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User Manual for RCC Series Controller

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1. 21 CHAPTER 8 REMOVABLE ous Saxon c qc Eua ERU fU cu 26 MEMO 0 26 o2 1 CIS 26 8 3 MicroSD File 26 8 4 Using Removable Media to Log Data eeeeessssseseseseeseeennneenene nennen nnn nnn nnn nnns 27 8 5 Using Removable Media to Load and Save Applications 27 8 6 Removable Media RM Function Blocks in 27 8 7 Filenames used with the Removable Media RM Function Blocks 27 8 8 System Registers used with RM ccccccccccccssesseeeceeeeeceeeeseeeeeeeeeeeeeesseeeeeeeeseeaeseeeceeeeesssaaaeeeeeeees 28 CHAPTER 9 GENERAL terres 29 ON es 29 9 2 Solid State Digital OULIDUIS 29 SUING A 30 SM WAP 30 9 4 1 Common cause of analog input tranzorb 31 s 1
2. vM a ae an nner 31 CHAPTER 10 CSCAPE 32 EG 32 10 2 6 E 32 10 3 15 60 614 33 10 3 1 Communicating via MJ1 Serial Port 35 10 3 2 Communicating via On Board Ethernet Port 35 TOs CONGUE CIEL 37 CHAPTER 11 REGISTER eee enter semen uo vuv ere een nears 39 1141 E ise NETTE 39 11 2 Useful S and ele NE 39 13 Map Ior ROO O Tc 42 TR 42 CHAPTER 12 MAINTENAN QGE 2 Dna Cut 43 12 1 Firmware 43 CHAPTER 13 TROUBLESHOOTING TECHNICAL SUPPORT 43 LED NORMAL E narum 43 131 Connecino 10 _____ 44 13 1 1 Connecting Troubleshooting Checklist serial port MJ1 44 13 1 2 Connecting Troubleshooting Checklist ETN port programming
3. 45 13 2 Local Controller and Local EER ie i nnne nnnm 45 SCENE 45 13 3 1 CsCAN Network Troubleshooting Checklist eeeeseseeeeesseeeeeeerneneenn nn 45 13 4 Removable Media Basic 46 13 5 Technical Support Contacts ccccccceeecceccseseeceecceeeseceessaeeeeeeceeeaeeeeesseeaseeessseaaeeeessseaseeeessaageeeess 46 SM gt 47 Page 6 of 48 HORNER AUTOMATION GROUP RCC User Manual Visual map of major tasks and key chapters FIRST STEP of ANY TASK DATASHEET Each RCC unit is sent with a datasheet in the box The datasheet 971 02 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 US http www heapg and Europe http www horner apg com QUICK START INSTALLATION PROG mv TROUBLESHOOTING Safety gm Compliance Safety Compliance Safety Compliance Compliance page 10 page 10 page 10 page 10 e 10 age 12 age 12 age 12 age 12 Mechanical Installation oage 15 Electrical Installation oage 17 Serial Communications oage 19 CAN Communications oage 20 EB page EB ae M
4. Removable media access WARNING Setting outputs ON in Do I O mode can result in injury or cause machinery to engage in an unsafe manner depending on the application and the environment 13 3 CSsCAN Network For complete information on setting up a CSCAN network refer to CAN Networks manual 799 by visiting the Horner websites for the address to obtain documentation and updates Network status node ID errors and baud rate in the controller system menu are all in reference to the CsCAN network These indications can provide performance feedback on the CsCAN network and can also be used to aid in troubleshooting 13 3 1 CsCAN Network Troubleshooting Checklist 1 Use the proper Belden wire type or equivalent for the network as specified in 799 2 The RCC does not provide 24VDC to the network An external voltage source must be used for other devices such as SmartStix 3 Check voltage at both ends of the network to insure that voltage meets specifications of attached devices 4 Proper termination is required Use 121 ohm or 120 ohm resistors at each end of the network The resistors should be placed across the CAN_HI and CAN_LO terminals 5 Measure the resistance between CAN and CAN LO If the network is properly wired and terminated there should be around 60 ohms 6 Check for duplicate node 10 Page 45 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 7 Keep proper wires together O
5. Connected Device Connected Device C Target Node 10 1 Connection Settings Timeout 3000 ms Cancel Page 34 of 48 IM HORNER AUTOMATION GROUP RCC User Manual If communication is established the target indicator will show the mode of the controller Target yy R as shown in the status section above in this chapter section Cscape Status Bar If the controller is not communicating ensure the target ID is set correctly The Target ID allows directing communications to a particular unit when multiple units are connected via a CSCAN network Units without CSCAN network ports respond to any network ID and do not require the ID to be configured To change the RCC target ID in Cscape go to Controller Set Local Network ID 10 3 1 Communicating via MJ1 Serial Port Start by configuring Cscape to use the correct communications port This can be done using the Tools Options Communication Port dialog in Cscape Connect the PC s serial port to the port labeled MJ1 on the RCC If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above If the controller is not communicating it may be required to set the target ID of the controller in Cscape The Target ID allows directing communications to a particular unit when multiple units are connected via a CsCAN network Units without CSCAN network ports respond to any network ID and d
6. Downloadable Protocols ETH1 1 Network evices Scan List ETH1 2 Hetyyork levice Scan List Cancel Download the configuration to Controller Connect LAN cable to the Controller in default LAN Port From Cscape go to Tools gt Editor Options gt Communication Port gt Configure Select Ethernet and enter IP address which is configured in the file The controller should get connected to Cscape If communications are successful the target indicator should show the mode of the controller Target yy R as shown in the status section above Page 36 of 48 10 4 IM HORNER AUTOMATION GROUP RCC User Manual I O Configuration An overview of configuration 1 2 3 Start the configuration by selecting the Controller I O Configure menu item If the RCC is connected to the PC press the Auto Config System button to automatically detect the Base model I O and any communication options If the RCC is not connected press the Config button to the right of the top of the unit This allows the base CPU to be selected Select RCC Series from the type drop down box Click Local I O Tab and then Configure to bring up the Module Configuration menu From here the I O registers can be viewed 1 0 RCC972 Configuration Model HE RCC972 Description Integrated Type Starting Ending Number of Register Register Registers Ta E 1 4 AJ 1
7. last time the Target Controller was compared to the configured Controller Model and Network match the configured Controller Model and Network R Running D Do l o e Model there may have been a change since the Idle Figure 10 1 Cscape Status Bar Page 32 of 48 IM AUTOMATION GROUP RCC User Manual 10 3 Establishing Communications The preferred method of communicating between Cscape and RCC is via serial MJ1 port The RCC can communicate with Cscape using serial port communications via 1 Port Ethernet and CAN CsCAN For communications other than MJ1 port please refer to the manual which ships with the communications adapter hardware being used for programming For RCC use Cscape Ver 9 30 SP6 or later Connect a PC Personal Computer running a Windows Microsoft operating system serial port to the MJ1 port on the RCC CBL600 adapter and cable can be used to connect the MJ1 port to the PC s USB port amans SD nan e ii t gt Figure 10 2 MJ1 Connector to be used via Serial or with Serial USB adapter to PC If the recommended CBL600 serial to usb adapter is used the following dialogs will appear to configure the USB port driver when a powered up unit is connected to the PC Found Hew Hardware Wizard Welcome to the Found New Hardware Wizard Windows will search for current and upd
