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Graco 312785C User's Manual

1. Fic 30 DeviceNet Port Pin Outs and PLC Connection 312785C 13962 43 Appendix A DeviceNet Slave Communication About DeviceNet DeviceNet is a connection based network In this con text the term connection refers to a communication path between two or more devices and not the physical cable connection to the DeviceNet network A connec tion must be established between two devices in order to transfer data There are two types of connection defined by the Devi ceNet specification Each has different characteristics and is suited to a specific type of communication e Connection Dedicated data transfer between a producer and one or more consumers The format of the data is known or implied by the connection e 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 communi cations 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 configur ing a connection have been removed with this connec tion set thus simplifying the network configuration Predefined Master Slave Connection Set T
2. Fy EMCODER C126 FiG 58 Configure Data Blocks the configuration and download it to the PLC NOTE e The maximum number of input bytes allowed is 244 e The maximum number of output bytes allowed is 244 e The maximum number of bytes overall is 436 312785 200 H D ETZDEL TE m 5 E7208 z Dg ET E1 65 Appendix B Profibus DP Slave Communication Graco Gateway Setup Once the PLC is setup the Gateway can be pro NOTE For a Gateway to communicate on Profibus grammed to fit its configuration 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 Gate way On the right hand pane click the Edit button to select the Option card Select Profibus Option card and click OK FIG 59 2KS Gateway LE 080108 Gateway LE Graco Config Edit View Link Help Da 0 3 i ose Option Card Selection x Programming Port RS 232 Comms Port RS 485 Comms Port Modbus Master E ProMix2KS Ethernet Protocol 1 Modbus TCP IP Slave EH G306TCP Block 1 Block 2 Block 3 Block 4 Block 5 Protocol 2 Protocol 3 Protocol 4 Services OPC Server lt amp
3. 0 31 3127856 Troubleshooting 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 screen is blank and PWR LED is power applied to the unit power applied to the unit Check power supply Units require 24 power supply Units require 24 VDC 10 Unit screen is blank and PWR LED is Contrast too low Graco Gateway Program one of the soft keys with the action as User Defined and the fol lowing code in the field On Pressed dispcontrast No primitives on the display Add objects to the User Interface in Graco Gateway Backlight is off Push one of the soft keys to turn it back on Backlight tube is broken Replace the backlight tube Unit continually cycles on and off Cross references between tags e g Remove one of the references or use Var1 uses Var2 as maximum which in formula tags for indirect reference turn uses Vari as minimum e g Form1 is equal to Var1 and used in minimum instea
4. 05 Programming Port RS 232 Comms Port R5 485 Comms Port Modbus Master ProMix2KS Ethernet Protocol 1 Modbus TCP IP Slave tm Block 1 Block2 Block3 Block 4 Block5 Protocol 2 Protocol 3 Protocol 4 Ry Services OPC Server FiG 21 Add Gateway Blocks 312785 Device Settings Enable Device Favour UI Writes Comms Delay 0 ms Delete This Device Add Block 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 win Hefer 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 appro priate values in the Select Address window and click dow will open OK The desired register address will populate the Start Address field 2 5 Gateway LE 080108 Gateway LE Graco Config E Edit View Link Help 3xmuauxin e Communications xi ose Block Settings Programming Port 5 232 Comms Port Start Address 400002 Edit H RS 485 Comms Port Modbus Master 7 ET ProMix2ks Block Size 7 Edit H 4 Ethernet TST
5. lt Back Cancel 41 EDS Image File 312785C the EDS registration and finish the process Rockwell Software s EDS Wizard E Final Task Summary This is a review of the task you want to complete You would like to register the following device G3 SERVER lt Back Cancel 42 Review EDS Registration General Module Scankst input Output Summary Available Devices Scanlist ill 01 G3 SERVER gt amp v Automap on Add Mode Active Electronic Key Upload from Scanner E Device Tine VV Download to Scanner 2 E COO E Fievigion Edit Parameters Minor or 43 Configure the DeviceNet Master 312785C EXIIT NENNEN 2x Edit 1 0 Parameters 01 G3 SERVER A xl d Strobed rf Change of State Cyclic Input Sire Bytes of state C Lu elle T Input Size fo a Bytes v Poled i Output Size fo 4 Bytes Input Size Bytes Heartbeat 250 Size 16 Bytes Poll Rate Ever Scan 4 Cae Appendix A DeviceNet Slave Communication Select the DeviceNet Master by navigating in the tree on the left hand side Navigate to DeviceNet gt Cate gory gt Communication Adapter 1756 DNB A Select the appropriate Major Rev and drag it into the network work space at the right Select
6. 5050 100 OPTION 2 cet SE DISPLAY RECIPE BIT 1 INPUT RECIPE BIT 2 INPUT RECIPE BIT 3 INPUT RECIPE BIT 4 INPUT RECIPE BIT 5 INPUT MEMBRANE 1 BOARD SWITCH WITH RIBBON 4 1 MIX INPUT 5 2 PURGE INPUT CABLE 6 3 JOB COMPLETE INPUT 5 POWER DIST 6 DIGITALINPUT COMMON 10 TERMINAL 1 DIGITAL INPUT COMMON T BLOCKS 2 RECIPE BIT 0 INPUT 4 5 6 7 8 i it 1 RECIPE CHANGE INPUT DISPLAY 2 INTEGRATION 3 BOARD 1 4 2 PURGE RECIPE CHG ACTIVE OUTPUT 5 3 MIX ACTIVE OUTPUT 6 MIX READY OUTPUT 7 6 FLOW CAL ACTIVE 7 FLOW RATE ALARM OUTPUT FLOW CONTROL CAL BLK 8 DIGITAL OUTPUT COMMON POWER 1 2 GUN TRIGGER WHT 2 1 DIGITAL OUTPUT COMMON POWER 12 3 DIGITAL IN COMMON RED 13 2 SPECIAL OUTPUT 1 4 REMOTE STOP 714 3 SPECIAL OUTPUT 42 13 4 SPECIAL OUTPUT 3 5 ALARM RESET BRN i 15 15 6 ALARM OUTPUT BLU amicam ies 3 DIGITAL OUTPUT COMMON POWER 16 7 DIGITAL OUTPUT COMMON ORG 17 H 18 9 FLOW RATE ANALOG IN PUR 9 19 10 FLOW RATE ANALOG COMMON GRAY i 10 FILL ACTIVE HARNESSES 24 YEL GRAY ORG BEACON TERMINAL BRN 0 RS485 INTEGRATION A WHT BLU BLOCKS RED 2 RS485 INTEGRATION B BLU WHT
7. Synchronise No Port Settings Baud Rate 125000 X Clear Port Settings Add Additional Device FiG 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 dor 2KS Gateway LE 080108 Gateway LE Graco Config File Edit Link Help nax ols Communications DSP x Programming Port RS 232 Comms Port Device Settings Enable Device Favour UI writes 5 485 Comms Port Modbus Master E a306TCP Block 1 Block 2 Block3 Block 4 Block5 Protocol 2 Protocol 3 Protocol 4 8 Services Ti OPC Server lt DeviceNet Option Card DeviceNet Interface Group 2 Server zm Block 1 FiG 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 00000 FIG 35 48 El 2 5 Delete This Device Add Gateway Block a amp Ethernet Protocol 1 Modbus TCPJIP Slave 312785C Appendix A DeviceNet Slave Communication NOTE For 16 bit support select Word as Word For 32 bit support select Word as Long The l
8. lt Back Cancel 38 Register the EDS File Select Register a single file and browse to the location where you saved the Gateway EDS file Rockwell Software s EDS Wizard 4 x Registration Electronic Data Sheet file s will be added to your system for use in Rockwell Software applications Register a single file Register a directory of EDS files Look in subfolders Named c Documents and Settings Desktop EDS Filessq3 eds 3 If there is an icon file with the same name as the file s you are registering then this image will be associated with the device To perform an installation test on the file s click Next lt Back Nest gt Cancel 39 Browse to Graco Gateway EDS File 52 Make sure that the EDS file validation is successful Rockwell Software s EDS Wizard E x T EDS File Installation Test Results This test evaluates each EDS file for errors in the EDS file This test does not guarantee EDS validity Installation Test Results v c documents and settingssdesktop eds filessg3 eds View file lt Back Cancel Fic 40 EDS Validation If desired select a new image file to represent the Gate Rockwell Software s EDS Wizard E Change Graphic Image You can change the graphic image that is associated with a device Product Types Change icon Generic Device G3 SERVER
9. xL Ee aed Real time Environmental conditions Operating temperature Storage temperature range Operating and storage humidity Vibration according 68 2 6 Shock according to IEC 68 2 27 ATUTUOO ECL A ass rinn aca eR at a OCA senate e dies Power Mounting Weight Gateway control box 312785C Technical Data 24 Vdc 10 200 mA minimum without expansion card 1 Amp maximum with expansion card fitted Requires Class 2 or SELV rated power supply 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 HS232 port via RJ12 RS422 485 port via RJ45 and RS232 port via RJ12 Transmit enable open collector lt 15 Vdc Vo 20 5 V 25 mA maximum 10 BASE T 100 BASE TX RJ45 jack is wired as a NIC Net work Interface STS Status LED indicates condition of Gateway module 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 and Type II cards Used for optional database
10. 15 GracoConfig Page 15 Setup the Database 16 Wap au a di rea 18 Modbus and I O Data 21 Start Mix Process 21 Stop MIX PrOGeSS EE LA 21 Color Change Process 21 Purge ProceSS ies 21 ProMix 2KS Active Alarms Modbus Register astare tesa 29 ProMix 2KS Modbus TCP Variable Map 30 ProMix 2KS Recipe Bits 31 Troubleshooting Lese 32 General Troubleshooting 32 Graco Gateway Messages Troubleshooting 35 Serial Communication Troubleshooting 36 Ethernet Communication Troubleshooting 37 LED FUNCIONS EET 38 System Electrical Schematic 39 PANS uiui cod oe es eR a 40 15V331 Gateway Ethernet Kit shown 40 15V963 Gateway DeviceNet Kit 40 15V964 Gateway Profibus Kit 40 Appendix A DeviceNet Slave Communication 42 iud ree d Xon Sec e X UP a 42 uev tni da Row d C pe 66 42 DeviceNet Port Protocols 42 About DeviceNet 44 Fat Wal xs utet 45 Automatic Update of the EDS File 51 Configure the RSNetWorx for DeviceNet Software 52 Configur
