g2-2 controlnet 2005/2012 series technical manual asset...

LT2005/2012CNTECH-1 01/03 www.numatics.com Subject to change without notice

G2-2 ControlNet 2005/2012 Series

Technical Manual

2005/2012 Series ControlNet Technical Manual

LT2005/2012CNTECH-1 01/03 www.numatics.com Page 1 Subject to change without notice

Table of Contents PAGE

About ControlNet ............................................................................................................................................................................ 3 Overview....................................................................................................................................................................................... 3 G2-2 ControlNet Features ......................................................................................................................................................... 3 Segment lengths (as defined by ControlNet specification).................................................................................................. 3

2005/2012 and G2-2 Introduction.................................................................................................................................................. 4 Product Overview........................................................................................................................................................................ 4

2005/2012 and G2-2 Electronics Modularity................................................................................................................................ 5 Discrete I/O ................................................................................................................................................................................ 5 Pneumatic Valve Manifold......................................................................................................................................................... 6

Distributing I/O with G2-2 Electronics ....................................................................................................................................... 7 G2-2 ControlNet System Versatility......................................................................................................................................... 8

2005/2012 Valve Unit....................................................................................................................................................................... 9 Z-Board™ and Solenoid Coil Connections to Output Drivers............................................................................................ 9

Z-Board™ Connectors.........................................................................................................................................................10 Z-Board™ and Ribbon Cable Example: ...........................................................................................................................11 Z-Board™ and Ribbon Cable with Valve Side Sub-d Example:.....................................................................................12

Module Configurations and Pinouts ............................................................................................................................................13 ControlNet Communication Module (Node) .......................................................................................................................13

Connector Types...................................................................................................................................................................13 Auxiliary Power Connector Pin Out...................................................................................................................................14

Rotary Switches..........................................................................................................................................................................15 Rotary Switch Settings .........................................................................................................................................................15 Rotary Switch Settings Example ........................................................................................................................................16

Comm. Module...........................................................................................................................................................................17 Discrete I/O Modules...............................................................................................................................................................18

Rules........................................................................................................................................................................................18 Module Types........................................................................................................................................................................18 Input Modules: ......................................................................................................................................................................19 Output Modules.................................................................................................................................................................... 22

Electrical Connections .................................................................................................................................................................. 24 Power Supply Wiring Diagrams.............................................................................................................................................. 24 Power Consumption................................................................................................................................................................. 25

Auxiliary Power Connection .............................................................................................................................................. 25 Discrete I/O Module(s) Power Jumper............................................................................................................................ 25 Power Rating ........................................................................................................................................................................ 25 Recommended External Fuses: ......................................................................................................................................... 25 Discrete I/O Power Jumper ............................................................................................................................................... 26 Discrete Sub-D Output Power Jumper ............................................................................................................................. 27

Power Consumption and External Fuse Sizing Guide Chart............................................................................................. 28 I/O Module(s) Wiring Diagrams........................................................................................................................................... 29

Definitions............................................................................................................................................................................. 29 Sinking Description............................................................................................................................................................. 29 Sourcing Description........................................................................................................................................................... 29 Sinking (NPN) Input Connection .................................................................................................................................... 29 Sourcing (PNP) Input Connection ................................................................................................................................... 29 Sinking (NPN) Output Connection.................................................................................................................................. 30 Sourcing (PNP) Output Connection................................................................................................................................. 30

ControlNet Configuration and Mapping ....................................................................................................................................31 EDS File ......................................................................................................................................................................................31 I/O Setup ................................................................................................................................................................................... 32



Outputs .................................................................................................................................................................................. 32 Inputs ..................................................................................................................................................................................... 32

I/O Sizes .................................................................................................................................................................................... 33 I/O Size - Manifold ............................................................................................................................................................. 33 I/O Size - Valve Side........................................................................................................................................................... 33 I/O Size - Discrete I/O Side ............................................................................................................................................. 33 Manifold I/O Sizing Worksheet........................................................................................................................................ 34 Bit Mapping Rules............................................................................................................................................................... 35 Valve Side .............................................................................................................................................................................. 35 Discrete I/O Side................................................................................................................................................................. 35

I/O Mapping............................................................................................................................................................................. 37 Example #1 ........................................................................................................................................................................... 37 Example #2........................................................................................................................................................................... 39 Example #3............................................................................................................................................................................41

Diagnostics – Comm. Module / Power Module....................................................................................................................... 43 LED Functions.......................................................................................................................................................................... 43 Internal Fuses ............................................................................................................................................................................ 44 Output Short Circuit Protection.............................................................................................................................................. 44

Status Bit Action During Fault Condition........................................................................................................................ 44 Appendix ......................................................................................................................................................................................... 45

System Specifications............................................................................................................................................................... 45 Factory Defaults Settings ......................................................................................................................................................... 46 Troubleshooting........................................................................................................................................................................ 47 Glossary of Terms ..................................................................................................................................................................... 48

Technical Support.......................................................................................................................................................................... 49



About ControlNet

Overview

ControlNet is a serial communication protocol used to network devices that wish to exchange time-critical application information in a deterministic and predictable manner and also eliminate labor intensive and expensive point to point wiring schemes. Allen Bradley originally developed ControlNet, but it is now supported by a multitude of manufacturers. ControlNet International is an independent organization that governs the ControlNet specification and oversees conformance testing for products, which will be used in a ControlNet system. ControlNet uses a RG-6 quad shield coax cable and can have up to 99 nodes. The protocol can transfer a maximum of 510 bytes of data per node cycle with a communication (baud) rates of 5 Mbit/ sec.. Maximum distance is depended upon cable media type and number of nodes. Refer to the section below for details. More information about ControlNet International can be obtained from the web site http://www.controlnet.org

G2-2 ControlNet Features

Features Description Address Setting Via Rotary Switches Baud Rates Supported 5 Mbit/sec. Bus Topology Linear bus, Tree, Star, mix of all three CE CE compliant Connection Sizes 16 Words (32 Bytes) of Input Data and

16 Words (32 Bytes) of Output Data Minimum requested packet interval (RPI)

5ms

NAP Port Network Access Port allows a temporary network connection at the node. The NAP uses a standard 8-pin RJ-45 connector.

Physical Media Coax – RG-6 quad shield, Single or Dual – Redundant Media Redundant Media The node supports redundant media. Two coax connectors are

provided (Trunk Line A & B). Termination Resistor (external)

A 75 ohms resistor is required at each end of each segment.

Segment lengths (as defined by ControlNet specification)

0

250

500

750

1000

2 16 32 48

Seg

men

t len

gth

(m)

Number of taps



2005/2012 and G2-2 Introduction

Product Overview

The 2005/2012 is a valve product line featuring a variety of valve configurations and electronic interface options. These include several Fieldbus communication protocols that can control up to 32 valve solenoid coils, on the valve side of the assembly, and up to 132 I/O points of I/O on the Discrete I/O side. This manual addresses the specifics of configuring and commissioning the Numatics 2005/2012 Series product line configured with the ControlNet communication interface. For more information relating to pneumatic valving and valve manifold assemblies, please refer to the Numatics 2005 & 2012 Series catalog, No. LT2005/2012-1.



