Allen-Bradley DF1 Assembly instructions

MUCM DF1 Application Manual
MUCM DF1
Installation and Programming Manual
This Manual describes the MUCM application for interfacing Allen-Bradley DF1 devices to a master of another
protocol.
Effective: 04 September 2002
Niobrara Research & Development Corporation
P.O. Box 3418 Joplin, MO 64803 USA
Telephone: [phone] or [phone]
Facsimile: [phone]
www.niobrara.com

Modicon, TSX Momentum Automation, Modbus, Modbus Plus are registered trademarks of Schneider
Automation.
Helm Loadgard Serial Interface is a trademark of Helm Instrument Company, Inc.
Allen-Bradley, A-B, DF1, and Data Highway are trademarks of Allen-Bradley Company.
Subject to change without notice.
© Niobrara Research & Development Corporation 2001,2002. All Rights Reserved.

3
Contents
1 Introduction .........................................................................................................................5
2 Installation.............................................................................................................................7
Module Installation.........................................................................................................7
Software Installation.......................................................................................................7
Serial Connections to the MUCM ..................................................................................7
Port 1 to Master .......................................................................................................7
Port 2 to the Personal Computer .............................................................................9
Loading the Applications into the MUCM.....................................................................9
DF1 to MUCM Port 2 ..................................................................................................10
3 Master Protocol to DF1 Bridge............................................................................11
Configure the MUCM ..................................................................................................11
DF1 Configuration ................................................................................................12
4 Examples...............................................................................................................................13
Example 1.....................................................................................................................13
Example 2.....................................................................................................................15
Example 3.....................................................................................................................16
Example 4.....................................................................................................................16
5 Troubleshooting ..............................................................................................................19
Module Lights ..............................................................................................................19
User Lights ...................................................................................................................19
Figures
Figure 2-1 MUCM to RS-232 DTE Port (9-pin) (MU2 Cable) ....................................................8
Figure 2-2 RS-485 SY/MAX Port (9-pin) (MU7 Cable) ..............................................................8
Figure 2-3 MUCM Layout .............................................................................................................9
Figure 2-4 MUCM to RS-232 PC DCE Port (9-pin) (MU1 Cable) .............................................9
Figure 2-5 MUCM RS-422 to DF1/Data Highway Convertor RS-422 .......................................10

4
Figure 4-1 Modbus Plus Example ................................................................................................14
Figure 4-2 Modbus TCP Example................................................................................................15
Figure 4-3 MUCM RS-422 to Helm Loadgard Serial Interface...................................................16
Figure 4-4 RNIM Example...........................................................................................................17
Tables
Table 4-1 Server Index Table For EPE5-TCP..............................................................................15
Table 5-1 Module Lights ..............................................................................................................19
Table 5-2 User Light Definitions .................................................................................................19

MUCM DF1 Application Manual 1Introduction 5
1
Introduction
The Niobrara MUCM is a TSX Momentum® compatible module that is capable of
running multiple applications for performing communication translations between se-
rial protocols. This document covers an application that allows masters of various
protocols to communicate with DF1 devices. This setup allows the master to be
placed onto an existing Data Highway network via a DF1 to Data Highway bridge.
One application is required to be loaded into the MUCM: app1.qcm contains the DF1
and other serial drivers, and the configuration software. This application must be run-
ning for the system to properly perform.
Port 1 of the MUCM is to be connected to the master to provide the interface to the
DF1 device. Port 2 is the DF1 port, and can be connected point to point with the DF1
device or, optionally, could be connected to a daisy chain of DF1 half duplex devices
using RS-232 to RS-485 convertors. The MUCM supports many DF1 devices includ-
ing Helm Instrument Company’s Loadgard Serial Interface. These devices are ac-
cessed via the master protocol by selecting the node ID assigned to each slave (0-254).
Port 1 is also the configuration port. When Application 2’s RUN/HALT switch is
switched to the memory protect mode, it interfaces to an ASCII terminal to provide
the user with a simple way to reconfigure the two serial ports.
The MUCM may be mounted on a DIN rail, or directly to a wall via mounting holes.

