PROSOFT MVI56-DFCMR-DF1

Description

1. Product Introduction

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The PROSOFT MVI56 – DFCMR – DF1 is a specialized network interface module crafted by ProSoft Technology, engineered to be fully compatible with Allen – Bradley’s ControlLogix (1756 chassis) programmable automation controllers (PACs). Its primary function is to address the need for seamless integration of ControlLogix systems with devices that rely on the DF1 protocol, a communication standard widely adopted in industrial settings, especially among Rockwell Automation products and numerous third – party devices.

In industrial environments where a diverse range of equipment coexists, and there is a requirement to connect ControlLogix PACs with older or specialized devices using the DF1 protocol, the MVI56 – DFCMR – DF1 emerges as a crucial solution. For example, in manufacturing plants with a mix of legacy Rockwell Automation PLCs and modern ControlLogix – based control systems, this module enables the transfer of data between these disparate systems, ensuring continuous operation and compatibility without the need for a complete overhaul of the existing infrastructure. This not only saves significant costs associated with system replacements but also allows for the efficient utilization of existing resources, making it an ideal choice for facilities aiming for gradual technological upgrades.

2. Functional Features

2.1 Dual Configurable DF1 Ports

The MVI56 – DFCMR – DF1 is equipped with two powerful DF1 ports, each of which can be user – configured to operate in either master or slave mode. This flexibility allows for a wide range of network topologies. For instance, in a large – scale manufacturing facility, one port can be set as a master to communicate with multiple slave devices such as older Rockwell Automation SLC 500 series PLCs, while the other port can function as a slave, receiving commands from a higher – level ControlLogix PAC. This setup enables seamless data flow across different levels of the automation hierarchy, facilitating better control and monitoring of the entire production process.

2.2 Asynchronous Data Transfer

Data transfer between the module and the ControlLogix processor occurs asynchronously to the DF1 network. The module utilizes its internal database to act as an intermediary for data exchange between the processor and the DF1 network. This asynchronous transfer mechanism ensures that the performance of the ControlLogix system is not hindered by the slower DF1 network speeds. In a packaging plant, for example, while the ControlLogix PAC is busy with high – speed control operations, the MVI56 – DFCMR – DF1 can continue to transfer data to and from DF1 – compliant devices such as label printers and conveyor belt controllers in the background, without causing any delays in the overall control process.

2.3 Reduced Data Block for Efficient Operation

The “reduced data block” feature of the MVI56 – DFCMR – DF1 is designed to optimize data handling. It allows for more efficient utilization of system resources by minimizing the amount of data that needs to be transferred and processed. In applications where data bandwidth is limited, such as in remote monitoring stations connected via a low – speed network, this feature ensures that only the necessary data is transmitted. For example, in a remote oil pipeline monitoring system, the module can be configured to transfer only critical data like pressure and flow rate readings, rather than unnecessary diagnostic or redundant information, thus conserving network resources and ensuring faster response times.

2.4 High Command Capacity

Each master port of the module is capable of handling up to 100 commands. This high command capacity makes it suitable for complex industrial applications where multiple devices need to be controlled and monitored simultaneously. In a large – scale power distribution substation, the MVI56 – DFCMR – DF1 can be used to communicate with various Rockwell Automation power monitoring devices, such as power meters and circuit breakers. With its high command capacity, it can send commands to read power consumption data, set alarm thresholds, and control the opening and closing of circuit breakers, all within a single communication cycle.

2.5 User – Definable Memory Usage

The module offers user – definable memory usage, allowing engineers to tailor the data storage and processing capabilities according to the specific requirements of the application. This means that in applications with different data storage needs, such as in a food processing plant where some processes require more data logging for quality control purposes while others need less, the memory allocation can be adjusted accordingly. For example, more memory can be allocated to store production batch data for traceability, while less memory is used for short – term operational data that is updated frequently.