2005/2012 and G2-2 Electronics Modularity Discrete I/O

The 2005/ 2012 product line is a completely modular system. As shown below, all of the G2-2 electronic modules plug together, allowing easy assembly and field changes. Additionally, all the PC boards containing active electronics (i.e. communication, I/O and MCM) are also modular allowing changes to be made without the need to dismantle the manifold.



Pneumatic Valve Manifold

The pneumatic valve manifold is also modular. The valve solenoid coil connections are made automatically using Z-Board™ technology (plug together PC boards which allow internal connection from solenoid coils to output drivers without the use of wires). This allows easy assembly and field changes.



Distributing I/O with G2-2 Electronics

The G2-2 series fieldbus manifold allows its discrete I/O points to be distributed from the central manifold by using various I/O modules (see pages 18-23). This distribution capability can be made at any time, even after the manifold has been installed and commissioned, although, network or communication rack configurations may be affected depending on the new total number of I/O points configured. The distributed I/O points can be used for various input devices and loads with many different termination options, including additional manifolds with Sub-D connector option. Please refer to Figure 1 on the following page for a sample configuration layout.



G2-2 ControlNet System Versatility

Figure 1 Example of network to PLC/IPC with distributed valve manifolds and I/O devices.



2005/2012 Valve Unit

Z-Board™ and Solenoid Coil Connections to Output Drivers

Z-Board™ plug together technology connects all valve solenoids to the valve coil output drivers, located in the communication node. The valve solenoid coil output drivers are divided into 2 separate 16 bit groups. Output group #1 is comprised of the first output word, bits 0-15, and output group #2 is comprised of the second output word, bits 16-31. Output group #1 connects directly to the Z-Boards™, while output group #2 is connected to Z-Boards™ via an internal ribbon cable or Valve Side Sub-D. The first output connects to the “14” (A) solenoid on the valve closest to the communication node. The 17th – 32nd solenoids interconnect via the Z-Boards™ to output group #2. For the maximum capability of 32 solenoids, the 16th and 17th solenoid coils must NOT be on the same sub-base.

Single solenoid Double solenoid Z-Board™ Z-Board™

Plug-in Manifold with Integral “Z-Board™” Eliminates Wiring

Output Group #1 Connector

Output Group #2 Connector

Earth Ground Pin #3

Common Pin #4

14(A) Solenoid Pin #1

12(B) Solenoid Pin #2



Z-Board™ Connectors The 2005/2012 valve series utilizes 2 different Z-Boards™ designs to achieve the single and double solenoid output functions that yield the possible 32 single, 16 double, or any combination of valve solenoid coil output capabilities.

Single Z-Board™ Double Z-Board™ Part # 256-640 (2012) Part # 256-151 (2005)

Part # 256-641 (2012) Part # 256-152 (2005)

Ribbon Connection Ribbon Connection Single Z-Board™ Double Z-Board™

Part # 256-642 (2012) Part # 256-742 (2005)

Part # 256-643 (2012) Part # 256-743 (2005)

single double

The 17th solenoid (output group #2’s first bit) must be accessed via either the valve side sub-d output module or a ribbon connector type Z-board.



Z-Board™ and Ribbon Cable Example: If fourteen (14) single solenoid and one (1) double solenoid valves are connected directly to the communication node via their Z-Boards™, and one (1) single solenoid and four (4) double solenoid valves are connected to the communication node via the ribbon cable, the following would be the valve side bit map:

Output Bit # 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Solenoid Coil Output # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 n/a n/a n/a n/a n/a n/a n/a

In the above example, Output Bits #15 and #26 thru #31 are allocated but not used.

S= Sgl. Sol. With Single Z-Board™ D= Dbl. Sol. With Double Z-Board™

Output Group #1 Connector to

Z-Board™

Output Group #2 Connector to Ribbon

Cable Output Group #2

Ribbon Connector Z-Board™

D S

15 16

17



Z-Board™ and Ribbon Cable with Valve Side Sub-d Example: If sixteen (16) single solenoid valves are connected directly to the communication node via their Z-Boards™, and a valve side sub-d connector is connected to the communication node via the ribbon cable, the following would be the valve side bit map:

Output Bit # 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Solenoid Coil Output # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

S= Sgl. Sol. With Single Z-Board™

Output Group #1 Connector to

Z-board™

Output Group #2 Connector to Ribbon Cable

Coil Outputs 17-32



Module Configurations and Pinouts

ControlNet Communication Module (Node)

This module is the communication interface to the manifold. It contains communication electronics and short circuit protected solenoid coil output drivers Factory Defaults Settings

Type Value Description Baud Rate 5M bit/sec. Data Rate is 5 Mbit/s Node Address 00 Node Address value

Input/ Output Connection Sizes

8 In / 4 Out Bytes (4 In / 2 Out Words) + Discrete I/O

The Input and Output Connection Size of the manifold system. The total number of I/O that the manifold is configured for, including diagnostic Status Input bits and Run/Idle Header. (See Bit Mapping Section For Additional Information)

LED Display Connector Types

An Industry standard “mini” connector is used for auxiliary power. The Aux. Power is a single keyway 4 pin male connector. The two ControlNet communication connectors are BNC type connectors.



Auxiliary Power Connector Pin Out

Pin # Function Description

1 +24VDC (Valves and Outputs)

Voltage used to power outputs (valve coils and discrete outputs)

2 Earth Ground Protective Earth (case) 3 0VDC Common 0VDC Common, for valve and I/O power

4 +24VDC (Node and Inputs)

Voltage used to power discrete inputs and node electronics

• Maximum current capacity on pin #3 (0VDC common) of auxiliary power connector is 8 Amps. The combined draw of Pin #1 (Valves & Outputs) and pin #4 (Node & Inputs) cannot exceed 8 Amps, at any given moment in time.

• Auxiliary power connector pin #4 supplies power to node electronics. This pin must be powered at all times for communication node to be functional.

ATTENTION

!

4 1

POWER

3 2

MALE



Rotary Switches

The Rotary switches allow the user to set the node address.

Rotary Switch Settings

Network Address:

Switch Description

NA 01 Sets the Ones Digits

NA 10 Sets the Tens Digits

• Address is set to a default setting of 00 prior to shipment. • Rotary switch settings do not take effect until power is cycled (turned

OFF and ON).

ATTENTION

!



Rotary Switch Settings Example

The example below shows the correct settings for the following requirements: Node Address = 73

Switch Settings:

Switch Setting Description

NA 01 3 Sets the Ones Digits of MAC ID to Three (3)

NA 01 7 Sets the Tens Digits of MAC ID to Two (2)



Comm. Module Replacement and / or spare parts for the G2-2 ControlNet module can be purchased by ordering the entire module (communications and power module), 239-1841 or by specifying individual components (see chart below).