11. bers ex 192 168 2 xxx if the mask is 255 255 255 0 e If arouter is present on the net Check the Graco Gateway device work Ethernet port Gateway address to match the router IP address Incorrect tag mapping Check that the tag is mapped to an existing register in the target device Values blink between the data and Incorrect tag mapping on one of the Delete tags one after another and tags on the display 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 Communications times out Increase the Slave Response or Device Timeout on the communica tion port or target device in Graco Gateway 312785C 3 Troubleshooting LED Functions Status STS LED The green Status LED provides information on the sta tus of the Graco Gateway including various stages of the startup routine and any errors that occur Rapidly Graco Gateway is currently running the Flashing boot loader and or being upgraded Steady Graco Gateway is operating normally User Communication Ports TX RX LEDs Transmitting Red Receiving Ethernet LEDs Yellow Link Established Steady Yellow Network Activity Flashing 10 BASE T Communications 10 BASE TX Communications 38 CompactFlash CF LED No CompactFlash card is present Steady Valid CompactFlash card is present Rapidly CompactFlash
12. 3 85485 INTEGRATION GROUND SHIELD 4 85485 NETWORK A WHT ORG E 5 RS485 NETWORK B ORG WHT 6 85485 NETWORK GROUND SHIELD J7 C FOIN BLK 8 L FOOUT BLU RE HMM WEB SERVER MODULE 312785C 39 Parts Parts 15V331 Gateway Ethernet Kit shown 15V963 Gateway DeviceNet Kit 15V964 Gateway Profibus Kit Ref No 10b 10c 40 Part No 15V339 15T752 n a 120369 15V345 111987 n a 186620 n a 15V966 15V965 15X492 Description PANEL back COVER DIN RAIL POWER SUPPLY 24 Vdc GROMMET cable entry CONNECTOR strain relief WIREWAY LABEL ground COVER wireway CONTROL BOX Gateway BOX DeviceNet includes items 20 23 and 27 used on 15 963 Kit only BOX Profibus includes items 20b 23 and 27 used on 15V964 Kit only BOX ethernet includes items 23 and 27 used on 15V331 Kit only Qty LL n Ref No 11 12 13 14 15 16 17 20a 20b 23 25 27 Part No 120838 103833 112443 15V344 121994 121700 n a n a 15V347 15V346 15T999 n a 258527 Description BLOCK clamp end SCREW machine BLOCK terminal ground CONNECTOR CABLE CAT 5 CABLE 2 connector WIRE copper 16 ga 9 in 230 mm WIRE copper 16 ga 9 in 230 mm CARD DeviceNet 15V963 Kit only CARD Profibus 15V964 Kit only CABLE USB not shown SCREW machine serrated
13. Ethernet 2 Protocol 1 Modbus TCP IP Slave Driver Picker Driver Selection Driver Modbus TCP IP Slave for Ethernet Port Protocol 2 m Manufacturer Protocol 3 Protocol 4 8 Services Ti OPC Server Driver No Driver Selected Encapsulated Modbus Master Version 1 01 Version 1 05 Ye kion 1 02 TCPIIP Slave Help Cancel 19 Select Protocol 16 Permitted IP Mask Clear Port Settings Add Additional Device 312785 Graco Gateway Network Communications Configuration See FIG 20 Right click on device to rename it to something meaningful for your system 2KS Gateway LE 080108 Gateway LE Graco Config File Edit View Link Help 4 Communications 05 Programming Port RS 232 Comms Port RS 485 Comms Port Modbus Master ProMix2KS H 4 Ethernet Protocol 1 Modbus TCP IP Slave gt Protocol 2 Protocol 3 Protocol 4 By Services Ty OPC Server Fic 20 Rename PLC1 4 See FIG 21 Add as many Gateway blocks as desired under each device 2KS Gateway LE 080108 Gateway LE Graco Config File Edit View Link Help Enable Device Favour UI Writes Comms Delay 0 ms Delete This Device Add Gateway Block E Settings Communications
14. Lenath 4 Word 0 Fill File Source 0 Dest 2 0 0 Lenath 4 Wire the DeviceNet Network All DeviceNet networks require a termination resistor at the two end nodes on the network Place a watt 120 ohm resistor between CAN H White and CAN L Blue of the DeviceNet connection 312785 Appendix B Profibus DP Slave Communication Overview This appendix describes the Gateway s support for Pro fibus DP and details the configuration steps necessary to set up a Graco Gateway with an 57300 PLC CPU315 2DP via Profibus It does not provide a detailed description of Profibus but only a brief introduc tion 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 sup ports both analog and discrete signals It has wide spread usage for such items as remote systems motor control centers and variable speed drives Profi bus DP communicates at speeds from 9 6 Kbps to 12 Mbps over distances from 100 to 1 200 meters f PLC Connection Profibus Option Card E S I C I C m BENI Appendix B Profibus DP Slave Communication 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
15. Profibus Port Protocols The Profibus option card has one Profibus port See FIG 47 Also see Appendix B Profibus DP Slave Communi cation on page 57 2 Fic 47 Profibus PLC Connection 312785C 13964 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 rel evant 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 O with 64 words length However since blocks are consecutive this means the first block start address
16. 15 in progress FCalActive 1 indicates the Flow Control Calibrate routine is in progress 5 1 Flow Rate Alarm 1 indicates the Flow Rate Alarm Warning is active 1 Special 1 1 indicates the Special 1 output is on monitor only Special 2 1 indicates the Special 2 output is on monitor only Special 3 1 indicates the Special 3 output is on monitor only Special 4 1 indicates the Special 4 output is on monitor 10 jojoojoo to o o ofo ojo ojojo Not Used 5 Not Used _ 12 Alarm 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 43 Alarm Potlife 1 indicates a Potlife Alarm is in process NOTE Shaded cells relate to the flow charts on pages 23 26 28 312785C Modbus and I O Data ProMix 2KS Active Alarms Modbus Register 40010 Table 3 ProMix 2KS Active Alarms Modbus Register 40010 Digital Input Binary 312785 29 Modbus and I O Data ProMix 2KS Modbus TCP Variable Map Table 4 ProMix 2KS Modbus TCP Variable Map EasyKey Status Register Description ere Limit High Limit 36Bt comi 8000 Fead Ony 40004 Actual ato 6B nne 0 9999 ReadOnly 40005 Active recipe 16Bt 0 ReadOnly 40006 1 remaning _ 1688
17. Appendix B Profibus DP Slave Communication Select the Network Settings tab and choose the Trans mission Rate that fits the application In this example it will be 12 Mbps The profile should be DP FIG 55 Properties subnet FROFIBUS Gena Network Settings FR FIBLIS Options Acres sz Dunge Trsremiezinn Aae FiG 55 Set Transmission Rate Close the popup windows by clicking OK HWConfig should now show the Profibus DP master system next to the PLC FiG 56 D UR 9 PS 307 CPU315 2DP 1 X2 13 DIB DOSs DC24V l 0 on Se co zd FiG 56 Profibus DP Master System 312785C PROFIBUS DP master system 1 63 Appendix B Profibus DP Slave Communication Add the Graco Gateway to the Profibus Network In the properties window that popped up select the Pro fibus address the Gateway will take on the network This address should be unique In this example the Gateway will take address 5 FIG 57 Click OK 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 Profi bus DP Master System The card is situated under Profi bus DP gt Additional Field Devices MMI Lh bmm LITT IE do T FiG 57 Add Graco Gateway to Profibus Network
18. P Direction Device to G3 Edit Protocol 1 Modbus TCP IP Slave Echt 1 01 Block 1 Select Address for Modbus TCP IP Slave E Block 2 cJ Block3 Data Item 4 Element Block4 No Selection 4 Block5 Protocol 2 Analog Inputs T Protocol 3 Digital Coils Signed Mode 16 bit Y Protocol 4 Digital Inputs Sy Services m Details Type Word Td OPC Server Fic 22 Mapping Gateway Blocks 18 Data Word as Long Word as Real Minimum Maximum Radix 400001 465535 Decimal Cancel Help 312785 3 See FIG 23 Click the Edit button next to the Block oize field on the right side of the window The Edit Value window will open Enter the number of Mod bus register addresses in the range from the start ing 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 JKS Gateway LE 080108 Gateway LE Graco Config Edit vie File 4 Link Graco Gateway Network Communications Configuration ghax o DSP Communications
19. Profibus Option Card Profibus Interface Fic 59 Select Profibus Option Card 66 Option Card Profibus Option Card Remove Option Card Option Card Options 312785 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 FIG 60 2 5 Gateway LE 080108 Gateway LE Graco Config File Edit View Link Dag xmumx n sl Communications 5 18 DSP Programming Port x R5 232 Comms Port RS 485 Comms Port Modbus Master Appendix B Profibus DP Slave Communication Driver Selection Driver Driver Selected 2 5 Ethernet ci Protocol 1 Driver Picker for Profibus Port 2 a306TCP Additional Device Block 1 Block 2 Block 3 Block 4 BlockS Protocol 2 Protocol 3 Protocol 4 Ry Services Server Manufacturer Driver Mo Driver Selected lt Profibus Option Card Profibus Interface Fic 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 2 5_ _1 080108 Gateway LE Graco Config File E
