PLX51-DF1-ENI
DF1 Router
DF1 to EtherNet/IPTM Router
June 27, 2019
USER MANUAL
Preface
Page 2 of 87
Preface
CONTENTS
1. Preface ............................................................................................................................... 5
1.1. Introduction to the PLX51-DF1-ENI ............................................................................. 5
1.2. Features ....................................................................................................................... 6
1.3. Architecture ................................................................................................................. 7
1.4. Additional Information .............................................................................................. 10
2. Installation ....................................................................................................................... 11
2.1. Module Layout .......................................................................................................... 11
2.2. Module Mounting ..................................................................................................... 13
2.3. Power ........................................................................................................................ 14
2.4. RS232 Port ................................................................................................................. 14
2.5. Ethernet Port ............................................................................................................. 14
3. Setup ................................................................................................................................ 15
3.1. Install Configuration Software .................................................................................. 15
3.2. Network Parameters ................................................................................................. 16
3.3. Creating a New Project .............................................................................................. 20
3.4. DF1 parameters ......................................................................................................... 22
3.5. Message Routing ....................................................................................................... 26
3.5.1. Bridge Mode....................................................................................................... 26
3.5.2. DF1 Slave Mode ................................................................................................. 34
3.5.3. Scheduled Tag Mode.......................................................................................... 40
3.5.4. Unscheduled Mode ............................................................................................ 43
3.6. Module Download ..................................................................................................... 44
3.7. RSLogix 5000 Configuration ...................................................................................... 47
3.7.1. Studio 5000 Configuration (Version 20+) .......................................................... 47
3.7.2. RSLogix 5000 Configuration (Pre-Version 20) .................................................... 51
4. Operation ......................................................................................................................... 55
4.1. Message Routing ....................................................................................................... 55
4.2. RSLogix 5000 assemblies ........................................................................................... 55
4.2.1. Input Assembly................................................................................................... 56
4.2.2. Output Assembly................................................................................................ 57
4.3. Unscheduled Messaging ........................................................................................... 57
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Preface
5. Diagnostics ....................................................................................................................... 63
5.1. LEDs ........................................................................................................................... 63
5.2. Module Status Monitoring ........................................................................................ 64
5.3. DF1 Packet Capture ................................................................................................... 70
5.4. Module Event Log...................................................................................................... 73
5.5. Web Server ................................................................................................................ 74
6. Technical Specifications ................................................................................................... 75
6.1. Dimensions ................................................................................................................ 75
6.2. Electrical .................................................................................................................... 76
6.3. Ethernet ..................................................................................................................... 76
6.4. DF1............................................................................................................................. 77
6.5. Agency Approvals & Certifications ............................................................................ 77
7. Appendix .......................................................................................................................... 79
7.1. Example - Logix CPU to DF1 Bridge Mode................................................................. 79
8. Support, Service & Warranty ........................................................................................... 83
8.1. Contacting Technical Support ................................................................................... 83
8.2. Warranty Information ............................................................................................... 85
9. Index ................................................................................................................................. 87
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Preface
1. PREFACE
1.1. INTRODUCTION TO THE PLX51-DF1-ENI
This manual describes the installation, operation, and diagnostics of the PLX51-DF1-ENI. The
PLX51-DF1-ENI provides intelligent data routing between EtherNet/IPTM and DF1 which can
help simplify the migration from PLC2, PLC3, PLC5, and SLC systems to ControlLogix® or
CompactLogixTM platforms, where a DF1 interface is required.
The module can also be used for remote programming, bridging between Ethernet and DF1.
Figure 1.1. - Migration Path
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Preface
Mode
Description
Message Initiator
Bridge
The PLX51-DF1-ENI redirects DF1 PCCC messages to a Logix
controller at a preconfigured EtherNet/IP path.
Logix PLC Mapping configuration may also be required.
This mode also supports remote programming using RSLogix
5 / 500.
Remote Device
DF1 Slave
The PLX51-DF1-ENI will convert DF1 PCCC messages to Logix
controller tag reads or tag writes.
No Logix PLC Mapping configuration is required.
Remote Device
Scheduled Tag
The PLX51-DF1-ENI transfers data between a DF1 device and
a number of Logix tags, using a preconfigured schedule.