Discrete I/O Modules

Rules

The maximum number of I/O modules that can be used on the Discrete I/O side of the manifold is 6. Modules can be connected in any combination and sequence of inputs and outputs up to the logical limitations of 132 I/O. Damage will occur if Discrete I/O and MCM Modules are inserted or removed with power applied. Module Types

Module Part #

Replacement I/O Board

Part # I/O Points

Module Size Connection Type I/O Type

Internal Status Bits

239-1304 256-646 Input 4 Narrow 4 x 12mm (1 input per conn.) Sinking (NPN) N/A 239-1305 256-648 Input 4 Narrow 4 x 12mm (1 input per conn.) Sourcing (PNP) N/A 239-1308 256-647 Input 8 Narrow 4 x 12mm (2 input per conn.) Sinking (NPN) N/A 239-1309 256-649 Input 8 Narrow 4 x 12mm (2 input per conn.) Sourcing (PNP) N/A 239-1312 256-654 Input 8 Wide 8 x 12mm (1 input per conn.) Sinking (NPN) N/A 239-1313 256-656 Input 8 Wide 8 x 12mm (1 input per conn.) Sourcing (PNP) N/A 239-1316 256-655 Input 16 Wide 8 x 12mm (2 input per conn.) Sinking (NPN) N/A 239-1317 256-657 Input 16 Wide 8 x 12mm (2 input per conn.) Sourcing (PNP) N/A 239-1868 256-796 Input 16 Narrow Dual 15 Pin Sub-D (8 inputs per Sub-D) Sinking (NPN) N/A 239-1870 256-798 Input 16 Narrow Dual 15 Pin Sub-D (8 inputs per Sub-D) Sourcing (PNP) N/A 239-1869 256-797 Input 16 Narrow 25 Pin Sub-D (16 inputs) Sinking (NPN) N/A 239-1871 256-799 Input 16 Narrow 25 Pin Sub-D (16 inputs) Sourcing (PNP) N/A 239-1306 256-650 Output 4 Narrow 4 x 12mm (1 input per conn.) Sinking (NPN) 4 239-1307 256-652 Output 4 Narrow 4 x 12mm (1 input per conn.) Sourcing (PNP) 1 239-1310 256-651 Output 8 Narrow 4 x 12mm (2 input per conn.) Sinking (NPN) 8 239-1311 256-653 Output 8 Narrow 4 x 12mm (2 input per conn.) Sourcing (PNP) 2 239-1314 256-658 Output 8 Wide 8 x 12mm (1 input per conn.) Sinking (NPN) 8 239-1315 256-660 Output 8 Wide 8 x 12mm (1 input per conn.) Sourcing (PNP) 2 239-1318 256-659 Output 16 Wide 8 x 12mm (2 input per conn.) Sinking (NPN) 16 239-1319 256-661 Output 16 Wide 8 x 12mm (2 input per conn.) Sourcing (PNP) 4

239-1460 256-722 Output 22 Wide 25 Pin Sub-D w/Aux Power (22 outputs) Sourcing (PNP) 6



Input Modules:

Part # Description Part # Description

239-1304 4 Inputs (Sinking-NPN) - 1 Input/Connector 239-1312 8 Inputs (Sinking-NPN) - 1 Input/Connector


239-1305 4 Inputs (Sourcing-PNP) - 1 Input/Connector 239-1313 8 Inputs (Sourcing-PNP) - 1 Input/Connector


239-1308 8 Inputs (Sinking-NPN) – 2 Inputs/Connector 239-1316 16 Inputs (Sinking-NPN) - 2 Inputs/Connector




239-1309 8 Inputs (Sourcing-PNP) - 2 Inputs/Connector 239-1317 16 Inputs (Sourcing-PNP) - 2 Inputs/Connector

Part # Description

239-1868 16 Inputs (Sinking-NPN) – 8 Inputs/Connector

Part # Description

239-1870 16 Inputs (Sourcing-PNP) – 8 Inputs/Connector

Byte X

Byte X+1

Byte X

Byte X+1



Part # Description

239-1869 16 Inputs (Sinking-NPN) – 16 Inputs/Connector

Part # Description

239-1871 16 Inputs (Sourcing-PNP) – 16 Inputs/Connector

ATTENTION

! Damage will occur if Discrete I/O and MCM Modules are inserted or removed with power applied.



Output Modules • 0.5 Amps per Output. (Consult factory for output loads greater than 0.5 Amps.) • Over current and short circuit protected • Status Bit for Short or Open Circuit

- Sinking Outputs utilize one status input for each output. - Sourcing Outputs utilize one status input for every four outputs


239-1306 4 Outputs (Sinking-NPN) - 1 Output/Connector 239-1314 8 Outputs (Sinking-NPN) - 1 Output/Connector


239-1307 4 Outputs (Sourcing-PNP) - 1 Output/Connector 239-1315 8 Outputs (Sourcing-PNP) - 1 Output/Connector

NOT FOR NEW APPLICATIONS

ATTENTION

! Damage will occur if Discrete I/O and MCM Modules are inserted or removed with power applied!




239-1310 8 Outputs (Sinking-NPN) – 2 Outputs/Connector 239-1318 16 Outputs (Sinking-NPN) - 2 Outputs/Connector

Part # Description Part # Description 239-1311 8 Outputs (Sourcing-PNP) - 2 Outputs/Connector 239-1319 16 Outputs (Sourcing-PNP) - 2 Outputs/Connector


239-1460 22 Outputs (Sourcing-PNP) – 22 Outputs/Connector 239-1713 16 Outputs (Sinking-NPN)

– 16 Outputs/Connector (Valve side only)

25 PIN SUB-D CONNECTOR

4 PIN POWER CONNECTOR

NOT FOR NEW APPLICATIONS

PIN 1

PIN 25

Valve Side Sub-D

PIN 1

PIN 25

25 PIN SUB-D FEMALE

CONNECTOR



Electrical Connections

Power Supply Wiring Diagrams

Single Power Supply Example (Male connector view)

• Please see page 28 for external fuse sizing guide. • When using molded connector power cables, Do Not rely on wire colors for

Pinout. Always use pin number references.

ATTENTION

!



Power Consumption

Auxiliary Power Connection

Aux. Power Connector Pin # Description

1 24 VDC Power for Valves & Discrete Outputs 4 24 VDC Power for Inputs & Node Electronics

Discrete I/O Module(s) Power Jumper

All of Numatics, Inc., G2-2 I/O modules have a selectable power source jumper. This jumper determines which Aux. Power connector pin (1 or 4) will power these modules. This option allows the user to select how each specific module will be powered during different conditions (i.e. E-Stop). Each I/O module can be set-up independently allowing individual Output and/or Input modules to remain active if needed.

Power Rating

• Maximum system current capability is 8 amps. Care should be taken not to exceed 8 amp draw through pin #3 0VDC common (Current of pin #1 and pin #4 combined).

• Discrete I/O current draw is dependent on the device(s) connected. It is critical to know what these values are in order to remain safely within the 8 amp limitation.

• Loads should not draw more than 0.5 amps of current from any one individual discrete output point. (Contact factory for higher current capabilities)

Auxiliary Power Connector Volts Tolerance Current Power Pin 1 +24VDC (Valves & Outputs) Solenoid Valve Coil 2012 (Each) 24VDC +10%/-15% 0.105 A 2.5 Watts Solenoid Valve Coil 2005 (Each) 24VDC +10%/-15% 0.042A 1.0 Watts Discrete Output 24VDC - 0.5 A max. * 12 Watts max. * Pin 4 +24VDC (Node & Inputs) Node 24VDC +/- 10% 0.097 A 2.3 Watts Discrete I/O Module (Each) 24VDC - 0.006 A 0.14 Watts Discrete I/O Status LEDs (Each) 24VDC - 0.015 A 0.36 Watts

Recommended External Fuses:

External fuses should be chosen based upon the physical manifold configuration. Please refer to page 28 for the fuse sizing chart.