8. 5 O Firmware Update RISM 12 CsCAN 2 Generic HM Ladder Controlled 3 Modbus 4 Modbus ASCII eSR35 36 SERIAL NUM This Station s 32 bit SerialNumber ______ 0 2 1 __ 5837 __ MODEL NUM This Station s Binary Model Number 0 65535 SR39 BlOSRevNumber 100 000 255 __ 5840 __ FPGA REV FPGAlmageRevNumber 10 000 255 SR41 __ LCD COLS Vertical PixelCount __ 5842 __ LCD ROWS Horizontal Pixel Cout __ 5843 KeypadType SR44 __ SEC ___ Real Time Clock Second 59 SR45 __ ___ Real Time ClockMinute 0 59 SR46 RTC HOUR Real Time Clock Hour 0 29 SR51 NET ___ Network ErrorCount BS SR52_ WDOG CNT Watchdog Tripped Error Count 0 6555 SR53 54 BAD LADDER Ladder Code Errorindex O 65534_ eSR55 F SELF TEST Filtered Bit Mapped Self Test Result 0 ____ 65535 eSR56 LAST KEY Key Code of Last Key Press or Release __ 25 SR57 BAK LITE LCD Backlight Dimmer Register 255 0 0 On 2522596 100 255 100 SR58 USER_LEDS User LED Control Status 65535 Page 40 of 48 IM HORNER AUTOMATION GROUP RCC User Manual Table 11 2 SR Registers Register Description Max Val SR59 60 Reserved o ___ SR63_ SS SmartStack
9. None gt 1 2 None gt Figure 7 2 Ethernet Module Configuration Page 22 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 4 Configure the Ethernet Module parameters as follows IP Address Enter the static IP Address for the Ethernet Module being configured Note P Addresses are entered as four numbers each ranging from 0 to 255 These four numbers are called octets and they are always separated by decimal points Net Mask Enter the Net Mask Sometimes called Subnet Mask being used by all nodes on the local network Typical local networks use Class C IP Addresses in which case the low octet rightmost number is used to uniquely identify each node on the local network In this case the default Net Mask value of 255 255 255 0 should be used Gateway Enter the IP Address of a Gateway Server on the local network that allows for communication outside of the local network To prevent the Ethernet Module from communicating outside the local network set the Default Gateway IP Address to 0 0 0 0 the default setting Status Register Enter an Register reference Such as R100 to indicate which 16 bit register will have the Ethernet Status word written to it Table 7 3 shows how this register value is formatted and explains the meaning of each bit in the Status Word Table 7 3 Ethernet Status Word Register Format High Byte Low Byte d HighBye Cw Byte B
10. 18 55 J Ladder Controlled Serial Communication cccccccseeeeeceecaeeeeeeeecaeeeeeeeecaaeeeeeeesaaaseeeessaaeeeeseesaaess 18 5 6 Downloadable Serial Communication Protocols sssssssssseeeeeeeeennns 18 CHAPTER 6 CAN COMMUNICATIONS cele e LLLeee rcc LLL Lire eee nere eaa a roD saa 19 19 62 eee eee 19 69 CAN FPO MING RENT 19 6 4 Cscape Programming CAN ccccccsssecccesescecceeseeccseseeecsaeeecseuseeessaseeessageeeesageeesssuseesssageeeens 20 6 5 Ladder Controlled CAN Communication ccccccceceeeeeeeeeeeeeeeeeeeeaeeseeeeesseaeeeeeessaaseeeessaeeeeeeeeeas 20 6 6 Using CAN for I O Expansion Network I O sese 20 CHAPTER 7 ETHERNET nhan ann nenas suas 21 7 1 Ethernet Module Protocols and 21 7 2 Ethernet System RequireMent cccccccccccceccseeeeceeeeeeeeeeeeeseeeeceeeeeseeeeeeeeseeaeeeeesseaeseeeesseeeeeeeeeeas 21 7 3 Ethernet Module 21 Page 5 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 7 4 Ethernet Module
11. AQ 7 4 Page 37 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 6 Next click 972 Configuration to configure Output value on STOP Contains items that allow the user to specify how the outputs behave when the controller is stopped These items can either hold their value or default to some value when the controller is stopped Analog input settings Adjust filter constant for system noise Module Configuratic 1 I O 72 Configuration Digital inputs active mode Positive Logic Megative Logic Digital Output State on Controller Stop 1 3 4 Output value on STOP AQ Goto Me Hold Last Value AQ Goto rJ Hold Last Value AGQ3 Goto 0 i Hold Last Value AQA Goto mum Hold Last Value Analog Input Settings Filter Constant H Filter Constant sets the level of digital filtering according to the following chart Digital filtering minimizes noise and jitter improves effective resolution and provides adequate speed for most temperature monitor control applications Yo Complete AT 0 20 40 60 80 100 Scans Page 38 of 48 IM HORNER AUTOMATION GROUP RCC User Manual CHAPTER 11 REGISTERS 11 4 Register Definitions When programming the RCC data is stored in memory that is segmented into different types This memory in the controller is referred to as registers Different groups of registers are defined as either bits or words 16 bits Multiple re
12. hour in 24 hour format 4 16 Substitutes the current minute 45 45 Substitutes the current second 34 34 Note that all the symbols start with the dollar sign character Date symbols are in upper case time symbols are in lower case The following are examples of the substituted time date filenames Page 27 of 48 IM HORNER AUTOMATION GROUP RCC User Manual Current date and time March 1 2013 3 45 34 PM Filename Data M D csv Data0301 csv Filename Year Y Month M aa D_ h csv Year04 Month03 aa01_15 csv Filename Month_ M Day_ D h_ m_ s csv Month_03 Day_01 15 45 34 csv Note Time Date requires setting on the RCC972 and is only maintained while the RCC is powered Time and Date will need to be reconfigured on power cycle 8 10 System Registers used with RM SR175 Status This shows the current status of the RM interface SR176 Free Space This 32 bit register shows the free space on the RM card in bytes 58178 Card Capacity This 32 bit register shows the total card capacity in kilobytes Possible status values are shown tn the table Table 9 2 RM Status Values RM interface OK Card present but unknown format No card in slot Card present but not supported Card swapped before operation was complete Unknown error For additional status information consult the Cscape help file Page 28 of 48 IM HORNER AUTOMATION GROUP RCC User Manual CHAPTER 9 GENERAL I O Note Each
13. is bootable and valid firmware files are found on it 2 After boot up pressing the LOAD switch for 3 seconds either starts a Firmware Load or an Application Load depending upon what files are found on the Micro SD If firmware files are found a Firmware Load is performed If firmware files are not found and the DEFAULT PGM file is found an Application Load is performed CHAPTER 13 TROUBLESHOOTING TECHNICAL SUPPORT Chapter 13 provides commonly requested troubleshooting information and checklists for the following topics Connecting to the RCC controller Local controller and local I O CsCAN Network Removable media In the event that this information is not enough please contact Technical Support at the locations indicated at the end of this chapter LED NORMAL FUNCTIONALITY LED Load Program Firmware Functionality LED Flashing Flashing Flashing Stops OK amp RUN Alternately Together Flash 1Hz Off ON No power 10 30Vdc applied applied Load program Download in Download fails Download Complete or firmwre Progress number of flashes unit reboots allow 30 indicates the error seconds Self test fail Self test pass I O forcing enabled RUN Stopmode Mode Mode Switch Normal Functionality Load switch Used for firmware updated as noted in previous section Run Stop switch 1 After boot up pressing the RUN STOP switch for 3 seconds toggles the RCC between RUN and
