QUCM Domino Printer Controller Application Manual

QUCM Domino Printer

Installation and Programming Manual

This Manual describes the QUCM application for interfacing a Domino Printer to a Modicon Quantum PLC sys-
tem.

Effective: 09 May, 2008

Niobrara Research & Development Corporation

P.O. Box 3418 Joplin, MO 64803 USA
Telephone: (800) 235-6723 or (417) 624-8918
Facsimile: (417) 624-8920
www.niobrara.com
Modicon and Quantum are trademarks of Schneider Electric.

Subject to change without notice.

© Niobrara Research & Development Corporation 2005-2008. All Rights Reserved.

 Contents

1 Introduction ......................................................................................................................... 5

2 Installation ............................................................................................................................. 7
QUCM Installation ......................................................................................................... 7
Serial Connections to the QUCM-OE ............................................................................ 7
Port 1 to Domino Printer ......................................................................................... 7
Port 2 to the Personal Computer ............................................................................. 7
Printer Configuration ...................................................................................................... 8
Loading the Applications into the QUCM ..................................................................... 8
FWLOAD QUCM Firmware Update. ..................................................................... 9
QLOAD Application 1 ............................................................................................ 9
PLC I/O Scanner Configuration ................................................................................... 10
PLC Command Register ........................................................................................ 12
PLC TOD Clock .................................................................................................... 13
Message Name Block ............................................................................................ 13
Message Text Block .............................................................................................. 14
Serial Number Block ............................................................................................. 15
QUCM Status Block .............................................................................................. 16

3 Web Server ......................................................................................................................... 17

Main Page ..................................................................................................................... 17
Config Extension Page ................................................................................................. 19
Upload Message from Printer ....................................................................................... 20
Build Message .............................................................................................................. 20

Figures
Figure 2-1 QUCM-OE to RS-232 (9-pin) (MM3 Cable) ............................................................ 7
Figure 2-2 Connections to QUCM-OE serial ports ........................................................................ 8
Figure 2-3 QUCM-OE to RS-232 PC Port (9-pin) (MM1 Cable) ................................................ 8
Figure 2-4 FWLOAD of QUCM Firmware ................................................................................... 9
Figure 2-5 QLOAD of Application 1 ........................................................................................... 10
Figure 3-1 QUCM Home Page ..................................................................................................... 18
Figure 3-2 Config Extension Web Page ....................................................................................... 19
Figure 3-3 Upload Message from Printer Web Page .................................................................... 20

3
Tables
Table 2-1 Write Ref Master Definitions ....................................................................................... 11
Table 2-2 Concept I/O Scanner Example ..................................................................................... 12
Table 2-3 Unity I/O Scanner Example ......................................................................................... 12
Table 2-4 PLC Command Register Bitmap .................................................................................. 13
Table 2-5 PLC TOD Clock Block ................................................................................................ 13
Table 2-6 Message Name Block ................................................................................................... 14
Table 2-7 Embedded Message Codes ........................................................................................... 14
Table 2-8 Message Text Block ..................................................................................................... 15
Table 2-9 Serial Number Block .................................................................................................... 15
Table 2-10 QUCM Status Block .................................................................................................. 16

4
 1
Introduction

The Niobrara QUCM is a TSX Quantum® compatible module that is capable of run-
ning multiple applications for performing communication translations between serial
protocols. This document covers an application provides a PLC controlled interface
with a Domino "A Series" printer using the A-comm Communications Protocol.
The QUCM-OE must be used in the local Quantum PLC processor rack. The module
is configured as an NOE-771-01 in the PLC and the I/O Scanner table is used to de-
fine the location of the printer data in the PLC.
The application, "qucm_domino_app1.qcm" is compiled and loaded into Application
1 of the QUCM-OE. The application includes multiple threads for simultaneously
servicing the printer, Modbus/TCP, Modbus Serial, and a built-in Web Server.
Serial Port 1 of the QUCM is used to connect to the Domino Printer via RS-232. A
Niobrara MM1 cable is needed to load the application into the QUCM.

QUCM Domino Printer Controller Application Manual 1 Introduction 5

 2
Installation

QUCM Installation
Mount the QUCM in an available slot in the register rack. Secure the screw at the
bottom of the module.

