G2-2 Series FIPIO Quick Start Manual
Getting Started
This is a brief document designed to quickly get you started setting up your valve manifold with an integrated
Numatics’ G2-2 Series FIPIO communication node.
1) Initial Unpacking and Inspection
1) Examine exterior of package for signs of damage. Report any damage to shipping carrier.
2) Remove wrapped manifold assembly from box.
a) Remove manifold assembly from anti-static packaging
b) Retain documentation for installation and configuration
3) Examine manifold assembly for any shipping damage such as:
a) Bent pins or connectors
b) Report any damage to shipping carrier immediately
4) Examine manifold assembly for proper ordered configuration. (Valves, I/O, Protocol, etc.)
2) G2-2 Introduction
Below is an example of a 2012 valve series manifold. This fieldbus manifold series is capable of addressing a
total of 224 I/O. The manifold can be viewed as having two sections to it, the
Side
. The
Valve Side
maximum of 6 modules totaling 192 Outputs, 96 Inputs, or various combinations. The communication
module has a M23 style 6-pin communication connector. The power module has a 4-pin power connector. Pinouts for these, along with I/O connectors, are labeled on the side of the respective modules.
supports a maximum of 32 solenoid coils and the
Module/
Network
Status LED's
Aux. Power
Communications
Module
Valve Side
Discrete I/O Side
Valve Side
(Maximum of 32 Solenoids)
Chassis Ground
LED's
Connection
Power
Module
Valve Side
Sub-D Output
Module
and the
supports a
Valve
End Plates
Valve
Solenoid LED
Status Indicator
Discrete I/O
Manual
Override
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3) FIPIO Communication Module Part Numbers
FIPIO Communication Replacement Part Numbers
Connector Type Description Part Number
Complete Module 239-2310
6-Pin M23
Communication
Connector
Communication Board 256-902
Auxiliary Power Board 256-904
Valve Driver Board 256-680
4 Amp Fuse 140-933
10 Amp Fuse 140-934
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4) MCM - Manual Configuration Module (for Self-Test Mode Function Only)
Rotary Switch
(SW4)
Rotary Switch
(SW3)
All DIP switches shown in the "OFF" position
The MCM is the module that allows the user to manually test the Numatics manifold using Self-Test mode.
The MCM consists of two DIP switch sets (SW1 and SW2) and two rotary switches (SW3 and SW4).
MCM Module Part Numbers
Description Part Number
Complete Module 239-1384
Replacement Board 256-684
DIP Switch
(SW2)
4
5
3
1
2
ON
DIP Switch
(SW1)
ON
4
325
678
1
8
6
7
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G2-2 Series FIPIO Quick Start Manual
5) Self-Test Mode
An internal diagnostic tool can also be enabled using the optional MCM module. This tool allows the user to
confirm that all of the Inputs and Outputs on the manifold are fully functional without needing a network
connection or controller. There are two test modes that the user can choose using SW2-8. The “Output” test
mode tests all the outputs by sequentially turning them ON one at a time. The “Input/Output” test mode
tests the inputs by causing all of the outputs to toggle between even and odd values when any input is made.
To use the Self-Test Mode, the user must first set some initial conditions using the MCM module. Follow
these steps to obtain the needed initial condition settings. Remember to remove power from the manifold
before making changes to the MCM when setting these initial conditions.
1) Disconnect power and air from the manifold!
2) Record current MCM settings.
3) Set the rotary switches to 99 (SW3 and SW4).
4) Make sure that SW1-5, SW2-1, and SW2-7 are in the “ON” position.
5) Select the desired test mode with SW2-8 (see table below)
Switch
SW2-8
6) Make sure that all of the other switches are in the “OFF” position.
The initial conditions are now set. To enable the Self-Test Mode, apply power to the manifold and make the
following changes within 5 to 10 seconds:
Self-Test Mode is terminated by removing power to the unit. Remember to return the MCM settings to their
original settings to return the communication node to normal operation.
!
esting
Mode
Output Off Sequentially turns all the outputs ON and OFF.
Input/
Output
Setting Description
Causes all of the odd outputs to come on and stay on until an
On
1) Set SW2-6 to the “ON” position.