PROSOFT MVI56-DFCMR-DF1

3. Technical Specifications

PROSOFT MVI56-DFCMR-DF1

4. Application Scenarios

4.1 Manufacturing (Legacy PLC Integration)

In a manufacturing plant that has been in operation for many years, there are often legacy Rockwell Automation PLCs, such as the MicroLogix series, still in use. The MVI56 – DFCMR – DF1 can be used to integrate these legacy PLCs with a new ControlLogix – based control system. For example, the legacy PLCs may be controlling individual machine operations, while the ControlLogix system is responsible for overall production line coordination. The module enables the transfer of production data from the legacy PLCs to the ControlLogix system, allowing for better production planning and quality control. This integration also allows for the gradual phasing out of legacy equipment as the production line is upgraded over time.

4.2 Power Monitoring and Control

In power generation and distribution facilities, there are numerous Rockwell Automation power monitoring devices that use the DF1 protocol. The MVI56 – DFCMR – DF1 can be used to connect these devices to a ControlLogix PAC. In a power substation, the module can communicate with power meters, voltage regulators, and circuit breakers. It can read real – time power consumption data, monitor voltage levels, and control the switching of circuit breakers. This enables the ControlLogix system to perform advanced power management functions, such as load balancing and fault detection, ensuring the reliable operation of the power grid.

4.3 Mining Operations

In mining operations, there are often a variety of industrial devices operating in harsh environments. The MVI56 – DFCMR – DF1, with its rugged design and wide operating temperature range, can be used to connect ControlLogix systems with DF1 – compliant devices such as conveyor belt controllers, ventilation system monitors, and mining equipment sensors. For example, it can transfer data from sensors on mining trucks regarding their load levels and engine performance to the ControlLogix system, which can then use this data for optimizing mining operations, scheduling maintenance, and ensuring the safety of the mining process.

5. Installation, Commissioning, and Maintenance

5.1 Installation

Chassis Preparation: Ensure that the ControlLogix 1756 chassis has an available empty slot (ranging from slot 1 – 16). Before starting the installation, power off the PAC to prevent any potential damage to the backplane. It is also crucial to wear an electrostatic discharge (ESD) wristband to protect the sensitive electronics of the module from electrostatic charges.

Module Mounting: Align the MVI56 – DFCMR – DF1 module precisely with the chassis guides. Gently but firmly seat the module into the selected slot, applying even pressure to avoid bending any of the pins. If the chassis has a locking screw mechanism, use it to securely fasten the module in place.

Wiring: For connecting the module’s communication ports to DF1 – compliant devices, use appropriate shielded cables. If using RS – 232 connections, ensure that the wiring follows the standard pin – out configuration. For RS – 485 or RS – 422 connections, pay attention to the proper wiring of the differential pairs (A and B) and ground wires. In a noisy industrial environment, proper grounding of the cable shields at both ends is essential to minimize electrical interference.

Power – On: After all the connections are made, turn on the ControlLogix PAC. Check the module’s LED indicators. The green “Power” LED should illuminate, indicating that the module is receiving power. The yellow “Backplane” LED should blink, signifying that the module has established a connection with the ControlLogix backplane.

5.2 Commissioning

Configuration Software Setup: ProSoft provides specific configuration software for the MVI56 – DFCMR – DF1. Install this software on a suitable PC. Connect the PC to the ControlLogix Ethernet port or, if required, use a USB adapter to connect to the module’s configuration port.

Protocol and Port Configuration:

Protocol Selection: In the configuration software, select the “DF1” protocol from the available protocol options.

Port Settings: Configure each port according to the requirements of the connected devices. This includes setting the baud rate, parity, data bits, and stop bits to match the settings of the DF1 – compliant devices. For example, if connecting to a Rockwell Automation PLC with a baud rate of 9600 bps, even parity, 8 data bits, and 1 stop bit, set the module’s port settings accordingly.

Master/Slave Mode Selection: Decide whether each port will operate in master or slave mode and configure the settings accordingly. If a port is to communicate with multiple slave devices, set it as a master. Conversely, if it is to receive commands from a higher – level device, set it as a slave.

Testing: Use the configuration software’s built – in testing tools to send test commands to the connected DF1 devices. For example, send a read command to a power meter to verify that it is correctly communicating with the module. Check the response received by the module to ensure that the data is being transferred accurately. Also, perform write commands to test the control functionality. For instance, if the module is connected to a conveyor belt controller, send a speed – setting command and verify that the conveyor belt adjusts its speed accordingly.