14. is stopped the operation of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined value By default analog outputs are set to a value of zero For more information on Stop State refer to the appropriate pages see Index for the configuration chapter for Cscape settings Page 31 of 48 IM HORNER AUTOMATION GROUP RCC User Manual CHAPTER 10 CSCAPE CONFIGURATION 10 1 Overview RCC hardware is programmed with a Windows based PC application called Cscape This application can be used to program configure monitor and debug all aspects of the RCC unit Please see the on line help provided with Cscape for additional details 10 2 Status Bar When the RCC is connected to a PC using Cscape software a Status Bar appears at the bottom of the screen The Cscape Status Bar can be used to determine if communications have been established between the RCC and the Cscape program Components of the Cscape Status Bar are explained below Message Line Equal Indicator indicates whether the current program in Cscape is equal to the program The contents of stored in the Target Controller these messages e f Equal the program in Cscape is the same as the program stored in the Target Controller are context e f Not Equal the program in Cscape is not the same as the program stored in the Target sensitive The Controller Message line can e f Un
15. the sole responsibility of the system integrator Page 3 of 48 IM HORNER AUTOMATION GROUP MAN2010 01 EN INTENTIONALLY LEFT BLANK Page 4 of 48 IM HORNER AUTOMATION GROUP RCC User Manual TABLE OF CONTENTS PREFACE ec ce secede n 2 LIMITED WARRANTY AND LIMITATION OF 3 ABOUT PROGRAMMING EXAMPLES 3 TABLE COI INS aac 5 INTENTIONALLY LEFT 8 CHAPTER 1 SAFETY COMPLIANCE 9 1 1 Safety Warnings and Guidelines sseeeesssssesssesssssessee eee nnne nnnm nnn nnn nnns 9 12 MEE C METTRA 10 jo EE 10 CHAPTER 2 INTRODUC TION arcas Ue su 11 vVi al Overview OF HOC H 11 2 1 1 Where to Find Information about the RCC 11 2 1 2 Four main types of information are covered in this 12 2149 Manual INOUE RRRCHET 12 22 COO 12 29 4 dps 6 HH 12 2 4 Require
16. 86 7087 7088 7089 76810 20511 70812 70813 70816 Page 39 of 48 IM HORNER AUTOMATION GROUP RCC User Manual Table 11 2 SR Registers Register Name Description SR2 ALRM SCR Current Alarm Screen Number O none O ____ 1023 9eSR3 575 SCR Current System Screen Number Q none O14 SR4 SELF TEST BitMappedSelf TestResult_ O 65535 __ 585 CS MODE Control Station Mode 0 Idle 1 Do VO 2 Run 0 2 SR6 SCAN RATE Average ScanRate 10 1000 SR7 MIN RATE __ MinimumScanRate 10 1000 9eSR8 MAX RATE Maximum ScanRate 10 1000 eSR9 10 EDIT BUF Data Field Edit Buffer __ 5 1316 Reserved S e e __ 5 2122 SD SIZE Security Data Table Size __ 9eSR23 LADDER Ladder Code CRC 0 65595 SR24 25 Reserved _ ___ _ y 9eSR26 IO lO Configuration Table CRC 0 65535 9eSR27 NET e Network Configuration Table CRC 0 6555 SR28 SD ____ Security Data Table 0 65535 Network Baud Rate CSCAN MODE Network Mode 0 network not required 1 network SR31 NET MODE required 2 network optimized 3 3 network required and optimized SR32_ LCD CONT LCD Display Contrastseting J0 255 SR33_ FKEY MODE Function Key Mode 0 1 Toggle __ 1 RS232 Serial Protocol Mode
17. G HORNER AUTOMATION GROUP User Manual for RCC Series Controller MAN1020 01 EN IM HORNER AUTOMATION GROUP RCC User Manual PREFACE This manual explains how to use the RCC Controller Copyright 2014 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 317 639 4279 Web http Awww heapg com Email techsopt heapg com Europe Tel 353 21 4321 266 Fax 353 21 4321 826 Web http Awww horner apg com Email tech support horner apg com Page 2 of 48 IM HORNER AUTOMATION GROUP MAN2010 01 EN LIMITED WARRANTY AND LIMITATION OF LIABILITY Ho
18. I O Selector TO SR64 __ SS STATUS SmartStack Base Status 0 2 __ 5 65 76 SS INFO 1 SmartStack Module 1 Information Structure _ __ 5 77488 SS INFO 2 SmartStack Module 2 Information Structure __ SR89 100 55 INFO 3 SmartStack Module 3 Information Structure __ SR101 112 SS INFO 4 SmartStack Module 4 Information Structure SR113 114 GOBJ SIZE Graphics Object Table Size _____8 26 SR115 116 GSTR SIZE Graphics String Table Size BK SR119 120 GTXT SIZE Graphics Text Table Size BK SR121 122 GFNT SIZE Graphics Font Table Size 8 _____ 256 ___ 9eSR125 GOBJ CRC Graphics ObjectTableCRC O 65535 eSR126 GSTR Graphics String Table CRC 0 6555 eSR127 GBMP Graphics BitmapTableCRC _ 0 65535 eSR128 GTXT Graphics Text Table CRC 0 65535 _ 58129 GFNT CRC Graphics Font Table CRC O 65555 9eSR130 PROT CRC Protocol Table CRC O 65595 Reed Reserved 163 o SR164 3 Read bit indicating Auto Restore of Register Data has been performed Fail Safe SR164 4 Read bit indicating Backup of Register Data has been performed Fail Safe SR164 5 Enable AUTORUN Fail Safe 581646 Enable AUTOLOAD FailSafe 4 SR164 7 JBackpt ggerbit 581648 Clear Backuptriggerbi
19. STOP modes Switch Erase Program Function LOAD and RUN STOP 1 After boot up pressing both Load and RUN Stop switches for 3 seconds performs an Erase All function which deletes all application programs Page 43 of 48 IM HORNER AUTOMATION GROUP RCC User Manual LED Diagnostic Functionality The leds are also used to indicate some fault conditions in the unit The two leds OK and RUN will flash a number of times depending upon the fault There will be a two second gap and the pattern will be repeated The number of flashes and the associated error are as follows No of flashes Fault Meaning The MAC ID is empt The internal MAC file is corrupt The MAC ID TXT file is invalid The MAC ID file is not found or the uSD card is empty or missing system files Diagnostic Led flashing table 13 4 Connecting to the RCC Cscape connects to the local controller automatically when the serial connection is made The status bar below shows an example of a successful connection This status bar is located in the bottom right hand corner of the Cscape window 253 Target 25318 Forces In general the Target number should match the Local number The exception to this is when the controller is being used as a pass through unit where other controllers on a CSCAN network could be accessed through the local controller Determine connection status by examining feedback next to Local amp Target in the statu
20. System This means that a PC with a MicroSD compatible card reader can read files that have been written by the RCC and can write files that can be read by the RCC However the RCC does not support long filenames but instead implements the 8 3 filename format This means that all file and directory names must consist of up to 8 characters followed by an optional dot and an optional extension with up to 3 characters Directories and sub directories can be nested up to 16 levels deep as long as each pathname string does not exceed 147 characters Page 26 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 8 5 Using Removable Media to Log Data Using Read and Write Removable Media function blocks an application ladder program can read and write RCC register data in the form of comma delimited files with a CSV extension These files are compatible with standard database and spreadsheet PC programs In addition an application ladder program can use Rename and Delete Removable Media function blocks to rename and delete files 8 6 Using Removable Media to Load and Save Applications A special file type with a PGM extension is used to store RCC application programs on MicroSD Pressing and holding the LOAD button for three seconds upon power up will load the program that is stored on the MicroSD more details in Chapter 11 Cscape can also save an application directly to a MicroSD card which is plugged into the PC s MicroSD compat