* Power consumption for each Discrete I/O point is dependent on the specific current draw of input sensor devices and output loads. Please consult the factory for output current requirements greater than 0.5 amps.

ATTENTION

!



Discrete I/O Power Jumper

I/O Power from pin # 1 I/O Power from pin #4 of Aux. Power Connector of Aux. Power Connector

Please refer to the table below for jumper setting and description.

Jumper Jumpered Setting Pins Description

Jumper Pos 1 “SP”

"S" & "P"

Factory Default - Output power is supplied by Pin # 1 of Aux. Power Connector. This allows discrete outputs to be disabled without disabling power to communication node.

Output Module

Jumper Pos 2 “UP”

"U" & "P"

Output power is supplied by Pin # 4 of Aux Power Connector. This allows discrete outputs to be supplied by the same connection that powers the communication node.

Outputs will not be disabled separately from the communication node.


"U" & "P"

Factory Default - Input power is supplied by Pin # 4 of Aux. Power Connector. This allows Input power to be supplied by the same connection which powers the communication node.

Input Module


"S" & "P"

Input power is supplied by Pin # 1 of Aux Power connector. This allows Input power to be supplied by the same connection that powers the valve coils and discrete outputs.

Wide I/O Modules (Modules with eight 12mm connectors) contain two jumpers; one for each group of four connectors.



Discrete Sub-D Output Power Jumper

Please refer to the table below for jumper setting and description.

Jumper Jumpered

Setting Pins Description


"S" & "P"

Output power is supplied by Pin # 1 of Aux. Power Connector. This allows all valves and discrete outputs to be disabled without disabling power to communication node.


"U" & "P"

Output power is supplied by Pin # 4 of Aux Power Connector. This allows all valves and discrete outputs to be supplied by the same connection that powers the communication node.

Outputs will not be disabled separately from the communication node.

Output Module

Jumper Pos 3 “XP”

“X” & “P” Factory Default - Output power is supplied by pin #1 of local 12mm Aux Power Connector. Outputs can be enabled/disabled via Local 12mm Aux Power Connector.

Local 12mm Aux. Power Connector (See Pg. 23 for Pin-Out)

Output Power from pin # 1 of Mini Aux. Power Connector

Output Power from pin #4 of Mini Aux. Power Connector

Output Power from pin #1 of local 12mm Aux. Power Connector

Fuse (4.0A)



Power Consumption and External Fuse Sizing Guide Chart

Power Consumption - Aux. Power Connector Pin #1 – (Valves and Outputs)

Description Current Number of Solenoid Valve Coils Energized Simultaneously

___ X 0.105 A (2012 Series) = __________Amps

___ X 0.042 A (2005 Series) = __________Amps +

Total load current drawn by simultaneously energized Discrete Outputs = __________Amps with Discrete Outputs Power Jumper in "SP" Position (Factory Default).

Total load current drawn by Sensor Devices from Discrete Inputs source = +

__________Amps with Discrete Input Power Jumper in "SP" Position.

Total: __________Amps Surge Compensation: X 1.25

Suggested External Pin #1 Fuse Value: __________Amps

Power Consumption - Aux. Power Connector Pin #4 – (Node and Inputs) Description Current

Communication Node Power Consumption = 0.097 Amps +

Total load current drawn by simultaneously energized Discrete Outputs = __________Amps with Discrete Outputs Power Jumper in "UP" Position. +

Total load current drawn by Sensor Devices from Discrete Inputs source = __________Amps with Discrete Inputs Power Jumper in "UP" Position (Factory Default). +

Number of I/O modules installed ___ X 0.006 A = __________Amps +

Number of Discrete I/O Status LEDs simultaneously on ___ X 0.015 A = __________Amps

Total: __________Amps Surge Compensation: X 1.25

Suggested External Pin #4 Fuse Value: __________Amps

• The standard power jumper configuration for all Output Modules is “SP”.

• The standard power jumper configuration for all Input Modules is “UP”.

• At any given moment in time, the combined current draw through pin #1 (Valves & Outputs) and pin #4 (Node & Inputs) cannot exceed 8 amperes. Therefore, the combined value of the two fuses on pin #1 and pin #4 should not exceed 10 amperes (8 ampere max by 1.25 surge compensation).



FEMALE

PIN 3=COMMON PIN 1=+24VDC

PIN 4=INPUT OVDC

(SINKING)

1

INPUT MODULE

3 4 Input/Signal

(SINKING) PIN 4=INPUT PIN 1=+24VDC PIN 3=COMMON

FEMALE

OVDC

MODULE INPUT 3

1

4

(NPN)

LOAD

I/O Module(s) Wiring Diagrams

Definitions

Sinking Description • NPN • Switching Negative • Positive Common

Sourcing Description • PNP • Switching Positive • Negative Common

Sinking (NPN) Input Connection Electronic Sensor Type Mechanical Sensor Type Sourcing (PNP) Input Connection Electronic Sensor Type Mechanical Sensor Type

LOAD

LOAD

FEMALE

PIN 3=COMMON PIN 1=+24VDC

PIN 4=INPUT OVDC

(SOURCING)

INPUT MODULE

3 4

1 FEMALE

PIN 3=COMMON PIN 4=INPUT

(SOURCING)

PIN 1=+24VDC OVDC

MODULE INPUT 3

1

4 Input/Signal

(PNP)

LOAD



Sinking (NPN) Output Connection

Sourcing (PNP) Output Connection

(COMM)

PIN 4=OUTPUT

PIN 3=NOT

.5A MAX.

(SINKING)

USED

MODULE

PIN 1=+24VDC

FEMALE

3

1

4

OUTPUT

OVDC

+24VDC

LOAD

PIN 3=COMMON

.5A MAX.

(SOURCING)

PIN 4=OUTPUT

OVDC

USED

MODULE

FEMALE

PIN 1=NOT

3

1

4

OUTPUT

OVDC

LOAD

+24VDC



ControlNet Configuration and Mapping

Configuration with RSLOGIX 5000

When setting up your node, specific values must be entered for the assembly instance with regards to Inputs, Outputs and Configuration (these values will remain constant for all Numatics’ G2-2 ControlNet nodes). The minimum “Size” values are determined from the actual physical configuration of the manifold. Please see the diagram below for an example taken from Allen Bradley’s RSLogix 5000 programming software.

Connection Parameters

Assembly Instance values:

Sizes:

Comm Format:

Description Decimal Hexadecimal

Input 100 64 Output 150 96

Configuration 1 1

Description Size (16 bits=1 word)

Input

Total Input Size value (in words) from manifold configuration (including status Input bits) + 2 Words of ControlNet Run/Idle Header (overhead). This is a minimum value; larger values may be specified for future expansion purposes.

