G2-2 ControlNet 2005/2012 Series Technical Manual

Transcription

1 G2-2 ControlNet 2005/202 Series Technical Manual LT2005/202CNTECH- 0/03

2 Table of Contents 2005/202 Series ControlNet Technical Manual PAGE About ControlNet... 3 Overview... 3 G2-2 ControlNet Features... 3 Segment lengths (as defined by ControlNet specification) /202 and G2-2 Introduction... 4 Product Overview /202 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 /202 Valve Unit... 9 Z-Board and Solenoid Coil Connections to Output Drivers... 9 Z-Board Connectors...0 Z-Board and Ribbon Cable Example:... Z-Board and Ribbon Cable with Valve Side Sub-d Example:...2 Module Configurations and Pinouts...3 ControlNet Communication Module (Node)...3 Connector Types...3 Auxiliary Power Connector Pin Out...4 Rotary Switches...5 Rotary Switch Settings...5 Rotary Switch Settings Example...6 Comm. Module...7 Discrete I/O Modules...8 Rules...8 Module Types...8 Input Modules:...9 Output Modules Electrical Connections Power Supply Wiring Diagrams Power Consumption Auxiliary Power Connection Discrete I/O Module(s) Power Jumper Power Rating Recommended External Fuses: Discrete I/O Power Jumper Discrete Sub-D Output Power Jumper Power Consumption and External Fuse Sizing Guide Chart I/O Module(s) Wiring Diagrams Definitions Sinking Description Sourcing Description Sinking (NPN) Input Connection Sourcing (PNP) Input Connection Sinking (NPN) Output Connection Sourcing (PNP) Output Connection ControlNet Configuration and Mapping...3 EDS File...3 I/O Setup LT2005/202CNTECH- 0/03 Page

3 Outputs Inputs I/O Sizes I/O Size - Manifold I/O Size - Valve Side I/O Size - Discrete I/O Side Manifold I/O Sizing Worksheet Mapping Rules Valve Side Discrete I/O Side I/O Mapping Example # Example # Example #3...4 Diagnostics Comm. Module / Power Module LED Functions Internal Fuses Output Short Circuit Protection Status Action During Fault Condition Appendix System Specifications Factory Defaults Settings Troubleshooting Glossary of Terms Technical Support LT2005/202CNTECH- 0/03 Page 2

4 About ControlNet Overview 2005/202 Series ControlNet Technical Manual 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 50 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 G2-2 ControlNet Features Features Address Setting Baud Rates Supported Bus Topology CE Connection Sizes Minimum requested packet interval (RPI) NAP Port Physical Media Redundant Media Termination Resistor (external) Description Via Rotary Switches 5 Mbit/sec. Linear bus, Tree, Star, mix of all three CE compliant 6 Words (32 Bytes) of Input Data and 6 Words (32 Bytes) of Output Data 5ms Network Access Port allows a temporary network connection at the node. The NAP uses a standard 8-pin RJ-45 connector. Coax RG-6 quad shield, Single or Dual Redundant Media The node supports redundant media. Two coax connectors are provided (Trunk Line A & B). A 75 ohms resistor is required at each end of each segment. Segment lengths (as defined by ControlNet specification) 000 Segment length (m) Number of taps LT2005/202CNTECH- 0/03 Page 3

5 2005/202 and G2-2 Introduction Product Overview 2005/202 Series ControlNet Technical Manual The 2005/202 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 32 I/O points of I/O on the Discrete I/O side. This manual addresses the specifics of configuring and commissioning the Numatics 2005/202 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 & 202 Series catalog, No. LT2005/202-. LT2005/202CNTECH- 0/03 Page 4

6 2005/202 and G2-2 Electronics Modularity Discrete I/O The 2005/ 202 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. LT2005/202CNTECH- 0/03 Page 5

7 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. LT2005/202CNTECH- 0/03 Page 6

8 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 8-23). 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 on the following page for a sample configuration layout. LT2005/202CNTECH- 0/03 Page 7

9 G2-2 ControlNet System Versatility 2005/202 Series ControlNet Technical Manual Figure Example of network to PLC/IPC with distributed valve manifolds and I/O devices. LT2005/202CNTECH- 0/03 Page 8

