Gateway 312785C User Manual

Instructions-Parts

Gateway Network

312785C

Communication Kits

Installation and program setup instructions for use with ProMix® 2KS Electronic Proportioners. For professional use only.

Not approved for use in European explosive atmosphere locations.

See page 3 for kit information.

Important Safety Instructions

Read all warnings and instructions in this manual and in your proportioning system manual. Save these instructions.

TI12933b

Contents

Graco Gateway Kits . . . . . . . . . . . . . . . . . . . . . . . . . 3

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Graco Gateway Overview . . . . . . . . . . . . . . . . . . . . 5

Install the Gateway Module Hardware . . . . . . . . . . 5

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Connect the Module to the EasyKey . . . . . . . . . . 7

Cabling Connections . . . . . . . . . . . . . . . . . . . . . . 7

Mount the Control on DIN Rail . . . . . . . . . . . . . 11

Install CompactFlash

Install the GracoConfig Software . . . . . . . . . . . . . 12

System Requirements . . . . . . . . . . . . . . . . . . . . 12

Load the Software . . . . . . . . . . . . . . . . . . . . . . . 13

Software Updates . . . . . . . . . . . . . . . . . . . . . . . 13

Download the Preconfigured Database to the

Gateway Module . . . . . . . . . . . . . . . . . . . . . 14

Graco Gateway Network Communications

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 15

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

GracoConfig Main Page . . . . . . . . . . . . . . . . . . 15

Setup the Database . . . . . . . . . . . . . . . . . . . . . 16

Map Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Modbus and I/O Data . . . . . . . . . . . . . . . . . . . . . . . 21

Start Mix Process . . . . . . . . . . . . . . . . . . . . . . . 21

Stop Mix Process . . . . . . . . . . . . . . . . . . . . . . . 21

Color Change Process . . . . . . . . . . . . . . . . . . . 21

Purge Process . . . . . . . . . . . . . . . . . . . . . . . . . 21

ProMix 2KS Active Alarms (Modbus Register

40010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

ProMix 2KS Modbus/TCP Variable Map . . . . . . 30

ProMix 2KS Recipe Bits . . . . . . . . . . . . . . . . . . 31

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

General Troubleshooting . . . . . . . . . . . . . . . . . . 32

Graco Gateway Messages Troubleshooting . . . 35

Serial Communication Troubleshooting . . . . . . . 36

Ethernet Communication Troubleshooting . . . . 37

LED Functions . . . . . . . . . . . . . . . . . . . . . . . . . 38

System Electrical Schematic . . . . . . . . . . . . . . . . 39

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

15V331 Gateway Ethernet Kit (shown) . . . . . . . 40

15V963 Gateway DeviceNet Kit . . . . . . . . . . . . 40

15V964 Gateway Profibus Kit . . . . . . . . . . . . . . 40

Card . . . . . . . . . . . . . . . 11

Appendix A: DeviceNet

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

DeviceNet Port Protocols . . . . . . . . . . . . . . . . . 42

About DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . 44

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Automatic Update of the EDS File . . . . . . . . . . . 51

Configure the RSNetWorx for

DeviceNet Software . . . . . . . . . . . . . . . . . . 52

Configure the Allen Bradley ControlLogix PLC . 55

Wire the DeviceNet Network . . . . . . . . . . . . . . . 56

Appendix B: Profibus

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Profibus Port Protocols . . . . . . . . . . . . . . . . . . . 57

About Profibus DP . . . . . . . . . . . . . . . . . . . . . . . 58

Setup the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Graco Gateway Setup . . . . . . . . . . . . . . . . . . . . 66

Appendix C: Graco Gateway to ControlLogix via

Ethernet IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

ControlLogix Configuration . . . . . . . . . . . . . . . . 73

Graco Gateway Configuration . . . . . . . . . . . . . 77

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 82

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 82

™

Slave Communication 42

™

DP Slave Communication 57

2 312785C

Graco Gateway Kits

15V331 Gateway Ethernet Kit

Allows communication between ProMix 2KS and a PLC over an ethernet. Enables process equipment to read variables while operating, as well as control the ProMix 2KS and change setup. It does not provide access to job and alarm logs.

15V963 Gateway DeviceNet Kit

Allows communication between ProMix 2KS and a PLC, using DeviceNet process control. Enables process equipment to read variables while operating, as well as control the ProMix 2KS and change setup. It does not provide access to job and alarm logs.

15V964 Gateway Profibus Kit

Allows communication between ProMix 2KS and a PLC, using Profibus process control. Enables process equipment to read variables while operating, as well as control the ProMix 2KS and change setup. It does not provide access to job and alarm logs.

Related Manuals

Component Manuals in English

Manual Description

312778 ProMix 2KS Automatic System

Installation

312779 ProMix 2KS Automatic System

Operation

312780 ProMix 2KS Automatic System

Repair-Parts

313386 Basic Web Interface/Advanced Web

Interface

312785C 3

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

4 312785C

Graco Gateway Overview

The Graco Gateway enables the ProMix 2KS to network with a programmable logic controller (PLC). Kits are available for Ethernet, DeviceNet, or Profibus protocols. The Graco Gateway will support many other protocols; contact Graco Technical Assistance for information to support your desired protocol.

NOTE: Only persons very familiar with their PLC communication architecture should use this hardware and software. This manual assumes that the person using the Graco Gateway has full understanding of the PLC equipment and related software.

NOTE: Network communications essentially operate with the same rules as Discrete I/O. However, network communications require placing correct values or adjusting appropriate bits within various Modbus registers (for example, see Table 4). These changes should only be made by qualified persons familiar with this type of communication.

The module allows for most PLCs to communicate with the ProMix 2KS via Modbus RTU protocol by bridging the gap between the desired communication protocol and RS485 Modbus RTU. As a result, the PLC has full access to all the registers for monitoring and controlling the ProMix 2KS. It is the responsibility of the integrator or user to ensure proper configuration of the communication hardware on the PLC side.

Install the Gateway Module Hardware

Location

This equipment is not for use in explosive atmospheres. Do not install equipment approved only for non-hazardous location in a hazardous area.

Install the Gateway module near the EasyKey™, in a non-hazardous area.

Mounting

1. See Dimensions, page 79.

2. Ensure that the wall and mounting hardware are strong enough to support the weight of the equipment, cables, and stress caused during operation.

3. Using the equipment as a template, mark the mounting holes on the wall at a convenient height for the operator and so equipment is easily accessible for maintenance.

4. Drill mounting holes in the wall. Install anchors as needed.

5. Bolt equipment securely.

Grounding

Your system must be grounded. Read Warnings, page 4.

The Gateway module is grounded through its connection to the EasyKey, which must be connected to a true earth ground. See the system installation manual. A ground wire and clamp, part no. 223547, is available from Graco.

312785C 5

Install the Gateway Module Hardware

USB Cable

(included), for initial

setup only

PLC Communication

Wire/Cable

(protocol dependent)

NON-HAZARDOUS AREA

Graco Gateway

Module

EasyKey

Computer (PC)

FIG. 1: Graco Gateway Typical Installation

2-wire twisted pair cable, with shield wire

TI13939a

Programmable Logic Controller (PLC)

6 312785C

Connect the Module to the EasyKey

FIG. 1 is only a guide showing installation of the Graco Gateway in a ProMix 2KS System; it is not a complete system design, Contact your Graco distributor for assistance in designing a system to suit your particular needs.

Install the Gateway Module Hardware

1. Shut off ProMix 2KS power (0 position). F shut off power at main circuit breaker.

IG. 2: Power Off

2. Connect a 2-wire twisted pair cable with shield wire from the EasyKey connector to the connector on the Gateway module. Connect a communications wire/cable (protocol dependent) from the Gateway module to the PLC. See F

IG. 3.

IG. 2. Also

0 = OFF

TI12657a

NOTE: Graco provides expansion cards for DeviceNet and Profibus protocols. DeviceNet setup procedures are on page 42. Profibus setup procedures are on page 57. See page 40 for Parts.

NOTE: If using the Graco Gateway in your system, disconnect its cable from the EasyKey before updating the ProMix 2KS software.

Cabling Connections

See FIG. 4 and FIG. 5 for typical cable connections in a ProMix 2KS system.

IG. 6 through FIG. 9 show other possible cable connec-

tions.

312785C 7

Install the Gateway Module Hardware

2-wire twisted pair cable, with

shield wire (to Gateway Module)

EasyKey (Bottom View)

TI12638a

USB Port

Gateway Module

TI12930a

Communication Wire/Cable (to PLC).

This connection is protocol dependent.

2-wire twisted pair cable, with shield wire (to EasyKey). See Wiring Diagrams on page 41 for pin connections.

FIG. 3: EasyKey and Module Cable Connection Points

8 312785C

Pin 1

RS232/PG

USB/PG

Install the Gateway Module Hardware

Common 24 Vdc +/- 10%

Pin 6

N/C

Power Connector

Pin 1

Pin 8

COMMS

Pin 1

Pin 6

COMMS

Green/

Amber

LED

Ye l l o w

LED

ETHERNET (NIC)

FIG. 4: Graco Gateway Port Pin Outs

Expansion

Port

TI13974a

TI13972a

FIG. 5: RS485 Communication Port (Typical ProMix 2KS Connection)

312785C 9

Install the Gateway Module Hardware

RS232/PG

USB/PG

ETHERNET

Green/Amber LED

Yellow LED

FIG. 6: Programming Ports

RS232/PG

TI13969a

TI13970a

FIG. 7: RS232/PG Communication Ports

RS232

TI13971a

IG. 8: RS232 Communication Ports

10 312785C

ETHERNET

IG. 9: Ethernet Connection

Install the Gateway Module Hardware

Green/Amber LED

Yel low LE D

Standard Ethernet Cable

TI13973a

Mount the Control on DIN Rail

The Gateway control mounts on a DIN rail. Tilt the control and push down onto the DIN rail, then push in. See F

IG. 10. A minimum clearance of 1 in. (25 mm) above

and below the control is required to ensure adequate ventilation.

TI13965a

1 in. (25 mm)

minimum

clearance top

and bottom

Install CompactFlash® Card

The CompactFlash socket accepts either Type I or Type II cards. These cards are available at most computer and office supply retailers. Use cards with a minimum of 4 Mbytes and a maximum of 2 Gbytes. Use the CompactFlash card for optional database storage only. See F

IG. 11.

Insert card with top side on the left. Do not insert

or remove card while

power is applied.

