Factory Gateway User Manual - Pro
Contents
1. ie Recommended Parts Connector Dsub25pinplug XM2A 2501 OMRON Cover Dsub25pin cover XM2S 2511 OMRON Dsub25pin cover XM2S 2521 OMRON Jack Screws XM2Z 0071 OMRON Cable CO MA VV SB5PX 28AWG Hitachi Cable Ltd K Use rough metric type M2 6x0 45 p threads used to secure the cable s set screws To confirm your PLC unit s connection specifications refer to the GP PRO PB III for Windows Device PLC Connection Manual in cluded in the GP PRO PB III C Package01 2 4 Factory Gateway Series User Manual Chapter 2 Specifications Use the following instructions to create your own cable e With an RS 422 cable The following pins must be shorted as follows 18 CSB and 19 ERB 21 CSA and 22 ERA Connecting the RS 422 cable s 9 TRMX and 10 RDA pins inserts a termination resistance of 100Q between 10 RDA and 16 RDB When making a cable for a Memory Link system use a 4 wire type cable With an RS 232C cable Do NOT use the following pins 9 TRMX 10 RDA 11 SDA 15 SDB 16 RDB 18 CSB 19 ERB 21 CSA 22 ERA Connect the 1 FG terminal only if it is required by a connected device amp This FACTORY GATEWAY unit s serial port is not isolated When the host PLC unit is also not isolated and to reduce the risk of damag Important ing the RS 422 circuit be sure to connect the 7 SG Signal Ground terminal e Pin 14 VCC DC 5V Outpu2. Usethe following steps to initialize the Factory Gateway unit s memory Turn the Factory Gateway unit s power supply OFF 2 Set dipswitch 4 to ON 3 Turn the Factory Gateway unit s power supply ON 4 The Factory Gateway unit s power PWR LED will change from green to red approximately 10 seconds is required for initialization 5 The Factory Gateway unit s power PWR LED will change from red to green 6 After checking that the Factory Gateway unit s power PWR LED has changed to orange turn the Factory Gateway unit s power supply OFF 7 Set dipswitch 4 to OFF 8 Turn the Factory Gateway unit s power supply ON Dip Switch 4 s initialization can be used for Ethernet related information Serial commu nication settings Sub net mask distribution data etc Network Project data and screen data System program 2 Way Driver and PLC communication protocol data cannotbe initialized Factory Gateway Series User Manual 3 9 Chapter 3 Installation and Wiring Mem 3 10 Factory Gateway Series User Manual 1 Troubleshooting 2 Periodic Instection Chapter 4 Troubleshooting 4 1 Troubleshooting The following information explains how to troubleshoot the Factory Gateway unit The first steps should always be to check the following items Is the Factory Gateway receiving the correct level of power Is the Device PLC receiving the correct level of power e Is the Factory Gateway correctly connected tot he
3. user for any damages losses or third party claims arising from any uses of this product All Company Manufacturer names used in this manual are the registered trademarks of those companies Copyright 2002 Digital Electronics Corporation Factory Gateway Series User Manual 1 Preface Table of Contents PRCT 1 Essential Safety Precautions cisissssccsssesescssecesescossosccesesnvsssoverseseesenenceteencssoassseucvsseneses 4 General Safety Precautions sssiscssisssccsssceccssvsscesesesstsoesscsesssesscesonvestvevevseecevensesseeseesss 7 About Factory Gateway Models siennes 8 Iu e PEKIN T P H RHn 8 UL e UL CSA Application Notes ciscsccsicssssssccossssscssovesssvossssoscossnsesssosnesesenssenccesseness 9 CE Marking Notes x sccssccssssccessssnasecseasscconssnenossessectesecnseacssenencdvocuencoessbaccuesenauseenessese 9 Documentation Conventions ssssesssssssssensessnsennsssscnes enneessesssssescesena eseesss es 10 1 1 Prior to Operating the Factory Gateway esssesesccessoccsscessccesocesocesoosssoessoee 1 1 L2 System DOSIUE S erit E ERRAT rane 1 2 1 3 ACCESSORIES RETE T T C u u cc 1 4 2 1 General Specifications scccscisenessssseccorscssescesenencssscensesencesceeevevenctveceensvasiennsccvens 2 1 2 1 F Bleetrical oops teenie essa 2 1 2 1 2 Environmental eee iot rere rt He er et aie S 2 2 2 1 3 SUCER nd Gr eA tn 2 2 2 2 Function
4. 3 Tool Connector 4 Ethernet Cable Connector 5 IP Address Seitings 6 Dip Switch Settings Chapter 3 Installation and Wiring 3 1 Installation The following information explains how to attach a 35mm DIN rail to the Factory Gateway Attachment Place the unit s curved bottom DIN Rail lip over the bottom of the DIN rail and tilt the unit up until the Factory top face attachment clip clicks Gateway into place A Be sure that the top and bottom faces of the unit are correctly oriented l and that the unit is vertical Incorrect installation may prevent heat from a Important dissipating correctly When removing the unit from the attachment clips hold the unit with your hand to prevent it from falling To prevent the Factory Gateway unit from being dislodged from the DIN Rail due to being struck or bumped from the side the following Stabilizer Clips are recommended BNL5P IDEC Corporation HDV 1 TOYO GIKEN Corporation Removal Up Use a standard screwdriver to T force the unit s attachment clip Standard B si up until the top of the unit is Screwdriver I freed from the rail Next tilt the j DIN Rail unit down and remove T When removing the unit from the attachment clips hold the unit with your important Pand to prevent it from falling Factory Gateway Ser