Output Total Output Size value (in words) from manifold configuration. This is a minimum value; larger values may be specified for future expansion purposes.

Configuration 0 (8 bits)

Description Data

Comm. Format “Data – INT”



EDS File

The EDS file contains configuration information required to establish communication to a node on a ControlNet network. The EDS file is available on the Numatics, Inc., website at www.numatics.com.

I/O Setup

Outputs

Outputs are defined as any valve solenoid coil and/or any output point from a discrete Output module. The Output connection size depends upon the physical configuration of the manifold. Please reference the following pages for a detailed explanation for calculating the Output connection size.

Inputs

Inputs are defined as discrete (points from discrete Input modules) and internal (Status Input bits produced by Output drivers). Thus, the Input connection size will include discrete Input points, internal Inputs (Status Input bits), and 4 bytes of Run/Idle Header. Please reference the following pages for a detailed explanation for calculating the Input connection size. If you want to mask off the run/idle header for clarity, create a user defined type with 2 members – HEADER, type DINT; and DATA type INT <input assembly size –2>]. Copy the data from the actual input tag to a tag of this structure, and then you can reference the structure’s DATA member using the element numbers



I/O Sizes

I/O Size - Manifold

The overall size of the Input/Output data for the manifold consists of the valve side size plus the Discrete I/O side size. In the G2-2 Series ControlNet node, the Input/Output size can vary from 8 to 32 bytes (4 to 16 words). Due to the many physical configuration possibilities of the G2-2 series, the worksheet on page 34 will allow accurate sizing of the Input/Output byte requirements.

I/O Size - Valve Side

The Connection size for the valve side of the manifold consists of an output bit for each valve solenoid coil driver and an input bit for the corresponding Status Input bit. The value for the valve side connection size is 4 bytes (2 words) of inputs and outputs. I/O Size - Discrete I/O Side

The connection size for the Discrete I/O side is automatically configured based on the I/O modules installed. The output connection size will consist of an output bit for each output point. The input connection size will consist of an input bit for each input point plus Status Input bits for corresponding outputs. Sinking (NPN) outputs will return one Status bit for each output bit. Sourcing (PNP) outputs will return one Status bit for every four output bits.

• Sinking (NPN) output modules return one Status bit for each output bit.

• Sourcing (PNP) output modules return one Status bit for every four output bits.



Manifold I/O Sizing Worksheet 1 : Choose up to six modules that you want to include on the Discrete I/O side of the manifold and place the sum of

the corresponding Input bytes and Output bytes in the boxes labeled, “Discrete I/O Byte Requirements” at the bottom of the page.

2 : Total the Input byte and Output byte values from the boxes labeled “Discrete I/O Byte Requirements”, “Run /Idle Header (Required)” and “Valve Byte Requirements”. This is the total Input / Output byte values required for the configured manifold

2

Narrow Module (4 Connector - 4/8 Points)Module # I/O Board # Description Input Bytes Output Bytes

239-1304 256-646 4 Inputs (Sinking-NPN) 1 0239-1305 256-648 4 Inputs (Sourcing-PNP) 1 0239-1308 256-647 8 Inputs (Sinking-NPN) 1 0239-1309 256-649 8 Inputs (Sourcing-PNP) 1 0239-1306 256-650 4 Outputs (Sinking-NPN) 1 1239-1307 256-652 4 Outputs (Sourcing-PNP) 1 1239-1310 256-651 8 Outputs (Sinking-NPN) 1 1239-1311 256-653 8 Outputs (Sourcing-PNP) 1 1

Wide Module (8 Connector - 8/16 Points)Module # I/O Board # Description Input Bytes Output Bytes

239-1312 256-654 8 Inputs (Sinking-NPN) 1 0239-1313 256-656 8 Inputs (Sourcing-PNP) 1 0239-1316 256-655 16 Inputs (Sinking-NPN) 2 0239-1317 256-657 16 Inputs (Sourcing-PNP) 2 0239-1314 256-658 8 Outputs (Sinking-NPN) 1 1239-1315 256-660 8 Outputs (Sourcing-PNP) 1 1239-1318 256-659 16 Outputs (Sinking-NPN) 1 2239-1319 256-6561 16 Outputs (Sourcing-PNP) 1 2

Sub -D I/O ModulesModule # I/O Board # Description Input Bytes Output Bytes

239-1868 256-796 16 Inputs - Dual 15 Pin Sub-D (Sinking-NPN) 2 0239-1870 256-798 16 Inputs - Dual 15 Pin Sub-D (Sourcing-PNP) 2 0239-1869 256-797 16 Inputs - 25 Pin Sub-D (Sinking-NPN) 2 0239-1871 256-799 16 Inputs - 25 Pin Sub-D (Sourcing-PNP) 2 0239-1460 256-722 22 Outputs - 25 Pin Sub-D (Sourcing-PNP) 1 3

Input Bytes Output Bytes

Discrete I/O Byte RequirementsValve Byte Requirements 4 4

Run Idle Header (Required) 4 0Total Input/Output Bytes for Manifold

Station #123456

Module #

1

2 Bytes = 1 Word



Bit Mapping Rules

The bit mapping for a G2-2 manifold varies with the physical configuration of the manifold. The following is a breakdown of the bit mapping rules associated with the 2005/2012 valve manifold.

Valve Side

1) Solenoid coil outputs are distributed to the valve coils using the Z-Boards™. 2) The valve solenoid coil output portion for the total output connection size is 4 bytes (2 words). 3) Each solenoid coil output has an associated Status Input bit (refer to “Output Short Circuit Protection”

section page 44 for functional details). This will affect the overall input connection size. 4) Solenoid coil output addressing begins at the 1st valve sub base nearest the node and continues in ascending

order away from the communication node. 5) Each sub base is allocated 1 or 2 output bits, depending on the Z-Board™ type installed. Single Z-Board™

allocates 1 output bit, double Z-Board™ allocate 2 output bits. 6) Z-Boards™ can be used in any arrangement (all singles, all doubles, or any combination) as long as output

group #1 and output group #2 bits do not overlap (i.e. combinations of Z-Boards™ could exist where the physical configuration of the manifold could exceed the output quantity capacity, see page 9).

7) When using valve side sub-d module the 1st output available will always be bit 16. Single solenoid valves can be used with double Z-BoardsTM. However, one of the

2 available outputs will remain unused.



Discrete I/O Side Outputs 1) The discrete output connection size portion is self-configuring in byte increments once an output module is plugged into back plane and power is applied.

2) Discrete output bits are mapped, in ascending order (away from the communication node), starting at Word No.2 (third word). 3) All discrete output modules have an associated internal Status Input bit, which will affect the total value of the input connection size. Sinking (NPN) output modules allocate one internal Status Input bit per output point. Sourcing (PNP) output modules allocate one internal Status Input bit for every 4 output points. 4) Output bits are always configured in byte increments, thus four point output modules will always use a

full byte (8 bits) when mapped. Although not used, the additional four bits in that byte are reserved. Inputs 1) The discrete input connection size portion is self-configuring in byte increments once an input module

is plugged into back plane and power is applied. 2) Internal Status Input bits, associated with the valve side output drivers, are always mapped before any physical input points. 3) All internal Status Input bits associated with any discrete output module are mapped in byte increments and in ascending order following any existing physical or internal Status Input bits. Refer to pages 37-42 for sample I/O mapping.