FIG. 11: Install a CompactFlash Card

TI13967a

TI13966a

FIG. 10: Mount the Control on a DIN Rail

312785C 11

Install the GracoConfig Software

GracoConfig software provides access to the Graco Gateway module hardware. The CD provided contains the GracoConfig software (GracoConfigXXX.exe, where the XXX represents the version control number). It also includes a preconfigured database which is essentially a setup file for the Gateway. The database file has a .gg2 extension.

The Graco Gateway provides conversions for many protocols, including the following:

• All Allen-Bradley protocols

• DeviceNet

• Ethernet TCP/IP

• Ethernet IP

• Mitsubishi

• Modbus (ASCII, RTU)

•Profibus

•Siemens

NOTE: Graco provides expansion cards for DeviceNet and Profibus protocols. DeviceNet setup procedures are on page 42. Profibus setup procedures are on page 57. See page 40 for Parts.

System Requirements

GracoConfig software will run on PCs with the following specifications:

• A Pentium class processor as required by the chosen operating system.

NOTE: GracoConfig software will operate with all versions of Microsoft

dows 2000 or above is recommended for more robust operation.

• RAM and free disk space as required by the chosen operating system.

• An additional 50MB of disk space for software installation.

• A display of at least 800 by 600 pixels, with 256 or more colors.

• USB port for downloading a configured database to the Gateway module.

Windows 98 and above. Win-

NOTE: Contact your Graco distributor or Graco Technical Assistance for information regarding additional supported protocols.

12 312785C

Load the Software

1. Connect the USB cable (23, supplied) between the USB port on the Gateway module and a USB port

on your PC. See F

USB Port

IG. 12.

TI12930a

USB Cable Strain Relief

Install the GracoConfig Software

IG. 14 will appear. Insert the CD in your PC’s

3. F CDROM drive. Select “Install the software from a list or specific location”, then click Next. The program location is C:\Program Files\Graco\GracoConfig\Device.

NOTE: The name of the driver may be different. Just accept the name and proceed by following the instructions on the screen.

IG. 12: Gateway Module USB Port

2. F

IG. 13 will appear. Select “Yes, this time only”, then

click Next.

IG. 13: Found New Hardware Screen

FIG. 14: Load Software from a Specific Location

Software Updates

Contact your distributor or Graco Technical Assistance for software updates.

312785C 13

Install the GracoConfig Software

Download the Preconfigured Database to the Gateway Module

Graco supplies a preconfigured database as a setup file for the Gateway, containing parameters which communicate between the Gateway and the ProMix 2KS. The file name has a .gg2 extension.

GracoConfig files are downloaded to the Gateway module using the Link menu. The programming link between the PC and the Gateway module uses the USB cable. Before downloading, check that the Communications Port is set to USB, as follows.

NOTE: During programming the Gateway module may ask for an updated driver. Follow the instructions on the screen to automatically find and select the drivers.

1. Go to Start>Programs>Graco>GracoConfig and run the program. The GracoConfig main page will

appear.

Link Pulldown Menu Update Symbol

2. Using the Link pulldown menu, select Options to open the Link Options window. Check that the Com-

munications Port is set to USB, and click OK.

IG. 16: Set Communications Port to USB

IG. 15: GracoConfig Main Page

3. Go to File>Open and select the file with the xx.gg2 extension. The file name should appear at the top of the window (F

4. Download the database using the Link>Update

command. As a shortcut, use the Update symbol on the toolbar. See F

NOTE: Downloading typically takes only a few seconds but may take longer if the software has to update firmware on the Gateway module.

IG. 15) once loaded.

IG. 15.

14 312785C

Graco Gateway Network Communications Configuration

Startup

To run GracoConfig, select the icon from the

Graco folder on the Programs section of your Start Menu. The main page will appear, showing the Commu-

nications button.

Communications Button

GracoConfig Main Page

Communications Button

The Communications button provides access to screens used to configure your system and setup parameters, allowing you to:

• Specify which protocols are to be used on the Gateway serial ports and on the Ethernet port.

• If using master protocols (ie., protocols by which the Gateway initiates data transfer to and from a remote device), you can specify one or more devices to be accessed.

• If using slave protocols (i.e., protocols by which the Gateway receives and responds to requests from remote devices or computer systems), you can set read or write access for specific data items.

• Move data between one remote device and another.

Balloon Help

IG. 17: Communications Button

The Balloon Help feature allows you to see help information for each icon in the main menu, or for each field

in a dialog box or window. It is controlled via the icon at the right-hand edge of the toolbar. Balloon Help has three user-selectable modes:

• Do Not Display disables balloon help

• When Mouse Over displays help when the mouse pointer is held over a particular field for a certain period of time

• When Selected displays help constantly for the currently selected field.

312785C 15

Graco Gateway Network Communications Configuration

Setup the Database

1. Double-click on the Communications button to open the preconfigured database (.gg2). The file is already setup for ProMix 2KS. See F

IG. 18.

IG. 18: Preconfigured Database

2. See F

IG. 19. Highlight Protocol 1. Click the Edit but-

ton on the right side of the window to open the Driver Picker window. Choose a protocol from the

lists provided, in this example Modbus and TCP/IP Slave. The system will create device PLC1.

FIG. 19: Select Protocol

16 312785C

3. See FIG. 20. Right click on device PLC1 to rename it to something meaningful for your system.

IG. 20: Rename PLC1

Graco Gateway Network Communications Configuration

4. See F

IG. 21. Add as many Gateway blocks as

desired under each device.

FIG. 21: Add Gateway Blocks

312785C 17

Graco Gateway Network Communications Configuration

Map Data

1. See FIG. 22. Select the block for data mapping. Click the Edit button next to the Start Address field on the right side of the window. The Select Address window will open.

2. Refer to Table 4 on page 30 for a Modbus map. Select the desired Modbus register address as a starting point (in this case 40002). Enter the appropriate values in the Select Address window and click OK. The desired register address will populate the Start Address field.

IG. 22: Mapping Gateway Blocks

18 312785C

3. See FIG. 23. Click the Edit button next to the Block Size field on the right side of the window. The Edit Value window will open. Enter the number of Modbus register addresses in the range from the starting address entered in step 2 to the desired ending address, inclusive. In this example, 7. The addresses must be contiguous. This means that each address must be available and addressable from the ProMix 2KS. If one of the 7 addresses does not exist within the ProMix 2KS Modbus structure, the complete block will not communicate.

Graco Gateway Network Communications Configuration

IG. 23: Setting Block Size

312785C 19

Graco Gateway Network Communications Configuration

4. See FIG. 24. Click OK. The range of addresses will appear under the appropriate Block on the left side of the window.

NOTE: In this example, a Modbus device master communicating via TCP/IP will have direct access to Modbus registers 40002 through 40008 of the ProMix 2KS.

For example, see Block 1 address line 1:

Modbus address

Modbus address (command) from TCP/IP master connected to Gateway.

of ProMix 2KS.

5. The Direction field typically should remain set to Device to G3.

FIG. 24: Block Mapping Data

20 312785C

Modbus and I/O Data

See Table 4 through Table 5 for Modbus register addresses and input/output data.

Reference the Discrete I/O listing of all the inputs and outputs (see page 30). Ensure these are fully understood. The same implementation used for Discrete I/O is used for the Network communication protocol.

For example: The Gun Trigger Input will now be a specific bit of Modbus Register 40040. Monitoring of Modbus Register 40041 for specific output status conditions will be required as explained in the Discrete I/O section of the ProMix 2KS Operation manual. The PLC will have to read the various bits, and in some cases (40040 and 40041 for example) must mask out the various bit positions to determine each of the separate input and output statuses. This requires experience and should not be done on the job site. A full understanding of the color change process as well as the required timing of various inputs and outputs is required.

NOTE: Analog input for flow control set point will now be a dedicated Modbus register. Register 40137 will require the specific flow rate (i.e. 125 cc/min). This is not a voltage reading but the actual flow target.

2. The Mix Active output should clear and Mix Ready should now be set.

NOTE: The ProMix 2KS will automatically go into Idle mode after 2 minutes of inactivity. A general alarm will be present and Mix Active will remain High. The Alarm bit (40010) will indicate the system Idle alarm. When a new Gun Trigger input is seen, the ProMix 2KS will resume mixing material where it left off. Do not toggle the Mix bit; doing so restarts the Mix process from the beginning.

Color Change Process

See FIG. 28, Table 1, and Table 2.

1. Verify that Mix Ready is set. This ensures that there are no alarms and that the system is ready for the next command.

2. Load ccNewRecipe (Modbus 40046) with a recipe number to color change to.

3. Set color change (40040 bit 6).

4. Verify that Purge_CC_Active is seen (40041 bit 0).

Start Mix Process

See FIG. 25, Table 1, and Table 2.

1. Verify that the Mix Ready bit (bit 2 of 40041) is on.

2. Turn on the Mix bit (bit 7 of 40040).

3. Verify that the Mix Active bit (bit 1 of 40041) is on, to ensure that the Mix request was received.

Stop Mix Process

See FIG. 26, Table 1, and Table 2.

1. Clear the Mix bit.

5. Clear color change bit (momentary only).

6. Do not change the ccNewRecipe value until a new

recipe change is requested.

7. The color change process will stop automatically as programmed. Monitor Purge_CC_Active bit for completion.

Purge Process

See FIG. 27, Table 1, and Table 2.

1. Verify that Mix Ready is set. This ensures that there are no alarms and that the system is ready for the next command.

2. Set purge (40040 bit 8).

3. Verify that Purge_CC_Active is seen (40041 bit 0).

4. When Purge_CC_Active bit clears, clear Purge_Start bit. Clearing this bit in the middle of a purge sequence will abort the purge sequence.

312785C 21

Modbus and I/O Data

Start Mix

Mode Process

Must be Alarm Condi-

tion or Active Recipe

61. See Alarm Pro-

cessing on page 26,

or Startup from Recipe

61 (see NOTE below)

NOTE: At power up the system defaults to Recipe 61, which is not a valid recipe number. Initiate a color change to Recipe 0 or a valid recipe number (1-60).

Is Mix Ready

bit = 1?

YESNO

Set Mix bit = 1

Is Mix Active

bit = 1?

YES

ProMix 2KS in Mix

Mode (Complete)

Mix Active = 1 while

the ProMix 2KS is in

Mix mode

FIG. 25. Start Mix Mode Process Flow Chart

22 312785C

Mixing Mode

Process

Mixing Mode is desired. PLC is polling to ensure

Mixing Mode is main-

tained.

Modbus and I/O Data

Check Alarm

Condition: is Alarm_

General bit = 1?

YES

Is Mix Active

bit = 1?

YESNO

Mixing Process active

2KS is in Standby. Go to

Start Mix Process, page

21.