5.3 Maintenance

Regular Visual Checks: On a monthly basis, visually inspect the module’s LED indicators. The “Power” LED should remain green, the “Backplane” LED should be steadily green, the “Application” LED should indicate normal operation (usually green), and the “Serial Activity” LED should blink periodically, indicating data transfer. If any of the LEDs show an abnormal state (e.g., red for error), it is an indication of a potential problem.

Cleaning: In dusty industrial environments, it is important to clean the module’s serial ports regularly. Use compressed air to blow away any dust or debris that may have accumulated in the ports. This helps to maintain good electrical connections and prevent communication issues.

Troubleshooting: If communication problems occur:

Wiring Check: First, verify the wiring connections. Check for any loose wires, incorrect pin – outs, or damaged cables. If using RS – 485 connections, ensure that the wiring polarity (A and B) is correct. If the “Serial Activity” LED shows no activity or is red, it may indicate a wiring problem.

Device Address and Configuration: Check the addresses of the DF1 – compliant devices and ensure that they match the configuration settings in the module. Incorrect device addresses can lead to communication failures. Also, review the protocol and port settings in the module’s configuration software to ensure they are still correct.

Diagnostic Tools: Use the configuration software’s diagnostic tools, such as the “Diagnostic Log”, to view any error messages. These messages can provide valuable information about the nature of the problem, such as a timeout error indicating that the module is not receiving a response from a device.

Firmware Updates: Periodically check ProSoft’s official website for firmware updates for the MVI56 – DFCMR – DF1. Download the latest firmware and use the configuration software to update the module. Firmware updates often include bug fixes, performance improvements, and new features. The update process usually takes less than 5 minutes and can be performed without significant downtime of the ControlLogix system.

Spare Module Storage: Keep a spare MVI56 – DFCMR – DF1 module in a dry environment with a temperature range of 0 °C to + 50 °C. This ensures that in case of a module failure, a quick replacement can be made, minimizing production downtime.

6. Service and Warranty

ProSoft Technology offers a 3 – year standard warranty for the MVI56 – DFCMR – DF1. This warranty covers any defects in materials and workmanship. In the event that the module fails due to a manufacturing defect within this period, ProSoft will repair or replace the module free of charge.

For customers with critical applications, ProSoft provides an optional Premium Industrial Support Plan. This plan extends the warranty coverage to 5 years and includes additional benefits such as:

24/7 Technical Support: In case of any technical issues, customers can reach out to ProSoft’s support team at any time. The support team aims to respond within 1 hour for critical communication outages, ensuring minimal disruption to the industrial operations.

On – site Support and Verification: Once a year, ProSoft technicians will visit the customer’s site to perform on – site verification of the DF1 protocol implementation. This includes checking the module’s configuration, communication performance, and compatibility with connected devices.

Expedited Replacement: In the event of a module failure, ProSoft will arrange for the delivery of a loaner module within 48 hours. This ensures that production can continue with minimal interruption while the faulty module is being repaired.

Customers also have access to a range of free resources:

Application Notes: ProSoft provides detailed application notes that offer guidance on using the MVI56 – DFCMR – DF1 in various industrial scenarios. For example, there are application notes on integrating the module with specific Rockwell Automation PLC models or using it in power – intensive applications.

Video Tutorials: These tutorials cover topics such as module installation, configuration software setup, and troubleshooting common issues. They are a valuable resource for technicians who are new to the module or need a refresher on specific tasks.

User Community: ProSoft maintains a user community where customers can share their experiences, tips, and solutions related to the MVI56 – DFCMR – DF1. This community provides a platform for knowledge sharing and problem – solving, allowing customers to learn from each other and stay updated on the latest best practices.

For modules that are out of warranty, ProSoft offers a flat – rate repair service at a cost of $250 per module. This service includes comprehensive diagnostic testing to identify the root cause of the problem, replacement of any faulty components, and updating the module’s firmware to the latest version. The repaired module comes with a 6 – month warranty, providing customers with peace of mind and ensuring the long – term reliability of their industrial communication infrastructure.