6Introduction 1MUCM DF1 Application Manual

MUCM DF1 Application Manual 2Installation 7
2
Installation
Module Installation
1 Mount the MUCM in an appropriate location on a DIN rail or in a cabinet.
Software Installation
The application files for the MUCM are included in the DF1.ZIP file. This file must
be unzipped using an application like PKUNZIP.EXE. A copy of PKUNZIP is in-
cluded on the standard NR&D software disk and is also available at
www.niobrara.com. The latest version of the DF1.ZIP file is located at
ftp.niobrara.com/mucm/DF1/DF1.zip
The latest version of this document in pdf format is located at:
ftp.niobrara.com/mucm/DF1/DF1.pdf
The DF1 communications protocol is available from Allen-Bradley at:
www.ab.com/manuals/cn/17706516.pdf
Serial Connections to the MUCM
Port 1 to Master
If connecting to a Modicon PLC, the Niobrara cable MU2 is ideal for this connection
since it includes a screw terminal RS-232 connection for the MUCM and a 9-pin male
RS-232 Modicon-style pinout for the PLC. This cable pinout is described in Figure
2-1.

8Installation 2MUCM DF1 Application Manual
Figure 2-1 MUCM to RS-232 DTE Port (9-pin) (MU2 Cable)
For an RS-485 connection to SY/MAX devices, Port 1 of the MUCM will be set to be
RS-485. The Niobrara cable MU7 is ideal for this connection since it includes an
RJ45 RS-485 connection for the MUCM and a 9-pin male RS-485 SY/MAX-style
pinout at the other end. This cable pinout is described in Figure 2-2.
Figure 2-2 RS-485 SY/MAX Port (9-pin) (MU7 Cable)
The master must be configured to match the serial settings of the MUCM Port 1. The
supported baud rates by both units are 1200, 2400, 9600, and 19200. 19200 baud is
the default.
Screw Terminal DE9P (male)
12
23
35
47
58
4
6
Screw Terminal DE9P (male)
14
23
32
41
5 Cable Shield 9
5
6
7
8

MUCM DF1 Application Manual 2Installation 9
Figure 2-3 MUCM Layout
Port 2 to the Personal Computer
A physical connection must be made from the personal computer to the MUCM in or-
der to download the applications. This link may be a serial connection from a COM
port on the personal computer to the RS-232 port on the MUCM. The Niobrara MU1
cable may be used for this connection. This cable is shown in Figure 2-4.
Figure 2-4 MUCM to RS-232 PC DCE Port (9-pin) (MU1 Cable)
Loading the Applications into the MUCM
The MUCM is rapidly evolving so be sure to upgrade the firmware in the module be-
fore loading the latest version of APP1.QCC. Most likely the QCOMPILE.EXE has
been updated so be sure to use the newest version. Firmware upload is as follows:
1 Move the RUN/LOAD switch on the module to LOAD.
2 Only the Pwr light should be on.
3 Connect the PC to MUCM Port 1 with an MU1 cable.
4 From the command line enter
> fwload mucm.fwl com1:
MUCM
MU1 Cable
MU2 Cable
Quantum
1 3 Rx1 Tx1 Rn1 Pwr
2 4 Rx2 Tx2 Rn2 Ready
TSX Momentum
Universal Communications
170 UCM 200 00
Niobrara R&D Corporation 9-30 VDC or AC
Tx Rx GND RTS CTS Tx+ Tx- Rx+ Rx- GND Run/Load
RS-232 RS-485
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RJ45 DE9S (female)
12
23
35
44
56
7
8