Serial Connections to the QUCM-OE

Port 1 to Domino Printer
The serial port of the QUCM-OE must be switched to RS-232. The Niobrara cable
MM3 is used to connect to the 3773H cable provided by Domino. The MM3 cable
pinout is shown in Figure 2-1.

RJ45 DE9P (male)

3 3
4 2
5 5
2 4
6
6 7
7 8

Figure 2-1 QUCM-OE to RS-232 (9-pin) (MM3 Cable)

Port 2 to the Personal Computer
A physical connection must be made from the personal computer to the QUCM in or-
der load the QUCM application program. This link may be a serial connection from a
COM port on the personal computer to the RS-232 port on the QUCM-OE. The

QUCM Domino Printer Controller Application Manual 2 Installation 7

 Niobrara MM1 cable may be used for this connection. This cable pinout is shown in
Figure 2-3.

140
QUCM
Niobrara
Fault
3773H Cable
Active 1 6
Ready 2 7
Run 3 8
4 9
Col 5 10
Lnk RN1 RN2
TXE TX1 TX2
RXE RX1 RX2

PC

MM3 Cable

MM1 Cable

Figure 2-2 Connections to QUCM-OE serial ports

RJ45 DE9S (female)

3 2
4 3
5 5
6 4
7 6
7
8

Figure 2-3 QUCM-OE to RS-232 PC Port (9-pin) (MM1 Cable)

Printer Configuration
The Domino Printer must be have its serial port configured for 38400 baud, 8 data
bits, 1 stop bit, and parity NONE.

Loading the Applications into the QUCM

The QUCM-OE must use the qucmtcpl.fwl firmware included in the
QUCM_SETUP.EXE file. This firmware is dated 25Jan2006 or later.

8 Installation 2 QUCM Domino Printer Controller Application Manual

 FWLOAD QUCM Firmware Update.
Firmware upload is as follows:
1 Remove the module form the rack.
2 Move the RUN/LOAD switch on the back of the module to LOAD.
3 Replace the module in the rack and apply power.
4 Only the 3 light should be on. (The Link and RX E-net lights may be on if the
E-net port is connected and there is traffic.)
5 Connect the PC to QUCM Port 1 with a MM1 cable.. Make sure that Port 1 is set
to RS232 mode with the slide switch below the port.
6 From the Windows’ Start button select:
"Start, Programs, Niobrara, QUCM, FWLOAD QUCM Firmware"
Verify that the file to load is qucmtcpl.fwl.
Also verify that the proper PC serial port is selected.
7 Press the "Start Download" button. The download will only take a few minutes
and it will notify the user when finished.
8 Remove the module from the rack and change the switch back to RUN.

Figure 2-4 FWLOAD of QUCM Firmware

QLOAD Application 1
1 Application 1 and 2 Switches must be in HALT.
2 Press "Start, Programs, Niobrara, QUCM, Apps, Domino, QLOAD Domino Ap-
plication 1"
3 Verify that the file to load is qucm_domino_app1.qcc

QUCM Domino Printer Controller Application Manual 2 Installation 9

 4 Select the Modbus Serial Tab
5 Verify the proper PC’s com port is selected.
6 Verify the the baud rate is 9600, 8 bits, Even parity and ASCII is NOT checked.
7 Select the Application 1 Radio Button.
8 Press the Start Download button. QLOAD will open a progress window to show
the status of the download.
After downloading the application, move switch 1 to RUN and the RN1 should come
on.

Figure 2-5 QLOAD of Application 1

PLC I/O Scanner Configuration

The QUCM must be added in the I/O Map as an NOE-771-01. The QUCM then may
have its Ethernet I/O Scanner configured. The first six I/O Scanner entries are the
only ones that are supported. The descriptions of each entry are shown in Table 2-1.
Specify IP Address - Check this box.

IP Address - Set the IP Address of the QUCM.

Subnet Mask - Set the Subnet Mask of the QUCM.

Gateway - Set the default gateway for the QUCM.

Framing - Normally this would be set for ETHERNET II.

Health Block - This is the starting 3x register or 1x coil of the 128 bits of status
for the I/O Scanner.

10 Installation 2 QUCM Domino Printer Controller Application Manual

 Diagnostic Block (Device Control Block) - This setting is ignored by the
QUCM. Leave blank.