Go to Alarm Process-

ing, page 26

FIG. 26. Mixing Mode Process Flow Chart

312785C 23

Modbus and I/O Data

Start

Must be Alarm

Condition or Active

Recipe 61. See

Alarm Processing

on page 26, or

Startup from Recipe

61 (see NOTE below).

Is Mix Ready

bit = 1?

YESNO

Set Purge bit = 1?

Is Purge_CC_Active

bit = 1?

YES

ProMix 2KS in

Purge_CC Mode

(Process Started)

Set Purge Bit = 0.

ProMix 2KS Purge

Process (Complete)

NOTE: At power up the system defaults to Recipe 61, which is not a valid recipe number. Initiate a color change to Recipe 0 or a valid recipe number (1-60).

(Wait for Mix Ready)

Is Mix Ready

bit = 1?

YES

FIG. 27. Purge Mode Process Flow Chart

24 312785C

Color Change

Process

(basic)

Modbus and I/O Data

Do nothing. Spraying at

desired recipe.

Ensure Color-

Change bit is seen

by ProMix 2KS

YES NO

Is Active Recipe = to desired recipe?

(Register 40005).

Purge_CC_Active

bit = 1?

YES

(Wait for Mix Ready)

Load ccNewRecipe

(Register 40046) with

recipe number to Color

Change to (0 through

60 is valid).

Set ColorChange (CC)

bit = 1.

Clear ColorChange (CC)

bit (momentary input).

CC process started.

Is Mix Ready

bit = 1?

Check Alarm

Condition: is Alarm_

General bit = 1?

YES

Process Alarm. See

Alarm Processing,

page 26.

ProMix 2KS Color

Change Process

(Complete)

FIG. 28. Color Change Mode Process Flow Chart

312785C 25

Modbus and I/O Data

Alarm Processing

See FIG. 29, Table 1, Table 2, and Table 3.

Alarm Processing

An Alarm Condition

has been found

previously.

Alarm_General = 1.

Determine the exact alarm

from Table 3 on page 29

and solve what caused the

alarm, as required.

Reset the alarm.

Reset_Alarm = 1.

NO YES

Is Mix Ready

bit = 1?

Check if Potlife

Alarm: is Alarm_

Potlife bit = 1?

YESNO

Two options:

• Purge or Color Change to remove mixed material in the line.

• Place in Mix mode and spray the Potlife Volume set in the ProMix 2KS.

NOTE: The Reset key only silences the alarm. To clear the alarm you must use one of these two options.

Go to next process,

as desired.

IG. 29. Alarm Processing Flow Chart

26 312785C

Modbus and I/O Data

Table 1: ProMix 2KS Digital Inputs (Modbus Register 40040)

Bit Digital Input Binary Name Details

0:5 0000000000XXXXXXRecipe Binary bits for viewing discrete inputs only. 6 000000000

1000000Color Change

Set bit to “1” to initiate Color Change (momentary)

(CC) 7 00000000 8 0000000

10000000Mix Set bit initiate Mix mode (maintain)

100000000Purge Set bit to “1” to initiate Purge sequence (maintained)

9 0000001000000000Job_Complete Set bit to “1” to initiate Job Complete input (momen-

tary)

10 0000010000000000External CC

Ready

Set bit to “1” to initiate External Color Change

(momentary) 11 0000100000000000Not Used 12 0001000000000000FC _Calibrate Set bit to “1” to initiate a Flow Control Calibrate input

(momentary) 13 0010000000000000Gun_Trigger Set bit to “1” to indicate the gun is actually triggered

(maintain while gun is triggered, remove when gun is

closed) 14 0

100000000000000Reset_Alarm Set bit to “1” to clear an active Alarm (momentary)

15 1000000000000000Remote Stop Set bit to remotely stop unit (momentary)

NOTE: Shaded cells relate to the flow charts on pages 23-26.

312785C 27

Modbus and I/O Data

Table 2: ProMix 2KS Digital Outputs (Modbus Register 40041)

Bit Digital Input Binary Name Details

0 000000000000000

1 Purge_CC_Active “1” indicates Purge or Color Change is in prog-

ress 1 00000000000000 2 0000000000000

10Mix_Active “1” indicates Mix is in progress

100Mix_Ready “1” indicates No Alarms and OK to Mix

3 0000000000001000CC_Fill_Active “1” indicates the Fill portion of a Color Change is

in progress 4 0000000000010000FCalActive “1” indicates the Flow Control Calibrate routine is

in progress 5 0000000000100000Flow_Rate_Alarm “1” indicates the Flow Rate Alarm/Warning is

active 6 0000000001000000Special_1 “1” indicates the Special_1 output is on (monitor

only) 7 0000000010000000Special_2 “1” indicates the Special_2 output is on (monitor

only) 8 0000000100000000Special_3 “1” indicates the Special_3 output is on (monitor

only) 9 0000001000000000Special_4 “1” indicates the Special_4 output is on (monitor

only) 10 0000010000000000Not Used 11 0000100000000000Not Used 12 0 0 0

1000000000000Alarm_General “1” indicates a General Alarm is in process. (If

Mix_Active is still High, then a Warning only.) See

ProMix 2KS Active Alarms (Modbus Register

40010) on page 29 for details on type.

13 0010000000000000Alarm_Potlife “1” indicates a Potlife Alarm is in process.

NOTE: Shaded cells relate to the flow charts on pages 23-26.

28 312785C

ProMix 2KS Active Alarms (Modbus Register 40010)

Table 3: ProMix 2KS Active Alarms (Modbus Register 40010)

Bit Digital Input Binary Name Details

Low Byte: 0 0000 0000 0000 0000 No Bits Set No Active Alarms Low Byte: 0 0000 0000 0000 0001 Comm_Error Low Byte: 0 0000 0000 0000 0010 Potlife_Alarm Low Byte: 0 0000 0000 0000 0100 Ratio_High_Alarm Low Byte: 0 0000 0000 0000 1000 Ratio_Low_Alarm Low Byte: 0 0000 0000 0001 0000 Overdose_A_Alarm Low Byte: 0 0000 0000 0010 0000 Overdose_B_Alarm Low Byte: 0 0000 0000 0100 0000 Dose_Time_A_Alarm Low Byte: 0 0000 0000 1000 0000 Dose_Time_B_Alarm Low Byte: 0 0000 0001 0000 0000 Mix_In_Setup_Alarm Low Byte: 0 0000 0010 0000 0000 Remote_Stop_Alarm Low Byte: 0 0000 0100 0000 0000 Purge_Volume_Alarm Low Byte: 0 0000 1000 0000 0000 CC_Comm_Error_Alarm Low Byte: 0 0001 0000 0000 0000 High_Flow_Alarm Low Byte: 0 0010 0000 0000 0000 Low_Flow_Alarm Low Byte: 0 0100 0000 0000 0000 System_Idle_Alarm Low Byte: 0 1000 0000 0000 0000 Setup_Change_Alarm High Byte: 0 0000 0000 0000 0001 Power_On_Alarm High Byte: 0 0000 0000 0000 0010 Defaults_Loaded_Alarm High Byte: 0 0000 0000 0000 0100 IO_Alarm High Byte: 0 0000 0000 0000 1000 Purge_Initiate_Error High Byte: 0 0000 0000 0001 0000 Material_Fill_Alarm High Byte: 0 0000 0000 0010 0000 Tank_A_Low_Alarm High Byte: 0 0000 0000 0100 0000 Tank_B_Low_Alarm High Byte: 0 0000 0000 1000 0000 Tank_S_Low_Alarm High Byte: 0 0000 0001 0000 0000 Auto_Dump_Complete High Byte: 0 0000 0010 0000 0000 Color/Catalyst_Purge_Alarm High Byte: 0 0000 0100 0000 0000 Color/Catalyst_Fill_Alarm High Byte: 0 0000 1000 0000 0000 Num_Alarm_Desc High Byte: 0 0001 0000 0000 0000 Spare3_Alarm High Byte: 0 0010 0000 0000 0000 Spare2_Alarm High Byte: 0 0100 0000 0000 0000 Spare1_Alarm High Byte: 0 1000 0000 0000 0000 Potlife_Buzzer

Modbus and I/O Data

312785C 29

Modbus and I/O Data

ProMix 2KS Modbus/TCP Variable Map

Table 4: ProMix 2KS Modbus/TCP Variable Map

EasyKey

* Read/Write

Status

Read Only 40003 Current flow rate 16 Bit cc/min 0 5000 Read Only 40004 Actual ratio 16 Bit none 0 9999 Read Only 40005 Active recipe 16 Bit none 0 60

Read Only 40006 Potlife 1 remaining 16 Bit sec 0 9999 Read/Write 40007 Job complete 16 Bit none 0 0xFFFF Read/Write 40008 Reset job total 16 Bit none 0 9

Read Only 40009 Potlife 2 remaining 16 Bit sec 0 9999

Read Only 40010 Active fault 32 Bit none 0 0xffffffff

Read Only 40032 Control version 32 Bit none 0 0xffffffff Read/Write 40040 Robot digital input 16 Bit none 0x0000 0xFFFF

Read Only 40041 Robot digital output 16 Bit none 0x0000 0xFFFF Read/Write 40046 New recipe 16 Bit none 0 60

Read Only 40048 Current fluid pressure 16 Bit psi 0 5000

Read Only 40049 V/P percent output 16 Bit % 0 100

Read Only **40056 Actual ratio reducer 16 Bit none 0 9999

Read Only 40114 Flow control option 16 Bit 0=proportioning only

Read/Write 40115 Flow setpoint data source 16 Bit 0=discrete

Read/Write 40120 Manual override percent

Read/Write 40125 Flow control range 16 Bit 0=0-300 cc/min

Read/Write 40126 Flow control tolerance 16 Bit % 0 99 Read/Write 40127 Flow control proportional

Read/Write 40128 Flow control integral gain Ki16 Bit default=40 0 9999

Modbus

1=1K flow control

(future)

2=2K flow control

3=pressure override

4=manual percent

override

1=network

16 Bit % 0 100

opening

1=0-600 cc/min

2=0-1200 cc/min

16 Bit default=400 0 9999

gain Kp

Read/Write 40129 Flow control alarm time 16 Bit sec 0 99 Read/Write 40137 Flow control setpoint 16 Bit cc/min 0 1200 Read/Write 43123 Flow control override

mode

Read/Write 43141 Flow control enable 16 Bit 0=off

* This column represents the rule that must be implemented by automation. Writing to Read Only registers must be

avoided.