5. Doing so may cause a fire or an elec tric shock Maintenance e The Factory Gateway uses a lithium battery for backing up its internal clock data If the battery is incorrectly re placed the battery may explode To prevent this please do not replace the battery yourself When the battery needs to be replaced please contact your local Factory Gateway distributor Factory Gateway Series User Manual 3 Preface AN CAUTIONS Installation e Be sure to securely connect all cable connectors to the Factory Gateway A loose connection may cause incor rect input or output Wiring e Ground the Factory Gateway s FG line separately from other units FG lines Putting these FG lines too close may cause an electric shock or unit malfunction Be sure to use a grounding resistance of 1000 or less and a 2mm or thicker wire or your country s applicable standard When wiring the Factory Gateway be sure that the rated voltage and terminal layout are within the designated range If the voltage supplied differs from the rated volt age or incorrect wiring or grounding is performed it may cause a fire or unit malfunction Use only the designated torque to tighten the Factory Gateway s terminal block screws If these screws are not tightened firmly it may cause a short circuit fire or Fac tory Gateway malfunction Be careful that metal filings and wiring debris do not fall inside the Factory Gateway since they can cause a fire Fa
6. terminal according to your countrys regulations Factory Gateway Error If lit a hardware error has occurred IncorrectIP Address Correctthe units current rotary switch IP Address settings m Check the units rotary switch IP Address settings and the Network Projects Sub net Mask settings Check is there is a problem with the Network Projects 2 Way Error ND Orange Provider information Tum Dip Switch 4 ON and restartthe unit After memory is initialized turn dip switch 4 OFF Next turn dipswitches 5 and 6 ON and perform forced setup using GP PRO PBIII for Windows Be sure to also send 2 Way Driver data normal tums green Turn Dip Switch 4 OFF when completed Tum Dip Switch 4 ON and restart the unit After memory is initialized turn dip switch 4 OFF Next turn dipswitches 5 and 6 ON and perform forced setup using GP PRO PBIII for Windows Be sure to also send 2 Way Driver data After initialization is completed PWR turns orange and STA turns green Turn Dip Switch 4 OFF when completed When unitrestarts PWR and STA both turn green System Error Screen Data Memory Error ONLINE Error from external source 2 Way Driver Error System Error Screen Data Memory Error Now initializing memory 2 Way Error Now initializing memory 4 2 Factory Gateway Series User Manual Chapter 4 Troubleshooting L N Problem Condition Possible Solution s PWR STA Next turn dipswitches 5 and 6 ON and perform
7. 2 Periodic Check POINTS siccsccsscassssessnssssescacesssenessonssoossessseassovsasosssassaassassceassee 4 5 Factory Gateway Series User Manual 3 Preface Essential Safety Precautions This manual includes procedures that must be followed to operate the FACTORY GATEWAY correctly and safely Be sure to read this manual and any related materials thoroughly to understand the correct operation and functions of the FACTORY GATE WAY unit B Safety Symbols Please pay attention to the following safety symbols and their meanings Indicates situations that may result in major AN WARNIN G machine damage severe bodily injury or death If the instructions are not followed Indicates situations that may result in damage A C A UTIO N to the machinery or minor bodily injury 1f the instructions are not followed A WARNINGS System Design e Please design your system so that equipment will not mal function due to a communication fault between the Fac tory Gateway and its host controller This is to prevent any possibility of bodily injury or material damage Do not use the Factory Gateway unit as a warning device for critical alarms that can cause serious operator injury machine damage or production stoppage Critical alarm indicators and their control activator units must be de signed using stand alone hardware and or mechanical interlocks The Factory Gateway is not appropriate for use with air craft control devices aerospace
8. Device PLC e Is the Factory Gateway unit s current protocol data correct for the type of Device PLC that is connected For details about the Factory Gateway Configuration Tool Error Messages refer to the Factory Gateway Configuration Tool Operation Manual Factory Gateway Configuration Tool Operation Manual Factory Gateway Series User Manual 4 1 Chapter 4 Troubleshooting 4 1 1 LED Status Indicators The Factory Gateway unit uses two LED indicators PWR nad STA to display the status of the Factory Gateway unit The following table describes the problems indicated by these LEDs and gives suggestions for how to solve each problem L Name Problem Condition Possible Solution s Power supply is notoperating No power Power terminal are not connected Power cord is cutor damaged Normally OFF if lit a hardware error has occurred Normally O FF If lit a hardware error has occurred Normally OFF if lit a hardware error has occurred Next turn dipswitches 5 and 6 ON and perform forced setup System Program Error using GP PRO PBIII for Windows Be sure to also send 2 Way Driver data Tum Dip Switch 4 ON and restartthe unit After memory is initialized turn dip switch 4 OFF Next turn dipswitches 5 and 6 ON and perform forced setup using GP PRO PBIII for Windows Be sure to also send 2 Way Driver data Possibly interference or static from power line or input line noise Either separate these lines or ground the units FG
9. Status Indicators Factory Gateway Series User Manual Chapter 2 Specifications H Serial I F TxD F When this indicator blinks data is being sent A TO Jd G Io MEME E I en this indicator blinks data is being received x SH J Reset Switch RST C 2 st XY Resets the Factory Gateway unit D J K DIP Switches s Control various Factory Gateway features 5 Factory settings are all OFF For details see 3 6 Setting Dip l K Switches a CE a Front L DIN Rail Attachment Holder L M Rotary Switches These switches are used to set the unit s IP Address The factory settings are 0 For details see 3 5 Setting IP i Addresses BIBGEJSEBIBEBO il o e Right Side This section is used only for maintenance by Pro face Do not open this cover Factory Gateway Series User Manual au Chapter 2 Specifications 2 5 Dimensions Unit mm in 37 1 46 9 0 35 105 4 13 8 0 31 TE in Fs Q on E n A OBASE T STA a Om ORD RST je lt gt Lp 131 5 16 EE Front Right Side 2 8 Factory Gateway Series User Manual 1 Installation 2 Wiring Cautions