21. al a Safety and Installation guidelines instructions Mechanical and Electrical b Descriptions of hardware features a Serial ports Removable Media Communication Options etc c Configuration and Use of the RCC d Maintenance and Support 2 1 3 Manual Index Major topics of interest may be found in the Index towards the end of this manual 2 2 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 Other Control Other Control Devices CAN Serial Devices Smart Stix I O a gt Drives RCX116 I O Base PLCs OPC Server Bar Code Readers Printers SCADA OPC Servers WX _____ VO Sensors Cscape Indicators OPC Server Alarms Encoders Modbus TCP Devices Pumps Relays Solenoids 2 3 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 32GB of storage of programs data logging and on site updating 5 networking port for communication with remote I O other controllers PCs Configurable serial protocols for communication to drives PLCs or other serial peripherals Advanced high speed
22. ated software by looking on pour computer an the hardware installation or an the Windows Update Web site with your permission Head aur privacy policy Can Windows connect to Windows Update to search Far amp nftware CO es this time only C Yes now and every time connect device Click Next ta continue Page 33 of 48 AUTOMATION GROUP RCC User Manual Now that the RCC is plugged in go to Cscape Tools Application Settings Communications and choose the USB port in this example Com 3 Escape untitled File Edt Program Controller Debug Screens View Window Help Security Project Navigator Project Navigator untitled 1 Unknown Mod StpCalc Strip Chart i Update SmartStack Module antra View Data List E 15 Logic Modules Main Loop Mod Project Navigator main Subroutine Mod Project Toolbox z SetPoints Output Window EE 10 Names 5 oof Af Data Logging backup Register Lontents e C Recipes 7117 Restore Register Contents Graphics xm Networking Spe TIU ripe t Editor Options Application Settings String Operations Add Target Target Name 18 Connection Medium C Com Port 3 C Ethernet C Can Interface OCS USB COM Port 20
23. capabilities Cscape programming software that allows all aspects of the RCC to be programmed and configured from one integrated application board Ethernet port 10 100Mbps for Cscape programming and application defined communication with Auto MDI MDI X Small compact din rail mountable logic controller with flexible built in I O Page 12 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 2 4 Required and Suggested Accessories The following list contains a sampling of required and suggested RCC accessories Visit the Horner websites to view updates on new products and accessories NOTE The RCC is not shipped with a programming cable in the box To obtain a programming cable order HE500CBL300 Table 2 1 RCC Accessories HECSP Cscape Software Package on a reusable USB flash drive with symbol library HE XCK Programming cables including a USB to serial adapter in a travel case HE CPK Cscape on a reusable USB flash drive Programming cables including a USB to serial adapter in a travel case 2 5 Useful Documents and References The following information serves as a general listing of Horner controller products and other references of interest with their corresponding manual numbers Visit the Horner websites to obtain user documentation and updates Table 2 2 CONTROLLER Reference Document numbers NOTE This list is not intended for users to determine which products are appropriate for their application
24. ces SmartStix SmartBlock or SmartRail to the RCC CAN port allows the RCC I O to be economically expanded and distributed A variety of modules are available for this purpose Page 20 of 48 IM HORNER AUTOMATION GROUP RCC User Manual CHAPTER 7 ETHERNET COMMUNICATION 7 1 Ethernet Module Protocols and Features The following table describes the Ethernet Module Protocols and features supported by RCC Protocol Feature Protocol Feature Description Table 7 1 Ethernet Module Protocols amp Features 7 2 Ethernet System Requirements Full Ethernet functionality requires PC running Cscape Programming Software Version 9 3 SP6 or later for configuration RCC controller with onboard Ethernet port FTP 6 protocols 7 3 Ethernet Module Specifications 10 BaseT Ethernet 10 Mbps zen 100 BaseTx Fast Ethernet 100 Mbps Modes Half or Full Duplex Auto Negotiation Both 10 100 Mbps and Half Full Duplex Connector Type Shielded RJ 45 mus Med ded 5 or better UTP Port Auto MDI MDI X Auto Crossover Table 7 2 Ethernet Module Specifications 74 Ethernet Module Configuration Note The following configuration is required for all applications regardless of the protocols used Additional configuration procedures must be performed for each protocol used To configure the Ethernet Module use Cscape Programming Software to perform the following steps 1 On the main Cscape screen select t
25. controller products differ in the features that they support If assistance is required refer to Technical Support Manual Description Manual Number Datasheet for RCC model User Manual for XLe XLt OCS models Other Useful References Manual Number Spark Quenchers for Arc and Noise Suppression output protection Page 13 of 48 HORNER AUTOMATION GROUP RCC User Manual 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 cut out sizes mounting procedures and other recommendations for the proper mechanical installation of the unit 3 2 RCC Dimensions eo000000202002000 RUN STOP LOAD MEMORY CARD 35 84mm 1 411 116mm 4 567 Figure 3 5 RCC Dimensions Page 14 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 3 6 3 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 extre
26. d and Suggested Accessories 13 25 Useful Documents and References sss enne 13 CHAPTER 3 MECHANICAL _ 14 EGO 14 ARCODON REN eee 14 3 6 3 nnne nnne nennen nnn nnn 15 MEE 15 MN a 15 Na VID ba 15 CHAPTER 4 ELECTRICAL INSTALLATION ccecceeeeeeeeeeeessneeeeeeeeeeeeesnseeeeeeeeooeeasseeesesseooeesneeeeees 16 AT OD 16 42 T 16 43 HOWTO Testior Good Ground e ice a iud itus c veta ea io C ooa Rate 16 d Web OWN d OFT gt 17 CHAPTER 5 SERIAL COMMUNICATIONS 18 941 De ee ee 18 D2 Port Descriptions eats aula 18 BI Ried 090 18 54 Cscape Programming Serial Port cccccsssseccccceeeeceeesseeeeceeeceeeseeeeesseaseeeeeseaeseeeesseaeeeeeeseaees
27. edia page ae 30 Config page 33 41 Maintenance page 45 Troubleshooting page 45 Page 7 of 48 IM HORNER AUTOMATION GROUP RCC User Manual INTENTIONALLY LEFT BLANK Page 8 of 48 IM HORNER AUTOMATION GROUP RCC User Manual CHAPTER 1 SAFETY COMPLIANCE 1 1 Safety Warnings and Guidelines When found on the product the following symbols specify 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 Division 2 WARNING The USB parts are for operational maintenance only Do not lea
28. esult 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 segmenis 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 15 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
29. gisters can usually be used to handle larger storage requirements For example 16 single bit registers can be used to store a Word or two 16 bit registers can be used to store a 32 bit value Below is a table of the type of registers found in the OCS Register Description and speed settings coming from an attached device settings to an attached device AIG Global Analog Input Specially defined 16 bit input registers that come from the network AQG Global Analog Output Specially defined 16 bit output registers that go to the network D Display Bit These are digital flags used to control the displaying of screens on a unit which has the ability to display a screen If the bit is SET the screen is displayed l Digital Input Single bit input registers Typically an external switch is connected to the registers IG Global Digital Input Specially defined single bit inputs that come from the network Key Bit Single bit flags used to give the programmer direct access to any front panel keys appearing on a unit 96M Retentive Bit Retentive single bit registers Digital Output Single bit output registers Typically these bits are connected to an actuator indicator light or other physical outputs QG Global Digital Output General Purpose Register 265 System Bit 658 System Register Temporary Bit 11 2 Useful S and SR registers Table 14 1 Common 96S Register Definitions Register 7681 7982 253 9054 255 70