10 2005/202 Valve Unit 2005/202 Series ControlNet Technical Manual 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 6 bit groups. Output group # is comprised of the first output word, bits 0-5, and output group #2 is comprised of the second output word, bits 6-3. Output group # 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 4 (A) solenoid on the valve closest to the communication node. The 7 th 32 nd solenoids interconnect via the Z-Boards to output group #2. For the maximum capability of 32 solenoids, the 6 th and 7 th solenoid coils must NOT be on the same sub-base. Output Group # Connector Plug-in Manifold with Integral Z-Board Eliminates Wiring Output Group #2 Connector Single solenoid Z-Board Double solenoid Z-Board Earth Ground Pin #3 Common Pin #4 4(A) Solenoid Pin # 2(B) Solenoid Pin #2 LT2005/202CNTECH- 0/03 Page 9

11 Z-Board Connectors The 2005/202 valve series utilizes 2 different Z-Boards designs to achieve the single and double solenoid output functions that yield the possible 32 single, 6 double, or any combination of valve solenoid coil output capabilities. Single Z-Board Part # (202) Part # (2005) Double Z-Board Part # (202) Part # (2005) single double Ribbon Connection Single Z-Board Part # (202) Part # (2005) Ribbon Connection Double Z-Board Part # (202) Part # (2005) The 7 th 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. LT2005/202CNTECH- 0/03 Page 0

12 Z-Board and Ribbon Cable Example: If fourteen (4) single solenoid and one () double solenoid valves are connected directly to the communication node via their Z-Boards, and one () 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: S= Sgl. Sol. With Single Z-Board D= Dbl. Sol. With Double Z-Board D S Output Group # Connector to Z-Board Output Group #2 Connector to Ribbon Cable Output Group #2 Ribbon Connector Z-Board Output # Solenoid Coil Output # n/a n/a n/a n/a n/a n/a n/a In the above example, Output s #5 and #26 thru #3 are allocated but not used. LT2005/202CNTECH- 0/03 Page

13 Z-Board and Ribbon Cable with Valve Side Sub-d Example: If sixteen (6) 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: S= Sgl. Sol. With Single Z-Board Coil Outputs 7-32 Output Group # Connector to Z-board Output Group #2 Connector to Ribbon Cable Output # Solenoid Coil Output # LT2005/202CNTECH- 0/03 Page 2

14 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. (See 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. LT2005/202CNTECH- 0/03 Page 3

15 Auxiliary Power Connector Pin Out Pin # Function Description +24VDC Voltage used to power outputs (valve coils and discrete (Valves and Outputs) outputs) 2 Earth Ground Protective Earth (case) 3 0VDC Common 0VDC Common, for valve and I/O power 4 +24VDC Voltage used to power discrete inputs and node (Node and Inputs) electronics 3 2 POWER 4 MALE! ATTENTION Maximum current capacity on pin #3 (0VDC common) of auxiliary power connector is 8 Amps. The combined draw of Pin # (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. LT2005/202CNTECH- 0/03 Page 4

16 Rotary Switches The Rotary switches allow the user to set the node address. Rotary Switch Settings Network Address: Switch NA 0 Sets the Ones Digits NA 0 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). ATTENTION LT2005/202CNTECH- 0/03 Page 5

17 Rotary Switch Settings Example The example below shows the correct settings for the following requirements: Node Address = 73 Switch Settings: Switch Setting Description NA 0 3 Sets the Ones Digits of MAC ID to Three (3) NA 0 7 Sets the Tens Digits of MAC ID to Two (2) LT2005/202CNTECH- 0/03 Page 6

18 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), or by specifying individual components (see chart below). LT2005/202CNTECH- 0/03 Page 7

