Instruction/ maintenance manual of the product 312785C Gateway
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312785C EN Instr uctions-P ar ts Gate wa y Netw ork Comm unication Kits Installation and pr ogram setup inst ructions for use with Pr oMix ® 2KS Electronic Proportioners. For pr ofessional use only . Not appr oved for use in Eur ope an explosive atmosphere locations.
2 312785C Contents Graco Gateway Kits . . . . . . . . . . . . . . . . . . . . . . . . . 3 Related M anuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Graco Gateway Overview .
Graco Gateway Kits 312785C 3 Graco Gate way Kits 15V331 Gatewa y Ethernet Kit Allows communication between ProMix 2KS and a PLC ov er an ethernet. Enables process equ ipment to read v ariables while operating, as well as control the ProMix 2KS and change setup .
Warnings 4 312785C Wa r n i n g s The f ollowing warnings are f or the setup , use, grounding, maint enance, and repair of this equipment. Th e exclama- tion point symbol ale r ts you to a gene ral warning and the hazard symbols ref er to procedure-specific risks .
Graco Gateway Overview 312785C 5 Graco Gate way Overvie w The Grac o Gate way ena bl es the ProMix 2KS to netw or k with a progr ammable logic contro ller (PLC).
Install the Gateway Module Ha rdware 6 312785C F IG . 1: Graco Gate way T ypical Instal lation TI13939a Computer ( PC) Progr ammab le Logic Controller (PLC) Graco Ga tewa y Module EasyK ey USB Cable (.
Install the Gateway Module Hardware 312785C 7 Connect the Module to the EasyKe y F IG . 1 is only a guide sho wing installation of th e Graco Gatew a y in a ProMix 2KS System; it is no t a complete system desig n, Contact your Graco dis tributor for assis- tance in designi ng a system to suit your particular needs .
Install the Gateway Module Ha rdware 8 312785C F IG . 3: EasyK ey and Module Cable Connection P oints TI12930a TI12638a 2-wire twisted pair cable , with shield wire (to Gatew ay Module) 2-wire twisted pair cable , with shield wire (to EasyK ey). See Wiring Diagrams on page 41 f or pin connections .
Install the Gateway Module Hardware 312785C 9 F IG . 4: Graco Gate way P ort Pin Outs TI13974a Green/ Amber LED RS232/PG USB/PG ETHERNET (NIC) Ye l l o w LED COMMS COMMS Expansion Po r t P ower Connect or 24 Vdc +/- 10% Common N/C Pin 6 Pin 1 Pin 6 Pin 1 Pin 8 Pin 1 F IG .
Install the Gateway Module Ha rdware 10 312785C F IG . 6: Prog ramming P or ts TI13969a Green/Amber LED RS232/PG USB/PG ETHERNET OR OR Y ellow LED F IG .
Install the Gateway Module Hardware 312785C 11 Mount the Contr ol on DIN Rail The Gatewa y cont rol mounts on a DIN rail. Tilt the con- trol and push down onto th e DIN rail, th en push in. Se e F IG . 10. A minimum clearance of 1 in. (25 mm) ab ove and below the cont rol is required to ensure adequate ventilation.
Install the GracoConfig Softw are 12 312785C Install the GracoConfig Software GracoConfig softwa re provides access to the Graco Gatew ay modu le hardw are. Th e CD provid ed contains the GracoConfig softw are (GracoConfigXXX.ex e, where the XXX represents the v ersion control number).
Install the GracoConfig Software 312785C 13 Load the Software 1. Connect the USB cab le (23, supplied) between t he USB por t on the Gate wa y module and a USB por t on y our PC . See F IG . 12. 2. F IG . 13 will appear . Select “Y es, this time only”, then click Ne xt.
Install the GracoConfig Softw are 14 312785C Download the Preconfigured Database to the Gate wa y Module Graco supplies a preconfigured database as a setup file f o r the Gatewa y, containi ng parameters which com muni- cate between the Gate wa y and the ProMix 2KS.