10 Installation 2MUCM DF1 Application Manual
Be sure to have the colon after the PC’s com port name. The download will only
take a few minutes and will inform when finished.
5 Change the switch back to RUN.
6 It is a good idea to press the RESET button after a firmware change.
Next, load APP1.QCC into the MUCM by the following method:
1 Move Switch 1 to Halt.
2 Connect the PC to MUCM Port 1 with an MU1 cable.
3 Load the QRPC file with qload.
> qload 1 app1 com1:9600,e,8,1 -a
Will load the file into application 1’s flash and set the program to automatically
start on power-up.
4 Place Switch 1 in RUN. The RN1 light should come on.
5 Place Switch 2 in the HALT position until ready to configure the MUCM.
DF1 to MUCM Port 2
After the software has been installed into the MUCM, Port 2 becomes the DF1 port.
The connection for the MUCM to the Allen-Bradley DF1 to Data Highway convertor
should be accomplished with the Niobrara SC902-ST if the convertor’s port is set to
RS-232(Refer to Figure 2-3). If the convertor’s port is set to RS-422, the diagram for
that cable is located in figure 2-5.
Figure 2-5 MUCM RS-422 to DF1/Data Highway Convertor RS-422
Screw Terminal DE9S (female)
16
22
39
41
55

MUCM DF1 Application Manual 3Master Protocol to DF1 Bridge 11
3
Master Protocol to DF1 Bridge
After the software has been loaded, and the RN1 light is lit, the MUCM is ready to be
used as a bridge between various protocols and Df1. A Modbus master should use
opcode x03 for an unprotected read, and opcode x06 or x16 for unprotected writes.
Any other opcode will not be translated. A SY/MAX priority or non-priority read or
write will also be translated. The master will transmit a normal query, and the MUCM
will transparently pass the slave ID to the DF1 device. The exception to this is if the
user forces the route to always be 1. This option only works with RNIM. On the DF1
side, the MUCM will use a predefined source ID that can be configured from the con-
figuration page. The default source ID is 0.
Note: Since Allen-Bradley PLC’s register spaces begin with 0 instead of 1, the master
must ask for a register number that is one higher than the actual desired register num-
ber.
Configure the MUCM
The MUCM is configured by a hyperterminal session. The PC is connected to the
MUCM’s Port 1 with an MU1 cable. Configure the hyperterminal session for 9600
baud, no parity, 8 data bits, 1 stop bit, no handshaking. The MUCM will set itself to
these settings, and transmit the configuration page when the Application 2 Run/Halt
switch is placed in the Memory Protect postion.
When the Application 2 switch has been set to Memory Protect, it will transmit the
configuration page to the hyperterminal. If at any time the information is not dis-
played, or is displayed incorrectly, pressing the Enter key will cause the MUCM to
retransmit the same page. From this main page, the user can configure Port 1 and the
DF1 port. The user can also select an option that will display all current settings. To
select an option, simply press the correspoding number for the option desired. There
is no need to press the Enter key.
Port 1 Configuration
The Modbus configuration page allows the user to select the baud rate, parity, data
bits, stop bits, protocol, and if necessary, the RNIM address that will be used to com-
municate with the master. The defaults are 19200, None, 8, 1, Modbus RTU, and 1
respectively. Be sure that these settings match the settings for the master. Again, sim-
ply press the corresponding number for the desired option.
When an option is selected, the MUCM will display the current setting, as well as all
available options for that particular setting. To accept the current setting, press the
Enter key. To change the setting, press the number of the desired option. The MUCM
will save that setting, and return to the previous configuration page. To exit the Port 1

12 Master Protocol to DF1 Bridge 3MUCM DF1 Application Manual
configuration page, press the X key. This will return the user to the main configura-
tion page.
NOTE: When Pass-Thru is selected for Port 1, only baude rate, parity, stop bits, and
data bits may be chosen for both ports. All other values may be changed, but will
have no effect on the application.
DF1 Configuration
The DF1 configuration page allows the user to change the settings for the DF1’s port.
Possible settings are baud rate, parity, data bits, stop bits, message timeout, node ID,
and starting register. The first four are set in the same manner as for the Modbus port.
Their default settings are 19200, None, 8, and 1, respectively.
The message timeout feature allows the user to select how long the MUCM will wait
for a reply to a query. The default timeout is 10000ms. The timeout is fully program-
mable by typing the desired time in milliseconds. Valid times are 0 to 30000ms.
The node ID is the DF1 network ID that identifies each device on the network. Each
node must have a unique ID. The default ID for the MUCM is 0. To change the ID,
select Node ID from the DF1 configuration page, and type the desired number, fol-
lowed by the Enter key. Valid numbers are 0-254.
The starting register allows the user to determine whether the translation starts at reg-
ister 0 or 1. Allen-Bradley PLC’s feature a register 0. If the starting register is set to
zero, then register 0 will actually be mapped to register 1 on Port 1. Otherwise, the
registers will map one to one.
Automatic Polling Configuration
Revisions of this application dated 20 August or later have the ability to automatically
read or write registers in a DF1 device. The setup is located in the options for the DF1
port. The user can select the entry number, local and remote registers, register count,
direction, and slave address. The local register is the register in the MUCM that will
be used to store the data. The remote register is the register in the DF1 device.