19 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 32 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 s Input 4 Narrow 4 x 2mm ( input per conn.) Sinking (NPN) N/A Input 4 Narrow 4 x 2mm ( input per conn.) Sourcing (PNP) N/A Input 8 Narrow 4 x 2mm (2 input per conn.) Sinking (NPN) N/A Input 8 Narrow 4 x 2mm (2 input per conn.) Sourcing (PNP) N/A Input 8 Wide 8 x 2mm ( input per conn.) Sinking (NPN) N/A Input 8 Wide 8 x 2mm ( input per conn.) Sourcing (PNP) N/A Input 6 Wide 8 x 2mm (2 input per conn.) Sinking (NPN) N/A Input 6 Wide 8 x 2mm (2 input per conn.) Sourcing (PNP) N/A Input 6 Narrow Dual 5 Pin Sub-D (8 inputs per Sub-D) Sinking (NPN) N/A Input 6 Narrow Dual 5 Pin Sub-D (8 inputs per Sub-D) Sourcing (PNP) N/A Input 6 Narrow 25 Pin Sub-D (6 inputs) Sinking (NPN) N/A Input 6 Narrow 25 Pin Sub-D (6 inputs) Sourcing (PNP) N/A Output 4 Narrow 4 x 2mm ( input per conn.) Sinking (NPN) Output 4 Narrow 4 x 2mm ( input per conn.) Sourcing (PNP) Output 8 Narrow 4 x 2mm (2 input per conn.) Sinking (NPN) Output 8 Narrow 4 x 2mm (2 input per conn.) Sourcing (PNP) Output 8 Wide 8 x 2mm ( input per conn.) Sinking (NPN) Output 8 Wide 8 x 2mm ( input per conn.) Sourcing (PNP) Output 6 Wide 8 x 2mm (2 input per conn.) Sinking (NPN) Output 6 Wide 8 x 2mm (2 input per conn.) Sourcing (PNP) Output 22 Wide 25 Pin Sub-D w/aux Power (22 outputs) Sourcing (PNP) 6 LT2005/202CNTECH- 0/03 Page 8

20 Input Modules: Part # Description Part # Description Inputs (Sinking-NPN) - Input/Connector Inputs (Sinking-NPN) - Input/Connector Part # Description Part # Description Inputs (Sourcing-PNP) - Input/Connector Inputs (Sourcing-PNP) - Input/Connector Part # Description Part # Description Inputs (Sinking-NPN) 2 Inputs/Connector Inputs (Sinking-NPN) - 2 Inputs/Connector LT2005/202CNTECH- 0/03 Page 9

21 Part # Description Part # Description Inputs (Sourcing-PNP) - 2 Inputs/Connector Inputs (Sourcing-PNP) - 2 Inputs/Connector Part # Description Inputs (Sinking-NPN) 8 Inputs/Connector Byte X Byte X+ Part # Description Inputs (Sourcing-PNP) 8 Inputs/Connector Byte X Byte X+ LT2005/202CNTECH- 0/03 Page 20

22 Part # Description Inputs (Sinking-NPN) 6 Inputs/Connector Part # Description Inputs (Sourcing-PNP) 6 Inputs/Connector! ATTENTION Damage will occur if Discrete I/O and MCM Modules are inserted or removed with power applied. LT2005/202CNTECH- 0/03 Page 2

23 Output Modules 0.5 Amps per Output. (Consult factory for output loads greater than 0.5 Amps.) Over current and short circuit protected Status for Short or Open Circuit - Sinking Outputs utilize one status input for each output. - Sourcing Outputs utilize one status input for every four outputs Part # Description Part # Description Outputs (Sinking-NPN) - Output/Connector Outputs (Sinking-NPN) - Output/Connector NOT FOR NEW APPLICATIONS Part # Description Part # Description Outputs (Sourcing-PNP) - Output/Connector Outputs (Sourcing-PNP) - Output/Connector! Damage will occur if Discrete I/O and MCM Modules are inserted or removed with power applied! ATTENTION LT2005/202CNTECH- 0/03 Page 22

24 Part # Description Part # Description Outputs (Sinking-NPN) 2 Outputs/Connector Outputs (Sinking-NPN) - 2 Outputs/Connector NOT FOR NEW APPLICATIONS Part # Description Part # Description Outputs (Sourcing-PNP) - 2 Outputs/Connector Outputs (Sourcing-PNP) - 2 Outputs/Connector Part # Description Part # Description 22 Outputs (Sourcing-PNP) 6 Outputs (Sinking-NPN) Outputs/Connector 6 Outputs/Connector (Valve side only) Valve Side Sub-D PIN 25 PIN SUB-D CONNECTOR 4 PIN POWER CONNECTOR PIN PIN SUB-D FEMALE CONNECTOR PIN 25 PIN LT2005/202CNTECH- 0/03 Page 23

25 Electrical Connections Power Supply Wiring Diagrams Single Power Supply Example (Male connector view)! ATTENTION 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. LT2005/202CNTECH- 0/03 Page 24