** For ProMix 3KS Systems only.

30 312785C

16 Bit 0=off (normal)

1=% open

2=pressure mode

1=on

ProMix 2KS Recipe Bits

Table 5: ProMix 2KS Recipe Bits

Recipe Bits Number 543210 543210

000000 0 100001 33 000001 1 100010 34 000010 2 100011 35 000011 3 100100 36 000100 4 100101 37 000101 5 100110 38 000110 6 100111 39 000111 7 101000 40 001000 8 101001 41 001001 9 101010 42 001010 10 101011 43 001011 11 101100 44 001100 12 101101 45 001101 13 101110 46 001110 14 101111 47 001111 15 110000 48 010000 16 110001 49 010001 17 110010 50 010010 18 110011 51 010011 19 110100 52 010100 20 110101 53 010101 21 110110 54 010110 22 110111 55 010111 23 111000 56 011000 24 111001 57 011001 25 111010 58 011010 26 111011 59 011011 27 111100 60 011100 28 011101 29 011110 30 011111 31 100000 32

Recipe Bits Number

Modbus and I/O Data

312785C 31

Troubleshooting

NOTE: This section covers the most common problems

encountered while setting up, programming or using the product. Do not forget to always download in the device after changing settings in Graco Gateway.

General Troubleshooting

PROBLEM CAUSE SOLUTION

Unit screen is blank and PWR LED is off.

Unit screen is blank and PWR LED is on.

Unit continually cycles on and off. Cross-references between tags, e.g.,

Unit cycles power after an operation. Most likely a program going in an

CF LED flashing slowly. CF card corrupted or invalid. Format the card from Graco Gateway

No power applied to the unit. Check power supply. Units require 24

VDC, ± 10%.

Contrast too low (Graco Gateway only).

No primitives on the display. Add objects to the User Interface in

Backlight is off. Push one of the soft keys to turn it

Backlight tube is broken. Replace the backlight tube.

Var1 uses Var2 as maximum which in turn uses Var1 as minimum.

Database is corrupted. Create a new database or send to

endless loop.

Program one of the soft keys with the action as User Defined and the following code in the field On Pressed: dispcontrast++

Graco Gateway.

back on.

Remove one of the references or use formula tags for indirect reference, e.g., Form1 is equal to Var1 and used in Var2 minimum instead of Var1.

technical support for debugging. Check if the operation launches pro-

gram containing loops with no exit point.

using the Link > Format Flash menu.

32 312785C

Troubleshooting

PROBLEM CAUSE SOLUTION

Unit shows “Version Mismatch”. The database currently in the device

does not match Graco Gateway’s

Download the database from Graco

Gateway again. firmware version. (Message occurs after a download with a new version of C2 interrupted before the database was downloaded.)

Unit shows “Invalid Database”. The database in the device is cor-

rupted or there are no databases in

Download a database from Graco

Gateway. the device.

Values show “----” No communication with target device. See Serial Communication Trou-

bleshooting (page 36) or Ethernet

Communication Troubleshooting

(page 37).

Value does not update. The tag on the screen is not linked

correctly.

Check the tag mapping making sure

the target device (PLC, etc.) register

is correct.

Check the primitive Data Source in

the user interface in case the word

WAS is displayed. Re-link the tag in

this case.

Value shows +BIG or –BIG. Not enough digits before the decimal

point to show the number. For exam-

Increase the number of digits before

the decimal point in the tag format. ple, data is 1000.5 and format is three digits before the decimal point and one after.

Value deviates by a factor of ten. The tag format is not correct. Change the decimal point position in

the tag format.

Value is invalid. Incorrect tag type. Check if the tag type corresponds to

the data type. Is the data a floating

point number and thus the tag a real

(Pi symbol), and not an integer (X

symbol)? Incorrect data mapping. Check if the tag is accessing the cor-

rect target device register. Incorrect primitive on the display. Check if the primitive corresponds to

the tag type. For example, primitive is

a Text Integer so the tag has to be an

integer. Data received is not what’s expected.

For example, bytes reversed in the word.

Use the transform property on the tag

to modify the data source. You might

have to try multiple solutions to solve

the issue.

312785C 33

Troubleshooting

PROBLEM CAUSE SOLUTION

Symbol or image leaves a trace when animated.

The background of the image is not refreshed.

Change the primitive Fill Format to Solid color.

Add the system variable dispcount in the background of the image to force the refresh.

Rich Bar Graph or Dial Gauge does not move

Tag minimum and maximum are not setup.

Check the tag’s minimum and maximum values. These are used by both primitives for minimum and maximum.

Trend Viewer curve stuck at the bottom.

No minimum and maximum setup on the data tags displayed in the viewer.

Check that all displayed tags in the trend viewer have a Minimum and a Maximum setup.

USB Drivers location for Windows. Location of the drivers unknown. The drivers are located under Graco

Gateway 2.0\Device installation folder. For example C:\Program Files\Graco Gateway\Device.

USB Driver installation. The operating system is unable to

find the driver or the installation failed.

In your operating system device manager, check if the Graco Gateway is present. If so, uninstall that device. Follow the USB installation guide.

Upgrading Graco Gateway did not upgrade the software version.

The option selected during the upgrade was Modify instead of

Launch the upgrade again and choose Repair when prompted.

Repair.

34 312785C

Troubleshooting

Graco Gateway Messages Troubleshooting

PROBLEM CAUSE SOLUTION

Device incompatible with file. The device you are trying to down-

load into doesn’t match the database device.

Unable to open communication port. The communication port you try to

download with is unavailable:

• Cable not connected. Check if the cable is connected cor-

• Incorrect download communica-

tion port.

• Port already used. Check that the communication port is

• Target device IP address incor-

rect.

• No USB Drivers. Check that the USB drivers were

No reply from terminal. Cable is not connected. Make sure the cable is connected or

If the message appears while downloading to the device.

CompactFlash required for upgrade. The version of Graco Gateway on the

PC is different from the target device firmware version when attempting a download via Ethernet.

The window is too small to allow editing.

The device returned an unexpected reply code.

The current User interface view is too small to allow editing.

The device you are trying to download to is not supported by this version of Graco Gateway.

Create a new database file corre-

sponding to your device (File > New).

rectly to the PC and the device pro-

gramming ports (USB or PG Port).

Check that Graco Gateway is

directed to the correct communica-

tion port (Link > Options).

not used by another service or soft-

ware especially for serial ports.

If you download via Ethernet, check

the IP address of the target device in

Link > Options.

installed successfully. Reinstall

Graco Gateway USB driver under the

PC device manager if necessary.

check above solutions.

Download again with Link > Update

or F9.

Insert a CompactFlash Card in the

target device.

Use another communication port for

download: USB or Serial.

Change the panel view using View >

Panel > Display only.

Update Graco Gateway to the latest

version available (contact your Graco

distributor or Graco Technical Assis-

tance). Choose Repair when upgrad-

ing.

312785C 35

Troubleshooting

Serial Communication Troubleshooting

This section is used to troubleshoot the communication between two devices linked via serial ports, i.e. RS232 or RS485.

TIP: For communication troubleshooting, it is strongly advised to create a new Graco Gateway database including only one data tag mapped to a known register in the target device.

PROBLEM CAUSE SOLUTION

Values show “----” Port settings do not match. Check that the port settings of the

Graco Gateway device match the target device (i.e. Baud, Parity, etc.).

Incorrect target device address. Check that the target device address

in Graco Gateway (in communications on the PLC symbol) matches the target device address setup.

Incorrect cable. Check the cable part number or

cabling to match your protocol.

Incorrect communication port. Check if the cable is connected to the

correct communication port.

Values blink between the data and “----”

If the above is correct, check that the protocol settings are on the correct communication port in Graco Gateway.

Communication port connector pins bent inward.

Incorrect tag mapping. Check that the tag is mapped to an

Incorrect tag mapping on one of the tags on the display.

Communications times-out. Increase the Slave Response or

Although unlikely, check the communication port connector pins on the Graco Gateway in case some are bent inward resulting in a bad contact with the cable.

existing register in the target device. Delete tags one after another and

download in-between. When the values on the screen stop blinking, the last deleted tag was mapped incorrectly or accessed an unknown register in the target device.

Device Timeout on the communication port or target device in Graco Gateway.

36 312785C

Troubleshooting

Ethernet Communication Troubleshooting

This section is used to troubleshoot the communication between two devices linked via Ethernet.

TIP: For communication troubleshooting, it is strongly advised to create a new Graco Gateway database including only one data tag mapped to a known register in the target device.

PROBLEM CAUSE SOLUTION

Values show “----” Incorrect target device IP address. Check the target device IP address in

Graco Gateway (in communications

on the PLC symbol) to match the tar-

get device IP address setup. Incorrect cable or wrong connection. Check the LED on the Graco Gate-

way device Ethernet port. If none are

lit, there are no connections. Check

the cable or that the Ethernet port is

enabled in Graco Gateway, see

below. Ethernet port disabled. Check that the Ethernet port in Graco

Gateway is enabled. Graco Gateway and target devices

are in a different address domain:

Values blink between the data and “----”

• If no routers are present on the

network.

• If a router is present on the net-

work.

Incorrect tag mapping. Check that the tag is mapped to an

Incorrect tag mapping on one of the tags on the display.

Communications times-out. Increase the Slave Response or

Check that the target device IP

address and Graco Gateway device

IP address are different but in the

same domain. (For example, both

start with the same three first num-

bers; ex: 192.168.2.xxx if the mask is

255.255.255.0).

Check the Graco Gateway device

Ethernet port Gateway address to

match the router IP address.

existing register in the target device.

Delete tags one after another and

download in-between. When the val-

ues on the screen stop blinking, the

last deleted tag was mapped incor-

rectly or accessed an unknown regis-

ter in the target device.

Device Timeout on the communica-

tion port or target device in Graco

Gateway.

312785C 37

Troubleshooting

LED Functions

Status (STS) LED

The green Status LED provides information on the status of the Graco Gateway, including various stages of

the startup routine and any errors that occur.

Status Indication

Rapidly Flashing

Steady Graco Gateway is operating normally.

Graco Gateway is currently running the boot loader and/or being upgraded.

User Communication Ports - TX/RX LEDs

Status Indication

Green Transmitting Red Receiving

Ethernet LEDs

Status Indication

Yellow (Steady)

Yellow (Flashing)

Green 10 BASE-T Communications Amber 10 BASE-TX Communications

Link Established

Network Activity

CompactFlash (CF) LED

Status Indication

Off No CompactFlash card is present. Steady Valid CompactFlash card is present. Rapidly

Flashing Flickering Unit is writing to the CompactFlash

Slowly Flashing

* Do not turn off power to the unit while this light is

flickering. The unit writes data in two minute intervals. Later Microsoft operating systems will not lock the drive unless they need to writer data; Windows 98 may lock the drive any time it is mounted, thereby interfering with logging. Contact Graco Technical Assistance for further information.