20. screen to automatically find and select the drivers 1 Goto Start gt Programs gt Graco gt GracoConfig and run the program The GracoConfig main page will appear Link Pulldown Menu Update Symbol Gateway LE 080108 Gateway LE Craco Config Edit View Link Help D ow E ZSXU I XIDn 15 GracoConfig Main Page 14 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 Link Options Communications Port C COMI COMZ cg 759 Link oma Fic 16 Set Communications Port to USB TCP Port 3 Goto File gt Open and select the file with the xx gg2 extension The file name should appear at the top of the window FIG 15 once loaded 4 Download the database using the Link gt Update command As a shortcut use the Update F symbol on the toolbar See FIG 15 NOTE Downloading typically takes only a few sec onds but may take longer if the software has to update firmware on the Gateway module 312785 Graco Gateway Network Communications Configuration 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
21. see o 9999 Read Write 40007 Jobcompiete 168 0 oF _ FReadWite 40008 Hesetjobioa 16Bt noe 0 9 _ ReadOnly 40009 2remaining 1688 sec o 9999 ReadOnly 40010 Acivefaut Bt 0 ReadOnly 40032 Contolverion 32Bit o Od _ FReadWrte 40046 Newredpe 16Bt 0 60 _ Read Only 40048 Current fuid pressure 1656 pi o 5000 Read Ony 40048 VP percent ouput te 0 Read Only 740056 Actual ratio reducer 1688 mone o 9999 _ Head Only 40114 Flow control option 16 Bit O proportioning only 4 1 1 flow control future 2 2 flow control 3 pressure override 4 manual percent override Read Write 40115 Flow setpoint data source 16 Bit O discrete 1 NENNEN 0 Read Write 40120 Manual override percent 16 Bit WIN Read Write 40125 Flow control range 16 Bit 020 300 120 600 cc min a 1200 cc min 16Bi _ 0 99 Head Write 40127 Flow control proportional 16 Bit default 400 9999 oe ee ee Bel a Ki Read Write 40129 Flow control alarm time 16 Bit Read Write 40137 Flow control Flow control setpoint 16 16Bit RW EI ew conto setpomt control override 16 aa O off n mode 1 open 2 mode Read Write 43141 Flow control enable 16 Bit 13 1
22. way SERVER data are mapped to YourDNB Slot Data 0 3 From the Output tab verify that the four words are mapped to YourDNBSIot O Data O 3 Apply the changes and save your RSNetWorx for Devi ceNet configuration 25 1756 General Module Scanlist Input Output ADR Summary Poled 16 2 0 0 0 Unmap Advanced gt Options Memory Assembly Data Start DWord 0 E 31 0 2 0 0 01 01 G3 SERVER RVER 01 G3 2 D Dataf1 2 D Data 2 G3 2 D Data 3 01 G3 5 j2z Daabl 4 2 2 0 Dataf8l Cancel Apply Help 312785C Appendix A DeviceNet Slave Communication Configure the Allen Bradley ControlLogix PLC Allen Bradley ControlLogix PLCs are programmed with HSLogix 5000 programming software To begin the DeviceNet configuration launch RSLogix 5000 from used your development PC i RSLogix 5000 DeviceNet 1756 L55 File Edi View Search Logic Communications Tools Window Help Redundancy a Controller DeviceNet 8 Controller Tags 09 Controller Fault Handler Power Up Handler E ra Tasks i MainTask 28 MainProgram Eg Program Tags Du MainRoutine Pod au Unscheduled Programs aa Motion Groups Ungrouped Axes Trends aa Data Types Pob Ep User Defined EN Strings EN Pr
23. 64 words out 256 383 256 383 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 PL COffset is the first byte number in the complete block mapping in the PLC here 256 WordAddress is the address mapped in the Gate way 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 ByteAddress is the address we are looking for in the PLC PL COffset is the first byte number in the complete block mapping in the PLC here 256 DwordAddress is the address mapped in the Gate way 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 con secutive FIG 57 312785C Appendix B Profibus DP Slave Communication 71 Appendix C Graco Gateway to ControlLogix via Ethernet IP Appendix C Graco Gateway to ControlLogix via Ethernet IP Overview This appendix describes the configuration steps neces sary to establish a communication path between the Graco Gateway and a
24. 8 Output Connection Points Data Offset 0000 Block Size Data Type as Long 78 312785C Dimensions Dimensions 16 57 in 420 9 mm 4 52 in 114 8 mm 15 07 in 382 8 mm imm 7 OOOO ID A i 5 31 134 9 mm 221 2 mm mu J 112930 TI12825b 312785 79 Dimensions 80 312785C Technical Data Electrical power Communication ports USB PQ POS ceras an doas o m CR es Serial Ports RS232 PG COMM Ports Ree RE UR uos DH485 TXEN On board user On board SDRAM Memory CATO
25. Baud Rate 125000 Clear Port Settings d evi Electronic Data Sheet Yes ents and 5 1 interFace eds l OWSe i NOTE Inputs and Outputs are with respect to the mas ter therefore inputs refer to data sent from the slave and read by the master 51 Appendix A DeviceNet Slave Communication Configure the RSNetWorx for DeviceNet Software HSNetWorx for DeviceNet is used to set up and manage a DeviceNet network To begin the configuration launch HSNetWorx for DeviceNet from your development PC Start a new network by selecting File New DeviceNet Configuration Hegister the EDS file generated by Gateway as shown in the previous section of this document by selecting Tools EDS Wizard gt Register an EDS file s Rockwell Software s EDS Wizard x Options What task do you want to complete Register an EDS file s This option will add a device s to our database C Unregister a device This option will remove a device that has been registered by an EDS file from our database Change a device s graphic image This option allows you to replace the graphic image icon file associated with device Create an EDS file This option creates a new EDS file that allows our software to recognize your device 59 19 C Upload EDS file s from the device This option uploads and registers the EDS file s stored in the device
26. Block Settings Programming Port RS 232 Comms Port Start Address 400002 Edit H RS 485 Comms Port Modbus Master ProMix2ks Block size 7 Eel Direction Device to 63 Edit Protocol 1 Modbus TCP IP Slave El Block 1 Block Control Block2 23 Block3 4 Block 4 Block Size Block5 Protocol 2 L Protocol 3 View Block Protocol 4 By Services T OPC Server 23 Setting Block Size 312785 19 Graco Gateway Network Communications Configuration 4 FIG See FIG 24 Click OK The range of addresses will appear under the appropriate Block on the left side of the window 2 5 080108 Gateway LE Graco Config File Edit View Link Help NOTE In this example a Modbus device master communicating via TCP IP will have direct access to Modbus registers 40002 through 40008 of the Pro Mix 2KS For example see Block 1 address line 1 Block 1 X 400002 ProMixzk5 400007 OM UM IET Modbus address of ProMix 2KS Modbus address command from TCP IP master connected to Gateway 5 The Direction field typically should remain set to Device to G3 DEK s taxol Communications E DSP xi Settings Programming Port 5 232 Comms Port Start Address 400002 Edit
27. Gateway LE 080108 Gateway LE Graco Config Edit View Link Help D a tbe x 17 Communications Button 312785 GracoConfig Page Communications Button The Communications button provides access to screens used to configure your system and setup parameters allowing you to e Specify which protocols are to be used on the Gate way serial ports and on the Ethernet port e f 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 e f 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 e Move data between one remote device and another Balloon Help The Balloon Help feature allows you to see help infor mation 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 e When Mouse Over displays help when the mouse pointer is held over a particular field for a certain period of time e When Selected displays help constantly for the cur rently selected field 15 Graco Gateway Network Communications Configuration Setup the Database 1 the preconfigured
28. database gg2 The file is already setup for 2KS See FIG 18 265 Gateway LE 080108 Gateway LE Graco Config File Edit View Link Help Double click on the Communications button to open 5 0 3 Communications E DSP x Programming Port RS 232 Comms Port RS 485 Comms Port Modbus Master ProMix2KS 4 Ethernet 2 Protocol 1 Modbus TCP IP sia Protocol 2 Protocol 3 Protocol 4 By Services Td OPC Server 18 Preconfigured Database 2 See FIG 19 Highlight Protocol 1 Click the Edit but ton on the right side of the window to open the Driver Selection Driver Modbus TCP IP Slave Driver Settings TCP Port 502 Session Limit 2 Word Ordering In Long Blocks Low Then High m In Real Blocks Low Then High Driver Security Do Not Restrict Permitted Data 0 Server Access Permitted IP Mask 0 Add Additional Device Clear Port Settings lists provided in this example Modbus and TCP IP Slave The system will create device PLC1 Driver Picker window Choose a protocol from the lt gt 205 Gateway LE 080108 Gateway LE Graco Config File Edit View Link Help Oealv ivax ols e Communications ix DSP Programming Port R5 232 Comms Port 5 485 Comms Port Modbus Master E ProMix2KS
29. 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 DP Master Output Block byte 256 to byte 383 Input Block byte 256 to byte 383 Fic 48 Master Slave Exchange 58 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 e 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 e This results in a range from word 0 to word 63 FIG 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 FIG 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 DP Slave Input Block word O to word 63 Output Block word O to word 63 312785C Appendix B Profibus DP Slave Communication Setup the PLC 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 Techni cal Assistance for Profibus GSD files The S