2) Set SW2-7 to the “OFF” position.
input is made. When an input is made, the outputs will toggle to
the even outputs.
Air should be disconnected to the manifold when attempting to run the
Self-Test Mode to prevent unwanted motion.
Communication lines should be disconnected before attempting to run the
Self-Test Mode.
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6) Communication Module 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
Network Address Restrictions:
Node address 00 is reserved for the fieldbus control system (i.e. the PLC)
Node address 63 is reserved for configuration and diagnostic terminals
Node address 01-62 are used for connecting industrial peripheral devices to FIPIO
(i.e. Numatics FIPIO node)
!
Rotary switch settings do not take effect until power is cycled (turned
OFF and ON).
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7) I/O Mapping Example
Example:
Assumed Settings
- Single Z-Boards
valves
- Double Z-Boards
valves
Discrete I/O Configuration
Module Type Part No.
No.
1 MCM 239-1384 -- --
8O Sourcing
2
3
4
5
(PNP)
16O Sourcing
(PNP)
4I Sinking
(NPN)
8I Sinking
(NPN)
Manifold I/O Configuration
Outputs and Mapping Location
Valve Outputs = 12
Allocated Unused
Valve Outputs = 20
Discrete Outputs = 24
Total Outputs = 56
Inputs and Mapping Location
Discrete Inputs = 12
Allocated and
Reserved Inputs = 4
Total Inputs = 16
TM
used with single solenoid
TM
used with double solenoid
In OutPos
Bytes
239-1315 1 1
239-1319 1 2
239-1304 1 0
239-1308 1 0
Byte 0; Bits 0-7
Byte 1; Bits 0-3
Byte 1; Bits 4-7
Bytes 2 - 3; Bits 0-7
Bytes 4,5 and 6;
Bits 0-7
Byte 6; Bits 0-3,
Byte 7; Bits 0-7
Byte 6; Bits 4-7
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I/O Mapping Table Example Continued
Output Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
1
2
3
4
5
6
Valve Coil
No. 8
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 7
Discrete
Output No. 7
Discrete
Output No. 15
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
1
2
3
4
5
6
7
Coil No. 8
Status
Coil No. 16
Status
Coil No. 24
Status
Coil No. 32
Status
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Input No. 7
Valve Coil
No. 7
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 6
Discrete
Output No. 6
Discrete
Output No. 14
Coil No. 7
Status
Coil No. 15
Status
Coil No. 23
Status
Coil No. 31
Status
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Input No. 6
Valve Coil
No. 6
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 5
Discrete
Output No. 5
Discrete
Output No. 13
Coil No. 6
Status
Coil No. 14
Status
Coil No. 22
Status
Coil No. 30
Status
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Input No. 5
Valve Coil
No. 5
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 4
Discrete
Output No. 4
Discrete
Output No. 12
Input Table
Coil No. 5
Status
Coil No. 13
Status
Coil No. 21
Status
Coil No. 29
Status
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Input No. 4
Valve Coil
No. 4
Valve Coil
No. 12
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 3
Discrete
Output No. 3
Discrete
Output No. 11
Coil No. 4
Status
Coil No. 12
Status
Coil No. 20
Status
Coil No. 28
Status
Allocated &
Reserved
Status for
Discrete
Outputs
No. 12-15
Discrete
Input No. 3
Discrete
Input No. 3
Valve Coil
No. 3
Valve Coil
No. 11
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 2
Discrete
Output No. 2
Discrete
Output No. 10
Coil No. 3
Status
Coil No. 11
Status
Coil No. 19
Status
Coil No. 27
Status
Allocated &
Reserved
Status for
Discrete
Outputs
No. 8-11
Discrete
Input No. 2
Discrete
Input No. 2
Valve Coil
No. 2
Valve Coil
No. 10
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 1
Discrete
Output No. 1
Discrete
Output No. 9
Coil No. 2
Status
Coil No. 10
Status
Coil No. 18
Status
Coil No. 26
Status
Status for
Discrete
Outputs
No. 4-7
Status for
Discrete
Outputs
No. 4-7
Discrete
Input No. 1
Discrete
Input No. 1