CompactFlash card is being checked.

card, either to store data or because the PC connected via the USB port has locked the drive.*

Incorrectly formatted CompactFlash card is present.

38 312785C

System Electrical Schematic

Non-Hazardous Area

OPERATOR INTERFACE

POWER

SUPPLY

BARRIER BOARD

POWER DIST. TERMINAL BLOCKS

I/O HARNESSES

12L1

UNUSED

2 3

+24VDC

OPEN

COMMON

MEMBRANE SWITCH WITH RIBBON CABLE

DISPLAY

1 2 3 4 5 6 7 8 9 10 11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

POWER HARNESS

DISPLAY BOARD

RJ45

J10

DC OK +24 VDC

COMMON COMMON

3 4

RJ45

FLOW CONTROL CAL. (BLK)

GUN TRIGGER (WHT )

DIGITAL IN COMMON (RED)

REMOTE STOP (GRN)

ALARM RESET (BRN)

ALARM OUTPUT (BLU)

DIGITAL OUTPUT COMMON (ORG)

POT LIFE (YEL)

FLOW RATE ANALOG IN (PUR)

FLOW RATE ANALOG COMMON (GRAY)

RS485 INTEGRATION A (WHT/BLU)

RS485 INTEGRATION B (BLU/WHT)

RS485 INTEGRATION GROUND (SHIELD)

RS485 NETWORK A (WHT/ORG)

RS485 NETWORK B (ORG/WHT)

RS485 NETWORK GROUND (SHIELD)

85-250 VAC

+12VDC I/S (RED) COM (BLACK) SHIELD

SHIELD

HARNESS

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6

ALARM

RJ45

REMOTE I/O INTEGRATION BOARD

TERMINAL BLOCKS

System Electrical Schematic

NON-HAZARDOUS AREA

LINE FILTER

OPEN

L1 N GND

GND LUG

2 3

POWER

ROCKER

SWITCH

1B 2A 2B

CABLE

(50' STD.)/

(100' OPTION)

MIX INPUT

PURGE INPUT

JOB COMPLETE INPUT

EXTERNAL CLR CHG READY

RESET ALARM INPUT

DIGITAL INPUT COMMON

RECIPE BIT 0 INPUT

RECIPE BIT 1 INPUT

RECIPE BIT 2 INPUT

RECIPE BIT 3 INPUT

RECIPE BIT 4 INPUT

RECIPE BIT 5 INPUT

RECIPE CHANGE INPUT

DIGITAL OUTPUT COMMON/POWER

PURGE/RECIPE CHG ACTIVE OUTPUT

MIX ACTIVE OUTPUT

MIX READY OUTPUT

FILL ACTIVE

FLOW CAL. ACTIVE

FLOW RATE ALARM OUTPUT

DIGITAL OUTPUT COMMON/POWER

SPECIAL OUTPUT #1

SPECIAL OUTPUT #2

SPECIAL OUTPUT #3

SPECIAL OUTPUT #4

DIGITAL OUTPUT COMMON/POWER

L1 N GND

(+24) YEL

(COM) GRAY

ORG BRN

RED

TERMINAL BLOCK

L1 N GND

BEACON

GND N L1

85-250 VAC

L1 N

CABLE

FO IN (BLK)

FO OUT (BLU)

RJ45

RJ45 BULKHEAD

3' (25'-200' OPTIONS)

RJ45

WEB SERVER

RJ45

MODULE

312785C 39

Parts

15V331 Gateway Ethernet Kit (shown)

15V963 Gateway DeviceNet Kit

15V964 Gateway Profibus Kit

Ref. No. Part No. Description Qty

1 15V339 PANEL, back 1 2 15T752 COVER 1 3 n/a DIN RAIL 1 4 120369 POWER SUPPLY, 24 Vdc 1 5 15V345 GROMMET, cable entry 2 6 111987 CONNECTOR, strain relief 1 7n/aWIREWAY 1 8▲ 186620 LABEL, ground 1 9 n/a COVER, wireway 1 10 CONTROL BOX, Gateway 10a 15V966 BOX, DeviceNet; includes

items 20a, 23, and 27; used on 15V963 Kit only

10b 15V965 BOX, Profibus; includes items

20b, 23, and 27; used on 15V964 Kit only

10c 15X492 BOX, ethernet; includes items

23 and 27; used on 15V331 Kit only

Ref. No. Part No. Description Qty

11 120838 BLOCK, clamp end 2 12 103833 SCREW, machine 4 13 112443 BLOCK, terminal, ground 1 14 15V344 CONNECTOR 1 15 121994 CABLE, CAT 5 1 16 121700 CABLE, 2 connector 1 17 n/a WIRE, copper, 16 ga.; 9 in.

(230 mm)

18 n/a WIRE, copper, 16 ga; 9 in.

(230 mm)

20a 15V347 CARD, DeviceNet; 15V963 Kit

only

20b 15V346 CARD, Profibus; 15V964 Kit

only 23 15T999 CABLE, USB; not shown 1 25 n/a SCREW, machine, serrated

hex-head 27 258527 CD ROM, software, Gateway;

not shown

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

Parts labeled n/a are not available separately. NOTE: All brand names or marks are used for identifica-

tion purposes and are trademarks of their respective owners.

40 312785C

Parts

Screw Location

(item 25)

USB Port

(ref item 23)

10a, b, or c 20a or b

7, 9, 121, 2

1314

TI12930a

DRRJ45 Network Terminals

12345678shsh

123

ASHB

ProMix 2KS EasyKey

RS485 Network Terminals

TI12931a

To 4

Wiring Diagrams

TI12929a

To 1 0

TI12932a

312785C 41

Appendix A: DeviceNet™ Slave Communication

Overview

This appendix describes the Gateway’s support for DeviceNet and details the configuration steps necessary to use this feature. It does not provide a detailed description of DeviceNet, but only a brief introduction, necessary to define the terms that are used throughout the remainder of this document.

Introduction

DeviceNet is a low-level network using the Controller Area Network (CAN) technology, to provide communication between a range of industrial devices, from simple devices such as sensors and actuators, to high-level devices such as controllers and HMIs.

DeviceNet Port Protocols

The DeviceNet option card has one DeviceNet port. See F

IG. 30. The port may be configured for various Devi-

ceNet protocols. Contact Graco Technical Assistance for currently supported protocols.

• CAN_H

Position 4 of the pluggable connector provides the CAN_H bus line (active high). This terminal is isolated from the Graco Gateway.

• V+ (optional 24 Vdc)

Position 5 of the pluggable connector is provided for optional 24 Vdc connections. This position is available only to tie 24 Vdc wires together. The DeviceNet option card neither provides or uses 24 Vdc power through this connection. The V+ position is not connected to any circuitry internal to the DeviceNet option card or Graco Gateway.

Also see Appendix A: DeviceNet

cation on page 42.

™

Slave Communi-

DeviceNet Option Card Pin Outs

• V-

Position 1 of the pluggable connector provides a CAN ground connection. This terminal is isolated from the Graco Gateway.

• CAN_L

Position 2 of the pluggable connector provides the CAN_L bus line (active low). This terminal is isolated from the Graco Gateway.

• DRAIN (optional)

Position 3 of the pluggable connector is provided for optional drain connections. This position is available only to tie drain wires together or to earth ground. There is no internal connection to earth ground. The DRAIN position is not connected to any circuitry internal to the DeviceNet option card.

42 312785C

LED

Appendix A: DeviceNet™ Slave Communication

V-

CAN_L

DRAIN

CAN_H

V+

TI13963a

PLC Connection

DeviceNet

Option Card

FIG. 30: DeviceNet Port Pin Outs and PLC Connection

XCDN

NET STS

V-

CAN_L

DRAIN

CAN_H

V+

TI13962a

312785C 43

Appendix A: DeviceNet™ Slave Communication

About DeviceNet

DeviceNet is a connection-based network. In this context the term connection refers to a communication path between two or more devices, and not the physical (cable) connection to the DeviceNet network. A connection must be established between two devices in order to transfer data.

There are two types of connection defined by the DeviceNet specification. Each has different characteristics and is suited to a specific type of communication.

• I/O Connection – Dedicated data transfer between

a producer and one or more consumers. The format of the data is known or implied by the connection.

• Explicit Messaging – Generic multi-purpose mes-

saging connection, typically command and response message commands.

Each connection type has an extensive number of parameters, which can affect the characteristics of the communication path. For many Master/Slave communications scenarios, a defined set of connections, together with their respective parameter settings exist under the collective name Predefined Master/Slave Connection Set. Many of the steps involved in creating and configuring a connection have been removed with this connection set, thus simplifying the network configuration.

• I/O Poll Connection: The Poll connection is an I/O connection over which Poll command and response messages are transferred. The Poll command is transmitted by the master, and is directed to a single slave device. The slave device in turn responds with a Poll response message. Both the Poll command and Poll response messages can contain any number of bytes.

• I/O Data Connection: The I/O Data connection is part of the Predefined Master/Slave Connection Set, but instead is included for devices, which support creating I/O data connections via the UCMM (Unconnected Message Manager).

Level of Support

The Gateway provides Group 2 Server level support: A UCMM capable device that is configured to act as a

Slave for the Predefined Master/Slave connection set.

Predefined Master/Slave Connection Set

The DeviceNet specification details a number of connections that facilitate data transfer between a Master and Slave devices. The following sections detail the connection types supported by the Gateway.

• I/O Bit-Strobe Connection: The Bit-Strobe connec- tion is an I/O connection over which Bit-Strobe I/O command and response messages are transferred. The Bit-Strobe command is broadcast by the Master device and is received by all slave devices simultaneously. The command message contains a single bit of information for each slave on the network. Each slave device is required to respond with a BitStrobe response message. The response message can contain up to 8 bytes of information.

44 312785C

Appendix A: DeviceNet™ Slave Communication

Hardware

To use DeviceNet on the Gateway, an option card must first be installed. The option card provides the hardware necessary to support the CAN physical layer specification as required by the DeviceNet standard.

Configuring the option card is a two-stage process; first the option card must be selected in Gateway (DeviceNet Option Card), and then the ‘DeviceNet Predefined Group 2 Server Driver’ configured to run on the newly created DeviceNet Interface port.

Gateway Configuration

The following example requires use of an Allen Bradley 1756-ControlLogix PLC, along with RSLogix 5000 and RSNetWorx for DeviceNet software and a Gateway.