30. momentary CC 7 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 Mx Set bit initiate Mx mode maintain bit initiate Mix mode maintain 8 nines bit to 1 to initiate Set bit to 1 to initiate Purge sequence maintained sequence maintained tary External CC Set bit to 1 to initiate External Color Change 00110001000 01010100 Used _Calibrate bit to 1 to initiate a Flow Control Calibrate input momentary 13 1 Gun Trigger Set bit to 1 to indicate the gun is actually triggered maintain while gun is triggered remove when gun is closed 54 o o 9o Ress Am Serb ta T to clear an active momenta _ 15 Stop Set bitte 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 Bin as B caos Purge or Color Change Is in prog ress 00000 Mix Mix Active Js 1 indicates Mixisinprogress Mix is in 1 indicates Mixisinprogress 00000 0000 100 Ready Mix Ready Ready 1 indicates No Alarms and 1 indicates No Alarms and to Mx to Mix CC Fill Active 1 indicates the Fill portion of a Color T
31. number For exam 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 Use the transform property on the tag For example bytes reversed in the to modify the data source You might word have to try multiple solutions to solve the issue 312785C 33 Troubleshooting PROBLEM CAUSE SOLUTION Symbol or image leaves a trace when The background of the image is not animated Rich Bar Graph or Dial Gauge does not move Trend Viewer curve stuck at the bot tom USB Drivers location for Windows USB Driver installation Upgrading Graco Gateway did not upgrade the software version 34 refreshed Tag minimum and maximum are not setup No minimum and maximum setup on the data tags displayed in the viewer Location of the dr
32. 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judicia
33. the Gateway Slave by navigating in the tree on the left Navigate to DeviceNet Vendor Graco Con trols 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 proper ties From the Scanlist tab select the Gateway SERVER from the Available Devices pane and add it to the Scan list pane Select the Edit Parameters button Cancel Restore 1 0 Sizes 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 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 25 1756 2 xi General Module Scanlist Input Output ADR Summary Node Type Size Map 01 63 Poled 16 2lData 0 0 AutahMap Unmap Advanced gt Options Memory Assembly Data Start DWord o Bits 31 0 21Data3 AT VER 2 l Dataf8l Apply Help 44 Apply and Save 54 Select the Input tab Verify that the four words of Gate
34. tion as follows a Switch to offline mode b Right click on the 1756 ENET B or 1756 ENBT A node under the Configuration in the Controller Organizer view and choose Add Module c Inthe Select Module Type window choose Generic Ethernet Module See FiG 71 d Click OK This will open the Module Properties window See FIG 72 IP Address dder Host IF 2441 Finish Button 73 Appendix C Graco Gateway to ControlLogix via Ethernet IP Module Properties Local 41 5 7 1 IP Address lF Adder Domain Name IP Address 192 168 2 100 Damen Mane Must Match IP Address en General T ac Piman DMS Subnet Mask Sener Secondan OHS d Do de dp Subnet Mask 255 zh 255 0 Sewel 0 0 192 E Set Button Enable Status Hurnina Cancel Fic 70 Port Configuration Window RSLogix 5000 3_ 1756 4 1 Fir gt wem fp ooo Window Hele Select Module Type Controller 53 Controller Tags Type jor Revision 59 Controller Fouk Handler TOULE 29 Handler z 5 Tasks Description Ei MahTask 17EB EMETZE 1756 Ethernat Bridge UB MeinProgram 17EE E WEB AA 1756 10 100 Bridge wE rhianesd Web Services Unscheduled Programs 1757 FFLD 1757 Faune Eel tinting Devic
35. 22 312785C Moabus and Data Mixing Mode Process Mixing Mode is desired PLC is polling to ensure Mixing Mode is main tained Is Mix Active bit 2 1 Mixing Process active Check Alarm 2KS is in Standby Go to Condition is Alarm Start Mix Process page General bit 1 21 Go to Alarm Process ing page 26 Fic 26 Mixing Mode Process Flow Chart 312785C 23 and Data NO Must be Alarm Condition or Active 61 See Alarm Processing on page 26 or Startup from Recipe 61 see NOTE below Is Mix Ready YES bit 1 Set Purge bit 1 Is Purge CC Active bit 1 Wait for Mix Ready ProMix 2 5 in Purge CC Mode Is Mix Ready Process Started bit 1 YES Set Purge Bit NOTE At power up the system defaults to Recipe 61 which is not a valid recipe number Initiate a color change to Recipe or a valid recipe number 1 60 FIG 27 Purge Mode Process Flow Chart 24 ProMix 2KS Purge Process Complete 312785C Color Change Process basic Do nothing YES Spraying at desired recipe Ensure Color 5 Change bit is seen Purge CC Active by ProMix 2KS bit 1 YES NO Is Mix Ready bit 2 1 Check Alarm Condition is Alarm General bit 2 1 NO YES Is Active Recipe to desired recipe Register 40005 Wait for Mix Ready YES Modb
36. 2930 6 15 ee 17 To 4 didi TI12929a 10 18 7112932 41 Appendix A DeviceNet Slave Communication Appendix A DeviceNet Slave Communication Overview This appendix describes the Gateway s support for Devi ceNet and details the configuration steps necessary to use this feature It does not provide a detailed descrip tion of DeviceNet but only a brief introduction neces sary 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 communica tion between a range of industrial devices from simple devices such as sensors and actuators to high level devices such as controllers and DeviceNet Port Protocols The DeviceNet option card has one DeviceNet port See FiG 30 The port may be configured for various Devi ceNet protocols Contact Graco Technical Assistance for currently supported protocols Also see Appendix A DeviceNet Slave Communi cation on page 42 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 Position 2 of the pluggable connector provides the CAN bus line active low This te
37. 3 You should now see a new ETHER 4 Download the new configuration to the control NET MODULE Gateway HMI branch of the ler Once the download is complete the controller 1756 ENET B node in the Configuration view will automatically establish a new Class1 connection You should also see three new entries in the Con with the Gateway troller Tags view e Gateway to view the input data Gateway HMI O to modify the output data e Gateway to view the configuration data ic 5000 3_ 1756 1 1 Edk Seerch Logic Communications Took Window aj E RUN Forces UK NoEdts Epo Cooler 53 Controller Tags Coroller Fault Handler 3 Power Up EE i i Mant sak i Mon rogram unscheduled Prozrame B3 HHELD ic Decimal 3 Mcbon Groups Td Desimal 27 Ungreuped 463 0 Desimal 3 Trend EH TERI T use ceto m Ep HE Stange 63 J Decimal Lg Predefined 863 Decimal n Module Defined corfiquracion H 172 9 8 PTHERNET MOOLLE 52 Fic 73 Ethernet Configuration Data 76 312785 Graco Gateway Configuration jr Ethernet Set
38. 5C Install the Gateway Module Hardware Install the Gateway Module Hardware EasyKey Bottom View er Jt Communication Wire Cable to PLC This connection is protocol dependent FiG 3 EasyKey and Module Cable Connection Points 112638 2 wire twisted pair cable with shield wire to Gateway Module Gateway Module E E USB Port 5556 m E CC O a 73 OOOOO B OOOO 7 mM i a P 112930 2 wire twisted pair cable with shield wire to EasyKey See Wiring Diagrams on page 41 for pin connections 312785C Install the Gateway Module Hardware 1 Common x 2 24 Vdc 10 8 zz N OO Power Connector 020 0 05 e 1 RS232 PG pel USB PG TxB Pin 1 Pin 8 COMMS COMM COMM RTS Pin 6 Tx ecTs Pin 1 Rx o Green Amber LED Yello
39. 64 ilu d Ero 0 itet 1 dad lu TE wort b Ln d rs vr ere Oe E alea Cid Tah m cg Dira mg CE 312785 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 BELT NS DRESS Appendix B Profibus DP Slave Communication More blocks can be inserted in the following slots to fit your application 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 con secutive It is however advised to keep the addresses consecutive to facilitate development FHE na Dtm apes poat zu bcd mE E eade Chal 1 weed OL 1 tard Pesta zen x3 PFEALL 2I E EP x 1g Compadbis PROFLE OF
40. 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 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 HSLogix 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 termi nal 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 l o 0 i V A 115057 Ethernet Connection to PLC Fic 68 Ethernet PLC Connection 72 312785 ControlLogix Configuration 1 Run the RSLogix 5000
41. Gateway Profibus Kit Allows communication between ProMix 2KS and a PLC using Profibus process control Enables process equip ment to read variables while operating as well as con trol the ProMix 2KS and change setup It does not provide access to job and alarm logs 312785C Graco Gateway Kits 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 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 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 e Use equipment only in well ventilated area e 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 o