30. he Controller menu and its I O Configure sub menu to open the I O Configuration dialog Figure 7 1 2 If configuring a different Product Model than the one shown in the I O Configuration dialog click on the topmost Config button select the desired PRODUCT Model and then click OK Page 21 of 48 IM HORNER AUTOMATION GROUP RCC User Manual Controller Local 1 0 CsCAN 1 0 LANT Seres Rcc Seres Description Micro PLC with low current ouputs Device Type HERCC 972 3 Properties Display Type Keypad Type Program Memory 125 K Bytes Serial Ports Contig Figure 7 1 I O Configuration Dialog Click the Config button to the right of LAN1 revealing the Ethernet Module Configuration dialog as shown in figure 7 2 Register Usage Default Settings Register Get settings from IP Address 192 168 254 124 ___ Configuration Use CAN ID for last Octet 35 x5 m5 rn Gateway 0 0 0 0 ___ Configuration Status Version ___ Protocol Support Resident Protocols J ICMP Ping C EGD Ethernet Global Data Configure Selected Protocol C SRTP Slave 90 30 Service Request C Modbus TCP Slave Ethernet IP File Server HTTP Web Server 7 ASCI Over TCP IP Downloadable Protocols ETN1 1
31. ible card reader by selecting the Export to Removable Media item on the Cscape File menu 8 8 Removable Media RM Function Blocks in Cscape NOTE For detailed information regarding RM function blocks and parameters refer to the help file in Cscape Software The following RM functional blocks are available in Cscape Software These function blocks will reference MicroSD when filename is prefixed with A or nothing the controller register space controller register space Allows renaming a file on the RM card The data in the file is not changed Delete RM csv Allows deleting a file on the RM card Copy RM csv Allows copying a file on the RM card The data in the file is not changed 8 9 Filenames used with the Removable Media RM Function Blocks The RM function blocks support the flash with a DOS Windows standard FAT 16 file system All names must be limited to the 8 3 format where the filename contains eight characters a period then a three character extension The entire filename including any path must be less than or equal to 147 characters When creating filenames and directories it is sometimes desirable to include parts of the current date or time There are six special symbols that can be entered into a filename that are replaced by the RCC with current time and date information Table 9 1 Filename Special Symbols Symbol Description ___ 22 22 o D Substitutes the current
32. it Bit 8 7 m te 1P Common Status Bit s Status Indication Status Values Minimum Maximum __ ____ J Reseved Aways Receive State Total Number of Active TCP Connections TCP Connections csCAN SRTP Modbus FTP HTTP oo v Version Register Enter a Register reference such as R101 to indicate which 16 bit register will have the Ethernet Firmware Version written to it The value stored in the Version Register is Ethernet Firmware Version 100 For example for Ethernet Firmware Version 4 30 the Version register will contain 430 Get Settings From Get settings from allows the programmer to either configure the IP Address Net Mask or Gateway for 2 functions Configuration or Register Configuration The configuration for the IP Address Net Mask or the Gateway will be assigned using the value in the Default Settings in this window Register The configuration for the IP Address Net Mask or the Gateway will be assigned using the values in the registers assigned Page 23 of 48 IM HORNER AUTOMATION GROUP RCC User Manual Ethernet Module Protocol Configuration The Protocol Support area contains a list of all the protocols supported by the platform being configured To activate a protocol check its checkbox For protocols that require additional configuration click on a listed protocol to select it and then click the Configure Selected Protocol butto
33. known there may have been a change since the last time the program Cscape was be empty compared to the Target Controller Current User File Modified Indicator indicates that indicates who is logged the file in the selected window has for purposes been modified but has not n saved Heady User HE XExx1 CsCAN Equal Local 1 Target 2 R no MOD Model forces Controller Model Network Model Confirmation Communications Status indicates the current status of the pass through Connector e Controller Model indicates the controller model for which the program in Cscape is configured e Local xx indicates the Network ID of the CONTROLLER to which the Cscape program is physically connected e Network indicates the type of network that the program through its serial port It can serve as a pass through in Cscape expects to use e g CSCAN device to other nodes on the network e Model Confirmation provides the following e Target yy R indicates the Network ID of the device with indications which the Cscape program is exchanging data Note The Local unit and Target unit can be the e Modelz the actual Target Controller matches the same unit or they can be separate units configured Controller Model and Network The following are status indicators e Model Not the actual Target Controller does not Cscape is not communicating with the remote unit no forces indicates no I O has been forced
34. m Power Port Pins Description J DC IN Input power supply positive voltage BENNETT DC IN Input power supply positive voltage OV Q4 Q3 Q2 Q1 OV 18 Figure 4 2 Power Connector Primary Power Port Page 17 of 48 IM HORNER AUTOMATION GROUP RCC User Manual CHAPTER 5 SERIAL COMMUNICATIONS 5 1 Overview All RCC models provide one serial port on the first 8 pin modular RJ45 connector which is labeled MJ1 The 1 serial port is RS232 By default MJ1 can be connected to the COM port of a PC running Cscape for controller programming In addition MJ1 can be used for application specific communication using a variety of standard data exchange protocols 52 Port Descriptions The 1 serial port contains an RS232 interface with RTS CTS handshaking 5 3 Serial Port Pinout Pin MJ1 Pins 8 OUT 6 OV Ground 45V Max 2 NC pt Figure 5 1 Port Detail 54 Programming via Serial Port The RCC serial port supports CSCAN Programming Protocol If a PC COM port is connected to the MJ1 serial port Cscape can access the RCC for programming and monitoring Programming can also be done via the CAN connection or Ethernet 5 5 Ladder Controlled Serial Communication Using Serial Communication function blocks MJ1 supports Generic Modbus Master and Modbus Slave Protocols In addition external mode
35. me 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 6 4 Orientation RCC should be mounted with locking DIN Tab facing down 3 6 5 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 solenoids see MANO0962 01 EN 3 6 0 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 Page 15 of 48 AUTOMATION GROUP RCC User Manual CHAPTER 4 ELECTRICAL INSTALLATION Note The datasheet is the first document to refer to for model specific information related to RCC models such as pin outs and other key installation information Visit the Horner websites to obtain datasheets user documentation and updates 41 Grounding Definition Ground The term ground is defined as a conductive connection between a circuit or piece of equipment and the ear