Configure the Gateway DeviceNet Option Card

Install the Gateway DN0000 option card in the Gateway as per the provided instructions.

Click on File>New to create a new Gateway database and select Gateway Series HMI – Gateway 10.

Enter the Communications section. In the tree on the left, select Gateway from the top of the tree. Select the Edit button at the right, and select the DeviceNet Option

Card from the dialog box as shown in F

IG. 31. Click OK.

IG. 31: Select DeviceNet Option Card

312785C 45

Appendix A: DeviceNet™ Slave Communication

The DeviceNet Option card appears at the end of the tree. Select the DeviceNet Interface from under the DeviceNet Option Card item.

IG. 32: Select DeviceNet Server

On the right hand pane, click on the Edit button to open the driver picker dialog box. Select the DeviceNet Pre-

defined Group 2 Server driver. F

IG. 32.

Set the appropriate Station Address, Baud Rate, and I/O Poll Size. Make sure the Data Format Settings are set to Transform: Swap Bytes In Word. F

IG. 33.

46 312785C

IMPORTANT NOTE: The I/O Polled Size is determined by the settings in both the DeviceNet Master and the registered .EDS file for the Gateway. To change these settings, see Automatic Update of the EDS File on

page 51 before setting up the PLC.

Appendix A: DeviceNet™ Slave Communication

IG. 33: Device Settings

312785C 47

Appendix A: DeviceNet™ Slave Communication

Create Gateway Blocks

Select the DeviceNet device from the tree at the left, and add two Gateway Blocks; one for Read Data and one for Write Data, using the Add Gateway Block button on the

right hand pane.

IG. 34: Add a Gateway Block

Select the first Gateway Block and select the Edit button at the right.

Set the block for I/O Polled Command Data, starting at element PollC 00000. F

IG. 35.

48 312785C

NOTE: For 16-bit support, select Word as Word. For 32-bit support, select Word as Long. The latter is recommended as DeviceNet uses 32 bits integer addressing.

Set the block size for 4, and the Direction for: Device To Gateway. This will be the Read Data block.

Appendix A: DeviceNet™ Slave Communication

IG. 35: Select Data Type (Word as Long)

312785C 49

Appendix A: DeviceNet™ Slave Communication

Select the second Gateway Block and set it up for I/O Polled Response Data 00000, with a length of 4, and the Direction Gateway To Device. This will be the Write Data Block. F

IG. 36 shows both Gateway blocks once com-

pleted.

IG. 36: DeviceNet Block Mapping

NOTE: Read and Write are from the Gateway point of

view. This means the master can send data in Block A, so the Gateway can read data. On the other hand, the master can only pull data from Block B, so the Gateway can only write data.

The addressing scheme available is outlined below:

BitC – Identifies the I/O Bit-Strobe command data (Master to Slave).

BitR – Identifies the I/O Bit-Strobe response data (Slave to Master).

PollC – Identifies the I/O Poll command data (Master to Slave).

PollR – Identifies the I/O Poll response data (Slave to Master).

DataC – Identifies the I/O Consumed Data (Master to Slave).

DataP – Identifies the I/O Produced Data (Slave to Master).

50 312785C

Automatic Update of the EDS File

Appendix A: DeviceNet™ Slave Communication

DeviceNet nodes use an EDS (Electronic Data Sheet) to describe the communications parameters available at each device on the DeviceNet network.

By design, each DeviceNet master can handle a maximum of 124 Input words and 123 Output words. In the default EDS file for the Gateway, the Input and Output data sizes are set at 16 bytes each. This equates to four words of data input and four words of data output. These values can be set higher, but it is important to note that if the default values are set higher, they might conflict with other DeviceNet implementations.

Gateway provides an EDS file generator tool to create a file that matches your Gateway settings. This file can therefore be used to configure the Master.

To generate this file, enter the Communications module and select the DeviceNet interface on the left. Under the Electronic Data Sheet, select Yes in Synchronize and choose the path and name where the file should be saved using the Browse button. F

IG. 37.

IG. 37: Automatic EDS Update

Saving the database using the File>Save command will synchronize and therefore update the EDS file.

Each time EDS parameters are modified, the EDS file will need to be re-registered within RSNetWorx for DeviceNet. These changes will also need to be reflected in the following locations:

• RSNetWorx master node Scanlist, Input Table, and Output Table

• ControlLogix PLC DeviceNet Scanner configuration

312785C 51

NOTE: Inputs and Outputs are with respect to the master, therefore inputs refer to data sent from the slave and read by the master.

Appendix A: DeviceNet™ Slave Communication

Configure the RSNetWorx for DeviceNet Software

RSNetWorx for DeviceNet is used to set up and manage a DeviceNet network. To begin the configuration, launch RSNetWorx for DeviceNet from your development PC.

Start a new network by selecting: File>New>DeviceNet Configuration.

Tools>EDS Wizard>Register an EDS file(s).

Make sure that the .EDS file validation is successful.

FIG. 40: EDS Validation

If desired, select a new image file to represent the Gateway.

IG. 38: Register the EDS File

Select Register a single file, and browse to the location where you saved the Gateway.EDS file.

IG. 39: Browse to Graco Gateway EDS File

IG. 41: EDS Image File

52 312785C

Appendix A: DeviceNet™ Slave Communication

Review the EDS registration, and finish the process.

IG. 42: Review EDS Registration

Select the DeviceNet Master by navigating in the tree on the left hand side. Navigate to: DeviceNet>Category>Communication Adapter>1756-DNB/A. Select the appropriate Major Rev and drag it into the network workspace at the right.

Select the Gateway Slave by navigating in the tree on the left. Navigate to: DeviceNet>Vendor>Graco Controls>Generic Device. Select the Gateway-SERVER and drag it into the network workspace at the right.

Configure the master to add the slave device to the scanlist. Right click the DNB module and select properties.

From the Scanlist tab, select the Gateway-SERVER from the Available Devices pane, and add it to the Scan-

list pane. Select the Edit I/O Parameters button.

FIG. 43: Configure the DeviceNet Master

312785C 53

Appendix A: DeviceNet™ Slave Communication

Make sure that the Strobed or Change of State boxes are not selected. In the Polled section, verify that the Input and Output sizes are 16 bytes. These must match the I/O Poll Size selections made above in the Gateway. In DeviceNet networks, 4 bytes constitute a full word. Therefore the 16 bytes selection represents 4 full words of addressable 32-bit data.

Select the Input tab. Verify that the four words of Gateway-SERVER data are mapped to YourDNBSlot:I.Data[0…3]. From the Output tab, verify that the four words are mapped to YourDNBSlot:O.Data[0…3].

Apply the changes, and save your RSNetWorx for DeviceNet configuration.

IG. 44: Apply and Save

54 312785C

Appendix A: DeviceNet™ Slave Communication

Configure the Allen Bradley ControlLogix PLC

Allen Bradley ControlLogix PLCs are programmed with RSLogix 5000 programming software. To begin the DeviceNet configuration, launch RSLogix 5000 from your development PC.

Create a ControlLogix program containing a valid DeviceNet Scanner. In this application a 1756-DNB was

used.

IG. 45: Create Valid DeviceNet Scanner

312785C 55

Appendix A: DeviceNet™ Slave Communication

Configure the DeviceNet Scanner to be address 0. Make sure to set up the 32-bit Input and Output memory spaces for a size of 32 (to match the configuration made above in both Gateway and RSNetWorx for DeviceNet).

Select the RSNetWorx tab, and navigate to the RSNetWorx for DeviceNet configuration that you have previously created. Open the configuration from here and

download it to the network.

IG. 46: Main Task Tree

In the Main Task tree, open the Main Routine Ladder Logic file. Create a rung of ladder to enable the DeviceNet network. The required output is always:

Local:YourDNBSlot:0.CommandRegister.Run

Create a few rungs by taking the DeviceNet Input data, Local:2:I.Data[0…3], and adding 1 to them. Store the results in Local:2:O.Data[0…3]. Based on the configuration in the Gateway, if values are changed on the Gateway Write tags, the Read tags will display the respective values, plus one.

Save and download this configuration to the ControlLogix PLC.

56 312785C

Wire the DeviceNet Network

All DeviceNet networks require a termination resistor at the two end nodes on the network. Place a ¼ watt 120 ohm resistor between CAN H (White) and CAN L (Blue) of the DeviceNet connection.

Appendix B: Profibus™ DP Slave Communication

Overview

This appendix describes the Gateway’s support for Profibus DP and details the configuration steps necessary to set up a Graco Gateway with an S7300 PLC, CPU315-2DP via Profibus. It does not provide a detailed description of Profibus, but only a brief introduction, necessary to define the terms that are used throughout the remainder of this document.

Introduction

Profibus DP stands for “Profibus for Decentralized Peripherals”. Profibus DP is a device level bus that supports both analog and discrete signals. It has widespread usage for such items as remote I/O systems, motor control centers, and variable speed drives. Profibus DP communicates at speeds from 9.6 Kbps to 12 Mbps over distances from 100 to 1,200 meters.

The protocol supported by the Profibus DP option card is Profibus DP Slave. Therefore, the Graco Gateway must be linked to a Profibus network with a PLC.

Profibus Port Protocols

The Profibus option card has one Profibus port. See F

IG. 47.

™

Also see Appendix B: Profibus cation on page 57.

DP Slave Communi-

Profibus Option

IG. 47: Profibus PLC Connection

PLC Connection

Card

TI13964a

312785C 57

Appendix B: Profibus™ DP Slave Communication

About Profibus DP

Profibus DP communication takes the form of block exchange. Profibus blocks are made of memory bytes where 2 bytes make a word and 4 bytes a double word, or Dword.

A block is a range of consecutive byte addresses and is unidirectional. This means the PLC will exchange data read only and write only blocks with DP slave units. Addresses in each device are independent and only relevant to the device for its own program. For example, the address range for the first block in the master can start at 256 with a 64 words block length and could result in the slave with a range starting from 0 with 64 words length.

However, since blocks are consecutive, this means the first block start address, in the above example 256, will be the slave start address 0. Then, 257 in the master would be 1 in the slave, and so on.

Block length can be defined in bytes, words, or double words. Since start addresses between the master and the slave can be different, one could give its start address and length in bytes, and the other in words.

For example, the master start address is byte 256, with a 64 words block length.

• This results in a range from byte 256 up to byte 383. The slave start address is word 0, with a 64 words block length.

• This results in a range from word 0 to word 63. F

IG.

48 illustrates this exchange.

NOTE: Do not forget that the Input block is independent from the Output block, and although the address range is the same, the data are different.

