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G2-2 Series ControlNet 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 ControlNet 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 series valve 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
. The
Side
Valve Side
supports a maximum of 32 solenoid coils and the
maximum of 6 modules totaling 192 Outputs, 96 Inputs, or various combinations. The communication
module has two BNC communication connectors. The power module has a 4-pin power connector. Pin-outs
for these, along with I/O connectors, are labeled on the side of the respective modules.
Module/
Network
Status LED's
Aux. Power
LED's
Valve Side
Discrete I/O Side
(Maximum of 32 Solenoids)
Chassis Ground
Connection
and the
supports a
Valve Side
Discrete I/O
Valve
End Plates
Valve
Valve Side
Sub-D Output
Module
Communications
Module
Power
Module
Manual
Override
Solenoid LED
Status Indicator
Subject to change without notice
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G2-2 Series ControlNet Quick Start Manual
3) MCM - Manual Configuration Module (for Self-Test Mode Function Only)
Rotary Switch
(SW3)
Rotary Switch
(SW4)
All DIP switches shown in the "OFF" position
DIP Switch
(SW2)
4
325 678
1
ON
DIP Switch
(SW1)
4
325
1
ON
6 7
8
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
Subject to change without notice
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Testing
G2-2 Series ControlNet Quick Start Manual
4) 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.
!
Mode
Output Off Sequentially turns all the outputs ON and OFF.
Input/
Output
•
•
Setting
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.
Description
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.
Subject to change without notice
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G2-2 Series ControlNet Quick Start Manual
5) Communication Module Rotary Switches
The Rotary switches allow the user to set the node address.
Rotary Switch Settings
Network Address:
Switch
NA 01 Sets the Ones Digits
NA 10 Sets the Tens Digits
•
•
!
Description
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).
Subject to change without notice
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G2-2 Series ControlNet Quick Start Manual
6) I/O Mapping Example
Example:
Assumed Settings
- Single Z-Boards
- Double Z-Boards
valves
- Run Idle Header (Overhead) will always take up
the first two Input words of the Input Map.
TM
used with single solenoid valves
TM
used with double solenoid
Discrete I/O Configuration
Pos
No.
1 MCM 239-1384 -- --
2
3
4
5
Manifold I/O Configuration
Outputs and Mapping Location
Valve Outputs = 12 Word 0; Bits 0-11
Allocated Unused
Valve Outputs = 20
Discrete
Outputs = 24
Total Outputs = 56
Inputs and Mapping Location
Discrete Inputs = 12 Word 5; Bits 0-3, 8-15
Allocated and
Reserved Inputs = 4
Total Inputs = 16
Module Type Part No.
8O Sourcing
(PNP)
16O Sourcing
(PNP)
4I Sinking
(NPN)
8I Sinking
(NPN)
239-1315 1 1
239-1319 1 2
239-1304 1 0
239-1308 1 0
Word 0; Bits 12-15
Word 1; Bits 0-15
Word 2; Bits 0-15
Word 5; Bits 4-7
In Out
Bytes
-7
Subject to change without notice
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G2-2 Series ControlNet Quick Start Manual
I/O Mapping Table Example Continued
Output Table
WORD BYTE
0
0
1
2
1
3
4
2
5
3 6
WORD BYTE
0
0
1
2
1
3
4
2
5
6
3
7
8
4
9
10
5
11
7 15 6 14 5 13 4 12 3 11 2 10 1 9 0 8
Valve Coil
No. 8
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 7
Discrete
Output No. 7
Discrete
Output No. 15
Valve Coil
No. 7
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 6
Discrete
Output No. 6
Discrete
Output No. 14
Valve Coil
No. 6
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 5
Discrete
Output No. 5
Discrete
Output No. 13
Valve Coil
No. 5
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 4
Discrete
Output No. 4
Discrete
Output No. 12
Input Table
7 15 6 14 5 13 4 12 3 11 2 10 1 9 0 8
Run Idle
Header
Run Idle
Header
Run Idle
Header
Run Idle
Header
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
Run Idle
Header
Run Idle
Header
Run Idle
Header
Run Idle
Header
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
Run Idle
Header
Run Idle
Header
Run Idle
Header
Run Idle
Header
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
Run Idle
Header
Run Idle
Header
Run Idle
Header
Run Idle
Header
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
BIT
BIT
Valve Coil
No. 4
Valve Coil
No. 12
Allocated &
Reserved
Allocated &
Reserved
Discrete
Output No. 3
Discrete
Output No. 3
Discrete
Output No. 11
Run Idle
Header
Run Idle
Header
Run Idle
Header
Run Idle
Header
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
Run Idle
Header
Run Idle
Header
Run Idle
Header
Run Idle
Header
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
Run Idle
Header
Run Idle
Header
Run Idle
Header
Run Idle
Header
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
Run Idle
Header
Run Idle
Header
Run Idle
Header
Run Idle
Header
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
1 Byte = 8 Bits
1 Word = 2 Bytes or 16 Bits
Subject to change without notice
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G2-2 Series ControlNet Quick Start Manual
7) 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
8) 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
•
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.