10. Sub net Mask and the default Factory Gateway settings refer to Factory Gateway Configuration Tool Operation Manual Also the port number will revert to 8000 after initialization Thus if the Factory Gateway unit tries to use a port other than 8000 data transfer cannot be performed Use of Port No 8000 is recommended 4 4 Factory Gateway Series User Manual Chapter 4 Troubleshooting E GP Viewer Screens Cannot be Displayed CAUSE When data is sent from the Factory Gateway Configuration Tool screen data is deleted SOLUTION GP Viewer screen data includes protocol data as well However if the Factory Gateway Configuration Tool software is used to change the Factory Gateway unit s protocol the new protocol in the Factory Gateway unit will be different from the previous protocol To prevent a possible data protocol type conflict however the Factory Gateway Configuration Tool automatically deletes all existing Factory Gateway screen data prior to sending a new protocol This however means that there is now no data for GP Viewer to read out and display To prevent this type of problem when using Pro Viewer to view Factory Gateway data be sure to always use GP PRO PRIII to send both screen and protocol data to the Factory Gateway unit 4 2 Periodic Check Points To keep your Factory Gateway unit in its best condition inspect the following points periodically Operation Environment Is the operating temperature wi
11. prior to attaching or detaching any connectors to or from the Factory Gateway L TOOL D ue T O PIR TOBASE TO STA O TxD O RxD O Tool Connector RST Bel on 3 6 Factory Gateway Series User Manual Chapter 3 Installation and Wiring 3 4 Ethernet Cable Connector The Factory Gateway Ethernet interface is IEEE802 3 compliant and transmits data at 10 Mbps The Ethernet connector s location is shown below min TOOL O PR 10BASE TO STA O TxD O RxD eS Ethernet Interface RST ele 7 LO E S iH a Front e It is strongly recommended that your Ethernetwork is in Note NSS stalled by a trained engineer 1 1 connections using a cross cable may not be possible depending on the type of personal computer and network card you are using Make sure to use a hub for connec tion 3 5 IP Address Settings To set the Factory Gateway unit s IP address the 8 side face rotary switches are used To set these switches you must first remove the right face Rotary Switch Cover The factory settings are all 0 Also the Factory Gateway unit s IP address is set using HEX The example below uses an IP address DEC of 192 168 0 1 PoP Adress Decimal 192 1688 0 1 _ Rotary Switch Settings Be sure to enter all IP address settings prior to connect Ge ing t
12. Pro face Human Machine Interface Factory Gateway User Manual Preface Thank you for purchasing the Pro face Graphic Logic Controller Factory Gateway Series hereby referred to as Factory Gateway or Factory Gateway unit This unit is designed to be connected to an External Device PLC etc that do not have their own Ethernet interface via the Pro Server system s Ethernet connection Pro Server allows the Factory Gateway unit to communicate with a host level PC without specialized programming This allows data collection and sharing of data with other PLC units Also Pro Server s Add on software GP Viewer and GP Web allow you to access factory floor data from a remote PC and even perform maintenance In this manual s examples the Mitsubishi MELSEC AnA Series PLC is used whenever possible connected in a one to one relationship with a Factory Gateway lt Note gt It is forbidden to copy the contents of this manual in whole or in part except for the user s personal use without the express permission of Digital Electronics Corporation of Japan 2 Theinformation provided in this manual is subjectto change without notice 3 This manual has been written with care and attention to detail however should you find any errors or omissions contact Digital Electronics Corporation and informthemof your findings Please be aware that Digital Electronics Corporation shall not be held liable by the
13. UL Registration Model 3080034 01 Notes B The Factory Gateway must be installed in other equipment B If the unit is installed in an area with no air conditioning system be sure to attach the DIN rail to the rear of the unit Also be sure the unit is installed so it is at least 100 mm away from all of the unit s directions except the rear side If these requirements are not met the heat generated by the unit s internal components may cause the unit to fail to meet UL standards requirements E The power supply unit connected to the I O unit must be a UL c UL CSA approved Class 2 power supply unit or Class 2 trans former When the Factory Gateway or multiple I O units under load are operated with a single power supply the amount of current consumption and full load current of the I O units must be within the rated load of the Class 2 power supply unit or Class 2 power supply transformer Be aware that the number of points which can be turned ON simultaneously may be limited depending on the amount of load and load current value A Class 2 power supply unit or Class 2 power supply transformer is C as being 30V and at 8A or less output less than 100VA defined by National Electorical Code CE Marking Notes The FGW SE41 24V is a CE Marked unit that conforms to EMC directives EN55011 Class A and EN61000 6 2 Caution While this unit is officially marked as conforming to the relevant EMC directives it is the user s f