NOTE: F

IG. 48 has no connection with the Input Block

and Output Block in Graco Gateway. The terminology used in the tags configuration is from the PLC point of view (DP Master). Refer to Graco Gateway Setup for more information.

byte 256 to byte 383

IG. 48: Master/Slave Exchange

DP Master

Output Block

Input Block

DP Slave

Input Block

word 0 to word 63

Output Block

word 0 to word 63

58 312785C

Appendix B: Profibus™ DP Slave Communication

Setup the PLC

The Siemens Simatic Manager software is used to set up the S7300 PLC. The following figures and explanations are extracted from this software.

Install the GSD file

The first step is to install the GSD file so Simatic is able to map data blocks to our device. Contact Graco Technical Assistance for Profibus GSD files.

Start Simatic Manager and open or create a new PLC project. Select the Simatic 300 Station in the navigation pane as shown in F

IG. 49.

IG. 49: Select Simatic 300 Station

Double-click Hardware in the right hand window. This will start the HWConfig where most of the work is done. The HWConfig shows the current PLC hardware configuration. Close this configuration (NOT HWConfig) and choose Options>Install GSD File… F

FIG. 50: Install the GSD File

IG. 50.

312785C 59

Appendix B: Profibus™ DP Slave Communication

Click Browse to select the folder were the GSD file downloaded previously is, select the file and click Install. F

IG. 51.

Once the GSD file is installed successfully, the PLC hardware setup can be opened again by doing Station and selecting the latest opened file which should be number 1.

If this is a new project, configure your PLC with the right modules.

IG. 51: Browse to GSD File

60 312785C

Setup the Profibus Network

Appendix B: Profibus™ DP Slave Communication

The following steps show how to set up the Profibus DP network. Skip these steps if your PLC application already possesses a Profibus DP network.

In the floating window that represents the PLC, double click the DP area to open the properties window as shown in F

IG. 52.

IG. 52: DP Properties Window

312785C 61

Appendix B: Profibus™ DP Slave Communication

In the General tab, click the properties button to open the Profibus properties. F

IG. 53: Open Profibus Properties

IG. 53.

In the properties window, go to the Parameters tab and click on the New button to create a new network. F

IG.

54.

FIG. 54: Create a New Profibus Network

62 312785C

Select the Network Settings tab and choose the Transmission Rate that fits the application. In this example, it will be 12 Mbps. The profile should be DP. F

IG. 55: Set Transmission Rate

IG. 55.

Appendix B: Profibus™ DP Slave Communication

Close the popup windows by clicking OK. HWConfig should now show the Profibus DP master system next to the PLC. F

IG. 56.

FIG. 56: Profibus DP Master System

312785C 63

Appendix B: Profibus™ DP Slave Communication

Add the Graco Gateway to the Profibus Network

To add the Graco Gateway to the Profibus network, drag the Gateway Profibus Card from the Catalog navigation situated on the right hand side of HWConfig to the Profibus DP Master System. The card is situated under Profibus DP>Additional Field Devices>MMI.

In the properties window that popped up, select the Profibus address the Gateway will take on the network. This address should be unique. In this example, the Gateway will take address 5. F

IG. 57. Click OK.

IG. 57: Add Graco Gateway to Profibus Network

64 312785C

Appendix B: Profibus™ DP Slave Communication

The Gateway is now on the Profibus DP network and selected. HWConfig shows the slots available under the Gateway to configure the data blocks to exchange.

Just drag and drop one of the data blocks available under the Gateway Profibus Card in the slot number 1. Simatic will automatically assign a start address (byte number) in the respective Input and output columns depending of the block type chosen. In this example, 64 words in and 64 words out.

More blocks can be inserted in the following slots to fit your application. F

IG. 58 shows an example with a 16

words input block in slot 2 and 5 words output block in slot 3. Addresses are given automatically but can be edited by the user.

NOTE: If the starting address for a block in slot 2 or above changes and creates a gap in the address range, it will not affect the Gateway blocks, as all data are consecutive. It is however advised to keep the addresses consecutive to facilitate development.

IG. 58: Configure Data Blocks

Save the configuration and download it to the PLC.

NOTE:

• The maximum number of input bytes allowed is

244.

• The maximum number of output bytes allowed is 244.

• The maximum number of bytes overall is 436.

312785C 65

Appendix B: Profibus™ DP Slave Communication

Graco Gateway Setup

Once the PLC is setup, the Gateway can be programmed to fit its configuration.

NOTE: For a Gateway to communicate on Profibus DP, a Profibus Option card has to be fitted in the unit. Refer to the device manual to find the proper option card and installation procedure.

Setup the Profibus Communication

Enter the communication module and select the Gateway. On the right hand pane, click the Edit button to select the Option card. Select Profibus Option card and click OK. F

IG. 59.

IG. 59: Select Profibus Option Card

66 312785C

The option card appeared in the communication tree. Select the Profibus Interface and click the Edit button to select a driver. Click OK to pick the Profibus DP driver. F

IG. 60.

Appendix B: Profibus™ DP Slave Communication

IG. 60: Select Profibus Server

Graco Gateway now displays the driver settings where the Station Address can be changed. This address is the Gateway address on the Profibus network. In our example, this address is 5 as setup in the PLC earlier.

NOTE: There are no Baud Rate settings as the Profibus option card detects the transmission rate automatically.

A device called PLC1 is now displayed under the Profibus Interface. This device represents the Profibus Master and can be renamed to fit the application. In this example, the name PLC1 remains. F

IG. 61.

FIG. 61: Block Settings

312785C 67

Appendix B: Profibus™ DP Slave Communication

Setup Tags

Once the communication is set up, tags can be created to access the PLC blocks. This is where the section Setup the Profibus Communication, page 66, is important.

First, create a variable that correspond to the data type required. In this example, an integer. F

IG. 62.

IG. 62: Create a Variable

Select the variable and rename it eventually. Then, click on Internal next to mapping on the right hand side pane, and select PLC1, which is the Profibus Master. F

IG. 63.

Select PLC1 from pulldown menu

FIG. 63: Variable Properties

68 312785C

Appendix B: Profibus™ DP Slave Communication

In the popup window, select the block type required. Two choices are available:

• Input block: The terminology input is from the Siemens perspective. Therefore this will be a block the Gateway will write to. The tag mapped to an input block has to be set up as Write Only.

• Output block: The terminology output is from the Siemens perspective. Therefore this will be a block the Gateway will read from. The tag mapped to an output block has to be set up as Read Only.

• Select the data offset, which points the address to read or write in the block. Select the data type to read or write. This defines how many bytes to access in the block to get the correct data. In this example we choose output block, with data offset 0 (Which points to 256 in the PLC) and as a Word. F

IG. 64.

IG. 64: Select Block Type

NOTE: Since the output block is a reading block from

the Gateway standpoint, this variable should be set up as Read Only as shown in Fig. 19. The same rule applies if the block is an input block, it should be set up as Write Only.

To avoid mistakes, the mapping shows with an R or W for output or input block respectively. F

IG. 65.

FIG. 65: Properties of Variable

312785C 69

Appendix B: Profibus™ DP Slave Communication

How Addressing Works

PLC addressing is in byte and uses the scheme shown in F

IG. 66.

Byte 0

Word 0

Byte 1

Dword 0

Byte 2

Word 2

Byte 3

Byte 4

Word 4

Byte 5

Dword 4

Byte 6

Word 6

Byte 7

Byte 8

Word 8

Byte 9

Note how a Dword or word address starts at the address of the first byte included in it.

The Gateway addressing follows a different scheme, as shown in F

IG. 67.

This means that the address number will be different when accessing words or Dwords in the Gateway data tags than the PLC. Table 6 shows the address relation-

ship for integer tags mapped as word in the Gateway.

Byte 0

Word 0

Byte 1

Dword 0

Byte 2

Word 1

Byte 3

Byte 4

Word 2

Byte 5

Dword 1

Byte 6

Word 3

Byte 7

Byte 8

Word 4

Byte 9

IG. 66. PLC Addressing Scheme

Block Type

64 words in, 64 words out 256...383 256...383 0...63 0...63

16 words in 384...415 - 64...79 -

5 words out - 384...393 - 64...68

Here, the word or Dword addresses follow the normal numeric increment and are not directly related to the word or bytes they are composed of.

IG. 67. Gateway Addressing Scheme

Table 6: Addressing Relationship

PLC Gateway

Input (bytes) Output (bytes) Input (words) Output (words)

70 312785C

Useful Formulas

The following formula can be used to find the byte num- ber from a word address:

ByteAddress = PLCOffset + (WordAddress x 2), where:

• ByteAddress is the address we are looking for in the PLC

• PLCOffset is the first byte number in the complete block mapping in the PLC, here 256

• WordAddress is the address mapped in the Gateway. So, for example, word 77 in the Gateway, would start at byte 410 in the PLC, and so would be composed of byte 410 and 411.

The following formula can be used to find the byte num- ber from a Dword address:

ByteAddress = PLCOffset + (DWordAddress x 4), where:

Appendix B: Profibus™ DP Slave Communication

• ByteAddress is the address we are looking for in the PLC

• PLCOffset is the first byte number in the complete block mapping in the PLC, here 256

• DwordAddress is the address mapped in the Gateway. So, for example, Dword 14 in the Gateway, would start at byte 312 in the PLC, and so would be composed of byte 312, 313, 314 and 315.

NOTE: For the formula to work, all the blocks in the PLC Profibus configuration for the Gateway have to be consecutive. F

IG. 57.

312785C 71

Appendix C: Graco Gateway to ControlLogix via Ethernet IP

Overview

This appendix describes the configuration steps necessary to establish a communication path between the Graco Gateway and a ControlLogix unit. You will need either a 1756-ENET/B or a 1756-ENBT/A together with a Logix5550 controller. It may be possible to upgrade a 1756-ENET/A to the required 1756-ENET/B by flashing the firmware; you should check the hardware version with your vendor before hand to ensure its suitability. You will also need Rockwell Software’s RSLinx and RSLogix 5000 software configuration utilities.

Introduction

In the following example, the ControlLogix will establish a Class1 connection and I/O data will be exchanged between the ControlLogix and the Graco Gateway terminal. The network parameters used in this example will almost certainly not apply to your application. Be sure to consult your network administrator when selecting appropriate values.

