, Division 2, Groups A, B,C and D
Hazardous Locations only. The operating temperature range is -10˚Cto +60˚C.
WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT
UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE
NON-HAZRDOUS.
ATTENTION - RISQUE D’EXPLOSION - NE DÉBRANCHEZ PAS L’ÉQUIPEMENT
SAUF SI L’ALIMENTATION A ÉTÉ COUPÉE OU SI LA ZONE N’EST PAS
DANGEREUSE.
Devices shall be installed into an enclosure suitable for the environment that is
only accessible with the use of a tool.
1. The RCC modules conveniently mount on a DIN rail.
2. Be sure the DIN rail is in a horizontal position before installing the unit.
3. The orientation shown to the right is necessary to prevent the unit from
slipping off the DIN rail.
4. Align the unit on the DIN rail then push the DIN rail clip until it clicks into
place. Check to ensure that the unit is secure on the DIN rail.
5. Do NOT mount the unit on its side as this may cause the unit from slipping
off the DIN rail.
NOTE: The spade connector for grounding and the DIN rail clip add to the
overall measurements. The CAN/PWR and LAN connectors also add to the
measurements.
NOTE: Screw holes and a spade connector are available for a mounting option.

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3.3.1 Temperature / Ventilation
Ensure that the DIN Rail layout design allows for adequate ventilation and maintains the
specified ambient temperature range. Consider the impact on the design if operating at the
extreme ends of the ambient 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 if DIN rail is mounted inside.
3.3.2 Orientation
RCC should be mounted with locking DIN tab facing down.
3.3.3 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 RCC
and noisy devices such as relays, motor starters, etc.
For details on output protection, especially when using contactors and solenoids see
MAN0962.
3.3.4 Shock and Vibration
The RCC 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 RCC to a location that minimizes
shock and/or vibration.

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CHAPTER 4: ELECTRICAL INSTALLATION
NOTE: The datasheet is the first document to refer to for model-specific information related
to RCC models for key installation information. Visit the Horner websites to obtain datasheets,
user documentation, and updates.
4.1 Grounding Definition
Ground: The term ground is defined as a conductive connection between a circuit or piece of
equipment and the earth. Grounds are fundamentally used to protect an application from
harmful interference causing either physical damage such as by lightning or voltage
transients or from circuit disruption often caused by radio frequency interference (RFI).
Grounding is also for the safety of the user.
4.2 Ground Specifications
Ideally, a ground resistance measurement from equipment to earth ground is 0Ω. In reality, it
typically is higher. The U.S. National Electrical Code (NEC) states the resistance to ground
shall not exceed 25Ω. Horner APG recommends less than 15Ωresistance from our equipment
to ground. Resistance greater than 25Ωcan cause undesirable or harmful interference to the
device.

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4.3 How to Test for Good Ground
In order to test ground resistance, a Ground Resistance Tester must be used. A typical Ground
Resistance Meter Kit contains a meter, two or three wire leads, and two ground rods.
Instructions are supplied for either a two-point or three-point
ground test.
Figure 04.1 –Two-Point Ground Connection Test
To power the RCC unit, V+ and V- wires are directly wired to one of the terminal strips, similar
to what is shown below on the RCC972. Earth Ground is the auxiliary spade at the bottom.
METAL WATER PIPE OR
OTHER GOOD GROUND
GROUND ROD
GROUND
DISCONNECTED
FROM SERVICE
GROUND RESISTANCE METER

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4.4 RCC972 Power Writing
Table 4.1 –Primary Power Port Pins
PIN
Signal
Description
V+
DC IN
Input power supply positive voltage
C
0V
Input power supply ground
To power up the RCC972, supply 10-32VDC to the
V+ and C connections on the Power & Input
connector.
OPTION: Attach ferrite core with a minimum of
two turns of the DC+ and DC- signals from the DC
supply that is powering the controllers.
4.5 RCC1410 Power Writing
To power up the RCC1410, supply 10-30VDC to the V1+ and V- connections on the Power &
Input connector. See image below.
OPTION: Attach ferrite core with a minimum of two turns of the DC+ and DC- signals from the
DC supply that is powering the controllers.