Graco Gateway Netw ork Communications Configura tion 312785C 15 Graco Gate way Netw ork Comm unications Configuration Star tup T o r un GracoCon fig, select the icon from the Graco f older on the Prog rams sect ion of your Star t Menu. The main page will app ear , showing the Commu- nications button.
Graco Gateway Network Communications Configuration 16 312785C Setup the Database 1. Double-click on the Communication s button to open the preconfigu red database (.gg2). The file is already setup f or ProMix 2KS. See F IG . 18. 2. See F IG . 19. Highlight Protocol 1.
Graco Gateway Netw ork Communications Configura tion 312785C 17 3. See F IG . 20. Right click on de vi ce PLC1 to rename it to something meaningful f or your system. 4. See F IG . 21 . Add as ma ny Gate wa y blocks as desired under each de vice. F IG .
Graco Gateway Network Communications Configuration 18 312785C Map Data 1. See F IG . 22. Select the bl ock f or data mapping. Click the Edit button next to the Star t Address fiel d on the right side of the windo w . The Select Address win- dow will open.
Graco Gateway Netw ork Communications Configura tion 312785C 19 3. See F IG . 23 . Click the Edit button ne xt to the Block Size field on the right side of the windo w .
Graco Gateway Network Communications Configuration 20 312785C 4. See F IG . 24. Click OK. The range of addresses will appear under t he appropriate Bloc k on the left side of the window . NO TE: In th is e x ample, a Modbus device master communicating via TCP/IP w ill hav e direct access to Modb us registers 40002 through 40008 of the Pro- Mix 2KS.
Modbus and I/O Data 312785C 21 Modb us and I/O Data See T able 4 through T ab le 5 f or Modbus register addresses an d input/output da ta. Ref erence the Discrete I/O listing of all t he inputs and outputs (see p age 30). Ensure these are fully under- stood.
Modbus and I/O Data 22 312785C F IG . 25. Start Mix Mode Pr ocess Flo w Char t Star t Mix Mode Process Is Mix Ready bit = 1? Must be Alar m Condi- tion or Active Recipe 61.
Modbus and I/O Data 312785C 23 F IG . 26. Mixing Mode Pr ocess Flo w Chart Mixing Mode Process Is Mix Active bit = 1? Chec k Alar m Condition: is Alar m_ General bit = 1? YES NO NO YES Mixing Mode is desired. PLC is polling to ensure Mixing Mo de is main- tained.
Modbus and I/O Data 24 312785C F IG . 27. Pur g e Mode Pr ocess Flow Chart Star t Is Mix Ready bit = 1? Must be Alarm Condition or Active Recipe 61. See Alarm Processing on page 26, or Star tup from Recipe 61 (see NOTE below).
Modbus and I/O Data 312785C 25 F IG . 28. Color Change Mode Pr ocess Flow Chart Process Alar m. See Alarm Processing , page 26. Color Change Process (basic) Is Purge_CC_Active bit = 1? Chec k Alar m Condition: is Alar m_ General bit = 1? YES NO NO YES Is Active Recipe = to desired recipe? (Register 40005).
Modbus and I/O Data 26 312785C Alarm Processing See F IG . 29, T able 1, T able 2 , and T able 3. F IG . 29. Alarm Pr ocessing Flow Chart Alarm Processing Is Mix Ready bit = 1? Check if P otli f e Alar m: is Alarm_ P otlif e bit = 1? YES NO NO YES An Alar m Condition has been found previously .
Modbus and I/O Data 312785C 27 NO TE: Shaded cells relate t o the flo w char ts on pages 23-2 6. T able 1: Pr oMix 2KS Digital Inputs (Modbus Register 4004 0) Bit Digital Input Binary Name Details 0 : 5 0000000000 X XXXXXR e c i p e B i n a r y b i t s f o r v i e w i n g d i s c r e t e i n p u t s o n l y .