TI15057a

Ethernet Connection to PLC

IG. 68: Ethernet PLC Connection

72 312785C

Appendix C: Graco Gateway to ControlLogix via Ethernet IP

ControlLogix Configuration

1. Run the RSLogix 5000 program and create a new configuration.

2. Add a 1756-ENET/B or a 1756-ENBT/A to your I/O configuration. You will need to:

a. Switch to offline mode.

b. Right click on the I/O Configuration node in the

Controller Organizer view and choose Add Module.

c. In the Select Module Type window, choose

1756-ENET/B or 1756-ENBT/A entry. RSLogix will open the Module Properties window. See F

IG. 69.

d. Enter the IP Address of the ENET/B or ENBT/A

interface.

e. Click Finish to add the interface to your I/O con-

figuration.

f. Download the configuration.

g. Switch to online mode and open the

1756-ENET/B or 1756-ENBT/A node properties under the I/O Configuration in the Controller Organizer.

h. Select the Port Configuration Tab from the Mod-

ule Properties window. See F

IG. 70.

i. Enter the IP Address and Subnet Mask. The IP

Address must match the IP Address entered in the Properties window (F

IG. 69).

j. Apply the settings using the Set button.

k. You can now verify the network module network

communications with your unit using suitable diagnostic tools such as Ping.

3. Add the Graco Gateway to the RSLogix configuration as follows:

a. Switch to offline mode.

b. Right click on the 1756-ENET/B or

1756-ENBT/A node under the I/O Configuration in the Controller Organizer view and choose Add Module.

c. In the Select Module Type window, choose

Generic Ethernet Module. See F

IG. 71.

d. Click OK. This will open the Module Properties

window. See F

IG. 72.

IP Address

Finish Button

IG. 69. Ethernet Module Properties

312785C 73

Appendix C: Graco Gateway to ControlLogix via Ethernet IP

IP Address

Subnet Mask

FIG. 70. Port Configuration Window

Set Button

IG. 71. Ethernet Module Selection

74 312785C

Appendix C: Graco Gateway to ControlLogix via Ethernet IP

e. In the Name field, enter a descriptive name to

identify the module. See F

IG. 72.

f. In the Address/Host Name field, enter the IP

Address of the Graco Gateway.

g. Enter 2 in the Input Assembly Connection Point

and a size of 2. This will match a read only Slave Gateway block configured in the Gateway, and will be used for reading data from the Gateway to the ControlLogix.

h. Enter 3 in the Output Assembly Connection

Point and a size of 2. This will match a read/write Slave Gateway block configured in the Gateway, and will be used for writing data from the ControlLogix to the Gateway.

i. Enter 1 in the Configuration Connection Point

and a size of 0. Configuration data is not supported by the Gateway.

j. Press Finish to add the Gateway to the I/O con-

figuration.

The connection points and sizes are arbitrary, as long as the connection point, size, and direction are matched in the configuration of the Gateway.

Connection point direction is always relative to the originator, which in the case of the current Gateway Ethernet/IP implementation is always the device and never the Gateway. An input connection therefore specifies data flow from the Gateway to the device, and an output connection specifies data flow from

the device to the Gateway.

IG. 72. Ethernet Module Properties

312785C 75

Appendix C: Graco Gateway to ControlLogix via Ethernet IP

See FIG. 73. You should now see a new ETHERNET-MODULE Gateway_HMI branch of the 1756-ENET/B node in the I/O Configuration view. You should also see three new entries in the Controller Tags view:

• Gateway_HMI:I to view the input data

• Gateway_HMI:O to modify the output data

• Gateway_HMI:C to view the configuration data

4. Download the new I/O configuration to the controller. Once the download is complete, the controller will automatically establish a new Class1 connection

with the Gateway.

IG. 73. Ethernet Configuration Data

76 312785C

Appendix C: Graco Gateway to ControlLogix via Ethernet IP

Graco Gateway Configuration

1. Ethernet Settings. Set the IP Address to

192.168.2.101. This should match the Address/Host Name entered in F

2. Protocol Settings. Select the Ethernet/IP Slave

Adapter communications driver.

The ENET/B module prefixes all output data with a header containing status information about the originator’s run/idle state. With the Run/Idle Header checked, the communications driver will automatically process the header, and data will be ignored if the device is in the Idle state. With the option unchecked, extra space must be allocated in the Gateway block to receive the status information; all data is accepted regardless of the device state.

IG. 72.

3. Device Settings. A Gateway block must be created

for each connection point.

For the purpose of configuring, the data transfer terms input and output are relative to the device and not the Gateway. An input connection is therefore specified as Gateway to Device, and an output con- nection is specified as Device to Gateway.

Connection point mapping is defined in the Start Address block setting and comprises the connection point instance and a data offset. The instance must match that specified by the originator; the offset can be used to skip over data not required by the Gate-

way, useful mainly on shared connection points.

IG. 74. Ethernet Block Settings

312785C 77

Appendix C: Graco Gateway to ControlLogix via Ethernet IP

The following settings mirror the I/O settings of the ControlLogix configuration detailed earlier.

a. Input Connection Point. Create a Gateway

block configuration (see Table 7).

Table 7: Input Connection Points

Connection Point 2 Data Offset 0000 Data Type Long as Long Block Size 2 Direction Graco Gateway to Device

b. Output Connection Point. Create a Gateway

block configuration (see Table 8).

Table 8: Output Connection Points

Connection Point 3 Data Offset 0000 Data Type Long as Long

4. Data Mapping. the connection points are now configured so that: Gateway_HMI:O >> PLC1:Block1 Gateway_HMI:I << PLC1:Block2

5. Testing. Using the RSLogix5000 program, you can modify tags Gateway_HMI:O and verify they are written into Var1 and Var2, and verify changes made in the Gateway to tags Var3 and Var4 are updated in Gateway_HMI:I. Ensure the device is in the Run mode, otherwise the data transfer will be ignored by the Gateway.

Block Size 2 Direction Device to Graco Gateway

78 312785C

Dimensions

16.57 in. (420.9 mm)

4.52 in.

(114.8 mm)

15.07 in. (382.8 mm)

5.31in.

(134.9 mm)

TI12930a

8.71in.

(221.2 mm)

TI12825b

312785C 79

Dimensions

80 312785C

Technical Data

Electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Vdc, +/- 10%. 200 mA minimum without expansion card; 1

Amp maximum with expansion card fitted. Requires Class 2 or SELV rated power supply.

Communication ports

USB/PG Ports . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RS232/PG Port . . . . . . . . . . . . . . . . . . . . . . . . .

COMM Ports . . . . . . . . . . . . . . . . . . . . . . . . . . .

DH485 TXEN Port . . . . . . . . . . . . . . . . . . . . . . .

Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STS: Status LED indicates condition of Gateway module.

Memory

On-board user memory . . . . . . . . . . . . . . . . . . .

On-board SDRAM . . . . . . . . . . . . . . . . . . . . . . .

Memory card . . . . . . . . . . . . . . . . . . . . . . . . . . .

Real-time clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical accuracy is less than 1 minute per month drift. Lithium

Environmental conditions

Operating temperature range. . . . . . . . . . . . . . .

Storage temperature range . . . . . . . . . . . . . . . .

Operating and storage humidity . . . . . . . . . . . . .

Vibration according to IEC 68-2-6 . . . . . . . . . . .

Shock according to IEC 68-2-27 . . . . . . . . . . . .

Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carbon steel and stainless steel. Installation category 1, Pollu-

Power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . Removable wire clamp screw terminal block. Wire gage capac-

Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Snaps onto standard DIN style top hat (T) profile mounting rails

Weight (Gateway control box only). . . . . . . . . . . . . . 15.1 oz (456.4 g)

Adheres to USB specification 1.1. Device only using Type B connection. Format and Baud rates for each port are individually software programmable up to 115,200 baud. RS232 port via RJ12. RS422/485 port via RJ45, and RS232 port via RJ12. Transmit enable; open collector, V

mA maximum. 10 BASE-T/100 BASE-TX, RJ45 jack is wired as a NIC (Network Interface Card).

TX/RX: Transmit/Receive LEDs show serial activity. Ethernet: Link and activity LEDs. CF: CompactFlash LED indicates card status and read/write

activity.

4 Mbytes of non-volatile Flash memory. 2 Mbytes CompactFlash Type II slot for Type I and Type II cards. Used for optional database storage only.

coin cell battery; typical lifetime of 10 years at 25°C. This unit is not field serviceable. All work must be done by a qualified technician.

0 to 50°C

-30 to +70°C 80% relative humidity, non-condensing, from 0 to 50°C Operational 5 to 150 Hz, in X, Y, Z direction for 1.5 hr, 2 g’s Operational 30 g, 11 msec in 3 directions Up to 2000 m

tion degree 2.

ity: 24 AWG to 12 AWG. Torque: 4.45-5.34 in-lb (0.5-0.6 N•m).

according to EN50022 -35 x 7.5 and -35 x 1.5.

=15 Vdc, VOL=0.5 V @ 25

312785C 81

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS, MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 312785

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised 09/2011

Gateway 312785C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Graco Gateway Kits

Related Manuals

Warnings

Graco Gateway Overview

Install the Gateway Module Hardware

Location

Mounting

Grounding

Connect the Module to the EasyKey

Cabling Connections

Mount the Control on DIN Rail

Install CompactFlash® Card

Install the GracoConfig Software

System Requirements

Load the Software

Software Updates

Download the Preconfigured Database to the Gateway Module

Graco Gateway Network Communications Configuration

Startup

GracoConfig Main Page

Setup the Database

Map Data

Modbus and I/O Data

Color Change Process

Start Mix Process

Stop Mix Process

Purge Process

ProMix 2KS Active Alarms (Modbus Register 40010)

ProMix 2KS Modbus/TCP Variable Map

ProMix 2KS Recipe Bits

Troubleshooting

General Troubleshooting

Graco Gateway Messages Troubleshooting

Serial Communication Troubleshooting

Ethernet Communication Troubleshooting

LED Functions

System Electrical Schematic

Parts

15V331 Gateway Ethernet Kit (shown)

15V963 Gateway DeviceNet Kit

15V964 Gateway Profibus Kit

Appendix A: DeviceNet™ Slave Communication

Overview

Introduction

DeviceNet Port Protocols

About DeviceNet

Hardware

Automatic Update of the EDS File

Configure the RSNetWorx for DeviceNet Software

Configure the Allen Bradley ControlLogix PLC

Wire the DeviceNet Network

Appendix B: Profibus™ DP Slave Communication

Overview

Introduction

Profibus Port Protocols

About Profibus DP

Setup the PLC

Graco Gateway Setup

Appendix C: Graco Gateway to ControlLogix via Ethernet IP

Overview

Introduction

ControlLogix Configuration

Graco Gateway Configuration

Dimensions

Technical Data

Graco Standard Warranty

Graco Information