GRAVIMETRIC GATEWAY PRE-SALES SUPPORT DOCUMENT December 3, 2003 Computer Communications Maguire Products Inc. 11 Crozerville Road Aston PA, 19014 610-459-4300 COPYRIGHT MAGUIRE PRODUCTS, INC. 2003
Table of Contents: Introduction 3 G2 Server / G2 Client System Requirements 4 Part List Overview 5 MLAN Network Parts Diagram 6 Startup Quick Overview 7 Wiring Your Own MLAN 8 Advanced Network Options Using Ethernet 11 General Contact Information 14
Introduction Gravimetric Gateway Software and the MLAN *** Communications Network Pre-Sales Support Document This document is intended to provide you with the information you will need to set up the Gravimetric Gateway program s communication network in the field. The Gravimetric Gateway program or referred to as G2, was designed to provide enhanced access and control of the Maguire Weigh Scale Blenders with material usage tracking reports and monitoring, remote access of the basic control settings, such as recipes (materials and settings), work order numbers, and operator numbers as well as advanced features like Advanced Inventory Management (AIMS) and Extrusion Control. Before the Gravimetric Gateway can connect to the Maguire Weigh Scale Blenders, a communication network must be installed and tested. This document will outline your options in the layout of this communication network. For additional information on the Gravimetric Gateway software see www.maguire.com/g2 or call 610-459-4300. Weigh Scale Blender (WSB) controllers can communicate over two different protocols, MLAN and RS232. Both are available at the DB9 port on the WSB controller. In a typical installation MLAN should be used in all factory installations. RS-232 may be used in lab testing; limited applications or short distances to Serial to Ethernet converters (G2-ES) but is NOT recommended for factory installations. If you are communicating over a distance greater than 50 feet or with more than one WSB then you must use the G2 Signal Amplifier (G2-SA). It utilizes optically isolated couplers for all communication lines to reduce the potential of noise and other electrical interference from entering the computer circuitry. The G2-SA also converts RS-232 communications to MLAN. The G2-SA also serves as a licensing security key and is required to be connected The Gravimetric Gateway Server can communicate to the Maguire weigh scale blenders either through serial using an available COM port on the G2 Server computer, and/or through Ethernet. Ethernet communications to the WSBs require either the use of an Ethernet to Serial converter (G2-ES-x) located at the controller(s) or the use of the Satellite COM Server, which uses a shared COM port of a computer other than the G2 Server PC. *** MLAN refers to Maguire Local Area Network. MLAN is one of two communication protocols used to communication with the Maguire Weigh Scale Blenders. In this document, MLAN does not refer to MLAN for Windows, which is an earlier version of communications software for use with the Maguire Weigh Scale Blenders.
G2 Server / G2 Client System Requirements Hardware and operating system requirements for the installation of the G2 Server and the G2 Client Software Computer System Requirements IBM-PC or Compatible (Pentium 233 or faster). We recommend that the G2 Server computer be dedicated to the purpose of collecting data for G2. Constant COM port communication between the G2 Server and the Maguire Weigh Scale Blenders may cause a noticeable lag in the processor when using the G2 Server computer for additional functions while the G2 Server is collecting data. Minimal HD Space 6 Gigabyte Hard Drive or larger for long term data collection Video Super VGA 1024 x 768 resolution recommended, 800 x 600 acceptable Memory Minimum 64 MB, preferably 128 MB or more Ports 2 available serial ports (1 port for mouse if no PS2 port available, 1 port for MLAN), 1 available printer port if printing reports is desired. Mouse PS2 preferable Operating System Recommendations G2 Server Windows NT/2000/XP G2 Clients Windows 95/98/ME/NT/2000/XP Windows NT, Windows 2000 and Windows XP are recommended for G2 Server Installations. Windows 95/98/ME not recommended for the G2 Server. G2 Clients can be installed on Windows 95/98/ME providing they are connecting to a G2 Server that is running on a Windows NT, 2000, or XP operating system. These recommendations are recommended but not required. G2 Server will run under Windows 95, 98, or ME however problems may arise due to the lack of long term stability of Windows 95, 98, and ME. If the G2 Server will run constantly for prolonged periods of time without a computer shutdown or re-boot, we recommend that the G2 Server be installed on a Windows NT, Windows 2000 or Windows XP system.
