Modbus And I/O Data; Start Mix Process; Stop Mix Process; Color Change Process - Graco ProControl 1KS Operation

Modbus and I/O Data

Modbus and I/O Data
See Table 10 and Table 11 for Modbus register
addresses and input/output data.
Reference the Discrete I/O listing of all the inputs and
outputs (see page 67). Ensure these are fully under-
stood. The same implementation used for Discrete I/O is
used for the Network communication protocol.
For example: The Gun Trigger Input will now be a 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 I/O section
of the ProControl 1KS Operation manual. The PLC will
have to read the various bits, and in some cases (40040
and 40041 for example) must mask out the various bit
positions to determine each of the separate input and
output statuses. This requires experience and should
not be done on the job site. A full understanding of the
color change process as well as the required timing of
various inputs and outputs is required.
NOTE: Analog input for flow control set point will now be
a dedicated Modbus register. Register 40137 will
require the specific flow rate (i.e. 125 cc/min). This is not
a voltage reading but the actual flow target.

Start Mix Process

See F . 68, Table 5, and Table 6.
IG
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 F . 69, Table 5, and Table 6.
IG
1. Clear the Mix bit.
2. The Mix Active output should clear and Mix Ready
should now be set.
NOTE: The ProControl 1KS 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 ProControl
1KS will resume mixing material where it left off. Do not
66
toggle the Mix bit; doing so restarts the Mix process
from the beginning.

Color Change Process

See F . 71, Table 5, and Table 6.
IG
1. Verify that Mix Ready is set. This ensures that there
are no alarms and that the system is ready for the
next command.
2. Load ccNewRecipe (Modbus 40046) with a recipe
number to color change to.
3. Set color change (40040 bit 6).
4. Verify that Purge_CC_Active is seen (40041 bit 0).
5. Clear color change bit (momentary only).
6. Do not change the ccNewRecipe value until a new
recipe change is requested.
7. The color change process will stop automatically as
programmed. Monitor Purge_CC_Active bit for com-
pletion.

Purge Process

See F . 70, Table 5, and Table 6.
IG
1. Verify that Mix Ready is set. This ensures that there
are no alarms and that the system is ready for the
next command.
2. Set purge (40040 bit 8).
3. Verify that Purge_CC_Active is seen (40041 bit 0).
4. When Purge_CC_Active bit clears, clear
Purge_Start bit. Clearing this bit in the middle of a
purge sequence will abort the purge sequence.
NOTE: It only requires three Modbus registers to pro-
vide full communications from the PLC to the ProControl
1KS. All other registers are on a need to view and moni-
tor basis.
40040Robot Digital In (Send/Edit Values in ProControl
1KS)
40041Robot Digital Out (READ ONLY - Active values)
40046Go To Recipe value for next ProControl 1KS rec-
ipe
3A1080H