42. GracoConfig software will operate with all versions of Microsoft Windows 98 and above Win dows 2000 or above is recommended for more robust operation e and free disk space as required by the chosen operating system e additional 5 of disk space for software installation e A display of at least 800 by 600 pixels with 256 or more colors e USB port for downloading a configured database to the Gateway module 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 FiG 12 USB Port T112930a USB Cable Strain Relief FiG 12 Gateway Module USB Port 2 FIG 13 will appear Select Yes this time only then click Next Welcome the Found New Hardware Wizard Windows will search for current and updated software by looking on your computer an the hardware installation or on the Windows Update Web site with your permission Head our privacy policy Can Windows connect ta Windows Update to search for software Yes this time only CO now and every time connect a device not this time Click to continue Fic 13 Found New Hardware Screen 312785C Install the GracoConfig Software 3 FiG 14 will appear In
43. H RS 485 Comms Port Modbus Master ProMix2ks Block Size 7 Edit H Ethernet TE T Direction Device to G3 Edit Protocol 1 Modbus TCP IP Slave dt Blocki Block Control 400002 2 5 400002 400003 ProMix2KS 400003 ProMix2KS 400004 Acknowledge General Edit ProMix2KS 400005 400006 ProMix2KS 400006 400007 ProMix2KS 400007 400008 ProMix2KS 400008 Block 2 Block 3 Block 4 BlockS Protocol 2 Protocol 3 Protocol 4 Services Td OPC Server x x x X 4000 x x x He Zee He 1 1 Export to File Delete This Block View Block 24 Block Mapping Data 20 312785 Modbus and 1 0 Data See Table 4 through Table 5 for Modbus register addresses and input output data Reference the Discrete listing of all the inputs and outputs see page 30 Ensure these are fully under stood The same implementation used for Discrete is used for the Network communication protocol For example The Gun Trigger Input will now be a spe cific bit of Modbus Register 40040 Monitoring of Mod bus Register 40041 for specific output status conditions will be required as explained in the Discrete 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 v
44. Instructions Parts gt 7 GRACO Gateway Network 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 e Head all warnings and instructions in this manual and in your proportioning system manual Save these instructions TI12933b PROVEN QUALITY LEADING TECHNOLOGY Contents Graco Gateway Kits 3 Related Manuals 3 Warnings separa pes Deer em 4 Graco Gateway Overview 5 Install the Gateway Module Hardware 5 ad dod doe Enea e ied 5 MOUNTING MT 5 5 Connect the Module to the 7 Cabling Connections 7 Mount the Control on DIN Rail 11 Install CompactFlash 11 Install the GracoConfig Software 12 System Requirements 12 Load the Software 13 Software Updates 13 Download the Preconfigured Database to the Gateway 0 14 Graco Gateway Network Communications Configuration 15 StartUp suo de ao oed a eS
45. O Bit Strobe command data Mas ter to Slave Identifies the I O Bit Strobe response data Slave to Master PollC Identifies the Poll command data Master to Slave PollR Identifies the I O Poll response data Slave to Master DataC Identifies the Consumed Data Master to Slave 50 312785C Automatic Update of the EDS File 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 maxi mum 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 2 5 080108 Gateway LE Graco Config File Edit View Link Help TA PAET ESME Co munications E DSP Programming Port x R5 232 Comms Port 5 485 Comms Port Modbus Master Driver Selection Driver DeviceNet Predefined Group 2 Server Edit Appendix A DeviceNet Slave Communication 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 gene
46. 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
47. arious bit posi tions 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 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 26 Table 1 and Table 2 1 Clear the Mix bit 312785C Modbus and I O Data 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 an
48. ation page 66 is important 2 5 Gateway LE 080108 Gateway LE Graco Config File Edit View Link Help ODeelvinvaxilols Communications DSP Block Settings Programming Port R5 232 Comms Port RS 485 Comms Port Modbus Master Select ProMix2KS Tad List H 4 Ethernet 89 5 9 Protocol 1 Modbus TCP IP Slave lt Tags EH 306 m Block 1 Block 2 Pick Block3 Pack Block Edit Block5 Protocol 2 W Protocol 3 Protocol 4 Services Ti OPC Server Profibus Option Card Sort Tags by Original Order Profibus Interface Profibus DP Create Tag Block 1 X Create FiG 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 FIG 63 2KS Gateway LE 080108 Gateway LE Graco Config File Edit View Link Help Oea axo Communications 5 18 F Block Settings rogramming Por R5 232 Comms Port Edit RS 485 Comms Port Modbus Master Select Edi ProMix2K5 ke Properties of Variable Select PLC1 from a Edit Protocol 1 Modbus TCP IP Sia pulldown menu EH 306 Blo
49. atter is recom mended 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 2 5 080108 Gateway LE Graco Config File Edit View Link Help Deelv ivaxilols i ose Block Settings Programming Port RS 232 Comms Port Start Address 5 485 Comms Port Modbus Master Black 5 ze Edit Er ProMix2kS E fo H 4 Ethernet METTRE 5 0 Protocol 1 Modbus TCP IP Slave Eg 306 Block 1 Block2 Block3 Element Block 4 No Selection 00000 LONG Block5 i I O Bit Strobe Command Data Y Bit Strobe Response Data E I O Polled Command Data Protocol 3 I O Polled Response Data Protocol 4 I O Consumed Data gt Ry Services Produced Data Details OPC server Type Word lt DeviceNet Option Card Minimum 00000 6 DeviceNet Interface Group 2 Server Maximum PollC65535 LONG Eg DEVI Radix Decimal Block 1 Data Type Block2 as Word Cancel Help FiG 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 Writ
50. ay 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 31 Click OK Sele Option Card Selection Option Card Not Fitted 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 2 5 080108 Gateway LE Graco Config File Edit View Link Help Communications E DSP H 4 Ethernet Protocol 1 Modbus TCP IP Slave TETERE Programming Port x R5 232 Comms Port H 5 485 Comms Port Modbus Master ProMix2KS E 6306 Block 1 Block 2 Block 3 Block 4 Block 5 Protocol 2 Protocol 3 Protocol 4 E Services 1 oec Server lt DeviceNet Option Card DeviceNet Interface 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 FIG 32 xi Driver Selection Driver No Driver Selected Settings Driver Picker for DeviceNet Manufacturer Set the appropriate Statio
51. card is being checked Flashing Unit is writing to the CompactFlash card either to store data or because the PC connected via the USB port has locked the drive Incorrectly formatted CompactFlash card is present Flickering Slowly Flashing Do not turn off power to the unit while this light is flickering The unit writes data in two minute inter vals 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 312785C System Electrical Schematic System Electrical Schematic Non Hazardous Area NON HAZARDOUS AREA lt lt lt lt lt lt lt lt lt lt SS lt 2 lt lt lt lt lt lt lt lt lt SS lt lt lt lt lt lt M SS EE lt lt lt lt lt lt mi lt lt lt lt SS m a a 7 OPERATOR INTERFACE 4 Li DCOK N FITER 24 VDC POWER 2 H N ND 11 TERMINAL SUPPLY N COMMON 250 COMMON 85250 VAC L jy rat ea ortae POWER HARNESS OPEN OPEN HARNESS 12VDC1 S RED COM BLACK BARRIER BOARD CABLE
52. cki Variable Data Block2 Mapping 24 Block 3 mmm Block 4 Driver Default Block5 Protocol 2 ACCESS Read and Write Protocol 3 Block Protocol 4 Storage Non Retentive Ry Services Ty server Information lt amp Profibus Option Card T EE Profibus Interface Profibus DF ommen B Block 1 Block2 Fic 63 Variable Properties 68 312785C Appendix B Profibus DP Slave Communication In the popup window select the block type required Two e Select the data offset which points the address to choices are available read or write in the block Select the data type to read or write This defines how many bytes to e block The terminology input is from the Sie access in the block to get the correct data In this mens perspective Therefore this will be a block the example we choose output block with data offset 0 Gateway will write to The tag mapped to an input Which points to 256 in the PLC and as a Word block has to be set up as Write Only FIG 64 e Output block The terminology output is from the Siemens perspective Therefore this will be a block Select Address for Profibus DP Fx the Gateway will read from The tag mapped to an output block has to be set up as Read Only ata Black lock Type Input Block Data Offset 0000 Byte FiG 64 Select Block Type NOTE Since the outpu
53. connection set 312785C 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 specifica tion 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 HSNetWorx for DeviceNet software and a Gateway 2 6 Gateway 080108 Gateway LE Graco Config D w Eit 5 Communications DSP 4 Programming Port x 5 232 Comms Port 5 485 Comms Port Modbus Master ProMix2KS Ethernet Protocol 1 Modbus Slave Ef 06 Block 1 Options Block2 Block 3 Block 4 Block5 Protocol 2 Protocol 3 Protocol 4 Sf Services Server Option Card Not Fitted CAN Option Card Fic 31 Select DeviceNet Option Card 312785 852321485 Option Card Appendix A DeviceNet Slave Communication Configure the Gateway DeviceNet Option Card Install the Gateway DNOOOO option card in the Gateway as per the provided instructions Click on File gt New to create a new Gatew
54. d of Var1 Database is corrupted Create a new database or send to technical support for debugging Unit cycles power after an operation Most likely a program going in an Check if the operation launches pro endless loop gram containing loops with no exit point CF LED flashing slowly CF card corrupted or invalid Format the card from Graco Gateway using the Link Format Flash menu 32 312785C Troubleshooting PROBLEM CAUSE SOLUTION Unit shows Version Mismatch The database currently in the device Download the database from Graco does not match Graco Gateway s 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 Download a database from Graco rupted or there are no databases in 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 Check the tag mapping making sure correctly 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 Increase the number of digits before point to show the