Parts list overview for implementing the G2 Server and the Maguire Local Area Network (MLAN) Please see diagrams below for details on what parts you may need to assemble your network. Part Number G2-SK G2-SA G2-SL G2-SLU MLAN-SE G2-SE G2-IR G2-D G2-C G2-CA G2-CB G2-ES-11 G2-ES-12 G2-DEMO G2-MR G2-SU G2-WU G2-PC Description G2 Starter Kit This consists of the following items: G2-SA, one G2-SL (single blender license), Latest available version of the G2 Installation CD-ROM and a G2 manual (also available on the installation CD-ROM). See below for explanation of each item in the G2-SK. Signal Amplifier for G2 communication. The G2-SA Includes a built-in security key. The security key can be re-programmable for additional licenses (seats) and added features through use of a Certificate License purchased from Maguire Products or your Maguire representative. Software License for addition WSBs. If the customer already has a G2-SA, a Certificate will be issued to enable communication to additional blenders. The certificate number can be entered into the G2 Client software to apply the update of additional licensed blenders. Software License UNLIMITED WSB COUNT Single Extender (may be referred to as a G2-SE) Used to boost the signal strength, may be placed in-line on the communication network at a distance of several hundred feet from the G2 Server 100' Initial Cable Run w/db9 Connector 20' Cable Drop w/db9 Connector Cable per foot (for run through ceiling) sold by the foot Cable Adapter for single blender communication or testing (includes G2 Lite) See Foot Note Connector Box for G2 network Ethernet to Serial converter Single COM port, 110 volt Ethernet to Serial converter Single COM port, 220 volt G2 Installation CD-ROM - May be used for G2 version updates, Demonstration or full installations. Maintenance Release CD-ROM Software Version Update CD-ROM MLAN to G2 License Upgrade converts MLAN licenses to G2 (includes starter kit). Upgrades WSB license count only, Not Data Conversion Pre-configured Desktop or rack mount G2 computer (call for quote, please specify desktop, rack mount, or other computer requirements)
Notes on Parts Listing: Depending on the layout you choose to use, some of the parts listed below are not required. You, the customer, may assemble the communication network to the blenders using off the shelf cable, junctions and DB-9 cable ends. It is recommended that you use available parts and cable equal to the specifications within this document. Refer to the wiring diagram at the end of this manual for a wiring example and the pin configuration. Otherwise you may purchase pre-terminated cables listed in the parts list to assemble the communications network. MLAN Network Parts Diagram This diagram outlines a typical MLAN structure. Use this diagram in conjunction with the parts listing above to help map out cable length (MLAN-IR, MLAN-C), number of connector boxes (MLAN-CB) and drops (MLAN-C) you will require for your application before placing your order.