Assumed Settings

• Single Z-Boards™ are installed for single solenoid valves and double Z-Boards™ are installed for double solenoid valves.

• Run/Idle Header (Overhead) will always take up the first two words of the Input map.

• Status Input Bits are mapped after the two words of Run/Idle Header (Overhead) and every output device thus the first physical Input will begin at “NODE6:I.DATA[4].8” in this example.

• Valve outputs have 1 Status bit per output point; PNP discrete Output modules have 1 Status bit for every 4 Output points

Sample address scheme: NODE6:X.DATA[Y].Z

X = (O) Output or (I) Input Y = Word No. Z = Bit No.

I/O Mapping

Example #1

PosNo.

Module Type Part No.

Input Size

Value Bytes

Output Size

Value Bytes

1 16O Sourcing (PNP)

239-1319 1 2 (1 Word)

2 8I Sourcing (PNP)

239-1309 1 0

3 4I Sinking (NPN)

239-1304 1 0

Valve Side Solenoid Outputs

---- 4 (2 Words)

4 (2 Words)

Run/Idle Header (Overhead)

---- 4 (2 Words)

0

Total I/O Bytes from manifold configuration.

11 6

Total I/O Words (16 bits) from manifold

configuration. 6 3

Node Address or Module Tag

I/O Station #3

I/O Station #2

I/O Station #1 Discrete Output (16O) NODE6:I.DATA[2].0-15

Discrete Input (4I) NODE6:I.DATA[5].0-3

Allocated (4I): NODE6:I.DATA[5].4-7


25 Pin Valve Side Sub-D Output

(16O) NODE6:O.DATA[1].0-15

NODE6:O.DATA[0].0-15

Valve Station #1

Valve Station #2

Valve Station #3

Valve Station #4

Valve Station #5

Valve Station #6

Valve Station #7

0

1

2

3 4

6 5

7

8



I/O Mapping Tables

Example #1

Output Table

WORD BYTE Bit 15

Bit 7 Bit 14

Bit 6 Bit 13

Bit 5 Bit 12

Bit 4 Bit 11

Bit 3 Bit 10

Bit 2 Bit 9

Bit 1 Bit 8

Bit 0

0 Valve Coil No. 8 Valve Coil No. 7 Valve Coil No. 6 Valve Coil No. 5 Valve Coil No. 4 Valve Coil No. 3 Valve Coil No. 2 Valve Coil No. 1

0 1

Valve Coil No. 16

Valve Coil No. 15

Valve Coil No. 14 Valve Coil No. 13 Valve Coil No. 12 Valve Coil No. 11 Valve Coil No. 10 Valve Coil No. 9

2 Valve Coil No.

24 Valve Coil No.

23 Valve Coil No.

22 Valve Coil No. 21

Valve Coil No. 20

Valve Coil No.19 Valve Coil No. 18 Valve Coil No. 17

1

3 Valve Coil No.

32 Valve Coil No.

31 Valve Coil No.

30 Valve Coil No.

29 Valve Coil No.

28 Valve Coil No.

27 Valve Coil No.

26 Valve Coil No.

25

4 Discrete Output

No. 8 (Pos. No.1)

Discrete Output No. 7 (Pos.

No.1)

Discrete Output No. 6 (Pos. No.

1)


No.1)


No.1)


No.1)

Discrete Output No.2 (Pos. No.1)


1) 2

5 Discrete Output

No. 16 (Pos. No.1)


No.1)


No.1)


No.1)


No.1)


No.1)


No.1)


1)

Input Table

WORD BYTE Bit 15

Bit 7 Bit 14

Bit 6 Bit 13

Bit 5 Bit 12

Bit 4 Bit 11

Bit 3 Bit 10

Bit 2 Bit 9

Bit 1 Bit 8

Bit 0

0 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead) 0

1 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

2 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead) 1

3 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

4 Status for Valve

Coil No. 8 Status for Valve







Coil No. 1 2

5 Status for Valve








Coil No. 9

6 Status for Valve




Coil No. 21 Status fo r Valve




Coil No. 17 3

7 Status for Valve








Coil No. 25

8 Allocated &

Reserved Allocated &



Reserved

Status for Discrete Outputs

No.13-16 (Pos. No. 1)


No. 9-12 (Pos. No. 1)


No. 5-8 (Pos. No. 1)


No. 1-4 (Pos. No. 1) 4

9 Discrete Input

No. 8 (Pos. No. 2)

Discrete Input No. 7

(Pos. No. 2)


(Pos. No. 2)


(Pos. No.2)


(Pos. No. 2)


(Pos. No. 2)


(Pos. No. 2)


(Pos. No. 2)

10 Allocated &




Reserved


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3) 5

11

The Status Input bits report the health of a corresponding output bit. To review the status bit action during a fault condition see page 43.



I/O Mapping

Example #2

PosNo.


Input Size

Value Bytes

Output Size

Value Bytes

1 8O Sourcing (PNP)

239-1315 1 1


239-1460 1 3 (2 Words)

3 16I Sinking (NPN)

239-1869 2 (1 Word) 0

4 4I Sinking (NPN)

239-1304 1 0


---- 4 (2 Words)

4 (2 Words)


---- 4 (2 Words) 0


13 8


configuration. 7 4

Assumed Settings • Double Z-Boards™ are installed for all valves. • Run/Idle Header (Overhead) will always take

up the first two words of the Input map. • Status Input Bits are mapped after the two

words of Run/Idle Header (Overhead) and every output device thus the first physical Input will begin at “NODE6:I.DATA[5].0” in this example.





Discrete Output (8O) NODE6:O.DATA[2].0-7

Discrete Output (22O) NODE6:O.DATA[2].8-15 NODE6:O.DATA[3].0-13

Allocated (2 O): NODE6:O.DATA[3].14-15

Discrete Input (4I) NODE6:O.DATA[6].0-3

Allocated (4I) NODE6:O.DATA[6].4-7

Discrete Input (16I) NODE6:O.DATA[5].0-15

I/O Station #4

I/O Station #1

I/O Station #2

I/O Station #3

0

11

15

10

12 13

14

17 16

1

3 2

5 4

7 6

8

9

NODE6:O.DATA[0].0-15 NODE6:O.DATA[1].0-15

Valve Station #1

Valve Station #2

Valve Station #3

Valve Station #4

Valve Station #5

Valve Station #6

Valve Station #7

Valve Station #8

Valve Station #9



I/O Mapping Tables

Example #2

Output Table

WORD BYTE Bit 15

Bit 7 Bit 14

Bit 6 Bit 13

Bit 5 Bit 12

Bit 4 Bit 11

Bit 3 Bit 10

Bit 2 Bit 9

Bit 1 Bit 8

Bit 0


0 1

Valve Coil No. 16

Valve Coil No. 15


2 Valve Coil No.

24 Valve Coil No.

23 Valve Coil No.


Valve Coil No. 20

Valve Coil No.19 Valve Coil No. 18 Valve Coil No. 17 1

3 Valve Coil No.

32 Valve Coil No.

31 Valve Coil No.

30 Valve Coil No.

29 Valve Coil No.

28 Valve Coil No.

27 Valve Coil No.

26 Valve Coil No.

25

4 Discrete Output

No. 8 (Pos. No.1)