Modbus and I/O Data 28 312785C NO TE: Shaded cells relate t o the flo w char ts on pages 23-2 6. T able 2: ProMix 2KS Dig ital Output s (Modbus Register 40041) Bit Digital Input Binary Name Details 0 .
Modbus and I/O Data 312785C 29 Pr oMix 2KS Active Alarms (Modbus Register 40010) T able 3: Pr oMix 2KS Active Alarms (Modb us Register 40010) Bit Digital I nput Binary Name Details Low Byte: 0 0000 00.
Modbus and I/O Data 30 312785C Pr oMix 2KS Modbus/TCP V ariable Map * This column represe nts the rule that must be imple mented b y automation. Writing to Read Only registers m ust be av oided.
Modbus and I/O Data 312785C 31 Pr oMix 2KS Recipe Bits T able 5: Pr oMix 2KS Recipe Bits Recipe Bits Number Recipe Bits Number 543210 543210 000000 0 100001 3 3 000001 1 100010 3 4 000010 2 100011 3 5.
Troubleshooting 32 312785C T r oubleshooting NO TE: This section covers the most common prob lems encountered while setting u p , programming or using the product. Do not f orget to alw ays downloa d in the device after chang ing settings in Graco Gate wa y.
Troubleshooting 312785C 33 Unit shows “V ersion Mismatch”. The da tabase currently in the de vice does not match Gr aco Gatew ay’ s fir mware version. (Message o ccurs after a download with a new version of C2 interr upted b ef or e the databa se was d ownload ed.
Troubleshooting 34 312785C Symbol or image lea ves a trace when animated. The bac kground of the image is not refreshed. Change the primitive Fill F or mat to Solid color . Add the system v ariable dispcount in the bac kground of the image to f o rce the refresh .
Troubleshooting 312785C 35 Graco Gatewa y Messages T roub leshooting PROBLEM CA USE SOLUTION De vice incompatible with file. The device y ou are tr ying to do wn- load into doesn’t match the database de vice. Create a ne w database file corre- sponding to your device (File > New).
Troubleshooting 36 312785C Serial Comm unication T r oubleshooting This section is used t o troub leshoot the communicatio n between two de vices linked via ser ial por ts, i.
Troubleshooting 312785C 37 Ethernet Comm unication T r oubleshooting This section is used to troub leshoot the communicatio n between t wo devices lin ked via Ether net.
Troubleshooting 38 312785C LED Functions Status (STS) LED The green Status LED pro vides info r mation on the sta- tus of the G raco Gatewa y, includ ing various stages of the star tup routine and any er rors that occur .
System Electrical Schematic 312785C 39 System Electrical Schematic Non-Hazar dous Area BARRIER BOARD OPERA TOR INTERF ACE 1 2 L1 N 85-250 VAC GND N L1 85-250 V AC 1 2 3 J5 +12VDC I/S (RED) COM (BLACK).
Parts 40 312785C Pa r t s 15V331 Gate wa y Ethernet Kit (shown) 15V963 Gate wa y DeviceNet Kit 15V964 Gatewa y Profib us Kit ▲ Replacement Danger an d W ar ning labels, tags, and cards are av ailable at no cost . P ar ts labeled n/a are not a vailab le separately .
Parts 312785C 41 TI12930a TI12932a TI12929a 3 4 56 8 10 11 12 13 14 15 17 14 18 18 17 14 7, 9, 12 1, 2 To 4 To 1 0 Wiring Diagrams TI12931a 12 3 45 67 8 s h s h 12 3 AS H B ProMix 2KS EasyK ey RS485 N.
Appendix A: DeviceNet ™ Sl ave Communication 42 312785C Appendix A: De viceNet ™ Sla ve Communication Overview This appendix describes the Gate wa y’ s suppor t f or Devi- ceNet and details the con figuration st eps necessar y to use this f eature.
