Instructions Gateway Network Communication Assembly

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InstructionsGateway NetworkCommunicationAssembly3A7639AUsed to control, monitor, and download production data from various Graco SystemControllers to a PLC or PC for automation or production information reporting. Forprofessional use only.Not approved for use in explosive atmospheres or hazardous (classified) locations.See pages 3 and 4 for information and model numbersfor each Gateway Assembly.Important Safety InstructionsRead all warnings and instructions in thismanual and in your proportioning systemmanual before using the equipment.Save all instructions.EN

ContentsRelated Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Gateway Assembly Overview . . . . . . . . . . . . . . . . . 3Gateway Assemblies . . . . . . . . . . . . . . . . . . . . . . 3Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Install the Gateway Assembly Hardware . . . . . . . . 7Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Connect Gateway Assembly Communication to the Graco System Controller . . . . . . . . . . . . . 8Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Power Connections . . . . . . . . . . . . . . . . . . . . . . . 9Communication Connections . . . . . . . . . . . . . . . 11Install SD Card (17R419) . . . . . . . . . . . . . . . . . . 18Install the Red Lion Crimson 3.0/3.1 SoftwareSystem Requirements . . . . . . . . . . . . . . . . . . . .Installing the Software . . . . . . . . . . . . . . . . . . . .Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking for Updates . . . . . . . . . . . . . . . . . . . .Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .Getting Assistance . . . . . . . . . . . . . . . . . . . . . . .Downloading to a Device . . . . . . . . . . . . . . . . . .Software Updates . . . . . . . . . . . . . . . . . . . . . . .Download the Preconfigured Database to theGateway Module . . . . . . . . . . . . . . . . . . . . .Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25B471 Gateway Ethernet Assembly . . . . . . . .25B472 Gateway DeviceNet Assembly . . . . . . .25B473 Gateway Profibus Assembly. . . . . . . . .25B486 Gateway Ethernet Assembly with FiberConversion Module 16K465 . . . . . . . . . . . .25B489 Gateway Ethernet Assembly with Ethernet Switch 15V342 . . . . . . . . . . . . . . .1919192020202121222324242626Appendix A: DeviceNet Secondary Communication . . . . . . . . . . . . . . . . . . . . . . . . 32Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32DeviceNet Port Protocols . . . . . . . . . . . . . . . . . . 32About DeviceNet. . . . . . . . . . . . . . . . . . . . . . . . . 34Appendix B: Profibus DP SecondaryCommunication . . . . . . . . . . . . . . . . . . . . . . . . 35Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Profibus Port Protocols. . . . . . . . . . . . . . . . . . . . 35About Profibus DP . . . . . . . . . . . . . . . . . . . . . . . 36Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38California Proposition 65 . . . . . . . . . . . . . . . . . . . . 38Technical Specifications . . . . . . . . . . . . . . . . . . . . 39Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40Graco Information. . . . . . . . . . . . . . . . . . . . . . . . . . 40Related ManualsManual inDescriptionEnglish312778ProMix 2KS Automatic System, Installation312779ProMix 2KS Automatic System, Operation312780ProMix 2KS Automatic System,Repair-Parts313386ProMix 2KS/3KS Web Interfaces, Instructions3A6948ProControl 1KE Plus Models, Instructions-PartsDCM and ADCM, Instructions24H372 ACS Module, Instructions28303320133A00063A25273A34692E-Flo DC Control Module Kit, InstructionsProDispense , Operation-PartsCrimson 3.1 User Manual (supplied withRed Lion Gateway Module)3A7639A