55. d that the system is ready for the next command 2 Load ccNewRecipe Modbus 40046 with a recipe number to color change to Set color change 40040 bit 6 4 Verify that Purge CC Active is seen 40041 bit O 5 Clear color change bit momentary only 6 Do not change 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 com pletion 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 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 21 Modbus and I O Data Start Mix Mode Process NO YES Is Mix Ready bit 1 Must be Alarm Condi Set Mix bit 1 tion or Active Recipe 61 See Alarm Pro cessing on page 26 or Startup from Recipe 61 see NOTE below Is Mix Active bit 1 NOTE At power up the system YES defaults to Recipe 61 which is not a valid recipe number Initiate a color change to Recipe or a valid recipe number 1 60 ProMix 2KS in Mix Mode Complete Mix Active 1 while the ProMix 2KS is in Mix mode 25 Start Mix Mode Process Flow Chart
56. diately with genuine manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Houte 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 com munication 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 However network communications require placing correct values or adjusting appropriate bits within various Modbus regis ters 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 b
57. dit View Link Help 1 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 Profi bus Interface This device represents the Profibus Mas ter and can be renamed to fit the application In this example the name PLC1 remains FIG 61 Sele Da Communications 05 x Programming Port x 5 232 Comms Port RS 485 Comms Port Modbus Master ProMix2KS H 4 Ethernet Black Size Direction xi Settings Start Address Eg a306TCP Block 1 Block2 Block3 m Block 4 Block5 h Protocol 1 Modbus TCP IP Slave Request Block Control General Acknowledge General Protocol 2 Protocol 3 Protocol 4 Services Ti OPC Server Profibus Option Card Profibus Interface Profibus DP B Block 1 Block2 FiG 61 Block Settings 312785 Export to File Delete This Block 67 Appendix B Profibus DP Slave Communication Setup Tags First create a variable that correspond to the data type MEE required In this example an integer FIG 62 Once the communication is set up tags can be created to access the PLC blocks This is where the section Setup the Profibus Communic
58. e lt Monon Groups 1757 FFPC A 175 Foundebon Fieldbus Process Controle LE Ungrouped Axes JITES LaSE Ethemet 10 100 Mbes Ethemet on 9 5335 Trends 1788 10 100 Mbps Bridae 72 Data Types TSA NT AA 1784 10 100 Mbps Ethernet Adapter User Defined Ge areng Ether el RI Lg Strings A Powe le 200 Vector Dive 20824 04 via 20 m Predefined TUO Power POL Veckor Drives 00480 via 2 148 Powerless TDI Vector Priser lex 700 Veckor Drive BET via zD EEIMIM E zd J EEEE TDO 2DUV E 700 D tive 208 2409 via 20 Vendor All Othe 120 Salact All Show ndog Digli Communication Centrale leer e FiG 71 Ethernet Module Selection 74 312785C e In the Name field enter a descriptive name to identify the module See FIG 72 Appendix C Graco Gateway to ControlLogix via Ethernet IP Enter 1 in the Configuration Connection Point and a size of 0 Configuration data is not sup ported by the Gateway f Inthe Address Host Name field enter the Address of the Graco Gateway j Press Finish to add the Gateway to the con figuration g Enter2 in the Input Assembly Connection Point and a
59. e Data Block FIG 36 shows both Gateway blocks once com pleted 2 5 080108 Gateway LE Graco Config File Edit View Link Help Communications E DSP Block Settings mE Programming Port RS 232 Comms Port Start Address PollCO0000 LONG Edit RS 485 Comms Port Modbus Master ProMix2kS Block Size a amp Ethernet GtoDeke Protocol 1 Modbus TCP IP Slave SERITUR EEG E a306TCP Blocki Block Control Block2 Edit Block3 Block 4 kn Block5 Protocol 2 N Protocol 3 Export to File Delete This Block View Block Protocol 4 Ry Services Tir OPC Server lt gt DeviceNet Option Card DeviceNet Interface Group 2 Server E Block 1 X Pollcoo000 LONG X 00002 10 6 X 00004 10 6 X 00006 10 6 Block2 X Pollcoo000 LONG X 00002 10 6 X 00004 10 6 X Pollco0006 LONG Fic 36 DeviceNet Block Mapping NOTE Read and Write are from the Gateway point of DataP Identifies the I O Produced Data Slave to Mas view This means the master can send data in Block A ter 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
60. e the Allen Bradley ControlLogix PLC 55 Wire the DeviceNet Network 56 Appendix B Profibus DP Slave Communication 57 OVEIVIEW 57 Hiat EOCILIC HOT heo Dat oom dL eie mt 57 Profibus Port Protocols 57 About Profibus 58 oetup the PLG iud ae Ree a eie 59 Graco Gateway Setup 66 Appendix C Graco Gateway to ControlLogix via Ethernet IP 72 OVGTVIOW dria huie ted 72 otc door 72 ControlLogix Configuration 73 Graco Gateway Configuration 77 5 1 0 5 79 Technical Data dtu 81 Graco Standard Warranty 82 Graco Information 82 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
61. edefined Module Defined Configuration 1756 Backplane 1756 4 tlale RIE IEEE LIBUS Module Properties 2 1756 DNB 3 5 _ General Connection RSNetwon Module Info Backplane Type 1756 DNB 1756 DeviceNet Scanner Vendor Allen Bradley Descrigtion E sit 3 pP d Electronic Keying Compatible Keying gt Bem zeb 3 DeviceNet Run Bit RunBit j E MainRoutine 45 Create Valid DeviceNet Scanner 312785 23 E 825 Jutput Size 2 8259 Create ControlLogix program containing a valid Devi ceNet Scanner In this application a 1756 DNB was ata Transfer ontral Re ster File Arith Logical Control Lenath Position Made Dest Expression Fill File ource Dest Local 2 00550 Length DeviceNet R a Soure Dest 2 00550 Length 55 Appendix A DeviceNet Slave Communication Configure the DeviceNet Scanner to be address O 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 f5 RSLogix 5000 DeviceNet 1756 L55 File dit View Search Logic Communications Tools Window Help a 5151 1 3 lal Select the RSNetWorx tab and navigate to the RSNet Worx for DeviceNet configuration that you have previ ously created Open the co
62. he DeviceNet specification details a number of con nections that facilitate data transfer between a Master and Slave devices The following sections detail the con nection types supported by the Gateway e I O Bit Strobe Connection The Bit Strobe connec is an connection over which Bit Strobe command and response messages are transferred The Bit Strobe command is broadcast by the Master device and is received by all slave devices simulta neously The command message contains a single bit of information for each slave on the network Each slave device is required to respond with a Bit Strobe response message The response message can contain up to 8 bytes of information 44 e 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 num ber of bytes e O Data Connection The 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
63. he correct communica tion port Link Options Port already used Check that the communication port is not used by another service or soft ware especially for serial ports Target device IP address If you download via Ethernet check rect the IP address of the target device in Link Options No USB Drivers Check that the USB drivers were installed successfully Reinstall Graco Gateway USB driver under the PC device manager if necessary No reply from terminal Cable is not connected Make sure the cable is connected or check above solutions If the message appears while down Download again with Link Update loading to the device or F9 CompactFlash required for upgrade version of Graco Gateway on the Insert a CompactFlash Card in the PC is different from the target device target device firmware version when attempting Use another communication port for download via Ethernet download USB or Serial The window is too small to allow edit The current User interface view is too Change the panel view using View ing small to allow editing Panel Display only The device returned an unexpected The device you are trying to down Update Graco Gateway to the latest reply code load to is not supported by this ver version available contact your Graco sion of Graco Gateway distributor or Graco Technical Assis tance Choose Repair when upgrad ing 312785C 35 T
64. hex head CD ROM software Gateway not shown Qty 2 A Heplacement 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 312785C 12 Parts Screw Location item 25 10a b orc 20a or b 14 4 USB Port DOO ref item 23 Bt 6666 OL JO r OOOO 14 DRRJ45 Network Terminals DOODOODGHS pu P AH 16 A BSH ProMix 2KS EasyKey OO RS485 Network Terminals 12931 312785C 4 17 Wiring Diagrams OOOO OO OO 8 11