No Logix or remote device configuration is required.
PLX51-DF1-ENI
Unscheduled
The PLX51-DF1-ENI transfers messages received from a Logix
Message Instruction.
Logix (Msg)
1.2. FEATURES
The PLX51-DF1-ENI is able to transfer data from a DF1 device to a maximum of eight Logix
controllers. The module operates in one of four modes, simplifying the configuration for all
applications.
Table 1.1. – Modes of Operation
The PLX51-DF1-ENI is configured using the ProSoft PLX50 Configuration Utility. This program
can be downloaded from www.prosoft-technology.com free of charge. The PLX50
Configuration Utility offers various configuration methods, including a controller tag browser.
Hereafter the PLX51-DF1-ENI will be referred to as the module.
The module can operate in both a Logix “owned” and standalone mode. With a Logix
connection, the input and output assemblies will provide additional diagnostics information
which will be available in the Logix controller environment.
The module uses isolated RS232 for DF1 communication providing better noise immunity. The
RS232 port also uses a terminal block for convenient installation. The module can also be used
in systems with redundant DF1 pathways.
A built-in webserver provides detailed diagnostics of system configuration and operation,
including the display of received DF1 communication packets, without the need for any
additional software.
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Preface
1.3. ARCHITECTURE
The figure below provides an example of the typical network setup.
Figure 1.2. - Example of a typical network setup
By converting and redirecting serial DF1 messages from legacy devices to EtherNet/IP, the
module provides an interface for data exchange to ControlLogix and CompactLogix platforms.
When connected to devices that provide more than one DF1 port, it is possible to implement
DF1 communication redundancy with the use of two PLX51-DF1-ENI’s. These can be
configured in one of two modes, either Simultaneous or Active / Standby.
In the Simultaneous mode, both modules route the same traffic to the same Logix controller.
Effectively, the Logix controller will receive two of each message and process both of them.
Active / Standby mode requires both modes to be Logix “Owned”. One of the modules has its
routing capability disabled, achieved by setting the Inhibit Routing bit in the output assembly.
Logic in the Logix controller can monitor the connection and performance of the Active
module and, if necessary, inhibit the Active module and un-inhibit the Standby module.
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Preface
Figure 1.3. - Redundant Architecture
The PLX51-DF1-ENI can be used in redundant Logix controller systems.
Systems that rely on a central ControlLogix communicating to a number of remote DF1
devices, e.g. MicroLogix and SLC stations, may find the PLX51-DF1-ENI useful when upgrading
to newer ControlLogix processors, which no longer have a serial port. These systems can easily
be upgraded using the PLX51-DF1-ENI without affecting the existing and often costly wireless
infrastructure.
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Preface
Figure 1.4. – Remote MicroLogix System
Figure 1.5. – Remote Programming (Half-duplex)
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Preface
Resource
Link
PLX50 Configuration Utility Software
www.prosoft-technology.com
PLX51-DF1-ENI User Manual
PLX51-DF1-ENI Datasheet
Example Code & UDTs
www.prosoft-technology.com
Ethernet wiring standard
www.cisco.com/c/en/us/td/docs/video/cds/cde/cde205_220_420/i
nstallation/guide/cde205_220_420_hig/Connectors.html
CIP Routing
The CIP Networks Library, Volume 1, Appendix C:Data Management
Map PLC/SLC messages
SLC to CompactLogix Migration Guide: Chapter 3 – Map PLC/SLC
Messages (1769-ap001_-en-p.pdf)
EtherNet/IP Network Configuration: Chapter 5 – Mapping Tags (enetum001_-en-p.pdf)
1.4. ADDITIONAL INFORMATION
The following documents contain additional information that can assist you with the module
installation and operation.
Table 1.2. - Additional Information
For professional users in the European Union
If you wish to discard electrical and electronic equipment (EEE), please contact your dealer
or supplier for further information.
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Installation
2. INSTALLATION
2.1. MODULE LAYOUT
The module has three ports at the bottom of the enclosure. The ports are used for Ethernet,
RS232 serial, and power.
The power port uses a three-way connector which is used for the DC power supply; positive
and negative (or ground) voltage, as well as the earth connection.