Gateway Assembly OverviewGateway Assembly OverviewThe Gateway Network Communication Assembly(referred to as Gateway Assembly throughout this manual) enables various Graco systems to communicatewith PLCs (programmable logic controllers) and networkcommunication systems. Communication assembliesare available for many different communication protocols, including Modbus TCP, Ethernet IP, DeviceNet,and Profibus. The Gateway Assembly supports manyother protocols; contact Graco Technical Assistance forinformation to support your desired protocol.NOTE: Only persons very familiar with their PLC andNetwork communication architecture should use thishardware and software. This manual assumes that theperson using the Gateway Assembly has full understanding of the PLC equipment and related software.NOTE: Network communications essentially operatewith the same rules as Discrete I/O. However, networkcommunications require placing correct values oradjusting appropriate bits within various registersdepending on the protocol. Network communicationsshould only be installed by qualified persons familiarwith this type of communication.The Red Lion Gateway Module allows for most PLCs tocommunicate with the various Graco systems via theprotocol selected by mapping registers from the Gracosystem to the PLC or communications hardware ofchoice. Software is available to do this, as well as preconfigured database mappings from Graco for variousGraco systems. As a result, the PLC has full access toall the registers for monitoring and controlling the Gracosystem. It is the responsibility of the integrator or user toensure proper configuration of the communication hardware on the PLC side.NOTE: The Red Lion Gateway Module (Graco part no.18C235) used in each Gateway Assembly is the corecommunication component of all five GatewayAssembly models covered in this manual. The Red LionGateway Module includes Modbus TCP, Modbus RTUSerial, and many other protocols.3A7639AGateway TerminologyThe following terminology is used throughout thismanual when referring to Gateway Assemblies o SystemControllerDefinitionRed Lion Gateway and protocolconverters.A Red Lion Gateway Module with anenclosure and power supply.Any Graco System Controller like, butnot limited to, EasyKey, ProDispense,ProControl 1KE Plus, GracoDCM/ADCM, ACS, etc.Gateway AssembliesModel 25B471 Gateway Ethernet AssemblyAllows communication between various Graco systemswith a PLC and other communications hardware over anethernet. Enables process equipment to read and writecommunication network variables from various Gracosystems.Model 25B472 Gateway DeviceNetAssemblyAllows communication between various Graco systemswith a PLC and other communications hardware usingDeviceNet process control. Enables process equipmentto read and write variables from various Graco systems.See Appendix A: DeviceNet SecondaryCommunication on page 32 for DeviceNet details.Model 25B473 Gateway Profibus AssemblyAllows communication between various Graco systemswith a PLC and other communications hardware usingProfibus process control. Enables process equipment toread and write variables from various Graco systems.See Appendix B: Profibus DP SecondaryCommunication on page 35 for DeviceNet details.3

Gateway Assembly OverviewModel 25B486 Gateway Ethernet Assemblywith 16K465 Fiber Conversion ModuleModel 25B489 Gateway Ethernet Assemblywith Ethernet SwitchAllows communication with a Graco ADCM and DCMcontrol module through a fiber cable in hazardous andnon-hazardous locations.Gateway Ethernet Assembly with an 8-port Ethernetswitch that allows communication with up to sevenGraco ACS modules via an Ethernet network.NOTE: This communication method is used for theADCM and DCM modules, regardless of where they areplaced.43A7639A

WarningsWarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Theexclamation 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 or on warning labels, refer back to these Warnings.Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of thismanual where applicable.WARNINGFIRE AND EXPLOSION HAZARDFlammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint orsolvent flowing through the equipment can cause static sparking. To help prevent fire and explosion: Use equipment only in well-ventilated area.Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic dropcloths (potential static sparking).Ground all equipment in the work area. See Grounding instructions.Never spray or flush solvent at high pressure.Keep work area free of debris, including solvent, rags, and gasoline.Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumesare present.Use only grounded hoses.Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless theyare anti-static or conductive.Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment untilyou identify and correct the problem.Keep a working fire extinguisher in the work area.ELECTRIC SHOCK HAZARDThis equipment must be grounded. Improper grounding, setup, or usage of the system can causeelectric shock. 3A7639ATurn off and disconnect power at the main switch before disconnecting any cables and beforeservicing or installing equipment.Connect only to grounded power source.All electrical wiring must be done by a qualified electrician and comply with all local codes andregulations.5

WarningsWARNINGEQUIPMENT MISUSE HAZARDMisuse can cause death or serious injury. Do not operate the unit when fatigued or under the influence of drugs or alcohol.Do not exceed the maximum working pressure or temperature rating of the lowest rated systemcomponent. See Technical Specifications in all equipment manuals.Use fluids and solvents that are compatible with equipment wetted parts. See TechnicalSpecifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. Forcomplete information about your material, request Safety Data Sheets (SDSs) from distributor orretailer.Do not leave the work area while equipment is energized or under pressure.Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.Check equipment daily. Repair or replace worn or damaged parts immediately with genuinemanufacturer’s replacement parts only.Do not alter or modify equipment. Alterations or modifications may void agency approvals and createsafety hazards.Make sure all equipment is rated and approved for the environment in which you are using it.Use equipment only for its intended purpose. Call your distributor for information.Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.Do not kink or over bend hoses or use hoses to pull equipment.Keep children and animals away from work area.Comply with all applicable safety regulations.PERSONAL PROTECTIVE EQUIPMENTWear appropriate protective equipment when in the work area to help prevent serious injury, includingeye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is notlimited to: 6Protective eyewear, and hearing protection.Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.3A7639A