36. ms can be connected and accessed using Init Dial and Answer Modem function blocks 5 8 Downloadable Serial Communication Protocols MJ1 supports downloadable protocols such as Allen Bradley DF1 CSCAN Master GE Fanuc SNP and Modbus Master NOTE Refer to the download section of the Horner websites for the list of latest supported protocols Page 18 of 48 IM HORNER AUTOMATION GROUP RCC User Manual CHAPTER 6 CAN COMMUNICATIONS Note For additional CAN information refer to the CAN Networks manual 799 the Horner websites 6 1 Overview All RCC models provide CAN networking options which are implemented with CL and CH connections at the terminal The can connections reside next to the Analog outputs on the controller I O terminal see below The CAN connection is terminated 120 ohm resistor at the end of the network wiring for proper functionality Figure 6 1 Connections Location Like the MJ1 serial port the CAN port can be used for RCC programming by connecting it to the CAN port of a PC running Cscape The CAN port also allows the RCC to exchange global data with other OCS RCS controllers CAN supports accessing of remote network I O devices SmartStix SmartBlock and SmartRail Modules 6 2 Port Description The RCC CAN ports implement the ISO 11898 2 physical layer and the CAN 2 0A data link layer standards Also since the CAN ports are powered by an internal isolated p
37. n This will open a new dialog with configuration options for the selected protocol For detailed information on individual protocol configuration refer latest version of ETN 300 Manual SUP0740 Page 24 of 48 IM HORNER AUTOMATION GROUP RCC User Manual NOTES Page 25 of 48 IM AUTOMATION GROUP RCC User Manual CHAPTER 8 REMOVABLE MEDIA 8 1 Overview All RCC models provide a Removable Media slot labeled Memory Card which supports standard MicroSD Flash memory cards MicroSD cards can be used to save and load applications to capture graphics screens and to log data for later retrieval Figure 8 1 Removable MicroSD Memory Card Slot 8 2 MicroSD Cards Cards labeled either MicroSD or TransFlash with up to 32 GB of Flash memory are compatible with the RCC Memory slot larger sizes were not tested at time of publication The Memory slot is equipped with a push in push out connector and a MicroSD card can be safely inserted into the Memory slot whether the RCC power is On or Off To install a MicroSD card Align its 8 pin gold edge connector down facing the front of the RCC unit as shown in Figure 9 2 then carefully push it all the way into the Memory slot Ensure that it clicks into place To remove the MicroSD card Push in on the top of the card gently to release the spring The card pops out for removal 8 3 MicroSD File System The MicroSD Memory slot uses the PC compatible FAT32 File
38. nal fusing on these outputs The digital outputs in the RCC are typically controlled via Q bits in the register mapping When the controller is stopped the operation of each output is configurable The outputs can hold the state they were in before the controller stopped or they can go to a predetermined state By default digital outputs turn off For more information on stop state see the Index to find pages referencing Cscape settings The digital outputs feature an output fault bit 96132 will turn on if any of the outputs experience a short circuit over current or the output driver overheats 9 3 Digital Inputs Note The digital inputs on the RCC are designed for low voltage DC inputs The inputs are designed to support both positive and negative input modes The mode is set by a configuration parameter in Cscape All the inputs on the unit must be configured to the same mode Positive Logic vs Negative Logic Wiring The RCC SERIES CONTROLLER can be wired for Positive Logic inputs or Negative Logic inputs ES 12 24VDC 001 XLEO36 Positive Logic In Negative Logic In Figure 10 6 Positive and Negative Inputs In positive logic mode a positive voltage applied to the input will turn the input The internal design of this mode is basically a resistor from the input to I O ground This mode is sometimes called sourcing In negative logic mode connecting the input to the I O ground or zero volts will turn the inpu
39. ne twisted pair is for V and V and the other twisted pair is used for CAN_HI and CAN_LO 8 Make sure the baud rate is the same for all controllers on the network 9 Assure shields are connected at one end of each segment they are not continuous through the network 10 Do not exceed the maximum length determined by the baud rate and cable type 11 Total drop length for each drop should not exceed 6m 20 feet A drop may include more than one node The drop length adds to the overall network length 12 Network should be wired in straight line fashion not in a star pattern 13 In applications requiring multiple power supplies make sure the V of all Supplies is connected together and to earth ground at one place only 14 In some electrically noisy environments it may be necessary to add repeaters to the network Repeaters can be used to add additional nodes and or distance to the network and protect the signal against noisy environments The Horner APG repeater is part HE200CGM100 13 4 Removable Media Basic Troubleshooting Description Action RCC does not read media card Attempt to reformat MicroSD card on PC Make sure the project file is saved as pgm file and not a file In addition to file must be pgm the file s I O configuration must match the RCC configuration for it to download RCC will not download project file Table 19 2 Removable Media Troubleshooting 13 5 Technical Support Contact
40. o not require the ID to be configured To change the Target ID of Cscape use the Controller Set Target Network ID dialog 10 3 2 Communicating via On Board Ethernet Port From Cscape go to Controller gt Configure and do auto configuration for the connected controller Click on Config of Ethernet amp go to Module Setup The IP address Net Mask and Gateway of the controller may be temporarily set from the system menu under the Set Networks menu item Once running or power cycled the configuration will come from the Cscape configuration stored in the unit In Module configuration dialog go to IP Address field enter unused IP Address and configure unused registers in Register field amp then click OK Screen shot for the same as follows Page 35 of 48 IM HORNER AUTOMATION GROUP RCC User Manual Register Usage Default Settings Register Get settings from Address 192 168 254 128 Configuration Use ID for last Octet Mask 256 255 258 0 FEET Configuration Gateway 0 0 0 0 Configuration Status Name Version diem Protocol Support Resident Protocols ICMP Ping ESD Ethernet Global Data Configure Selected Protocal SRTP Slave 80 30 Service Request Modbus TCP Slave Ethernet TP File Server Web Server ASCH Over TCP IP