The RS232 port uses a four-way connector. This provides connection for the communication
transmit (TX), receive (RX), and ground (GND) conductors. The fourth connection is used for
shielding the cable in high-noise environments.
The Ethernet cable must be wired according to industry standards, which can be found in the
additional information section of this document.
Figure 2.1. - PLX51-DF1-ENI side and bottom view
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Installation
DIP Switch
Description
DIP Switch 1
Used to force the module into “Safe Mode”. When in “Safe Mode”, the module will
not load the application firmware and will wait for new firmware to be downloaded.
This should only be used in the rare occasion when a firmware update was interrupted
at a critical stage.
DIP Switch 2
This will force the module into DHCP mode which is useful when you have forgotten
the IP address of the module.
DIP Switch 3
Reserved
DIP Switch 4
Reserved
The module provides three diagnostic LEDs. These LEDs are used to provide information
regarding the module system operation, the Ethernet interface, and the auxiliary
communication interface (RS232).
Figure 2.2. – PLX51-DF1-ENI front and top view
The module provides four DIP switches at the top of the enclosure as shown in the top view
figure above.
Table 2.1. - DIP Switch Settings
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Installation
2.2. MODULE MOUNTING
The module provides a DIN rail clip to mount onto a 35mm DIN rail.
Figure 2.3 - DIN rail specification
The DIN rail clip is mounted on the bottom of the module, toward the back. Use a flat screw
driver to pull the clip downward. This will enable you to mount the module onto the DIN rail.
Once the module is mounted onto the DIN rail, the clip must be pushed upward to lock the
module onto the DIN rail.
Figure 2.4 - DIN rail mouting
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Installation
2.3. POWER
A three-way power connector is used to connect Power+, Power– (GND), and earth. The
module requires an input voltage of 10 to 28 VDC. Refer to the technical specifications section
in this document.
Figure 2.5 - Power connector
2.4. RS232 PORT
The four-way RS232 connector is used to connect the transmit (TX), receive (RX), and GND
conductors for serial communication. The shield terminal can be used for shielded cable in
high noise environments.
NOTE: The shield of the RS232 port is internally connected to the power
connector earth. Thus, when using a shield it is important to connect the Earth
terminal on the power connector to a clean earth. Failing to do this can lower
the signal quality of the RS232 communication.
NOTE: When using a shielded cable, it is important that only one end of the
shield is connected to earth to avoid current loops. It is recommended to
connect the shield to the PLX51-DF1-ENI module, and not to the other DF1
device.
Figure 2.6 - RS232 connector
2.5. ETHERNET PORT
The Ethernet connector should be wired according to industry standards. Refer to the
additional information section in this document for further details.
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Setup
3. SETUP
3.1. INSTALL CONFIGURATION SOFTWARE
The network setup and configuration of the PLX51-DF1-ENI is done in the ProSoft PLX50
Configuration Utility. This software can be downloaded from www.prosoft-technology.com.
Figure 3.1. - ProSoft PLX50 Configuration Utility Environment
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Setup
3.2. NETWORK PARAMETERS
The module has DHCP (Dynamic Host Configuration Protocol) enabled as factory default.
Thus, a DHCP server must be used to provide the module with the required network
parameters (IP address, subnet mask, etc.). There are a number of DHCP utilities available,
however it is recommended that the DHCP server in the PLX50 Configuration Utility be used.
Within the PLX50 Configuration Utility environment, the DHCP server can be found under the
Tools menu.
Figure 3.2. - Selecting DHCP Server
Once opened, the DHCP server will listen on all available network adapters for DHCP requests
and display their corresponding MAC addresses.
Figure 3.3. - DHCP Server
NOTE: If the DHCP requests are not displayed in the DHCP Server, it may be
due to the local PC’s firewall. During installation, the necessary firewall rules
are automatically created for the Windows firewall.
Another possibility can be another DHCP Server is operational on the network
and it has assigned the IP address.
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Setup
To assign an IP address, click on the corresponding “Assign” button. The IP Address
Assignment window opens.
Figure 3.4. - Assigning IP Address
The required IP address can then be either entered, or a recently used IP address can be
selected by clicking on an item in the Recent List.
If the “Enable Static” checkbox is checked, then the IP address will be set to static after the IP
assignment, thereby disabling future DHCP requests.