14. Y GATEWAY operating from its lithium battery the degree of error is 65 seconds per month Variations in operating conditions and battery life can cause this error to vary from 380 to 90 seconds per month For systems where this degree of error will be a problem the user should be sure to monitor this error and make adjustments when re quired See Factory Gateway Configuration Tool Operation Manual 2 2 2 Interfaces Asynchronous Transmission RS 232C RS 422 Data Length 7 or 8 bits Stop Bit 1 or 2 bits Parity None Odd or Even Data Transmission S peed 2 400 to 187 500bps Serial Interface EEE8023 I0BASE T Asynchronous TTL level nonprocedural command I F During screen file development Used for transferring data between the GLC application software and the GLC Used for data transfer with the 2 P ortfeature Tool Connector Factory Gateway Series User Manual 2 3 Chapter 2 Specifications 2 3 Interface Specifications 2 3 1 Serial Interface This interface can be either RS 232C or RS 422 Connects FACTORY GATEWAY to Host PLC This interface uses a socket type connector ye 0e loue us 1 Fromeground 2 o Send data as NE 3 RD Receive data 5 2320 PRS Request send 85 2320 ps ts Chearsena 52320 6 DR Data SetReady RSX 8 b cemere exc 3 a Temminaton RS Para NngmdcsteRR2 2c J O Oo O Oo o O Oo Oo Oo Oo O 000000000000
15. al Specifications eoo esee ena iota ok aret oaa ao eese tp raa e epo p rep PY Yos EPE YE UP EF eiae e ePS 2 3 22AN I ETE 2 3 2 22 TN TIAC S SE inn ENEMIES EL MM 2 3 2 3 Interface Specifications uec eee eese epos rh Ya oe Pa ken Pp Yeah aae UE Py E Yep Ch Ya EE P9 eS Eee epe re een 2 4 2 3 1 Serial Interface su 2 4 2 4 Part Names and Functions s sssssesosssssssssossssssssssssssssssososoesssssosesssssssosssssssssss 2 6 2 5 DiM nsiolhsS M 2 8 3 1 Installati i m 3 1 3 2 Wiring CANONS sssssssssssssssssisssssossssssssssssssssses ssssdosssso ssassis sssssssssss s dssodsssa s 3 2 3 2 1 Connecting the PG wer CONS 3 2 222 Connecting tbe Pawer S pply een inset 3 4 ES EE Gori esr TP 3 5 3 24 VO Signal Line Cautlolls 3a nada a preis 3 6 3 3 Tool CONNECT 3 6 3 4 Ethernet Cable Connector ssciccsssscosssessseossesssoseosssasssssssoosssessscussoesseossesasnsssssee 3 7 N Factory Gateway Series User Manual Preface 3 9 IP Address Select 3 7 20 gt Dip Switch Settings assescipa niv Dd PO VERE VERE HE E XEXE YR nen 3 8 30 1 Im aizine Memory norai secun iude inen Qu suns Ute A E eEG 3 9 CHAPTER4 TROUBLESHOOTING 4 1 4 1 Troubleshooting 4 1 4 1 1 LED Status Indicators seesseseeeeeeeenennn nennen 4 2 41 2 PrODISI SO ID o tips een im perhaps bau teris utei tap qu S inn eu uud 4 4 4
16. als Organic Solvents e Do not use paint thinner or organic solvents to clean the Factory Gateway Factory Gateway Series User Manual 7 Preface About Factory Gateway Models model numbers GP Type with Model Series Name Comments Screen Creation Number The Factory Gateway Series in this manual refers to the following Factory Gateway Software UL c UL Approved Factory Gateway FactoryGateway FGW SE41 24V CE Marked FGW SE Package Contents The following items are included in the Factory Gateway s package Before using the Factory Gateway please confirm that all items listed here are present E Factory Gateway Unit 1 Bi Installation Guide 1 FGW SE41 24V ru TOOL Q OPR BASE TO STA On Installation ud Guide RST Ree 4 ES H 66658888 This unit has been carefully packed with special attention to quality However should you find anything damaged or missing please contact your local Factory Gateway distributorimmediately Factory Gateway Series User Manual Preface UL c UL CSA Application Notes The FGW SE41 24V is a UL c UL CSA listed product UL File No E220851 The FGW SE41 24V unit conforms to the following standards B ULS08 Electrical Control System for Industry B CAN CSA C22 2 No 1010 1 Safety requirements for electrical equipment for measurement and laboratory use FGW SE41 24V
17. ateway unit separate the input output 3 SUR SUA Factory and operation unit lines see Diagram 1 4e Gateway Main FGW Toincr the noise resistance qualit oincrease the noisere ceq y ee Pawar of the power cord twist each power p wire before attachin i i a 2 1 0 device g the Ring Terminal I O power The power supply cord must not be Dia 2 source bundled or positioned close to main i Factory circuitlines high voltage high current Main power Gateway orinput outputsignallines see Diagram 99259 Factory 2 Gateway e Connecta lightning surge absorber see Diagram 3 to deal with power surges I O power T P I O device e To avoid excess noise make the power cord as short as possible a Ground the surge absorber E1 Main circuit power Unit separately from the Factory Gate Important Way unit E2 Dia 3 Select a surge absorber with a maximum circuit voltage that is greater than that of the power supply s peak voltage o Factory Lightning surge absorber 3 4 Factory Gateway Series User Manual Chapter 3 Installation and Wiring 3 2 3 Grounding A CAUTION Do NOT use common grounding since it can lead to an accident or machine breakdown Connect the FG terminal found on the back of the Factory Gateway unit to an exclusive ground diagram A Another device A Exclusing Grounding BEST Factory Gateway A 4 Make sure that the grounding resistanc
18. ce PLC Connection Manual included in the GP PRO PB III software 4 Certain PLC types and models cannot be connected Refer to the GP PRO PB III for Windows Device PLC Connec tion Manual included in the GP PRO PB III software 5 For the full range of compatible PCs refer to the following manual Refer to the GP PRO PB III for Windows Operation Manual included in the GP PRO PB III software 6 Normally maintenance data transfer is possible using an Ethernet network However depending on the data transfer cable used a Factory Gateway System Error may occur preventing communication Factory Gateway Series User Manual 1 3 Chapter 1 Introduction 1 3 Accessories All optional equipment listed here is produced by Digital Electronics Corporation B Available Software Product Name Model No This software is used to setup the P ro Pro Server Pas ude Server System This software consists of 2 PSW ED01 V40 elements a server Pro Server anda for Windows Ver 4 0 seting entry program P ro S tudio Required Used to setup and send protocol data to the F Din Maia Factory Gateway unit Add on software for onfiguration Too P ro Server Required Used to create projects and screen data that GP PRO PBIII for Windows can be senti the Factory Gateway and then 12434 GPW PBO1W V60 displayed using GP Viewer or GP ERO Maes Web Depending on the cable used serial data transfer can also be used Installed in the P ro S e