26 Power Consumption Auxiliary Power Connection Aux. Power Connector Pin # Description 24 VDC Power for Valves & s 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 ( 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 # 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 +24VDC (Valves & Outputs) Solenoid Valve Coil 202 (Each) 24VDC +0%/-5% 0.05 A 2.5 Watts Solenoid Valve Coil 2005 (Each) 24VDC +0%/-5% 0.042A.0 Watts 24VDC A max. * 2 Watts max. * Pin 4 +24VDC (Node & Inputs) Node 24VDC +/- 0% A 2.3 Watts Discrete I/O Module (Each) 24VDC A 0.4 Watts Discrete I/O Status LEDs (Each) 24VDC A 0.36 Watts! ATTENTION * 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. Recommended External Fuses: External fuses should be chosen based upon the physical manifold configuration. Please refer to page 28 for the fuse sizing chart. LT2005/202CNTECH- 0/03 Page 25

27 Discrete I/O Power Jumper I/O Power from pin # 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 Output Module Input Module Jumper Pos SP Jumper Pos 2 UP Jumper Pos 2 UP Jumper Pos SP "S" & "P" "U" & "P" "U" & "P" "S" & "P" Factory Default - Output power is supplied by Pin # of Aux. Power Connector. This allows discrete outputs to be disabled without disabling power to communication node. 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. 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 power is supplied by Pin # 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 2mm connectors) contain two jumpers; one for each group of four connectors. LT2005/202CNTECH- 0/03 Page 26

28 Discrete Sub-D Output Power Jumper Local 2mm Aux. Power Connector (See Pg. 23 for Pin-Out) Fuse (4.0A) Output Power from pin # of Mini Aux. Power Connector Output Power from pin #4 of Mini Aux. Power Connector Output Power from pin # of local 2mm Aux. Power Connector Please refer to the table below for jumper setting and description. Jumper Jumpered Setting Pins Description Jumper Pos SP "S" & "P" Output power is supplied by Pin # of Aux. Power Connector. This allows all valves and 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 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. Jumper Pos 3 XP X & P Factory Default - Output power is supplied by pin # of local 2mm Aux Power Connector. Outputs can be enabled/disabled via Local 2mm Aux Power Connector. LT2005/202CNTECH- 0/03 Page 27

29 Power Consumption and External Fuse Sizing Guide Chart Power Consumption - Aux. Power Connector Pin # (Valves and Outputs) Description Current Number of Solenoid Valve Coils Energized Simultaneously X 0.05 A (202 Series) = Amps X A (2005 Series) = Amps + Total load current drawn by simultaneously energized s = Amps with s Power Jumper in "SP" Position (Factory Default). Total load current drawn by Sensor Devices from s source = + Amps with Power Jumper in "SP" Position. Total: Amps Surge Compensation: X.25 Suggested External Pin # Fuse Value: Amps Power Consumption - Aux. Power Connector Pin #4 (Node and Inputs) Description Current Communication Node Power Consumption = Amps + Total load current drawn by simultaneously energized s = Amps with s Power Jumper in "UP" Position. + Total load current drawn by Sensor Devices from s source = Amps with s Power Jumper in "UP" Position (Factory Default). + Number of I/O modules installed X A = Number of Discrete I/O Status LEDs simultaneously on X 0.05 A = Amps + Amps Total: Amps Surge Compensation: X.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 # (Valves & Outputs) and pin #4 (Node & Inputs) cannot exceed 8 amperes. Therefore, the combined value of the two fuses on pin # and pin #4 should not exceed 0 amperes (8 ampere max by.25 surge compensation). LT2005/202CNTECH- 0/03 Page 28

30 I/O Module(s) Wiring Diagrams Definitions Sinking Description NPN Switching Negative Positive Common LOAD Sourcing Description PNP Switching Positive Negative Common LOAD Sinking (NPN) Input Connection Electronic Sensor Type Mechanical Sensor Type Input/Signal INPUT MODULE INPUT MODULE 4 (NPN) LOAD FEMALE PIN =+24VDC PIN 3=COMMON OVDC PIN 4=INPUT (SINKING) FEMALE PIN =+24VDC PIN 3=COMMON OVDC PIN 4=INPUT (SINKING) Sourcing (PNP) Input Connection Electronic Sensor Type Mechanical Sensor Type Input/Signal INPUT MODULE INPUT MODULE 4 (PNP) LOAD FEMALE PIN =+24VDC PIN 3=COMMON OVDC PIN 4=INPUT (SOURCING) FEMALE PIN =+24VDC PIN 3=COMMON OVDC PIN 4=INPUT (SOURCING) LT2005/202CNTECH- 0/03 Page 29