41. of 48 IM HORNER AUTOMATION GROUP 1 2 Grounding Grounding is covered in various chapters within this manual 1 3 Compliance RCC User Manual To check for compliance and updates visit the Horner website US http www heapg com or Europe http www horner apg com Page 10 of 48 IM HORNER AUTOMATION GROUP RCC User Manual CHAPTER 2 INTRODUCTION 21 Visual Overview of RCC CAN Connections Analog Out Analog In RUN STOP Run Stop and LOAD Load Recessed SD Card MEMORY Buttons CARD LAN Ethernet Port MJ1 Serial RS 232 ok 1 LED Indicators 7a W PWR bd ee sd V DC Outputs DC Inputs Figure 2 1 Overview of the RCC 2 1 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 a The datasheets for all RCC models are available on the Horner websites b Datasheets contain pin outs and other model specific information b User Manual This manual provides general information that is common to RCC models and can be downloaded from our web Visit the Horner website US http www heapg com Europe http www horner apg com to obtain user documentation and updates Page 11 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 2 1 2 Four main types of information are covered in this manu
42. on problems 45 Connecting Checklist 45 CsCAN Checklist 46 CsCAN Network 46 Local Controller I O 46 Removable Media 47 troubleshooting technical support 45 Troubleshooting Checklist serial port MJ1 Programming 45 Troubleshooting Checklist Ethernet port Programming For RCCe only 46 Two Point Ground Connection Test 16 USB 20 33 46 Visual Overview of RCC and Topics 11 Where to Find Information 11 RCC Dimensions 14 RCC Manual PREFACE 2 RCC OCS Accessories 13 RCC OCS Dimensions 14 Page 48 of 48
43. ower supply external CAN power is not required 6 3 CAN Port Wiring Note The CN L and CN H Communication wires must be terminated with a 120 ohm resistor CAN Port Assignments CAN Ground Black ______ ____ Data Low In Out 8 SHLD Shield Ground None Page 19 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 6 4 Cscape Programming via CAN The CAN port supports CSCAN Programming Protocol If a PC has a CAN interface installed via PCI card or USB and the PC CAN port is connected to the RCC CAN port Cscape can access the RCC for programming and monitoring In addition the RCC supports single point programming of all RCC and other OCS RCS devices that are connected to the CAN port network If the PC COM port is connected to the RCC Mu1 serial port the can act as a pass through gateway allowing Cscape to access all RCC and OCS RCS devices that are attached to the CAN port network 65 Ladder Controlled CAN Communication Using Put and Get Network Words function blocks the CAN port can exchange digital and analog global data with other RCC or OCS RCS devices nodes attached to the CAN port network In addition Put and Get Network Heartbeat function blocks allow nodes on the CAN port network to regularly announce their presence and to detect the presence or absence of other nodes on the network 6 6 Using CAN for I O Expansion Network I O Connecting Network I O devi
44. rner 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 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 r
45. roller port MJ1 proper adapter programming cable alleviates this Page 44 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 5 Check that a Loaded Protocol or ladder is not actively using MJ1 Using the STOP recessed button on the controller will make MJ1 available to Cscape 6 Make sure the COM port of the PC is functioning An RS232 serial loopback and Microsoft HyperTerminal can determine positively if the COM port is working Or connect to an alternate device to determine if the port is working 7 Successful communications with USB to serial adapters vary If in doubt Horner APG offers a USB to serial adapter Part number HE500USB600 13 1 2 Connecting Troubleshooting Checklist ETN port programming 1 Programming and debugging must use MJ1 or Ethernet Port 2 Controller must be powered up 3 Ensure that correct IP address is given in the Ethernet field and correct Mode is selected in Cscape Tools Editor Options Communications Port 4 Ensure that the Ethernet Cable is connected between the controller and the Ethernet Hub 9 Make sure the Ethernet cable is functioning properly 13 2 Local Controller and Local I O The system menu provides the following status indications that are useful for troubleshooting and system maintenance Self test results diagnostics RUN and OK status Network status and usage Average logic scan rate Application memory usage Loaded firmware versions Loaded protocols
46. s For manual updates and assistance contact Technical Support at the following locations North America Tel 1 877 665 5666 Fax 317 639 4279 www heapg com Email techsppt heapg com Europe Tel 353 21 4321 266 Fax 353 21 4321826 www horner apg com Email tech supoport hornerapg com Page 46 of 48 IM HORNER AUTOMATION GROUP Main Index Q bits 30 Accessories 13 Analog Inputs 30 Analog Outputs 31 CAN Comm Cscape Programming 20 I O Expansion Network 1 0 20 Ladder Controlled 20 Overview 19 Ports 19 CAN Communications 19 CE 10 COM 18 20 40 45 46 COM port 34 45 46 Communicating via MJ1 Serial Port 36 Communication options 21 Communications Port 34 45 46 Compliance CE 10 Csape Program Via Serial Port 18 Cscape 12 13 18 19 20 27 29 30 31 32 33 35 36 43 45 46 Configuration Procedures 38 Establishing Communications 33 Overview 32 Status Bar 32 CSCAPE CONFIGURATION 32 datasheet 7 29 30 31 Default Gateway 23 Devices to Connect to RCC 12 Digital Inputs 30 Dimensions 14 ELECTRICAL INSTALLATION 16 Ethernet 33 40 Ethernet Communication 21 Ethernet Module Default Gateway 23 IP Address 23 Net Mask 23 Status Register 23 Version Register 23 Ethernet Module Configuration 21 Ethernet Module Protocol Configuration 24 Ethernet Module Protocols and Features 21 Ethernet Module Specifications 21 Ethernet System Requirements 21 RCC User Man
47. s bar of Cscape Local If a number shows next to Local then communication is established to the local controller Cscape is unable to access the COM port of the PC This could mean that Cscape is configured for a COM Local Port port that is not present or that another program has control of the COM port Only one Cscape window can access a port at a time Subsequent instances of Cscape opened will indicate No Port Cscape has accessed a PC COM port but is not communicating with the controller This typically occurs Local No Com when the controller is not physically connected Local 222 Unknown communication error Close Cscape power cycle the controller and reopen Cscape with a blank ME project Check Local Target 1 R D If idle R run or D do I O shows next to Target number then communication is established to the target controller Target 2 Communication is not established to the target controller Check node ID of controller and set Target to match Make sure local connection is established Table 12 1 Cscape Target 8 Local Numbers 13 1 1 Connecting Troubleshooting Checklist serial port MJ1 Programming 1 Programming and debugging must use 2 Controller must be powered up 3 Ensure that the correct COM port is selected in Cscape Tools Editor Options Communications Port 4 Ensure that a straight through non null modem serial cable is being used between PC and cont
48. t Usage of this unit _____ l For additional information on system bits and registers refer to the on line help found in 11 3 Register Map for RCC I O Registers Description 11 4 Resource Limits Table 11 4 Resource Limits 2 per ID Eihotnoi CsCAN Ping EGD SRTP Modbus TCP Master Downloadable protocol amp Slave Ethernet IP FTP or HTTP 10 MBd or 100 MBd 125 kBd 250 kBd 500 kBd or CsCAN 1 MBd Serial Ports 2 RS 232 RS 485 Ports Software Selectable IDs Per CSCAN Network 64 w o repeat 253 w 3 repeaters Ladder Code Page 42 of 48 IM HORNER AUTOMATION GROUP RCC User Manual CHAPTER 12 MAINTENANCE 121 Firmware Updates The RCC products contain field updatable firmware to allow new features to be added to the product at a later time Firmware updates should only be performed when a new feature or correction is required Warning Firmware updates should only be performed when the equipment being controlled by the RCC is in a safe non operational state Communication or hardware failures during the firmware update process can cause the controller to behave erratically resulting in injury or equipment damage Make sure the functions of the equipment work properly after a firmware update before returning the device to an operational mode Load switch 1 Pressing the LOAD switch during power up boots from the Micro SD card This starts a Firmware Load if the Micro SD