Appendix A: DeviceNet ™ Sl ave Communication 312785C 43 F IG . 30: De viceNet P ort Pin Outs and PLC Connection XCDN NET STS CAN_L DRAIN CAN_H V+ V- V- LED CAN_L DRAIN CAN_H V+ TI13962a TI13963a De .
Appendix A: DeviceNet ™ Sl ave Communication 44 312785C About De viceNet De viceNet is a connection-based network. In this con- te xt the ter m connection ref ers to a communication path between t wo or more de vices, and not the ph ysical (cab le) connection to the De viceNet network.
Appendix A: DeviceNet ™ Sl ave Communication 312785C 45 Har dware T o use Device Net on the Gatew ay, an op tion card must first be installed. The op tion card provides the hardw are necessar y to suppor t the CAN ph ys ical la yer specifica- tion as required b y the DeviceNet stan dard.
Appendix A: DeviceNet ™ Sl ave Communication 46 312785C The De viceNet Option card appears at the end of the tree. Select the DeviceNet Interface from unde r the De viceNet Option C ard item. On the right hand pane , click on the Edit b utton to open the driver pic ker dialog bo x.
Appendix A: DeviceNet ™ Sl ave Communication 312785C 47 IMPORT ANT NOTE: The I/O P olled Size is determined by the settings in bo th the DeviceNet Master and the registered .EDS file f or the Gate wa y. T o change these settings, see A utoma tic Update of the EDS File on page 51 be fore sett ing up the PLC .
Appendix A: DeviceNet ™ Sl ave Communication 48 312785C Create Gatewa y Blocks Select the De vic eNet device from the tree a t the left, and add tw o Gate wa y Bloc ks; one fo r Read Data and one f or Write Da ta, using the Add Gatewa y Block button on the righ t hand pane.
Appendix A: DeviceNet ™ Sl ave Communication 312785C 49 NO TE: For 16-bit suppo r t, select W ord as Word. F or 32-bit support, select Word as Long. The latter is recom- mended as De viceNet uses 32 bits integer add ressing. Set the b lock size f or 4, and the Direction for: Device T o Gatew ay.
Appendix A: DeviceNet ™ Sl ave Communication 50 312785C Select the second Gatewa y Block and set it up f or I/O P olled Respon se Data 00000, with a length of 4, and the Direction Gatew ay T o Device. This will be the Write Data Block. F IG . 36 sho ws both Gatew ay b locks once com- pleted.
Appendix A: DeviceNet ™ Sl ave Communication 312785C 51 A utomatic Update of the EDS File De viceNet nodes use an EDS (Electronic Data Sheet) to describe the communication s parameters a vailab le at each de vice on the De viceNet network. By design, each De viceNet mast er can handle a maxi- mum of 124 I nput words and 123 Output w ords.
Appendix A: DeviceNet ™ Sl ave Communication 52 312785C Configure the RSNetW orx for De viceNet Software RSNetW orx for De viceNet is used to set up and ma nage a DeviceNet network. T o begin the conf iguration, launch RSNetWorx f or De viceNet fr om you r de velopment PC .
Appendix A: DeviceNet ™ Sl ave Communication 312785C 53 Re view the EDS registration, and finish the process. Select the De viceNet Master b y navigating in the tree on the left hand sid e. Na v igate to: DeviceNet>Cate- gor y>Communicatio n Adapter>17 56-DNB/A.
Appendix A: DeviceNet ™ Sl ave Communication 54 312785C Mak e sure that the Strobed or Chang e of State bo x e s are not selected . In the P olled section, v er ify that the Input and Outp ut sizes are 16 b ytes. These must match the I/O P oll Size selections made abo ve in the Gate wa y.