65. iemens Simatic Manager software is used to set up the 57300 PLC The following figures and explana tions are extracted from this software Start Simatic Manager and open or create a new PLC project Select the Simatic 300 Station in the navigation pane as shown in FIG 49 STATI Manager 57 2 Edt 5 PLC Mew Options Window Help Exe 2 sp md nere a 8 mE E SI Pro E Program Files Siemens renTisZpepnjs57 xl 57 Programi Sources gy Blocks Press Fi ta get Helo Adapter MPT Fic 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 config uration Close this configuration NOT HWConfig and choose Options gt Install GSD File 50 MATIC PC SIMATK PC Fic 50 Install the GSD File 312785C 59 Appendix B Profibus DP Slave Communication Click Browse to select the folder were the GSD file Once the GSD file is installed successfully the PLC downloaded previously is select the file and click Install hardware setup can be opened again by doing Station FIG 51 and selecting the latest opened file which should be number 1 If this is a new project configure your PLC with the right modules Install GSD Files Install GSD File
66. ires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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 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 GRACO INC AND SUBSIDIARIES BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2009 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised 09 201 1
67. ivers unknown The operating system is unable to find the driver or the installation failed The option selected during the upgrade was Modify instead of Hepair Change the primitive Fill Format to Solid color Add the system variable dispcount in the background of the image to force the refresh Check the tag s minimum and maxi mum values These are used by both primitives for minimum and maxi mum Check that all displayed tags in the trend viewer have a Minimum and a Maximum setup The drivers are located under Graco Gateway 2 0 Device installation folder For example Files Graco Gateway Device In your operating system device man ager check if the Graco Gateway is present If so uninstall that device Follow the USB installation guide Launch the upgrade again and choose Repair when prompted 312785C Troubleshooting Graco Gateway Messages Troubleshooting PROBLEM CAUSE SOLUTION Device incompatible with file The device you are trying to down Create a new database file corre load into doesn t match the database sponding to your device File gt New device Unable to open communication port The communication port you try to download with is unavailable e Cable not connected Check if the cable is connected cor rectly to the PC and the device pro gramming ports USB or PG Port Incorrect download communica Check that Graco Gateway is tion port directed to t
68. n 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 Block Settings Stort Aderess 03 0000 Edt Device En 53 Edt Delete This Block Select Address For EtherNek p lave Long Az Long Appendix C Graco Gateway to ControlLogix via Ethernet IP The following settings mirror the settings of the 4 Data Mapping the connection points are now con ControlLogix configuration detailed earlier figured so that Gateway HMI O gt gt PLC1 Block1 a Input Connection Point Create a Gateway Gateway lt lt PLC1 Block2 block configuration see Table 7 5 Testing Using the RSLogix5000 program you can Table 7 Input Connection Points modify tags Gateway HMI O and verify they are written into Var1 and Var2 and verify changes made Connection Point in the Gateway to tags Var3 and Var4 are updated in Data Offset 0000 Gateway Ensure the device is in the Run mode otherwise the data transfer will be ignored by Data pee Ll as Long the Gateway Graco Gateway to Device b Output Connection Point Create a Gateway block configuration see Table 8 Table
69. n Address Baud Rate and I O Poll Size Make sure the Data Format Settings are set to Transform Swap Bytes In Word FIG 33 46 Driver No Driver Selected Predefined Group 2 Server Version 1 01 312785C Appendix A DeviceNet Slave Communication IMPORTANT NOTE The 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 2KS_Gateway_LE 080108 Gateway LE Graco Config File Edit View Link Help 4 Communications i ose Driver Selection 4 Programming Port 5 232 Comms Port Driver DeviceNet Predefined Group 2 Server Edit 5 485 Comms Port Modbus Master Er ProMix2KS Device Settings Ethernet Protocol 1 Modbus TCP IP Slave Node Address 1 Data Format 06 Block 1 Data Transfer Settings Block2 Enable Command Response Block3 B Block 4 I O Strobed No 1 a Block5 Protocol 2 I O Polled Yes 16 16 Protocol 3 Protocol 4 Jen ES Services server Electronic Data Sheet d lt DeviceNet Option Card 4 DeviceNet Interface Group 2 Server Filename HEISE
70. n 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 Communications times out Increase the Slave Response or Device Timeout on the communica tion 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 e f norouters are present on the Check that the target device network address and Graco Gateway device IP address are different but in the same domain For example both start with the same three first num
71. nfiguration from here and download it to the network 4 ETT ur mcer E1 3 Controller DeviceNet Controller Tags h EI Controller Fault Handler 0 3 Power Up Handler ge Tasks 2 69 MainTask MainProgram A Program Tags H 22 MainRoutine 0 3 Unscheduled Programs aa Motion Groups o L Ungrouped Axes E Trends 51 69 Data Types 0 Cg User Defined Cg Strings p Predefined eC Module Defined E1 3 Configuration 1756 Backplane 1756 4 Found in File not found Launch RSNetWorz for DeviceNet 4 A MainRoutine Ready Fic 46 Main Task Tree In the Main Task tree open the Main Routine Ladder Logic file Create a rung of ladder to enable the Devi ceNet 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 Local 2 O Data 0 3 Based on the configura tion in the Gateway if values are changed on the Gate way Write tags the Read tags will display the respective values plus one Save and download this configuration to the Control Logix PLC 56 a View and edit the DeviceNet network B DeviceNet File dnt foo0 Tech Notes DeviceNet Configuration T 8923 DeviceNet dnt Browse Fill File Source D Dest Local 2 0 Data D
72. on This column represents the rule that must be implemented by automation Writing to Read Only registers must be avoided For ProMix 3KS Systems only W 0 312785C Moabus and Data ProMix 2KS Recipe Bits Table 5 ProMix 2KS Recipe Bits lt lt CO SF OINI SE SF Fe tc fF LEO JF LEO OY J LEO LEY LEO gt Q 5 2 or Olr Olr Olr Oir Yt O rl to tc OMI QN MI TIO CN n NI NINN QN CN QN CO CO Q 5 2 Olr Olr Olr Olr T rer ir
73. program and create a new configuration 2 Adda 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 Configuration node in the Controller Organizer view and choose Add Mod ule c Inthe Select Module Type window choose 1756 ENET B or 1756 ENBT A entry RSLogix will open the Module Properties window See 69 d Enter the IP Address of the ENET B or ENBT A interface e Click Finish to add the interface to your con figuration f Download the configuration g Switch to online mode and open the 1756 ENET B or 1756 ENBT A node proper ties under the Configuration in the Controller Organizer Module Properties Local 1756 EHET B 2 1 1756 Ethernet Bridoe Allee Brodeu Local Description Slot Electronic Fic 69 Ethernet Module Properties 312785C C Hort Appendix C Graco Gateway to ControlLogix via Ethernet IP h Select the Port Configuration Tab from the Mod ule Properties window See FiG 70 i Enter the IP Address and Subnet Mask The IP Address must match the IP Address entered in the Properties window FIG 69 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 Add the Graco Gateway to the RSLogix configura
74. r 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 e 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 imme
75. raco Gateway Module USB Cable included for initial setup only EasyKey PLC Communication Wire Cable protocol dependent 2 wire twisted pair cable with shield wire E Computer PC Programmable Logic Controller PLC T113939a FiG 1 Graco Gateway Typical Installation 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 assis tance in designing a system to suit your particular needs 1 Shutoff ProMix 2KS power 0 position FiG 2 Also shut off power at main circuit breaker 0 OFF 7112657 Fic 2 Power 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 FIG 3 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 dis connect its cable from the EasyKey before updating the ProMix 2KS software Cabling Connections See FIG 4 FIG 5 for typical cable connections in a ProMix 2KS system FiG 6 through FiG 9 show other possible cable connec tions 31278
76. rate 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 FIG 37 2 5 Device Settings a amp Ethernet Protocol 1 Modbus TCP IP Slave Node Address Swap Bytes in Word z E G306TCP Block1 Data Transfer Settings Block2 Enable Command Response Block3 Block4 Strobed l Block5 W Protocol 2 I O Polled Yes 16 16 Protocol 3 I O Data Protocol4 i M E Services Ti OPC Server lt DeviceNet Option Card Synchronise 4 DeviceNet Interface Group 2 Server El Filename m Block 1 X Pollcoo000 LONG X 000020 6 X Pollco0004 LONG X 00006 Block 2 X PollCOO000 LONMG X Pollco0002 LONG X 00004 10 6 X PollCOO006 LONG Close Fic 37 Automatic EDS Update Saving the database using the File gt 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 Devi ceNet These changes will also need to be reflected in the following locations e RSNetWorx master node Scanlist Input Table and Output Table e ControlLogix PLC DeviceNet Scanner configuration 312785 Port Settings