49. t on The internal design of this mode is basically a resistor from the input to the positive I O voltage usually 12 or 24 volts This mode is sometime called sinking 9 4 Analog Inputs NOTE See the data sheet for the RCC model being used and see the appropriate page in this manual see Index for details on how to use Cscape to configure the digital filtering The analog inputs on the RCC allow voltage or current measurement from a variety of devices Analog inputs read 0 20mA current only The analog inputs have a digital filter that can be used to filter electrical noise that may be unavoidable in some installations The downside to digital filtering is the inputs will respond more slowly to sudden changes in the actual input Page 30 of 48 IM HORNER AUTOMATION GROUP RCC User Manual 9 4 1 Common cause of analog input tranzorb failure If a 4 20mA circuit is initially wired with loop power but without a load the analog input could see 24Vdc This is higher than the rating of the tranzorb This can be solved by not connecting loop power prior to load connection or by installing alow cost PTC in series between the load and the analog input Digi Key 235 1074 ND or equiv Figure 10 7 Analog input tranzorb troubleshooting 9 5 Analog Outputs Note Refer to the datasheet for RCC model being used for details on jumper settings The analog outputs on RCC devices provide 0 20mA current output When the controller
50. t_ 4 SR164 9 CLONE triggerbit SR164 10 LOAD CLONE triggerbit Jo Status indicating Make Clone Fail This bit goes 1 1 high when Make Create clone fails o SR164 12 Status indicating Load Clone Fail This bit goes high when Load clone fails 29 165 174 SR175 oe Current Removable Media interface status a e SR176 177 Removable Indicates free space on the Removable Media card Media in bytes SR178 179 nemovable Indicates the total card capacity in bytes p Media EE EMI IM 258180 SR181 ALM UNACK aoe Alarm high bit indicates what SR182 ALM ACT Active Alarm high bit indicates what group 4 NENNEN SR183 SYS BEEP System Beep Enable 0 disabled 1 enabled Ld SR184 USER BEEP Software configurable 0 1 ON SR185 SCR SAVER Screen Saver Enabled 0 disabled 1 enabled 13330 _____ SR186 SCR SA TM Screen Saver Time in minutes delay SR187 NET USE verage Net Usage of all units on the CAN network SR188 NET MIN Minimum Net Usage of all units on the CAN network Page 41 of 48 IM HORNER AUTOMATION GROUP RCC User Manual Table 11 2 SR Registers Register Description Max Val SR189 NET MAX Maximum Net Usage of all units on the CAN 34 network SR190 NT TX AVG Average Net Usage of this unit MENS SR191 NT TX MIN Minimum Net Usage of this unit S SR192 Maximum Ne
51. th 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 42 Ground Specifications Ideally a ground resistance measurement from equipment to earth ground is 0 ohms In reality it typically is higher The U S National Electrical Code NEC states the resistance to ground shall not exceed twenty five 25 ohms Horner APG recommends ess than fifteen 15 ohms resistance from our equipment to ground Resistance greater than twenty five 25 ohms can cause undesirable or harmful interference to the device 43 Howto 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 GROUND RESISTANCE METER GROUND LL od DISCONNECTED e FROM SERVICE rou ni a TEE GROUND ROD METAL WATER PIPE OR OTHER GOOD GROUND Figure 4 1 Two Point Ground Connection Test Page 16 of 48 HORNER AUTOMATION GROUP RCC User Manual 44 Primary Power Port To power the RCC unit V and V wires are directly wired to the terminal strip shown below Earth Ground is the auxiliary spade at the bottom 4 1 No
52. ual Features 12 Firmware Updates 44 Front Panel and USB Programming Connector 33 fusing 30 General I O Overview 29 GENERAL I O 29 Ground Specification 16 Grounding Locations of Information 10 Grounding Definition 16 IP Address 23 LIMITED WARRANTY 3 Maintenance 44 Manual Index 12 MECHANICAL INSTALLATION 14 Micro SD Cards 26 Installing Removing 26 Micro SD System 26 Net Mask 23 13 Noise 15 Orientation 15 Temperature 15 Panel Box Shock and Vibration 15 Power Connector Primary Power Port 17 Primary Power Port 17 Primary Power Port As Viewed Looking at the RCC OCS 17 17 PROGRAMMING EXAMPLES 3 References Useful documents 13 register mapping 29 30 registers 40 Registers Definitions 40 I O 43 Resource Limits 43 Removable Media Load Save Applications 27 Log Data 27 Overview 26 REMOVABLE MEDIA 26 Removable Memory Card Slot Photograph 26 safety compliance 9 Safety Warnings Guidelines 9 Page 47 of 48 IM HORNER AUTOMATION GROUP Serial Comm Cscape Programming 18 Downloadable Protocols 18 Ladder Controlled 18 Overview 18 Ports 18 Wiring 18 SERIAL COMMUNICATIONS 18 Solid State Digital Outputs 29 sourcing 29 30 stop state 30 Table of Contents 5 target ID 36 Target ID 36 target indicator 35 36 37 Technical Support 2 13 44 47 Contacts 47 Testing for Good Ground 16 Troubleshooting RCC User Manual Comm
53. 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 and other key installation information Visit the Horner websites to obtain datasheets user documentation and updates 10 30VDC E amp LOAD 1 0 30VDC_C O CAN High CAN Low RCC971AIO RCC972 DIO 9 1 Overview The RCC is a compact unit that contains high density very versatile I O Using the I O properly requires wiring to the proper terminals unit and configuring Cscape properly This section will offer some tips and suggestions to configure the I O properly For the register mapping of the I O refer to the Index at the end of this manual for the pages referencing register mapping 9 2 Solid State Digital Outputs Solid state digital outputs are generally used to activate lamps low voltage solenoids relays and other low voltage and low current devices NOTE The digital outputs used on the RCC are sourcing outputs This means the output applies a positive voltage to the output pin when turned ON When turned off the output applies approximately zero volts with respect to the I O ground Page 29 of 48 IM HORNER AUTOMATION GROUP RCC User Manual The digital outputs used in the RCC have electronic short circuit protection and current limiting While these electronic protections work in most applications some application may require exter
54. ve permanently connected unless area is known to be non hazardous WARNING EXPLOSION HAZARD BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE NON HAZARDOUS WARNING Battery May Explode If Mistreated Do Not Recharge Disassemble or Dispose Of In Fire 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 larger Adhere to the following safety precautions whenever any type of connection is made to the module Connect the green safety earth ground first before making any other connections a 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 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 Before each use inspect all cables for breaks or cracks in the insulation Replace immediately if defective h d Page 9

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