Appendix A: DeviceNet ™ Sl ave Communication 312785C 55 Configure the Allen Bradley Contr olLogix PLC Allen Bradle y ControlLogix PLCs are prog rammed with RSLogix 5000 prog ramming softw are. T o begin the De viceNet c onfiguration, la unch RSLogix 5000 fr om yo ur de velopment PC .
Appendix A: DeviceNet ™ Sl ave Communication 56 312785C Configure the De viceNet Scanner to be addr ess 0. Mak e sure to set up the 3 2-bit Input and Output memory spaces f or a size of 32 (to match the configur ation made abov e in both Gatewa y and RSNetWorx f or DeviceNet).
Appendix B: Profibus ™ DP Slave Communication 312785C 57 Appendix B: Pr ofib us ™ DP Sla ve Communication Overview This appendix describes the Gate wa y’ s support for Pr o- fib u s DP and details the configur ation steps necessar y to set up a G raco Gatewa y with an S7300 PLC , CPU315-2DP via Profib us.
Appendix B: Profibus ™ DP Slave Communication 58 312785C About Pr ofibus DP Profib us DP communica t ion tak es the form of bloc k e xchange. Profib us bloc ks are made of memor y b ytes where 2 bytes make a word and 4 bytes a double w o rd, or Dword.
Appendix B: Profibus ™ DP Slave Communication 312785C 59 Setup the PLC The Siemens Simatic Manager software is used to set up the S7300 PLC . The f ollowing figures and e xplana- tions 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 bl ocks to our device .
Appendix B: Profibus ™ DP Slave Communication 60 312785C Click Bro wse to select the folder w ere the GSD file downloaded pre viously is, select the file and clic k Install.
Appendix B: Profibus ™ DP Slave Communication 312785C 61 Setup the Profib us Network The f ollowing steps show how to set up the Profibus DP network.
Appendix B: Profibus ™ DP Slave Communication 62 312785C In the Gener al tab, clic k the proper ties but ton to open the Profib us proper ties. F IG . 53. In the properties window , go to the P arameters tab and click on the Ne w button to create a new network.
Appendix B: Profibus ™ DP Slave Communication 312785C 63 Select the Netwo r k Settings tab and choo se the T rans- mission Rate that fits the app lication. In this e xam ple, it will be 12 Mbps. The profile should be DP . F IG . 55. Close the popup windo ws by clicking OK.
Appendix B: Profibus ™ DP Slave Communication 64 312785C Add the Graco Gate way to the Pr ofibus Network T o add the Graco Gate wa y to the Profib us network, drag the Gatewa y Pro fibus Card from the Cata log navigation situated on the right ha nd side of HWConfig to the Profi- bus DP Master System.
Appendix B: Profibus ™ DP Slave Communication 312785C 65 The Gate wa y is now on the Profib us DP network and selected. HWConfig shows the slo t s a v ailable under the Gate wa y to configure the data bloc ks to e xchange. Ju st drag and drop one of the dat a b locks av ailabl e under the Gate wa y Profibus Card in the slot n umber 1.
Appendix B: Profibus ™ DP Slave Communication 66 312785C Graco Gatewa y Setup Once the PLC is setup , the Gatew ay c an be pro- gra mmed to fit its configuration . NO TE: Fo r a Gate wa y to communicate on Profib us DP , a Profibus Option card has to be fitted in the unit.
Appendix B: Profibus ™ DP Slave Communication 312785C 67 The option card app eared in the comm unication tree. Select the Profib us Interfa ce and click th e Edit b utton to select a driver . Click OK to pick the Profib us DP dr iver . F IG . 60. Graco Gate wa y now displa ys the driver settings wher e the Station Address can be ch anged.
Appendix B: Profibus ™ DP Slave Communication 68 312785C Setup T ags Once the commu nication is set up , tags can be create d to access the PLC bloc ks. This is where the sect ion Setup the Pr ofibu s Comm unication , page 66, is impor tant. First, crea te a v ar iab le that correspond to the dat a type required.