77. ridging 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 communi cation hardware on the PLC side 312785C Graco Gateway Overview Install the Gateway Module Hardware Location This equipment is not for use in explosive atmo spheres Do not install equipment approved only for non hazardous location in a hazardous area Install the Gateway module near the ina 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 equip ment 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 accessi ble 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 connec tion 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 Install the Gateway Module Hardware NON HAZARDOUS AREA G
78. rminal is iso lated from the Graco Gateway e 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 CAN_H Position 4 of the pluggable connector provides the CAN_H bus line active high This terminal is iso lated from the Graco Gateway V optional 24 Vdc Position 5 of the pluggable connector is provided for optional 24 Vdc connections This position is avail able only to tie 24 Vdc wires together The Devi ceNet option card neither provides or uses 24 Vdc power through this connection The V position is not connected to any circuitry internal to the Devi ceNet option card or Graco Gateway 312785C CAN L DRAIN CAN H Appendix A DeviceNet Slave Communication 13963 DeviceNet Option Card PLC Connection P
79. roubleshooting 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 tar get device i e Baud Parity etc Incorrect target device address Check that the target device address in Graco Gateway in communica tions 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 If the above is correct check that the protocol settings are on the correct communication port in Graco Gate Way Communication port connector pins Although unlikely check the commu bent inward nication port connector pins on the Graco Gateway in case some are bent inward resulting in a bad contact with the cable Incorrect tag mapping Check that the tag is mapped to an existing register in the target device Values blink between the data and Incorrect tag mapping on one of the Delete tags one after another and tags on the display download in between Whe
80. s from the drectow Ju A Documents AML GispbireersProfibus BiOwse a ee Detaull g3pb Beab SD CDSP Profibus Card GSP 8 OU00 4 250000 Install Show Log Seect Al Deselect All 51 Browse to GSD File 60 312785C Setup the Profibus Network 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 ILI S00 SEE nm E 57 3 14 E 7 a 1 Fic 52 DP Properties Window 312785C Orda number Appendix B Profibus DP Slave Communication In the floating window that represents the PLC double click the DP area to open the properties window as shown in FIG 52 57 V2 5 JH BHM BES 325 1 BHO E 61 Appendix B Profibus DP Slave Communication In the General tab click the properties button to open the Profibus properties FiG 53 Properties DP RD 5z 1 FiG 53 Open Profibus Properties In the properties window go to the Parameters tab and click on the New button to create a new network FIG 54 Properties interface DP ROSEL l x Fic 54 Create a New Profibus Network 62 312785C
81. sert the CD in your PC s CDROM drive Select Install the software from a list or specific location then click Next The program location is C Program Files Graco GracoCon fig Device NOTE The name of the driver may be different Just accept the name and proceed by following the instructions on the screen Found Mew Hardware Wizard This wizard helps you install software for MS Connect 5100 If your hardware came with an installation CD lt 4 floppy disk insert it now What da you want the wizard to do CO Install the software automatically Recommended Install from a list or specific location Advanced Click Next to continue Fic 14 Load Software from a Specific Location Software Updates Contact your distributor or Graco Technical Assistance for software updates 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 communi cate between the Gateway and the ProMix 2KS The file name has a 002 extension GracoConfig files are downloaded to the Gateway mod ule 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
82. 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 Gate way to the ControlLogix 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 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 Module Properties ETHERHET MODULE 1 1 Generic Macule MV endar Allen Bradley Marne Conmechon PFarameterz Assembly Instance Input e p me 3 4 Output Configuration Mest gt Help Lomm Format Data Acddiesz Host IP 192 1E8 3 t Host Mame Fic 72 Ethernet Module Properties 312785C 75 Appendix C Graco Gateway to ControlLogix via Ethernet IP See FIG 7
83. storage only Typical accuracy is less than 1 minute per month drift Lithium 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 tech nician 0 to 50 30 to 70 80 relative humidity non condensing from 0 to 50 Operational 5 to 150 Hz in X Y Z direction for 1 5 hr 2 05 Operational 30 g 11 msec in 3 directions Up to 2000 m Carbon steel and stainless steel Installation category 1 Pollu tion degree 2 Hemovable wire clamp screw terminal block Wire gage capac ity 24 AWG to 12 Torque 4 45 5 34 in Ib 0 5 0 6 Nem Snaps onto standard DIN style top hat T profile mounting rails according to EN50022 35 x 7 5 and 35 x 1 5 15 1 oz 456 4 g 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
84. t 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 FiG 65 Properties of Variable Variable Data Mapping PLCT WOOOO BYTE Access Read Only E Non Retentive Information Comment OK Cancel Fic 65 Properties of Variable 312785C 69 Appendix B Profibus DP Slave Communication How Addressing Works The Gateway addressing follows a different scheme as shown in FIG 67 PLC addressing is in byte and uses the scheme shown in FIG 66 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 Word 8 Byte 8 Note how a Dword or word address starts at the address of the first byte included in it Byte 9 Fic 66 PLC Addressing Scheme Here the word or Dword addresses follow the nor mal numeric increment and are not directly related to the word or bytes they are composed of Fic 67 Gateway Addressing Scheme Table 6 Addressing Relationship Gateway Input bytes Output bytes Input words Output words 3 64 words in
85. t most computer and office supply retailers Use cards with a minimum of 4 Mbytes and a maximum of 2 Gbytes Use the Com pactFlash card for optional database storage only See FIG 11 Insert card with top side on the left Do not insert or remove card while power is applied T113967a Fic 11 Install a CompactFlash Card 11 Install the GracoConfig Software 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 pro tocols 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 NOTE Contact your Graco distributor or Graco Techni cal Assistance for information regarding additional sup ported protocols 12 System Requirements GracoConfig software will run on PCs with the following specifications e Pentium class processor as required by the cho sen operating system NOTE
86. tings Set the IP Address to 192 168 2 101 This should match the Address Host Name entered in FIG 72 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 orig inator s run idle state With the Run Idle Header checked the communications driver will automati cally 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 B Bl m Programming Port Rz 232 Comms Port Rz 485 Comms Port Ethernet 2 M Protocol L Echeret T Slave X 008 0000 te Yarl Do LOX Block ee 9220000 0020001 2 Protocol 2 Connection Point Protocol 3 Protocal Data Bb Server Data FiG 74 Ethernet Block Settings 312785C Black sie Direction Appendix C Graco Gateway to ControlLogix via Ethernet IP 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 co
87. us and I O Data NO 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 ProMix 2KS Color Change Process Complete Process Alarm See Alarm Processing 28 Color Change Mode Process Flow Chart 312785C page 26 25 and Data Alarm Processing See FIG 29 Table 1 Table 2 and Table 3 NO Determine the exact alarm from Table 3 on page 29 and solve what caused the alarm as required the alarm Reset Alarm 1 Is Mix Ready bit 1 Fic 29 Alarm Processing Flow Chart 26 Alarm Processing An Alarm Condition has been found previously Alarm General 1 Check if Potlife Alarm is Alarm Potlife bit 2 1 YES Two options Purge or Color Change to remove mixed material in the line e 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 YES Go to next process as desired 312785C Modbus and I O Data Table 1 ProMix 2KS Digital Inputs Modbus Register 40040 Digital Input Binary 08 X X X for viewing discrete inputs only otto 1 to nitate Color Change
88. w 13974 ETHERNET NIC FiG 4 Graco Gateway Port Pin Outs 113972 Fic 5 RS485 Communication Port Typical ProMix 2KS Connection 312785C Install the Gateway Module Hardware RS232 PG OR USB PG um OR ETHERNET 13969 Green Amber LED Yellow LED FIG 6 Programming Ports RS232 PG 13970 Fic 7 RS232 PG Communication Ports 13971 Fic 8 RS232 Communication Ports 10 312785C ETHERNET Green Amber LED Yellow LED FiG 9 Ethernet Connection Mount the Control on DIN Rail The Gateway control mounts on a DIN rail Tilt the con trol and push down onto the DIN rail then push in See FIG 10 A minimum clearance of 1 in 25 mm above and below the control is required to ensure adequate ventilation 13965 1 in 25 mm minimum clearance top and bottom 13966 Fic 10 Mount the Control DIN Rail 312785C Install the Gateway Module Hardware Standard Ethernet Cable 13973 Install CompactFlash Card The CompactFlash socket accepts either Type Type cards These cards are available a

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