19. ctory Gateway malfunction or incorrect operation Unit Disposal e When this unit is disposed of it should be done so ac cording to your country s regulations for similar types of industrial waste 6 Factory Gateway Series User Manual Preface General Safety Precautions e Do not install the Factory Gateway where the ambient tem perature can exceed the allowed range Doing so may cause the Factory Gateway to malfunction or shorten its operation life Do not restrict or limit the Factory Gateway s naturally occurring rear face ventilation or store or use the Fac tory Gateway in an environment that is too hot e Do not use this unit in areas where large sudden tem perature changes can occur These changes can cause condensation to form inside the unit possibly causing the unit to malfunction e Do not allow water liquids metal or charged particles to enter inside the Factory Gateway s case since they can cause either a Factory Gateway malfunction or an elec trical shock e Do not use or store the Factory Gateway in direct sun light or in excessively dusty or dirty environments Do not store or use the unit where strong jolting or ex cessive vibration can occur Do not store or use the Factory Gateway where chemi cals such as organic solvents etc and acids can evapo rate or where chemicals and acids are present in the air Corrosive chemicals Acids alkalies liquids containing salt Flammable chemic
20. e is less than 1000 7 o The FG and SG lines are connected internally in the Factory Gateway TRUCOS ui When connecting the SG line to another device be sure that the de sign of the system connection does not produce a shorting loop The grounding wire should have a cross sectional area of at least 2 mm Create the grounding point as close to the Factory Gateway unit as possible and keep the wire as short as possible Replace thin wire with a thicker wire and place it in a duct If exclusive grounding is not possible use acommon connection point diagram B Another device B Common Grounding OK Factory Gateway Qe re If the equipment does not function properly when grounded XV disconnect the ground wire from the FG terminal Factory Gateway Series User Manual 3 5 Chapter 3 Installation and Wiring 3 2 4 1 0 Signal Line Cautions e Tohelp prevent noise and interference problems separate all communication lines from power lines by placing them in a separate duct e If different wires must be placed in the same duct separate them with an earthed grounded divider 3 3 Tool Connector A data transfer cable can be attached to the Factory Gateway unit s tool connector The location of the Factory Gateway unit s tool connector is shown in the following diagram AN WARNINGS To prevent an electrical shock be sure to unplug the Fac tory Gateway unit s power cord from the main power sup ply
21. equipment central trunk data transmission communication devices nuclear power control devices or medical life support equipment due to these devices inherent requirements of extremely high levels of safety and reliability 4 Factory Gateway Series User Manual Preface WARNINGS e When using the Factory Gateway with transportation ve hicles trains cars and ships disaster and crime pre vention devices various types of safety equipment non life support related medical devices etc redundant and or fail safe system designs should be used to ensure the proper degree of reliability and safety Installation High voltage runs through the Factory Gateway Never disassemble the Factory Gateway otherwise an electric shock can occur Do not modify the Factory Gateway unit Doing so may cause a fire or an electric shock Do not use the Factory Gateway in an environment where flammable gasses are present since operating the Fac tory Gateway may cause an explosion Wiring e To prevent an electric shock be sure to confirm that the Factory Gateway s power cord is not connected to the main power when connecting any cords cables or lines to the Factory Gateway Be sure to replace the Factory Gateway s plastic terminal block cover after wiring is completed since operating the Factory Gateway without the cover may lead to an elec tric shock Do not use power beyond the Factory Gateway s speci fied voltage range
22. es mu nl 3 RS 232C Cable 4 GP410 IS00 O RS 422 Cable Coe GP230 1S11 O 5 GP230 IS12 0 ep for Multi link cable LT RS 422 Connector Terminal Adapter Host GP070 CN10 O 4 Mitsubishi PLC Controller 2 Port Adapter A Q C FX Series 6 PLCs etc OX Il Cable piped GP070 MDCB11 ac Adapter Il GP070 MD11 Mitsubishi PLC A Series 6 sO Program Port I F Cable GP430 IP10 O Mitsubishi PLC FX Series 6 yw Program Port I F Cable GP430 IP11 O 1 2 Factory Gateway Series User Manual Chapter 1 Introduction Pro Server Pro Studio Factory Gateway Configuration Tool GP PRO PBIII for Windows GP Viewer GP Web Screen Compiler 4 cy 2 1 Q e alle e ell Data Transfer Cable SN GPW CB02 E GP PRO PBIII for ae O ETa Windows zl Personal Computer G n eee 4 Factory Gateway PLC Interfaces Interfaces 1 Ethernet 4 RS 232C Port 2 Tool Connector 5 RS 422 Port 3 Serial Interface 6 Programming Console Port 1 Required when using GP Web 2 Required when using GP Viewer 3 For information about compatible PLC types and software refer to the GP PRO PB III for Windows Devi