Appendix B: Profibus ™ DP Slave Communication 312785C 69 In the popup wind ow , select the b lock type requ ired. T wo choices are av ailable: • Input block: The term inology input is from the Sie- mens perspectiv e. Theref ore this will be a bloc k the Gatew ay will write to.
Appendix B: Profibus ™ DP Slave Communication 70 312785C How Ad dressing W orks PLC addressing is in b yte and uses the scheme sho wn in F IG . 66. The Gate wa y addressing f ollows a diff erent scheme, as shown in F IG .
Appendix B: Profibus ™ DP Slave Communication 312785C 71 Useful Formulas The f ollowing f or mula can be used to fin d the byt e nu m- ber from a word address: ByteAddress = PLCOffset + (W ordAddres.
Appendix C: Graco Gateway to Co ntro lLogix via Ethernet IP 72 312785C Appendix C: Graco Gate way to Contr olLogix via Ethernet IP Overview This appendix de scr ibes the configur ation steps neces- sary to estab lish a communication path between the Graco Gate wa y and a Cont rolLogix unit.
Appendix C: Graco Gateway to Contro lLogix via Ethernet IP 312785C 73 Contr olLogix Configuration 1. Run the RSLogix 5000 prog ram and create a ne w configuration. 2. Add a 1756-ENET/B or a 1756-ENBT/A to y our I/O configuration. Y ou will need to: a.
Appendix C: Graco Gateway to Co ntro lLogix via Ethernet IP 74 312785C F IG . 70. P ort Configuration Wind ow IP Address Subnet Mas k Set Button F IG .
Appendix C: Graco Gateway to Contro lLogix via Ethernet IP 312785C 75 e. In the Na me field, ente r a descr iptive name to identify the modu le. See F IG . 7 2. f . In the Address/Host Name field, enter the IP Address of t he Graco Gatewa y. g. Enter 2 in the Input Assemb ly Connection P oint and a size of 2.
Appendix C: Graco Gateway to Co ntro lLogix via Ethernet IP 76 312785C See F IG . 73. Y o u should now see a n ew ETHER- NET -MODULE Gate wa y_HMI branch of t he 1756-ENET/B node in the I/ O Configuratio n view .
Appendix C: Graco Gateway to Contro lLogix via Ethernet IP 312785C 77 Graco Gatewa y Configuration 1. Ethernet Settings . Set th e IP Address to 192.168.2. 101. This shoul d match the Address/ Host Name entered in F IG . 72. 2. Proto col Settings. Select the Ether net/IP Slav e Adapter communic ations dr iver .
Appendix C: Graco Gateway to Co ntro lLogix via Ethernet IP 78 312785C The f ollowing settings mirror th e I/O settings of the ControlLogix configur ation detailed earlier . a. Input Connection P oint. Create a Gatew a y bl ock co nfiguration (see T able 7).
Dimensions 312785C 79 Dimensions TI12825b 16.57 in. (420.9 mm) 15.07 in. (382.8 mm) 4.52 in. (114.8 mm) 5.31in. (134.9 mm) 8.71in. (221.2 mm) TI12930a.
Dimensions 80 312785C.
Technical Data 312785C 81 Te c h n i c a l D a t a Electr ical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Vdc, +/- 10%. 200 mA minimum without expansion card ; 1 Amp maximu m with e xpansion card fitted. Re quires Class 2 or SEL V rated p ower supply .
All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. Original instructi ons. This manual contains Eng lish.
An important point after buying a device Gateway 312785C (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Gateway 312785C yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Gateway 312785C - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Gateway 312785C you will learn all the available features of the product, as well as information on its operation. The information that you get Gateway 312785C will certainly help you make a decision on the purchase.
If you already are a holder of Gateway 312785C, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Gateway 312785C.
However, one of the most important roles played by the user manual is to help in solving problems with Gateway 312785C. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Gateway 312785C along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