Install the Gateway Assembly HardwareInstall the Gateway Assembly HardwareLocationMounting1. See Dimensions, page 38.This equipment is not for use in explosiveatmospheres or hazardous locations. To reduce therisk of fire or explosion, do not install equipmentapproved only for non-hazardous location in ahazardous location.Install the Gateway Assembly near the Graco SystemController in a non-hazardous location.2. Ensure the wall or mounting structure is sturdyenough to support the assembly and connectioncabling, and without excessive vibrations that couldcause reduced component performance or failure.3. Using the equipment as a template, mark themounting holes on the wall at a convenient heightfor the operator and so equipment is easily accessible for maintenance.4. Drill mounting holes in the wall. Install anchors asneeded.5. Bolt equipment securely.NON-HAZARDOUS LOCATIONGateway AssemblyUSB Cable(included with allmodels); for initialsetup onlyGraco System ControllerPLC CommunicationWire/Cable(protocol dependent)2-wire twistedpair cable, withshield wire,CATV cable orfiber optic cableComputer (PC)TI13939bProgrammable Logic Controller (PLC)FIG. 1: Gateway Assembly Typical Installation3A7639A7

Install the Gateway Assembly HardwareConnect Gateway AssemblyCommunication to the GracoSystem ControllerFIG. 1 is only a guide showing installation of the Gateway Assembly in a ProMix 2KS System; it is not a complete system design. Contact your Graco distributor forassistance in designing a system to suit your particularneeds. This procedure is an example of how to connectthe Gateway Assembly to a Graco EasyKey, though itmay also apply to other Graco System Controllers.5. Connect a communications wire/cable (protocoldependent) from the Gateway Module to the PLC.(See Communication Connections, page 11.)NOTE: Graco provides expansion cards for DeviceNetand Profibus protocols. DeviceNet setup procedures areon page 32. Profibus setup procedures are on page 35.See Parts, page 26, for part numbers.NOTE: When using the Gateway Assembly in your system, disconnect both communication cables (one to theGraco System Controller and the other to the PC orPLC) before updating the system software.Grounding1. Shut off power at the main circuit breaker2. Shut off ProMix 2KS power (0 position). See FIG. 2.The equipment must be grounded to reduce the riskof static sparking and electric shock. Electric or staticsparking can cause fumes to ignite or explode.Improper grounding can cause electric shock.Grounding provides an escape wire for the electriccurrent.3. Turn off power to the Graco EasyKey and theGateway Assembly before connecting ordisconnecting communication cables.NOTE: For specific system communication circuitconnections and register mapping details, refer to thefollowing product family manuals: ProMix 2KS (312779),ProControl 1KE (3A6948 and 332013), Graco ACSModule (3A0006), and Graco ProDispense (3A3469).0 OFFGateway AssemblyGrounding is provided by both a proper power connection and a grounding screw on the enclosure. For a proper power connection, see PowerConnections, page 9, and Electrical Schematics,page 16, for details and grounding locations. For the enclosure grounding screw (4), use aground wire (35) and clamp (supplied). Remove thegrounding screw (4). Attach the ground wire (35)end, as shown, and tighten the ground screw (4)securely. Connect the ground clamp to a true earthground.:TI12657aFIG. 2: Power Off4. Connect a 2-wire twisted pair cable (provided withassemblies 25B471-25B473), see FIG. 5, with shieldwire from the EasyKey connector to the connectoron the Gateway Module.435FIG. 3: Enclosure Grounding83A7639A