MUCM DF1 Application Manual 4Examples 13
4
Examples
Example 1
Figure 4-1 displays an example Modbus to DF1 bridge using a Modicon
Bridge/Multiplexer to bridge between Modbus Plus and Modbus RTU. A Quantum
PLC polls the DF1 device across Modbus Plus, and the MUCM converts the message
to DF1.
The Quantum sends a query using the MSTR block out the Modbus Plus port with a
route of 35, 2, 1. Port 2 of the Bridge/MUX has been configured as a network port to
which multiple devices may be connected. The message is therefore received by the
Bridge/MUX(drop 35), translated to Modbus RTU, and routed out port 2 to slave de-
vice 1.
The MUCM will receive the Modbus RTU message at port 1 for device 1, translate
the message to DF1, and route it out port 2 to Node ID 1. When the DF1 device re-
sponds to the query, the MUCM will receive the response at port 2, convert the mes-
sage to Modbus RTU, and route back out port 1. The Bridge/MUX will receive the
reply, and route the appropriate Modbus Plus message back to the PLC.

14 Examples 4MUCM DF1 Application Manual
Figure 4-1 Modbus Plus Example
MUCM
Quantum
Bridge/MUX
MU2 Cable
MB+ = 1
MB+ = 35
DF 1
MU1 Cable
Node ID = 1
Port 2
1 3 Rx1 Tx1 Rn1 Pwr
2 4 Rx2 Tx2 Rn2 Ready
TSX Momentum
Universal Communications
170 UCM 200 00
Niobrara R&D Corporation 9-30 VDC or AC
Tx Rx GND RTS CTS Tx+ Tx- Rx+ Rx- GND Run/Load
RS-232 RS-485
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MUCM DF1 Application Manual 4Examples 15
Example 2
Figure 4-2 displays an example of how the MUCM could be used to put data from a
DF1 device onto Modbus TCP.
This example allows the SMS computer to see the data in the DF1 device connected to
port 2 of the MUCM. The EPE5’s Port 1 must be set to Modbus Gate protocol, and an
MU7 cable should be used between the EPE5 and the MUCM. The MUCM’s port 1
must be set to RS-422 communications.
Table 4-1 shows the entry that must be in the Modbus Server table for the PC to be
able to communicate with the DF1 device. SMS will connect to the EPE5-TCP using
index 1. Index 1 points to the entry in the server table, and routes the message out
Port 1 to the MUCM, which sends the message to the DF1 device.
Figure 4-2 Modbus TCP Example
Table 4-1 Server Index Table For EPE5-TCP
1
2
3
4
EPE5
PLUS
E-net Act
E-net Err
Active
Busy
Error
EPE5-TCP-D
Personal Computer
running SMS-3000
Modbus Drop = 101
IP Address
206.223.51.33 IP Address
206.223.51.145
DF 1
MU7 Cable
MU1 Cable
MUCM
1 3 Rx1 Tx1 Rn1 Pwr
2 4 Rx2 Tx2 Rn2 Ready
TSX Momentum
Universal Communications
170 UCM 200 00
Niobrara R&D Corporation 9-30 VDC or AC
Tx Rx GND RTS CTS Tx+ Tx- Rx+ Rx- GND Run/Load
RS-232 RS-485
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Drop TYPE Route
1 OTHER 101,1