Discrete Output No. 7

(Pos. No.1)


(Pos. No. 1)


(Pos. No.1)


(Pos. No.1)


Pos. No.1)

Discrete Output No.2

(Pos. No.1)


(Pos. No. 1) 2

5 Discrete Output

No. 16 (Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No. 2)

6 Discrete Output

No. 24 (Pos. No.2)


(Pos. No.2)


(Pos. No. 2)


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)

Discrete Output No.18

(Pos. No.2)


(Pos. No. 2) 3

7 Allocated &


Reserved


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No. 2)

Input Table

WORD BYTE Bit 15

Bit 7 Bit 14

Bit 6 Bit 13

Bit 5 Bit 12

Bit 4 Bit 11

Bit 3 Bit 10

Bit 2 Bit 9

Bit 1 Bit 8

Bit 0

0 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead) 0

1 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/I dle Header

(Overhead)

2 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead) 1

3 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

4 Status for Valve








Coil No. 1 2

5 Status for Valve








Coil No. 9

6 Status for Valve








Coil No. 17 3

7 Status for Valve








Coil No. 25

8 Allocated &






Reserved


No. 5-8 (Pos. No. 1)


No. 1-4 (Pos. No. 1)

4

9 Allocated &


Reserved


No. 29-32 (Pos. No. 2)


No. 25-28 (Pos. No. 2)


No.21-24 (Pos. No. 2)


No. 17-20 (Pos. No. 2)


No. 13-16 (Pos. No. 2)


No. 9-12 (Pos. No. 2)

10 Discrete Input

No. 8 (Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3) 5

11 Discrete Input

No. 16 (Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)

12 Allocated &




Reserved


(Pos. No. 4)


(Pos. No. 4)


(Pos. No. 4)


(Pos. No. 4) 6

13



I/O Mapping

Example #3

PosNo.


Input Size

Value Bytes

Output Size

Value Bytes

1 8O Sourcing (PNP)

239-1315 1 1


239-1319 1 2 (1 Word)

3 8I Sinking (NPN)

239-1308 1 0

4 4I Sinking (NPN)

239-1304 1 0


---- 4 (2 Words)

4 (2 Words)


---- 4 (2 Words) 0


12 7


configuration. 6 4

Assumed Settings • Run/Idle Header (Overhead) will always

take up the first two words of the Input map.

• Status Input Bits are mapped after the two words of Run/Idle Header (Overhead) and every output device thus the first physical Input will begin at “NODE6:I.DATA[5].0” in this example.




I/O Station #4

I/O Station #1

I/O Station #2

I/O Station #3

Discrete Input (4I) NODE6:I.DATA[5].8-11 Allocated (4I) NODE6:I.DATA[5].12-15


Discrete Output (16O) NODE6:O.DATA[2].8-15 NODE6:O.DATA[3].0-7

Discrete Output (8O) NODE6:O.DATA[2].0-7


NODE6:O.DATA[0].0-15 NODE6:O.DATA[1].0-15



I/O Mapping Tables

Example #3

Output Table

WORD BYTE Bit 15

Bit 7 Bit 14

Bit 6 Bit 13

Bit 5 Bit 12

Bit 4 Bit 11

Bit 3 Bit 10

Bit 2 Bit 9

Bit 1 Bit 8

Bit 0


0 1

Valve Coil No. 16

Valve Coil No. 15


2 Valve Coil No.

24 Valve Coil No.

23 Valve Coil No.


Valve Coil No. 20

Valve Coil No.19 Valve Coil No. 18 Valve Coil No. 17 1

3 Valve Coil No.

32 Valve Coil No.

31 Valve Coil No.

30 Valve Coil No.

29 Valve Coil No.

28 Valve Coil No.

27 Valve Coil No.

26 Valve Coil No.

25

4 Discrete Output

No. 8 (Pos. No. 1)


(Pos. No. 1)


(Pos. No. 1)


(Pos. No. 1)


(Pos. No. 1)


(Pos. No. 1)


(Pos. No. 1)


(Pos. No. 1) 2

5 Discrete Output

No. 16 (Pos. No. 2)


(Pos. No. 2)


(Pos. No. 2)


(Pos. No. 2)


(Pos. No. 2)


(Pos. No. 2)


(Pos. No. 2)


(Pos. No. 2)

6 Discrete Output

No. 24 (Pos. No.2)


(Pos. No.2)


(Pos. No. 2)


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No.2)


(Pos. No. 2) 3

7

Input Table

WORD BYTE Bit 15

Bit 7 Bit 14

Bit 6 Bit 13

Bit 5 Bit 12

Bit 4 Bit 11

Bit 3 Bit 10

Bit 2 Bit 9

Bit 1 Bit 8

Bit 0

0 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead) 0

1 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

2 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead) 1

3 Run/Idle

Header (Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)


Run/Idle Header

(Overhead)

Run/Idle Header

(Overhead)

4 Status for Valve








Coil No. 1 2

5 Status for Valve








Coil No. 9

6 Status for Valve








Coil No. 17 3

7 Status for Valve








Coil No. 25

8 Allocated &

Reserved Allocated & Reserved Allocated &

Reserved Allocated & Reserved Allocated &

Reserved Allocated & Reserved


No. 5-8 (Pos. No. 1)


No. 1-4 (Pos. No. 1)

4

9 Allocated &




Reserved


No.21-24 (Pos. No. 2)


No. 17-20 (Pos. No. 2)


No. 13-16 (Pos. No. 2)


No. 9-12 (Pos. No. 2)

10 Discrete Input

No. 8 (Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3)


(Pos. No. 3) 5

11 Allocated &




Reserved


(Pos. No. 4)


(Pos. No. 4)


(Pos. No. 4)


(Pos. No. 4)

The Status Input bits report the health of a corresponding output bit. To review the status bit action during a fault condition see page 43.



Diagnostics – Comm. Module / Power Module

LED Functions

Upon power up, the LEDs indicate the status of the unit. The Power Module of the G2-2 ControlNet node has four LEDs; two for internal fuse integrity and two for Aux. Power status. The Communication module also has four status LEDs

Communication Module LED Name Color Status Description

-- OFF Module is not initialized

Green/Red ALTERNATING Self test of bus controller ON Faulted unit, must be restarted

Channel

& Red

FLASHING Incorrect node configuration; i.e. duplicate MAC ID -- OFF Channel is disabled, depending on the network configuration

ON Normal operation of channel Green

FLASHING Temporary errors (node will self correct) or node is not configured to go online

Red FLASHING Media Fault or no other nodes on the network

Channel or

Green/Red FLASHING Incorrect network configuration ON Module is initialized Green

FLASHING Module is waiting for initialization ON Major fault, module must be restarted

Module Status (MS)

Red FLASHING Minor fault, MAC ID has been changed after initialization, etc.