Slave IP Address - This setting is ignored by the QUCM. Leave 0.0.0.0 or

1.1.1.1 for Unity.

Unit ID - This setting is ignored by the QUCM.

Health Timeout - This setting is ignored by the QUCM. Leave at 0.

Repetitive Rate - This setting is ignored by the QUCM. Leave at 0.

Read Ref Master (RD Master Object) - This setting is ignored by the QUCM.
Leave blank or set to %MW1.

Read Ref Slave (RD Slave Index) - This setting is ignored by the QUCM. Leave
blank or 0.

Read Length - This setting is ignored by the QUCM. Leave at 0.

Last Value (Input) - This setting is ignored by the QUCM. Leave at Hold Last.

Write Ref Master (WR Master Object) - This is the PLC location that holds
the starting register for a given block of data. This value must be a 4x register or
%MW. Table 2-1 shows the definitions of each of the six I/O Scan entries.

Write Ref Slave - This value must be 40001 through 40006 for entries 1 through
6 of the scan table. Unity requires the values to be 1 through 6.

Write Length - This setting is must be 1 for entries 1 through 6 of the scan table.

Table 2-1 Write Ref Master Definitions

Scan Description Length More
Entry (in words) Information
1 PLC Command Table 2-4
1
Register
2 PLC TOD Clock 8 Table 2-5
Starting Register
3 Start of Message 50 Table 2-6
Name Block
4 Start of Message 1001 Table 2-8
Text Block
5 Serial Number 2 Table 2-9
6 Start of QUCM 20 Table 2-10
Status Block

QUCM Domino Printer Controller Application Manual 2 Installation 11

 Table 2-2 Concept I/O Scanner Example
X Specify IP IP Address 206.223.51.145 Subnet 255.255.255.0

Gateway 206.223.51.1 Framing Ethernet II

Master Module Slot 5:
(slot) 140-NOE-771-01
Health Block 300123
Diagnostic Block
Slave IP Unit Health Rep Read Read Read Last Write Write Write Notes
Address ID Tout Rate Ref Ref Len Valu Ref Ref Len
Master Slave e Master Slave
1 0.0.0.0 1 0 0 0 Hold 400009 400001 1 PLC Command
2 0.0.0.0 2 0 0 0 Hold 400101 400002 1 TOD Clock
3 0.0.0.0 3 0 0 0 Hold 400901 400003 1 Message Name
4 0.0.0.0 4 0 0 0 Hold 401001 400004 1 Message Text
5 0.0.0.0 5 0 0 0 Hold 400951 400005 1 Serial Number
6 0.0.0.0 6 0 0 0 Hold 400010 400006 1 Status Block
7
8
9

Table 2-3 Unity I/O Scanner Example

TCP/IP 10/100 Regular connection Module No Messaging
Address Yes IO Scanning
RackModule No Global Data
1 3 No SNMP
No Address Server
Health Block %IW123 Device Control Block

Slave IP Unit Health Rep RD Read Read Last Write Ref WR WR Description
Address ID Tout Rate Master Ref Len Value Master Slave Len
Object Slave Index
1 1.1.1.1 1 0 0 %MW1 0 0 Hold %MW9 1 1 PLC Command
2 1.1.1.1 2 0 0 %MW1 0 0 Hold %MW101 2 1 TOD Clock
3 1.1.1.1 3 0 0 %MW1 0 0 Hold %MW901 3 1 Message Name
4 1.1.1.1 4 0 0 %MW1 0 0 Hold %MW1001 4 1 Message Text
5 1.1.1.1 5 0 0 %MW1 0 0 Hold %MW951 5 1 Serial Number
6 1.1.1.1 6 0 0 %MW1 0 0 Hold %MW10 6 1 Status Block
7
8
9

PLC Command Register

The first entry in the I/O Scanner tells the QUCM where to look for the PLC Com-
mand Register. The individual bits of this register control the action of the QUCM
and consequently the Domino printer. The normal operation is that the PLC will load
up the appropriate values in the Message Name, Text, and Serial Number blocks and
then set corresponding command bit. The QUCM will then pull out the proper data

12 Installation 2 QUCM Domino Printer Controller Application Manual

 from the PLC, perform the appropriate action, and then signal the PLC that the action
is completed by setting a bit in QUCMstatus[0]. In most cases the PLC will then need
to clear the bit in PLCcommand[0] and wait for the QUCMstatus[0] bit to then clear
before setting the bit again.