Startup Quick Overview Basic Configuration - What You Need The basic layout of a MLAN communications network will depend on the distance from the G2 Server to the Blender(s) and the number of blenders. The basic requirements are as follows: 1. G2 Starter Kit (G2-SK, includes one G2-SL) 2. One G2-SL per each additional blender 3. One initial run (G2-IR) 4. One 20 drop per blender (G2-D) 5. Enough MLAN cable to wire everything together (G2-C) 6. One connector box per blender (G2-CB) Basic G2 Communication Network Layout
Wiring your own Maguire Local Area Network (MLAN) For those of you that would like to make up your own cables follow these instructions: MLAN TO CONTROLLER CABLE PINOUT MLAN-IR DB9 Connector pin (or terminal strip) Wire Color MLAN-D DB9 Connector pin 1 Black 1 4 Red 4 6 White 6 7 Green 7 5 Shield connected to hood The shield is connected at all points including at the controller. At the controller the shield should be connected to the housing of the controller. This shield is intended to tie all external noise to ground at the MLAN-SA or the computer, while minimizing the chance of noise entering the WSB controllers. The shield is not connected to pin 5 of the controller; however, it is connected at the computer. MLAN requires four (4) conductor cable with a shield for conveying information. Wire size should be 18 to 22 gauge. Use 18 gauge for the long runs (especially over 500 feet). Twentytwo (22) gauge is recommended for the drops to each controller. Twenty-two (22) gauge wire is used at each controller termination because it solders more easily to the DB9 connector required at each WSB controller location. We recommend: CAROL WIRE, Part #C2555 or BELDON WIRE, Part #9402 Conductors are Black, Red, White, and Green, plus a shield. Black is the positive power supply (16 to 24 volts) Red is the neutral from the power supply White is communication from PC to WSB controller Green is communication from WSB controller to PC Wiring generally requires a single cable run through the ceiling over all the process machines with drops to each controller. This main wire may T off to other locations if required for more efficient wiring. RS-232 Communication (for limited applications) RS-232 uses a direct connection from the computer to the WSB controller. This type of communication is reliable for short runs where little or no noise or static interference is present. This may be the case in a lab or another closely controlled environment. A low noise environment is not common in a factory and we do NOT recommend RS-232 for factory installation. Other restrictions are that the computer must be close (less than 50 feet) to the WSB controller and can only communicate with a few units (maximum of three). If all three conditions are met, then you may cable directly to the RS-232 serial port on your computer without any other
hardware interface. Under these circumstances, the MLAN-SA is not required. The proper pin connections are as follows: RS-232 TO WSB CONTROLLER CABLE PINOUT WSB DB9 Connector Computer Connector pin # DB9 or DB25 3 3 2 2 2 3 5 5 7 and 1 6, 7, 8 4, 5, 6 pins tied together Do NOT use a standard off-the-shelf cable. Standard cables have ALL pins connected, or at least more than just those listed above. ALL pins connected will NOT work. You must wire a special cable according to the diagram provided. Wiring Consideration The wiring of your communication lines is very important for reliable operation. To minimize problems, consider the following: 1. Communication lines are low voltage lines. Be sure that these lines are not bundled to any high voltage lines. If you run them in conduit, do not run high and low voltage lines together. 2. It is not necessary to run this wire in conduit. If you do run cables without conduit, do not wire tie these lines to material conveying lines or other conduit containing high voltage or high amperage electrical lines. 3. Keep all communication lines away from all vacuum loader-conveying lines. Conveying plastic produces extreme static charges. An electrical line, even in conduit that runs next to a vacuum line can introduce extreme static pulses into the processor. Keep these lines separated from conveying lines.
Advanced Network Options Using Ethernet for Blender Communications An option for communications to the network of blenders is the use of Ethernet to Serial converters. Ethernet to Serial converters can be purchased through Maguire Products as G2- ES-11 (110 volt) and G2-ES-12 (220 volt). The G2-ES is used to convert the RS-232 serial communications port of the Weigh Scale Blender to Ethernet. Communications between the G2 Server and the Weigh Scale Blenders is then achieved through the TCP/IP protocol, over the Ethernet network. Installing an Ethernet network is more complex than a simple RS-232 network and requires knowledge of Ethernet wiring and the use of specialized tools and wiring configuration standards. For that reason, a qualified network technician with an understanding