OFF No connection is opened Module Owned (OWNED)

Green ON A connection is opened to the module

Power Module LED Name Color Status Description

ON Internal fuse F1 is open; No power is internally provided to valves or outputs. Communication NOT affected. Fuse 1 Red

OFF Internal fuse F1 is OK (valid only when power is applied to +24V VLV / OUT pin on Aux. Power connector.

ON DC Power applied to +24V VLV / OUT pin on Aux. Power Connector. +24V VLV / OUT Green OFF No DC Power present at +24V VLV / OUT pin on Aux. Power connector.

ON Internal fuse F2 is open; No power is internally provided to node electronics or inputs. Communication Node will not function. Fuse 2 Red

OFF Internal fuse F2 is OK (valid only when power is applied to +24V NODE / IN pin on Aux. Power connector.

ON DC Power applied to+24V NODE / IN pin on Aux. Power connector. +24V NODE / IN Green OFF No DC Power present at +24V NODE / IN pin on Aux. Power connector.



Internal Fuses

Fuse Function and Description

Fuse # Description Size Part Number Type

F1 Fuse for Aux. Power connector Pin #1 (Valves & Outputs).

10 A max. fast acting 140-934 Mini ATO

F2 Fuse for Aux. Power connector Pin #4 (Node & Inputs).

4A max. fast acting 140-933 Mini ATO

Fuse Status LED - Indicates the internal fuse integrity

Status Indication Description Off Internal Fuse is Intact Condition normal.

Red Internal Fuse is Blown Electrical Overload / Over Current Condition

Output Short Circuit Protection Status Bit Action During Fault Condition

Output Type Output State

Fault Condition Status Bit

No Fault 0 Valve Solenoid Coil Driver or Sinking (NPN) Discrete Outputs ON

Fault - Short Circuit, Over Temp/Over Current 1 No Fault 0 Valve Solenoid Coil Driver or

Sinking (NPN) Discrete Outputs OFF Fault - Open Load 1 No Fault 0 Sourcing (PNP)

Discrete Outputs ON

Fault - Short Circuit, Over Temp/Over Current 1

Fuse (F2)

Fuse (F1)



Appendix

System Specifications

Electrical Valves: 24 VDC + 10%, -15% Node and Discrete I/O: 24 VDC +/- 10% Supply Voltage

Current Total current on the Aux. Power Connector (Pin 1 - “Valves & Outputs” and Pin 4 - “Node & Inputs”) must not exceed 8 amperes.

Internal Fuses Pins #1 and #4 on the Auxiliary Power Connector are each internally fused with a 4 and 10 ampere (maximum) MINI ATO type fuses. External fuses should be chosen depending upon manifold configuration. Please refer to power consumption chart on page 28 for additional fuse sizing

Recommended External Fuse

information. Spike Suppression Output spike suppression is internally provided for both discrete and valve outputs.

Discrete Outputs (Sinking (NPN) or Sourcing (PNP))

Maximum 0.5 amperes per output (Sinking (NPN) or Sourcing (PNP)). All outputs are short circuit protected and have internal spike supression. Contact factory for higher current requirements.

Valve Solenoid Coil Output Drivers

Maximum 0.5 amperes per output. All output points are short circuit protected and have internal spike supression.

Operating Temperature for Electronic Components

23 to 114°F (-5 to 46°C)



Factory Defaults Settings

Description Default Node Address 00

Baud Rate 5 M bit/sec. Input Module Power Jumper UP

Output Module Power Jumper SP Valve Side - I/O Connection Size 4/4 Bytes (2/2 Words) I/O Side - I/O Connection Size Self-Configuring. See Page 35

Run/Idle Header – I/O Connection Size 4/0 Bytes (2/0 Words)



Troubleshooting

Symptom Possible Cause Solution

Power must be present between pin #2 and pin #3 on the communication connector and between pin #4 and pin #3 on the auxiliary power connector for the node to function properly.

24VDC must be present between pin #4 and pin #3 of the auxiliary power connector even if Discrete I/O modules are not installed See page 13 for Details

All LEDs off

Power not properly applied

Fuse LEDs displays red Blown internal fuses

Check for external shorts to Input connector from external sensor devices or cable and repair. Replace internal fuse. If problem persists contact factory.

The wrong valve solenoid coils are being energized.

Z-BoardTM type mismatch. Single Z-BoardTM present where double Z-BoardTM expected or vice versa.

Check that correct Z-BoardTM types are installed. Check that ribbon cable (output group #2) is connected to appropriate valve station. See page 35 for bit mapping rules

Valve outputs do not energize. All node LEDs normal.

Output power not present or connected in properly on Aux. Power connector.

Check for 24VDC on pin #1 of Aux. Power connector of Comm. module. Check for 24VDC on Pin #1 of 12mm local Aux Power connector of 25 Pin Sub-D Discrete Output Module, if applicable



Glossary of Terms

The following is a list and description of common terms and symbols used throughout this document:

Bit Smallest unit of digital information either a “0” or “1”

Bit mapping Chart showing which bit is connected to which physical input or output point

Byte 8 bits (1/2 word)

Change of State I/O message type in which either the expiration of the transmission timer or a change in input state triggers data production.

Comm. Fault One or more of the I/O connections have timed out.

Cyclic I/O message type in which data production is triggered by the expiration of the transmission timer.

Discrete I / O The Inputs / Outputs that are available via the “Discrete I/O” side of manifold

EDS file Electronic Data Sheet. A text file, which contains specific product information, definitions of product capabilities and configurable parameters necessary for operation on a ControlNet network.

G2-2 A Numatics product series of electronics which features modular backplane technology that allows various Discrete I/O components and Communication modules to be added, removed or changed in the field

Ground This term is used to indicate an earth ground

I/O Any combination of Inputs and Outputs

Idle A zero (0) length poll massage (i.e.: scanner in program mode)

MAC ID Media Access Connection Identification (00-99) – Node (network drop) address

Maximum Scheduled Node

Node with highest MAC ID that can use scheduled time on a link.

NEMA National Electrical Manufacturers Association

NUT Network Update Time. Repetitive time interval in which data can be sent on the link,

Polled I/O message type in which the devise consumes I/O data from its master and produces I/O data when the master requests it.

RPI Requested Packet Interval. The measure of how frequently the node requires the transmission of data from the target application (scanner).

RS NetWorx Allen-Bradley’s ControlNet configuration software

Sinking (NPN) Method of connecting electrical circuits in which the zero (0) volt DC side is switched and the common is positive

Sourcing (PNP) Method of connecting electrical circuits in which the positive side is switched and the common is zero (0) volts DC.

Status Input bit A bit in the input table that reports the health of a corresponding output. Indicates short circuit or open coil (load) diagnostics

Word 2 Bytes (16 bits)

Z-BoardTM Circuit board installed in the valve sub-base which electrically connects the valve solenoid to the electrical /electronics interface. Available in single or double solenoid versions.



Technical Support

For technical support, contact your local Numatics distributor. Additional assistance is available from Numatics Inc. at (248) 887-4111 and ask for Technical Support. Issues relating to network set-up, PLC programming, sequencing, software related functions, etc… should be handled with the appropriate product vendor. Information on EDS files, local distributors, and other Numatics, Inc. products and support issues can be found on the Numatics, Inc. WEB site at: http://www.numatics.com

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