Valve Coil
No. 1
Valve Coil
No. 9
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 0
Discrete
Output No. 0
Discrete
Output No. 8
Coil No. 1
Status
Coil No. 9
Status
Coil No. 17
Status
Coil No. 25
Status
Status for
Discrete
Outputs
No. 0-3
Status for
Discrete
Outputs
No. 0-3
Discrete
Input No. 0
Discrete
Input No. 0
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8) Output Short Circuit Protection (Status Input Bits)
Status Input Bits report the integrity of the load being driven by the output driver. They must be mapped to the
scanner as part of the Input Size Value. Please refer to the table below for Status Input Bit action during fault
condition:
Output Type Output State Fault Condition Status Bit
Valve Solenoid Coil Driver or
Sinking (NPN)
Discrete Outputs
Discrete Outputs
9) Ground Wiring
All Numatics Inc. communication nodes should be grounded during the installation process. These
grounding guidelines can be found in National Electrical code IEC 60204-1 or EN 60204-1. There also is a,
“ATTENTION: CONNECT TO EARTH GROUND FOR PROPER GROUNDING OF UNIT”, label
attached to the chassis ground connection point on the G2-2 series communication node housing. This label
also points out where the grounding guidelines can be found.
!
ON
OFF
ON
No Fault
Fault No Fault
Fault No Fault 0 Sourcing (PNP)
Fault -
Short Circuit, Over Temp/Over Current 1
Open Load 1
Short Circuit, Over Temp/Over Current 1
Proper grounding will alleviate and prevent many intermittent problems
with network communication.
When grounding to a machine frame, please ensure that the machine frame
itself is already properly grounded.
Better grounding can be achieved when larger diameter (lower gauge) wire
is used.
0
0
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10) Communication Module Connector Pin-Out
FIPIO BUS Connection – 6-Pin M23 Connector Pin-Out
Pin No. Description
1 No Connection
2 D+
3 No Connection
4 D-
5 D+
6 D-
Connector Shell Protective Earth (Case Ground)
Pin-O ut
Aux. - MINI
FIPIO
MALE
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11) Auxiliary Power Connector Pin-Out
Pin No. Function Description
1
2 Earth Ground Protective Earth (Case Ground)
3 0VDC Common 0VDC Common, for Valves, I/O, and Node Power
4
+24VDC
(Valves and Outputs)
+24VDC
(Node and Inputs)
Voltage Used to Power Outputs
(Valve Coils and Discrete Outputs)
Voltage Used to Power Discrete Inputs and Node Electronics
Pin-Out
Aux. - MINI
4
!
1
Maximum current capacity on the 0VDC common pin of the auxiliary
power connector is 8 Amps. The combined draw of the +24VDC Valves and
Outputs and +24VDC Node and Inputs pins cannot exceed 8 Amps, at any
given moment in time.
The auxiliary power +24VDC Node and Inputs pin supplies power to the
node electronics. This pin must be powered at all times for communication
node to be functional.
3
2
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12) Power Consumption
Auxiliary Power Connection (Standard)
Aux. Power
Connector Pin No.
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 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 the 0VDC common pin (Current through all +24 VDC Pins 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 Voltage Tolerance Current Power
+24VDC (Valves & Outputs)
Solenoid Valve Coil 2005 (Each) 24VDC +10%/-15% 0.042 A 1.0 Watts
Solenoid Valve Coil 2012 (Each) 24VDC +10%/-15% 0.105 A 2.5 Watts
Solenoid Valve Coil 2035 (Each) 24VDC +10%/-15% 0.105 A 2.5 Watts
Solenoid Valve Coil ISO - SPA (Each) 24VDC +10%/-15% 0.160 A 4.0 Watts
Discrete Output 24VDC - 0.5 A max. * 12 Watts max. *
Discrete I/O Status LEDs (Each) 24VDC - 0.015 A 0.36 Watts
+24VDC (Node & Inputs)
Node 24VDC +/- 10% 0.040 A 0.96 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 the next
page 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.
Description
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