16 Examples 4MUCM DF1 Application Manual
Example 3
This example describes the use of the DF1 application to interface a Quantum PLC to
a Helm Loadgard Serial Interface. The configuration and connection to the Quantum
is the same as in Example 1. Figure 4-3 shows the connection from the MUCM to the
Loadgard.
Figure 4-3 MUCM RS-422 to Helm Loadgard Serial Interface
Example 4
This example describes an interface between an RNIM radio network and an Allen-
Bradley SLC 5/04 processor. A SY/MAX Model 650 will poll the remote PLC via a
network of RNIM’s and radios.
The 650 generates a TREAD or TWRITE with a route of 100,0,53,153. The MUCM
is set for RNIM address 53, and will translate the message to a DF1 unprotected read
or write at address 153. The MUCM may also translate it to address 1 if the forced
route option is set.
Screw Terminal DB25
13
216
314
42

MUCM DF1 Application Manual 4Examples 17
Figure 4-4 RNIM Example
Example 5
Example 5 is a continuation of example 4, but with a second DF1 device daisy
chained to the the MUCM through a modem. In this configuration, it is necessary for
harware handshaking. This is what the Pass-thru mode is used for. Figure 4-5 shows
this example.
RNIM
MUCM
DF 1
MU1 Cable
0
1
SY/MAX
POWER
NET Tx Error
NET RX Error
Tx 1
Rx 1
Tx 0
Rx 0
NETWORK
1
4
650
SY/MAX
Radio
Radio
Thumbwheel set for 00
Model 650
RNIM Address 53
1 3 Rx1 Tx1 Rn1 Pwr
2 4 Rx2 Tx2 Rn2 Ready
TSX Momentum
Universal Communications
170 UCM 200 00
Niobrara R&D Corporation 9-30 VDC or AC
Tx Rx GND RTS CTS Tx+ Tx- Rx+ Rx- GND Run/Load
RS-232 RS-485
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18 Examples 4MUCM DF1 Application Manual
Figure 4-5 Pass Thru Example
MUCM
DF 1
MU4 Cable
Radio
RNIM Address 53
1 3 Rx1 Tx1 Rn1 Pwr
2 4 Rx2 Tx2 Rn2 Ready
TSX Momentum
Universal Communications
170 UCM 200 00
Niobrara R&D Corporation 9-30 VDC or AC
Tx Rx GND RTS CTS Tx+ Tx- Rx+ Rx- GND Run/Load
RS-232 RS-485
M
e
mRH
M
e
mRH
1 3 Rx1 Tx1 Rn1 Pwr
2 4 Rx2 Tx2 Rn2 Ready
TSX Momentum
Universal Communications
170 UCM 200 00
Niobrara R&D Corporation 9-30 VDC or AC
Tx Rx GND RTS CTS Tx+ Tx- Rx+ Rx- GND Run/Load
RS-232 RS-485
M
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mRH
M
e
mRH
DF 1
Modem Modem
MU11 Cable
DDC2I
MUCM
Pass Thru Mode

MUCM DF1 Application Manual 5Troubleshooting 19
5
Troubleshooting
Module Lights
The MUCM has several lights that indicate the status of the module. Table 5-1 shows
the meanings of these lights.
Table 5-1 Module Lights
User Lights
The MUCM-SE has 10 application driven lights numbered 1-10. The meaning of
these lights while the APP1 program is running is shown in Table 5-2.
Table 5-2 User Light Definitions
Light Meaning
Pwr This light will be on while there is power to the module.
Ready This light will be on while a tophat is communicating to the MUCM.
RN1 This light should be on to indicate app1 is running.
TX1 Comes on when the module is transmitting on serial port 1.
RX2 Comes on when the module is receiving on serial port 1.
RN2 This light should not come on since there is no app2 loaded.
TX1 Comes on when the module is transmitting on serial port 1.
RX2 Comes on when the module is receiving on serial port 1.
Light Meaning
1 Lights when a DF1 read is sent
2 Lights when a DF1 write is sent
3 Lights when application is in config mode.
4 Lights when application is in config mode.