of computer networks and the installation of the TCP/IP protocol may be required. Detailed instructions for G2-ES setup are supplied with each G2-ES unit. REQUIREMENTS: Use of an Ethernet network for G2 communications to one or more Maguire Weigh Scale Blenders requires the following: Each Weigh Scale Blender requires a G2-ES. The G2-ES will be mounted within 6 feet of the Weigh Scale Blender and requires a source of power (110v or 220v) within 6 feet. Models available through Maguire Products are: G2-ES-11 G2-ES-12 Ethernet to Serial converter Single COM port, 110 volt Ethernet to Serial converter Single COM port, 220 volt Recommended Ethernet cable for G2 communications is: Cat5e STP (shielded, twisted pair), 24AGW solid cable. Cat5 is acceptable but has a shorter maximum distance; CAT5 is rated to 100 meters, CAT5e is rated to 350 meters. The Cat5e Ethernet cable must be run from each blender s G2-ES back to the G2 Server. If two or more blenders are in use requiring more than one G2-ES, an Ethernet hub or switch is required as a central junction for all Ethernet cables. All Ethernet cables, including the G2 Server s Ethernet cable, each blender s G2-ES, and any optional G2 Client computers, will be plugged into the Ethernet hub or switch. If only a single blender is in use requiring one G2-ES and one run of Ethernet cable from the G2 Server PC to the G2-ES, a hub or switch is not require however the Ethernet cable must be configured as a crossover type cable. See crossover cable diagram at the end of this document. Each Cat5e cable run should not exceed 350 meters (Cat5 100 meters). If longer lengths are required, use of a repeater may be necessary to maintain signal strength. Stranded cable should not be used due to its significantly limited maximum distance (10 meters, 33 feet). When installing the Ethernet cable, avoid sources of Electro- Magnetic interference (EMI) such as vacuum loader lines, transformers, high voltage lines, florescence lighting, etc.
The G2 Server PC must be configured to use the TCP/IP protocol. A Static I.P. address must be assigned to the G2 Server PC if the Server is to be accessed from other PCs on the network using the G2 Client software. Each G2-ES will be assigned a static I.P. address and specific serial settings. Configuration instructions are provided with each G2-ES and are also available online at http://www.maguire.com/page.php/g2manuals.htm Each Maguire Weigh Scale Blender must be assigned a unique ID number between 001 and 254 using the *66 function. See your Weigh Scale Blender manual for further instructions on how to set the ID number. Example diagram of a G2 Ethernet Network Key points in the diagram above: Each Maguire Weigh Scale Blender is connected directly to it s own G2-ES through a special Null Modem serial cable (provided with the G2-ES). Each G2-ES includes its own 12-volt transformer and must be supplied power within 6 feet of the G2-ES. All Ethernet cables (Cat5e recommended) are run back to a central location and plugged into an Ethernet hub or switch. The G2 Server PC is also connected to the Hub as well as any optional G2 Client PCs. Connected to the G2 Server s COM Port is the G2-SA. The G2-SA contains the security key, which is required for licensing of more than a single Weigh Scale Blender. The G2-SA is also a signal amplifier, which is used in serial communication applications. In Ethernet applications, the G2-SA is only used as a security key. It is possible to use both a serial and Ethernet network at the same time for G2 communications. Although it is generally not configured in this way, the serial output to Blenders port on the G2-SA can communicate with some blenders while the Ethernet network can communicate with other blenders.
Client Only PCs communicate directly with the G2 Server over the Ethernet network via the TCP/IP protocol. Each cable is terminated at both ends with RJ-45 modular connectors designed for shielded, solid cable. Wiring configurations typically are T568B wiring patterns. Note: Ethernet network parts and accessories are not included in the MLAN parts listing but may be special ordered through the developers of G2, Green Bridge Station Technologies. See contact information at the end of this document. Below is a diagram for a crossover type cable that would be used for a direct run from the G2 Server PC s network interface card (NIC), to the G2-ES. This would only be used in a single blender setup where an Ethernet hub or switch would not be necessary.
For more information or for additional documents and manuals, visit our web site at the following addresses: General Product information: www.maguire.com G2 Server Software: www.maguire.com/g2 General Contact Information: Maguire Products, Inc. 11 Crozerville Road Aston, PA 19014 USA Tel: 1-888-459-2412 +1-610-459-4300 Fax: +1-610-459-2700 If additional G2 support is needed contact: Green Bridge Station Technologies Website: www.gbs.com E-Mail: g2@maguire.com Phone: 610-358-9800 Fax: 610-358-9896