No Fault
Fault No Fault
Fault No Fault 0 Sourcing (PNP)
Fault -
Short Circuit, Over Temp/Over Current
Open Load
1
Short Circuit, Over Temp/Over Current
1
1
0
0
Subject to change without notice
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9) 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)
•
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.
Voltage Used to Power Outputs
(Valve Coils and Discrete Outputs)
Voltage Used to Power Discrete Inputs and Node Electronics
4
1 3
2
Subject to change without notice
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G2-2 Series ControlNet Quick Start Manual
10) 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 which are described below.
Communication Module
LED Name Color Status Description
Green Red FLASHING Self test of bus controller
Green Red FLASHING Incorrect network configuration
MS
(Module Status)
(Module Owned)
Power Module
LED Name Color Status Description
FUSE 1 Red
+24V VLV/OUT Green
FUSE 2 Red
+24V NODE/IN Green
Off OFF Module is not initialized
Red
Off OFF Channel is disabled, depending on the network configuration
Green
Red FLASHING Media Fault or no other nodes on the network
Green
Red
Green
ON Faulted unit, must be restarted
FLASHING Incorrect node configuration; i.e. duplicate MAC ID
ON Normal operation of channel
FLASHING
ON Module is initialized
FLASHING Module is waiting for initialization
ON Major fault, module must be restarted
FLASHING Minor fault, MAC ID has been changed after initialization, etc.
OFF No connection is opened OWNED
ON A connection is opened to the module
OFF
ON
OFF No DC Power present at
ON DC Power applied to
OFF
ON
OFF No DC Power present at
ON DC Power applied to
Temporary errors (node will self correct) or node is not configured to
go online
Internal fuse
+24V
Internal fuse F1 is open; No power is internally provided to valves or
outputs. Communication NOT affected.
Internal fuse F2 is OK (valid only when power is applied to
+24V
Internal fuse F2 is open; No power is internally provided to node
electronics or inputs. Communication Node will not function.
VLV / OUT
NODE / IN
F1
is OK (valid only when power is applied to
pin on Aux. Power connector).
+24V
VLV / OUT
+24V
NODE / IN
VLV / OUT
NODE / IN
+24V
pin on Aux. Power connector.
+24V
pin on Aux. Power connector.
pin on Aux. Power Connector.
pin on Aux. Power connector.
pin on Aux. Power connector.
Subject to change without notice
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. This is a
G2-2 Series ControlNet Quick Start Manual
11) Configuration with RSLOGIX 5000
When commissioning your ControlNet node, specific values must be entered in the “Connection Parameters”
section for the “Assembly Instance” column with regards to “Input Size”, “Output Size”, and
“Configuration”. The “Size” values are determined from the actual physical configuration of the manifold
(i.e. how many and which I/O modules are installed on the manifold). The size values are a minimum value;
higher values can be used if future manifold I/O expansion is required. Below is a sample screen shot taken
from Allen Bradley’s RSLogix 5000 programming software, it shows where the appropriate values for the
Node Address, Assembly Instance, Size
and
Configuration
must be entered.
Module Properties
Comm. Format:
Connection Parameters:
Description Data
Comm. Format “Data – INT”
Description
Input
Output
Configuration
Assembly Instance
Values
100 (Decimal) or
64 (Hexadecimal)
150 (Decimal) or
96 (Hexadecimal)
1 (Decimal) or
1 (Hexidecimal)
Size
(16 Bits=1 Word)
Total Input Size value (in words) from manifold
configuration (including status Input bits) + 2 Words
of ControlNet Run/Idle Header (overhead)
minimum value; larger values may be specified for
future expansion purposes.
Total Output Size value (in words) from manifold
configuration. This is a minimum value; larger values
may be specified for future expansion purposes.
0
Subject to change without notice
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12) Factory Default Settings
Unless otherwise requested, all standard G2-2 Series ControlNet manifolds ship with specific factory default
settings. Below is a list of the factory default settings:
Description Default Settings
Node Address 0
Baud Rate 5 Mbit/sec
Input Module Power Jumper
+24VDC Node and Inputs pin on the Aux. power connector)
Output Module Power Jumper
+24VDC Valves and Outputs pin on the Aux. power connector)
Valve Side Output Bytes 4 Bytes (32 Allocated Valve Coil Outputs)
Discrete I/O Side - I/O Bytes Self-Configuring
13) Technical Support
For technical support, contact your local Numatics distributor. If further information is required,
please call 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 device files, technical manuals, local distributors, and other Numatics, Inc. products
and support issues can be found on the Numatics, Inc’s WEB site at www.numatics.com
For general help or more information regarding the fieldbus you may access the ControlNet International
homepage found at www.controlnet.org
(Input sensor power supplied by
(Output module power supplied by
based on the I/O modules installed.
PU
SP
Subject to change without notice
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