Once the IP address window has been accepted, the DHCP server will automatically assign the
IP address to the module and then read the Identity object Product name from the device.
The successful assignment of the IP address by the device is indicated by the green
background of the associated row.
Figure 3.5. - Successful IP address assignment
It is possible to force the module back into DHCP mode by powering up the device with DIP
switch 2 set to the On position.
A new IP address can then be assigned by repeating the previous steps.
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Setup
NOTE: It is important to return DIP switch 2 back to the Off position, to avoid
the module returning to a DHCP mode after the power is cycled again.
In addition to the setting the IP address, a number of other network parameters can be set
during the DHCP process. These settings can be viewed and edited in the PLX50 Configuration
Utility Application Settings, in the DHCP Server tab.
Once the DHCP process has been completed, the network settings can be set using the
Ethernet Port Configuration via the Target Browser.
The Target Browser can be accessed under the Tools menu.
Figure 3.6. - Selecting the Target Browser
The Target Browser automatically scans the Ethernet network for EtherNet/IP devices.
Figure 3.7. - Target Browser
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Setup
Right-clicking on a device, reveals the context menu, including the Port Configuration option.
Figure 3.8. - Selecting Port Configuration
The Ethernet port configuration parameters can be modified using the Port Configuration
window.
Figure 3.9. - Port Configuration
Alternatively, these parameters can be modified using RSLinx.
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Setup
3.3. CREATING A NEW PROJECT
Before you configure the module, a new PLX50 Configuration Utility project must be created.
Under the File menu, select New.
Figure 3.10. - Creating a new project
A PLX50 Configuration Utility project will be created, showing the Project Explorer tree view.
To save the project use the Save option under the File menu.
Selecting Add under the Device menu.
Figure 3.11. - Adding a new device
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Setup
In the Add New Device window, select the PLX51-DF1-ENI, and click the Ok button.
Figure 3.12 – Selecting a new PLX51-DF1-ENI
The device appears in the Project Explorer tree as shown below, and its configuration window
opened.
The device configuration window can be reopened by either double clicking the module in
the Project Explorer tree or right-clicking the module and selecting Configuration.
Figure 3.13. – PLX51-DF1-ENI configuration
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Setup
Parameter
Description
Instance Name
This parameter is a user defined name to identify between various PLX51-DF1-ENIs.
Description
This parameter is used to provide a more detailed description of the application for the
PLX51-DF1-ENI.
IP Address
IP address of the PLX51-DF1-ENI.
Major Revision
The major revision of the PLX51-DF1-ENI.
ENIP Retry Limit
The amount of EtherNet/IP retries the module will make once no response was received
from the Logix Controller.
ENIP TimeOut
The time in milliseconds after which a retry is sent. Once the first retry is sent, the next
retry will be sent after the same amount of time. This will repeat until the ENIP Retry
Limit is reached.
Operating Mode
The Operating Mode determines how the DF1 messages are routed:
In DF1 Slave mode, the module automatically routes the DF1 message and function to
the correct Logix tag. In this mode, the PLX51-DF1-ENI maps the DF1 request to the
preconfigured tag. Communication in this mode is initiated by the remote DF1 device.
In Scheduled mode, the PLX51-DF1-ENI will initiate the exchange between the remote
DF1 device and Logix. Either by reading data from a DF1 device and writing it into a
preconfigured Logix tag or vice versa. Communication in this mode is initiated by the
PLX51-DF1-ENI.
In Unscheduled mode, the PLX51-DF1-ENI routes Logix messages to the remote DF1
device and returns the result. There is little configuration required in the PLX51-DF1-ENI
as the routing information is configured by Logix for each message transaction.
Communication in this mode is initiated by Logix.
In Bridge mode, the module uses the PCCC message exchange to read or write various
tags in the Logix controller. Therefore, in this mode, the module relies on the Logix
controller to map the DF1 request to the preconfigured Logix tag.
Communication in this mode is initiated by the remote DF1 device.
Refer to the message routing section for an explanation of the routing operation.
3.4. DF1 PARAMETERS
The DF1 parameters are configured by the PLX50 Configuration Utility. Refer to the additional
information section for documentation and installation links for the ProSoft PLX50
Configuration Utility. The DF1 parameter configuration consists of a general configuration as
well as a serial configuration. When downloading the configuration into the module, it will be
saved in non-volatile memory that persists when the module is powered down.