Table 2-4 PLC Command Register Bitmap

Block entry Description Notes
bit 0 Print Message Message Name stored in PLC gets printed.
bit 1 Send Message to Printer Message Name and Text stored in PLC gets sent
to Printer.
bit 2 Send new Serial Number to Printer Long Serial Number value for Message Name
stored in PLC gets sent to Printer.
bit 3 Set Printer Clock to PLC Time Sets both the QUCM and Printer Clocks.
bit 4 Clear Product Count in Printer
bit 5 Query Serial Number from Printer Queries Serial Number for Message Name
stored in PLC and returns to QUCMstatus[18]
and [19]
bit 6 All Messages OFF-LINE Removes all messages from Printer’s Print
queue.
bit 7 Read Product Count from Printer

PLC TOD Clock

Entry 2 in the I/O Scanner table is the starting register of the PLC TOD Clock. These
8 registers are defined in Table 2-5. When the PLC sets PLCcommand[0].3 then the
QUCM will poll the data from the PLC TOD Clock, set its own clock, and send the
new time/date to the Printer. The QUCM will then set QUCMstatus[0].3 when the
clocks are all set.

Table 2-5 PLC TOD Clock Block

Block Entry Description Notes
TOD[0] Command Bitmap See PLC Documentation
TOD[1] Day of Week 1=Sunday
TOD[2] Month 1-12
TOD[3] Day 1-31
TOD[4] Year Last 2 digits of year (assumes 20xx)
TOD[5] Hours 0-23
TOD[6] Minutes 0-59
TOD[7] Seconds 0-59

Message Name Block

The Message Name is a 50 word block of registers in the PLC where the cable name
data is stored in packed ASCII (two characters per register). The string is terminated
with the following ASCII characters [EOT]. Table 2-6 shows an example of the name
"Test 123 ABC[EOT]".

QUCM Domino Printer Controller Application Manual 2 Installation 13

 Table 2-6 Message Name Block
Block Entry Example Data Example
(hex) (ASCII)
Name[0] 5465 Te
Name[1] 7374 st
Name[2] 2031 1
Name[3] 3233 23
Name[4] 2041 A
Name[5] 4243 BC
Name[6] 5B45 [E
Name[7] 4F54 OT
Name[8] 5D00 ]

Message Text Block

The Message Name is a block of 1000 words with the print string stored in packed
ASCII format. There are several embedded codes that my be used to insert a sequen-
tial footage code, do not print, insert date codes, and end of text. Table 2-7 shows the
possible embedded codes. Table 2-8 shows the register data for "Test
[MMM/DD/YYYY][EOT]" where MMM is the Text Month attribute, DD is the day,
and YYYY is the four digit year attribute.

Table 2-7 Embedded Message Codes

Text Description
[EOT] End of Text, must be at the end of the print message.
[DNP] Do Not Print
[SQFTG] Insert sequential footage code
[MMDDYYYY] MM = two digit month
MMM = text month
DD = day of month
YYYY = four digit year
YY = two digit year
JD = julian day of the year
WN = week number
DOW = day of week

14 Installation 2 QUCM Domino Printer Controller Application Manual

 Table 2-8 Message Text Block
Block Entry Example Data Notes
(hex)
text[0] 5465 Te
text[1] 7374 st
text[2] 205B [
text[3] 4D4D MM
text[4] 4D44 MD
text[5] 4459 DY
text[6] 5959 YY
text[7] 595D Y]
text[8] 5B45 [E
text[9] 4F54 OT
text[10] 5D00 ]

Serial Number Block

The Serial Number is a block of 2 words that form a long integer read from the PLC
by the QUCM. The first word is the high word and the second is the low word. The
QUCM will read the Message Name and Serial Number from the PLC and then send
the new serial number to the stored Message Name in the printer. Table 2-9 shows an
example of the serial number 1234567 (decimal) = x0012D687 (hex).

Table 2-9 Serial Number Block

Block Entry Example Data
(hex)
Serial[0] 0012
Serial[1] D687

QUCM Domino Printer Controller Application Manual 2 Installation 15

 QUCM Status Block
The QUCM Status is a block of 20 words written to the PLC by the QUCM. Table
2-10 shows the definitions of the QUCM Status Block.