Install the Gateway Assembly HardwarePower Connections1. Disconnect power to the Graco System Controller.2. Disconnect power to the Gateway Assembly.3. Loosen the screws (3) and remove the enclosurecover (2). See Parts, starting on page 24.Improper wiring may cause electric shock or otherserious injury if work is not performed properly. This equipment must be grounded. Connect onlyto a grounded power source. All electrical wiring must be done by a qualifiedelectrician and comply with all local codes andregulations.4. Route the power cable from a 100-240V, 50/60 Hz,AC power source through the hole provided in thebottom of the enclosure (1).NOTE: The strain relief fitting or connector must beprovided in the field according to local electrical codes.5. Connect the supply ground wire to the groundterminal block (9) in the enclosure (1).NOTICEIf power and grounding connections are not doneproperly, the equipment will be damaged and thewarranty voided.The Gateway Assembly is rated for 100-240 VAC, 50-60Hz, with a maximum of 1 amp current draw. Powerconnections are common to all Graco Assembly models.See FIG. 4. For specific wiring details, see ElectricalSchematics on page 16.NOTE: A means of disconnect must be provided duringinstallation. Branch circuit protection of 15 ampmaximum must be provided during installation. Powerwires must be made of copper and have a minimumtemperature rating of 140 F (60 C). The wire gauge sizemust be 12-14 AWG.3A7639A6. Connect the incoming power wires (L and N) to thelabeled L and N terminals on the 24 V power supply(10). Gently pull on all connections to verify they areproperly secured.7. Torque the power input terminal screws to 0.56 N m(5 in-lb).8. Connect the communication cables (see Communication Connections, pages 11-13, and ElectricalSchematics, pages 16-18).9. Verify that all items are connected properly, thenreplace the enclosure cover (2) and tighten thescrews (3).9

Install the Gateway Assembly Hardware13131414 1010Models 25B472 and 25B473Model 25B47110141410Model 25B486Model 25B489FIG. 4. Power Connections103A7639A

Install the Gateway Assembly HardwareCommunication ConnectionsFor example, See FIG. 9 and FIG. 10 for typical cable connections in aProMix 2KS system. FIG. 11 and FIG. 12 show other possible cable connections. A Graco EasyKey (ProMix 2KS) requires an RS485connection. See FIG. 6.An DCM/ADCM (ProControl 1KE Plus andIntelligent Paint Kitchen) requires a fiber opticconverter and connection. See FIG. 7.An ACS controller can use an RS485 or EtherNetswitch; determine the protocol to be used and makethe appropriate connection. See FIG. 8.Refer to your Graco system manual for communicationprotocol and connection requirements to complete yourspecific Gateway Assembly installation. System manuals have details for protocol and connections.USB PortCommunication Wire/Cable (to PLC).This connection is protocol dependent.Models 25B471/2/3come with 50 ft. of thetwisted pair cable foran RS485 connection.2-wire twisted paircable, with shield wire.See Electrical Schematics on page 16 forpin connections.FIG. 5: Gateway Ethernet Assembly Cable Connection Points - Model 25B4713A7639A11

Install the Gateway Assembly HardwareGateway AssemblyUSB PortModels 25B471/2/3come with 50 ft. of thetwisted pair cable foran RS45 connection.External controlnetwork cable2-wire twisted paircable, with shield wire(to EasyKey). SeeElectrical Schematicson page 17 for pin connections.FIG. 6: Gateway DeviceNet and Profibus Assembly Cable Connection Points - Models 25B472 and 25B473Gateway Assemblywith Fiber Optic communication conversion to the PC/PLCUSB PortOptional fiber optic cablefor connection to anADCM or DCM module.Cable options are, 17T898 (3 m)16M172 (15 m)16M163 (30 m)17B160 (100 m)FIG. 7: Gateway Ethernet Assembly w/Fiber Optic Conversion Cable Connection Points - Model 25B486123A7639A

Install the Gateway Assembly HardwareGateway Assemblywith EtherNet Switch for EtherNet conversion to the PC/PLCUSB PortEthernet network cableFIG. 8: Gateway Ethernet Assembly w/Ethernet Switch Cable Connection Points - Model 25B4893A7639A13

CTS PIN 1RxCOMMCOMMTxRTS PIN 6Install the Gateway Assembly HardwareRS2321 COMMON2 24 VDC /- 10%3 N/CPOWERCONNECTORTxB PIN 1TxARxARxBTxENCOMMTxBTxA PIN 8RS232/PGRS485CTS PIN 1RxCOMMCOMMTxRTS PIN 6COMMSRS232COMMSYELLOWLEDGREEN/AMBERLEDUSBETHERNET (NIC)USB/PGti38199aFIG. 9: Gateway Module Port Pin OutsRS485TxBTxARxARxBTxENCOMMTxBTxACOMMSFIG. 10: RS485 Communication Port (Typical ProMix 2KS Connection)143A7639A

Install the Gateway Assembly HardwareGREEN

The Red Lion Gateway Module (Graco part no. 18C235) used in each Gateway Assembly is the core communication component of all five Gateway Assembly models covered in this manual. The Red Lion Gateway Module includes Modbus TCP, Modbus RTU Serial, and many other protocols. Gateway Terminology. The following terminology is used throughout this

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