23. forced setup OFF System Program Error using GP PRO PBIII for Windows Be sure to also send 2 Way Driver data Factory Settings Download Provider information and protocol data from Pro customer enters only Studio IP address Now transferring Unitis operating normally and sending data Possibly interference or static from power line or inputline Error from external DR noise Either separate these lines or ground the units FG source terminal according to your county s regulations Emi sae Turn Dip Switch 4 ON and restart the unit After memory is initialized turn dip switch 4 OFF Next turn dipswitches 5 Orange Data Memory Error Data transfer error and 6 ON and perform forced setup using GP PRO PBIII for Windows Be sure to also send 2 Way Driver data Factory Gateway Error Possible hardware error Factory Settings IP Address has not yetbeen entered Setthis data via the customer has not units side face rotary switches After unitis restarted PWR entered IP address turns orange and STA turns green IncorrectIP Address Correctthe units current rotary switch IP Address settings Check the units rotary switch IP Address settings and the Orange SUDSEMOSISEITU Network Projects Sub net M ask settings Turn Dip Switch 4 ON and restart the unit After memory is initialized turn dip switch 4 OFF Next turn dipswitches 5 and 6 ON and perform forced setup using GP PRO PBIII for Windows Be sure to also se
24. he Factory Gateway unit to the power supply If power NSS is connected to the Factory Gateway unit prior to setting these switches a communication 2 Way feature error will occur In this case please disconnect the Factory Gate way unit s power supply set these switches and recon nect the power supply Factory Gateway Series User Manual 3 7 Chapter 3 Installation and Wiring La The Subnet Mask and Default Gateway settings are Note not set via these switches They are set using the Pro x Server with Pro Studio for Windows software and then sent to the Factory Gateway unit See Pro Server with Pro Studio for Windows Operation Manual The IP Addresses should be set as follows 00 00 00 01 gt 7F FF FF FE 0 0 0 1 to 127 255 255 254 80 00 00 01 gt BF FF FF FE 128 0 0 1 to 191 255 255 254 C0 00 00 01 gt DF FF FF FE 192 0 0 1 to 223 255 255 254 After setting the IP Addresses be sure to reattach the cover 3 6 Dip Switch Settings The Factory Gateway unit s Dip Switches are used to set the following features Startup Transfer Mode Initialize Internal Memory Enable System Data Overwrite Enable 2 Way Driver Overwrite The switches are numbered from one to eight from bottom to top Factory settings are OFF Cad 2 Rem iy OFF Startup in transfer Startup in on line Startup transfer mode i Normally OFF mode mode P Initialize internal Do NOT initialize 9 a
25. i is memoryatstartup memoryatstart up 5 Enable System Data Overwrite Overwrite Enabled Overwrite Disabled Normally OFF 6 Enable 2 Way Driver Overwrite Overwrite Enabled Overwrite Disabled Normally OFF 3 Ree Wray Normally OFF Normally the Factory Gateway automatically changes to transfer mode To disable this use DIP switch NO 1 Also be sure to set the switch back to OFF after data trans fer is completed If the PWR LED has changed to orange the unit has changed to transfer mode 2 Normally the Factory Gateway reboots the system after data transfer If Switch No 4 is left ON every time the Factory Gateway transfers data internal memory s data will be initialized deleted After you finish using Switch No 4 be sure to set the switch to OFF before transferring data again 3 The System and the 2 Way Driver data can only be overwritten using GP PRO PBIII for Windows 3 8 Factory Gateway Series User Manual A Put a Important Chapter 3 Installation and Wiring DIP switches are used to help the Factory Gateway recover from er rors Turning a switch ON forces that switch s feature such as initializ ing internal memory ON To ensure the integrity of your data please keep these switches OFF when they are not being used e When changing the Dip Switches be sure the tool item you use is insu lated to prevent accidental damage to the unit 3 6 1 Initializing Memory
26. ies User Manual 3 1 Chapter 3 Installation and Wiring 3 2 Wiring Cautions 3 2 1 Connecting the Power Cord A WARNINGS To avoid an electric shock be sure the power cord is unplugged from the power supply when connecting the power terminals to the Factory Gateway unit The Factory Gateway FGW SE41 24V unit is designed to use only with DC24V power Using any other level of power can damage both the power supply and Factory Gateway unit Since there is no power switch on the Factory Gateway unit be sure to attach a breaker type switch to its power cord When the FG terminal is connected be sure the wire is grounded Oth erwise an electric shock can occur when the unit is broken A To prevent the Ring Terminals from short circuiting when the terminal IZ block attachment screws are loosened use sleeve type Ring Termi Jmpodtsnt nals When the FG terminal is connected be sure that the wire is grounded Not grounding the Factory Gateway unit will result in excessive noise Use your country s applicable standard for grounding e The SG and FG terminals are connected internally in the Factory Gate way unit When connecting the SG line to another device be sure that the de sign of the system connection does not produce a shorting loop La Wherever possible use thick wires max 2 mm for power Note terminals and twist the wire ends before attaching the ring v terminals Besure to use the f