The General configuration tab consists of the following parameters:
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Table 3.1 - General configuration parameters
Setup
The DF1 General configuration window is opened by either double clicking on the module in
the tree or right-clicking the module and selecting Configuration.
Figure 3.14. - General Configuration
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Setup
Parameter
Description
Protocol
The protocol parameter configures the module to operate in full duplex, half
duplex, or Radio Modem mode on the DF1 network.
BAUD Rate
The BAUD rate configures at what speed the data is sent across the RS232 serial
network. The module provides the following speeds:
1200, 2400, 4800, 9600, 19200, 38400, 57600, and 115200
Parity
This parameter configures the parity of the module’s RS232 serial port. The
module allows for Even, Odd, or None parity setting.
Error Detection
The module can be configured to perform either BCC or CRC checksum validation
on incoming and outgoing packets. CRC checksums is a much stronger validation
method when compared to BCC but is more processor intensive to perform.
Embedded Responses
This parameter configures the module to add the acknowledge responses in the
data payload. You can configure the module to be Auto Detect or On.
This function is only available in Full Duplex mode.
Bridge Half-Duplex Mode
This parameter configures the port as a DF1 Slave or DF1 Master.
The Serial - DF1 configuration tab is shown in the figure below. The DF1 Serial configuration
window is opened by either double clicking on the module in the tree or right-clicking the
module and selecting Configuration.
Figure 3.15 - Serial DF1 configuration
The Serial – DF1 configuration tab consists of the following parameters:
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Setup
Retry Limit
This determines how many times the module must retry and message exchange
before failing it.
ACK Timeout
This is used to determine the interval between retries when a message exchange
has failed.
Reply Msg Wait
This is the minimum delay before the DF1 reply is transmitted to the DF1 device.
Node Address
This is only configurable in Unscheduled mode. In all other modes the node
address is dynamically changed to suite the required mapping.
Enable
Duplicate Detection
This configures the module to check for duplicate packets and flagging them
when they occur.
Enable Store and Forward
When using the Radio Modem protocol, the PLX51-DF1-ENI can be used to
repeat messages from other nodes on the radio network (only relevant for DF1
Radio Modem protocol).
Repeat Delay
When repeating packets from other nodes on the Radio network, this setting
determines the delay before repeating the packet (only relevant for DF1 Radio
Modem protocol).
Nodes to Repeat
When Store and Forward has been enabled, the Nodes to Repeat list is all the
nodes numbers of the devices from which the PLX51-DF1-ENI must repeat the
messages (only relevant for DF1 Radio Modem protocol).
Table 3.2 - Serial DF1 configuration parameters
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Setup
3.5. MESSAGE ROUTING
The module can be configured to route DF1 data in one of four modes:
Bridge mode
DF1 Slave mode
Schedule Tag mode
Unscheduled mode
3.5.1. BRIDGE MODE
The Bridge Mode can be used for redirecting messages between the DF1 and Ethernet port.
This mode allows for various remote programming options and well as mapping DF1 (PCCC)
messages to a Logix controller when using the Logix PLC mapping feature.
To open the Bridge map configuration window by double clicking on the module in the tree
or right-clicking the module and selecting Configuration. Once in the configuration window
select the third tab at the top Bridge. The Bridge map configuration is shown in the figure
below.
Figure 3.16 - Bridge map configuration
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Setup
The module can emulate more than one destination DF1 Node Address, and thus route
multiple messages to different Ethernet devices. For this reason it is important to enter the
correct associate DF1 Node address in each mapping record.
When using PCCC data messaging the connection class can be configured by selecting either
Class 3 or Unconnected (UCMM) messaging. This is done by selecting from the Connection
drop-down box in the Bridge tab.
The controller paths can either be entered manually or you can browse to them by clicking
the Browse button. The Target Browser requires the controller to be available on the network.
The Target Browser will open and automatically scan for all EtherNet/IP devices.
If the Ethernet/IP module is a bridge module, it can be expanded by right-clicking on the
module and selecting the Scan option.
Figure 3.17. - Scanning node in the Target Browser
Figure 3.18. - Target Browser selection
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