Table 2-10 QUCM Status Block

Block Entry Description Notes
QUCMstatus[0] QUCM Status Bitmap bit 0 = Printer told to print message
bit 1 = Message Text sent to printer
bit 2 = Serial Number sent to printer
bit 3 = Printer Clock Set
bit 4 = Product Count Cleared
bit 5 = Query Serial Number Finished
bit 6 = All messages Off-Line Finished
bit 7 = Product Count Finished
bit 15 = Printer communicating with QUCM OK
QUCMstatus[1] Products Detected HI High word of long value
QUCMstatus[2] Products Detected LO Low word of long value
QUCMstatus[3] Products Printed HI High word of long value
QUCMstatus[4] Products Printed LO Low word of long value
QUCMstatus[5] Machine Time ON in Hrs HI High word of long value
QUCMstatus[6] Machine Time ON in Hrs LO Low word of long value
QUCMstatus[7] Jet Time ON in Hrs High word of long value
QUCMstatus[8] Jet Time ON in Hrs Low word of long value
QUCMstatus[9] Pump Time ON in Hrs High word of long value
QUCMstatus[10] Pump Time ON in Hrs Low word of long value
QUCMstatus[11] Ink Temperature
QUCMstatus[12] Gun Body Temperature
QUCMstatus[13] Sensor Bitmap bit 0 = State of Gutter Sensor
bit 1 = State of Cabinet Monitor
QUCMstatus[14] Ink Level 0=Empty, 1=Low, 2=OK, 3=High
QUCMstatus[15] Solvent Level 0=Empty, 1=Low, 2=OK, 3=High
QUCMstatus[16] Print Engine State Bitmap bit 0 = Fault
bit 1 = Standby
bit 2 = Ink ON, Jet OFF
bit 3 = Jet ON, MOD OFF
bit 4= Jet ON, HV OFF
bit 5 = Sequencing ON
bit 6 = Sequencing OFF
bit 7 = Bleeding Head
bit 8 = Resetting Modulation
bit 9 = Manual
QUCMstatus[17] Cabinet Monitor State Bitmap bit 0 = OK
bit 1 = Fault
QUCMstatus[18] Serial Number from Printer High word of long value
QUCMstatus[19] Serial Number from Printer Low word of long value

16 Installation 2 QUCM Domino Printer Controller Application Manual

 3
Web Server

The QUCM Domino Printer application supports a simple Web server to aid in testing
operations of the system.

Main Page
The main (Home) web page shows the revision of the QUCM application, the serial
port configurations, the status of the PLC rack communication, the currently loaded
Message Name, Message, Serial Number, and the source of the present message. Ad-
ditionally, the hexadecimal values of the QUCM’s active Name and Message Text are
displayed. Links are provided to view the Config Extension Data, Upload a message
from the printer, store a message back to the PLC, and Build a message from the Pro-
tocolFileBuilder PC program.
If the message includes non-printable attributes then they are displayed as a link with
a roll-over box to show the attribute fields. These links are not yet functional and will
return to the home page if clicked.

QUCM Domino Printer Controller Application Manual 3 Web Server 17

 Figure 3-1 QUCM Home Page

18 Web Server 3 QUCM Domino Printer Controller Application Manual

Config Extension Page
The Config Extension web page shows the PLC 4x registers used by this application
as well as the data that the QUCM reads from or writes to the PLC.

Figure 3-2 Config Extension Web Page

QUCM Domino Printer Controller Application Manual 3 Web Server 19

Upload Message from Printer
This page is used to query the printer for a stored message. The message name must
be exactly match the stored name in the printer. A successfully queried message will
be in the QUCM for display on the web page. It is then possible to load that message
(name and text) back into the PLC by clicking the "Store Message to PLC" link.

Figure 3-3 Upload Message from Printer Web Page

Build Message
This page is used to build a message in the QUCM and then load it into the PLC mes-
sage area. The message name is entered as straight text terminated with [EOT]. The
message text is also entered as straight text terminated with [EOT]. The QUCM then
strips out the print message text. A successfully loaded message will be in the QUCM
for display on the web page. It is then possible to load that message (name and text)
back into the PLC by clicking the "Store Message to PLC" link.

20 Web Server 3 QUCM Domino Printer Controller Application Manual