27. inal application of this unit in a larger system i e the machinery wiring control panel installation method etc that will determine if this unit maintains or loses this conformance marking Therefore it is strongly advised that the user investigate and confirm whether their overall system i e all related machinery and equipment also conforms with these EMC directives Factory Gateway Series User Manual 9 Preface Documentation Conventions The list below describes the documentation conventions used in this manual T Indicates important information or procedures that must be followed m Important for correctand risk free software device operation Data Collection Indicates the Pro Server with Pro Studio for Windows software P ro Software Server is used as a server and Pro Studio is used as a data setup tool Configuration Tool sold as optional Add on software Indicates the GP PRO PBIII for Windows software GP PRO PBIII for Windows is also included in the GP PRO PBIII C Package software Intended primarily for the creation and maintenance of operator interface GP unit screens itcan also create screens for GP Viewer and GP Web Screen Creation Software Pro Server uses this add on software to display and sample screens GP Viewer created using the Screen Creation Sofware This add on software displays screens created using the Screen Creation Sofware using the Internet Explorer software PLC JAbbre
28. ing GP Web or GP Viewer screen creation software Note must first be installed screens created and data sent to the Factory Gateway unit Factory Gateway Configuration Tool Opera tion Manual This manual explains the hardware settings used to set up the FActory Gateway unit For detailed information about operation of the Factory Gateway Configuration Tool or Pro Server with Pro Studio for Windows please refer to the following manuals Factory Gateway Configuration Tool Operation Manual Pro Server with Pro Studio for Windows Operation Manual Factory Gateway Series User Manual 1 1 Chapter 1 Introduction 1 2 System Design The following diagram represents the main selection of devices connectable to the Factory Gateway unit E Factory Gateway RUN Mode RE Peripherals itMode D ClientPC Internet Host PC Pro Server Intranet Pro Studio GP Viewer GP Web Server IIS Ethernet Factor y Gateway Unit a Qe cl 2s CQ ow I ea ee en X T3 E S Mitsubishi GPP i Software l ME l l Personal l l Computer l Lh m eee ee ee ee eee ee X ee ee ee eee es
29. nd 2 Way Driver data 2 Way Driver Error t When a hardware error occurs please contact your local Pro xo face distributor for service and repair Factory Gateway Series User Manual 4 3 Chapter 4 Troubleshooting 4 1 2 Problem Solving The following data explains possible solutions for Factory Gateway unit related problems E Connecting power causes the unit to initialize memory PWR LED red gt orange CAUSE Dip Switch 4 is turned ON SOLUTION Turn Dip Switch 4 OFF and restart the Factory Gateway unit E Unable to Transfer Data CAUSE Dip Switch 3 is turned ON setting the unit in transfer mode SOLUTION Turn Dip Switch 3 OFF and restart the Factory Gateway unit CAUSE 2 The protocol transferred to the Factory Gateway unit is incorrect SOLUTION Check the Pro Studio Status Monitor to confirm the type of PLC the Factory Gateway is connected to Send new protocol if necessary CAUSES3 The Ethernet type s protocol has been sent SOLUTION The Factory Gateway is not designed to work with the Ethernet protocol Send the correct protocol to the Factory Gateway from the GP PRO PBIII for Windows software using the forced setup CAUSE 4 The Subnet Mask and the Default Gateway have been initialized SOLUTION When Disp Switch 4 is used to initialize the unit the Subnet Mask and the Default Gateway are also initialized To use these items again resend that data from Pro Studio For information about the
30. nversion adapter to convert serial data to Interface unitthatallows use of both Factory 2 PortAdapter Il GP 070 M D11 gateway and M isubishi A Q C and FX series equipmentin the same location 2PortAdaperil catie 2PortAdapericatie GP070 MDCB11 Connects the Factory Gateway to the 2 P ort Adapter Il Mitsubishi A Series we cap Es Programming Portl F Cable GP 430 IP 10 O Connects directly to M Isubishis PLC I F P rogramming Console S imultaneous use of Mitsubishi FX Series GP 430 IP 11 0 program console however is not possible Programming P ortl F Cable l For details about the range of connectable PLCs Refer to the GP PRO PB III for Windows Device PLC Connec tion Manual included with the GP PRO PB III software B Maintenance Items Product Name Model No comeco TT Side face connector cover Factory Gateway Series User Manual 1 5 Chapter 1 Introduction emo 1 6 Factory Gateway Series User Manual Chapter 2 Specifications 2 1 General Specifications 2 1 1 Electrical Rated Voltage DC Rated Voltage Range DC 19 2V tp DC 28 8V Allowable Voltage Drop In Rush Current Voltage Endurance AC 500V 20mA for 1 minute between charging and FG terminals Ure ONS General Specifications Functional Specifications Interface Specifications Part Names and Functions Dimensions 10M Q or more atDC 500V between charging and FG terminals Factory Gateway Series User Manual Cha
31. ollowing size ring terminals Over 3 2mml0 13in Under enon Ring Terminal Suggested Ring Terminal V2 MS3 made by JST 3 2 Factory Gateway Series User Manual Chapter 3 Installation and Wiring co TOOL O PIR 10BASE TO STA O TxD O RxD RST O TO e gi gt 1 i FO FG AN Er FG i B Ring Terminals re Power Input Front Terminal Block Positive Electrode Negative Electrode FG Groundin terminal connected to Factory Gateway chassis When connecting the power cord be sure to follow the procedures given below 1 Confirm that the Factory Gateway unit s Power Cord is unplugged from the power supply 2 Use a screwdriver to remove the Power Input Terminal Block s clear plastic cover 3 Remove the screws from the middle three 3 terminals align the Ring Terminals and reattach the screws See 3 2 2 Connecting the Power Supply A Confirm that the wires are connected correctly importan The torque required to tighten these screws is 0 5 to 0 6 Nem 4 Replace the Power Input Terminal Block s clear plastic cover Suggested Ring Terminal V2 MS3 made by JST Factory Gateway Series User Manual 3 3 Chapter 3 Installation and Wiring 3 2 2 Connecting the Power Supply Whensupplying power to the Factory Dia 1 G
32. pter 2 Specifications 2 2 2 1 2 Environmental torage Temperature Ambient Humidity Atmosheric Endurance GLC Operation Altitude Vibration Resistance Noise Immunity via noise simulator Electrostatic Discharge 2 1 3 Structural External Dimensions 0 C tp 55 C 20 C to 60 C 10 RH to 90 RH non condensing wetbulb tem perature 39 C max 1096 RH to 90 RH non condensing wetbulb tem perature 39 C max 0 1mg m max non conductive levels Free of corrosive gasses 800hP a to 1 114hP a 2000 meters max IEC61131 2 J IS B 3501 compliant 147m s three times for each X Y Z direction EC61131 2 J IS B 3501 compliant When Vibration is NOT Continuous 10Hz t 57Hz 0 075mm 57Hz to 150Hz 9 8m s When Vibration is Continuous 10Hz to 57Hz 0 035mm 57Hz to 150Hz 4 9m s 10 times 80 min for each X Y Z direction Noise Voltage 1200Vp p P ulse Duration lus ContactDischarge M ethod 6kV 100Q max or your country s applicable standard W37mm x H131mm x D105mm 1 46 in x 5 16 in x 4 13 in Approx 0 6 kg 1 32 lb Cooling Method Natural air circulation Factory Gateway Series User Manual Chapter 2 Specifications 2 2 Functional Specifications 2 2 1 Clock Clock Accuracy 65 seconds month atroom temperature GX e The FACTORY GATEWAY unit s internal clock has a slight NQY error At normal operating temperatures and conditions with the FACTOR
33. rver P C and used to 3 view or perform maintenance on data in a GP Viewer 1 0 or later PSW GV01 V10 PLC thats connected b the Factory Gateway unit Add on S ofware Used to create or maintain PLC device data that can be viewed with InternetE xplorer 4 sofware This data is taken from a PLC GE Wen ver LS or BET Ve device thatis connected to the Factory Gateway unit GP Web system includes server clientand GP PRO PBIII software B Tool Connector Product Name Model No Dati Transer Cable GPW CB02 Connects the Factory Gateway to a personal computer Transfers screen data and user programs 1 Installed from Pro Server with Pro Studio for Windows CD ROM With Ver 4 0 CD ROMs this software may not be included In this case please download the software from the www pro face com home page 2 With Ver 6 0 add on software is required Please download this software from the www pro face com home page 3 Required when using GP Viewer 4 Required when using GP Web 5 Normally maintenance data transfer is possible using an Ethernet network However depending on the data transfer cable used a Factory Gateway System Error may occur preventing communication 1 4 Factory Gateway Series User Manual Chapter 1 Introduction B Serial Interfaces Description RS 232C Cable GP 410 IS 00 O Interface cables between the host P LC and the RS 422 Cable GP 230 IS 11 0 Factory Gateway RS 422 Terminal Block Co
34. t is not protected To prevent damage or unit malfunction use only the designated level of current The SG and FG terminals are connected internally in the Factory Gateway unit When connecting the SG line to another device be sure that the design of the system connection does not produce a shorting loop Factory Gateway Series User Manual 2 5 Chapter 2 Specifications 2 6 A Tool Connector 2 4 Part Names and Functions Connects the data transfer cable when transferring data for maintenance or when using 2 Port feature B Ethernet I F 10BASE T Provides a 10BASE T interface C Network Status LED These LEDs are positioned vertically and indicate the Ethernet data transfer status Transferrin a Front TOOL O PR OBASE TO SFA ow O RD RST Notconnected to network Network trouble Ready to transfer data D Serial I F Dsub 25pin Used for the Dsub25 pin s RS 232C and RS 422 cables Is connected to the Host PLC 2 3 Interface Specifications E Power Input Terminal Block Connects the power cord F Power LED PWR This LED indicates the Factory Gateway s status LED Coreen Nomalopenton med Wimememsmemn Not Lit System program error G Error Status LED STA Factory Gateway Status Green Normal operation Red System error Screen memory data is damaged 2 Way feature error System Program Error For details see 4 1 1 LED
35. thin the allowable range 0 C to 55 C Is the operating humidity within the specified range 10 RH to 90 RH wet bulb temperature of 39 C or less s the operating atmosphere free of corrosive gasses Electrical Specifications s the input voltage DC 19 2V to DC 28 8V appropriate Related Items Are all power cords and cables connected properly Have any become loose Is the DIN rail holding the unit securely Factory Gateway Series User Manual 4 5 Chapter 4 Troubleshooting Mem oo 4 6 Factory Gateway Series User Manual
36. viation for Programmable Logic Controller This driver software is used as a protocol converter between external devices PLCs etc and PCs Factory Gateway GP and GLC series units D Indicates additional important information Indicates an important hint or explanation 10 Factory Gateway Series User Manual 1 Prior to Operating the Factory Gateway 2 System Design C h apte r 3 Accessories 1 Introduction 1 1 Prior to Operating the Factory Gateway Use the following steps to create projects for the Factory Gateway unit Factory Gateway Setup and Wiring Setup Chapter 3 Installation Wiring and Wiring GP PRO PBIII Device IP Address Setup PLC Connection Manual Vv Software Installation 2 E Pro Server with Pro Pro Server with Pro Studio for Windows Studio for Windows Operation Manual Factory Gateway Configuration Tool Factory Gateway Con Lh figuration Tool Operation Manual Create Network Project File Search for Factory Gatewa Register Factory Gateway as a node Pro Server with Pro Enter Factory Gateway Network Settings Studio for Windows Operation Set up wiring M I anua lt Send Network Project File Factory Gateway Serial Data Transfer Start up Factory Gateway Configuration Tools Search for Factory Gateway Factory Gateway Set up Serial Data Transfer Settings Configuration Tool Operation Select and set up protocol Manual Send protocol and setting data Sr When us
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