31 Sinking (NPN) Output Connection OUTPUT MODULE 3 4 FEMALE OVDC LOAD PIN =+24VDC (COMM) PIN 3=NOT USED PIN 4=OUTPUT (SINKING).5A MAX. +24VDC Sourcing (PNP) Output Connection OUTPUT MODULE 3 4 OVDC LOAD FEMALE +24VDC PIN =NOT USED PIN 3=COMMON OVDC PIN 4=OUTPUT (SOURCING).5A MAX. LT2005/202CNTECH- 0/03 Page 30

32 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: Description Decimal Hexadecimal Input Output Configuration Description Input Output Configuration Size (6 bits= word) Total Input Size value (in words) from manifold configuration (including status Input bits) + 2 Words of ControlNet (overhead). This is a 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 (8 bits) Comm Format: Description Comm. Format Data Data INT LT2005/202CNTECH- 0/03 Page 3

33 EDS File I/O Setup 2005/202 Series ControlNet Technical Manual 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 Outputs Inputs 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 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. 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 LT2005/202CNTECH- 0/03 Page 32

34 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 6 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. LT2005/202CNTECH- 0/03 Page 33

35 Manifold I/O Sizing Worksheet : 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 (Required) and Valve Byte Requirements. This is the total Input / Output byte values required for the configured manifold Narrow Module (4 Connector - 4/8 Points) Module # I/O Board # Description Input Bytes Output Bytes Inputs (Sinking-NPN) Inputs (Sourcing-PNP) Inputs (Sinking-NPN) Inputs (Sourcing-PNP) Outputs (Sinking-NPN) Outputs (Sourcing-PNP) Outputs (Sinking-NPN) Outputs (Sourcing-PNP) Wide Module (8 Connector - 8/6 Points) Module # I/O Board # Description Input Bytes Output Bytes Inputs (Sinking-NPN) Inputs (Sourcing-PNP) Inputs (Sinking-NPN) Inputs (Sourcing-PNP) Outputs (Sinking-NPN) Outputs (Sourcing-PNP) Outputs (Sinking-NPN) Outputs (Sourcing-PNP) 2 Sub -D I/O Modules Module # I/O Board # Description Input Bytes Output Bytes Inputs - Dual 5 Pin Sub-D (Sinking-NPN) Inputs - Dual 5 Pin Sub-D (Sourcing-PNP) Inputs - 25 Pin Sub-D (Sinking-NPN) Inputs - 25 Pin Sub-D (Sourcing-PNP) Outputs - 25 Pin Sub-D (Sourcing-PNP) 3 Station # Module # Input Bytes Output Bytes Discrete I/O Byte Requirements Valve Byte Requirements Run Idle (Required) 4 0 Total Input/Output Bytes for Manifold 2 Bytes = Word LT2005/202CNTECH- 0/03 Page 34

36 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 2005/202 valve manifold. Valve Side ) 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 st valve sub base nearest the node and continues in ascending order away from the communication node. 5) Each sub base is allocated or 2 output bits, depending on the Z-Board type installed. Single Z-Board allocates 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 # 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 st output available will always be bit 6. Single solenoid valves can be used with double Z-Boards TM. However, one of the 2 available outputs will remain unused. LT2005/202CNTECH- 0/03 Page 35

37 Discrete I/O Side Outputs ) 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 ) 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 for sample I/O mapping. LT2005/202CNTECH- 0/03 Page 36

38 I/O Mapping Example # Assumed Settings Single Z-Boards are installed for single solenoid valves and double Z-Boards are installed for double solenoid valves. will always take up the first two words of the Input map. Status Input s are mapped after the two words of and every output device thus the first physical Input will begin at NODE6:I.DATA[4].8 in this example. Valve outputs have Status bit per output point; PNP discrete Output modules have Status bit for every 4 Output points Sample address scheme: NODE6:X.DATA[Y].Z I/O Station #3 I/O Station #2 I/O Station # (4I) NODE6:I.DATA[5].0-3 Allocated (4I): NODE6:I.DATA[5].4-7 (8I) NODE6:I.DATA[4].8-5 (6O) NODE6:I.DATA[2].0-5 Node Address or Module Tag X = (O) Output or (I) Input Y = Word No. Z = No. 25 Pin Valve Side Sub-D Output (6O) NODE6:O.DATA[].0-5 NODE6:O.DATA[0].0-5 Pos No. 2 3 Module Type 6O Sourcing (PNP) 8I Sourcing (PNP) 4I Sinking (NPN) Part No. Valve Side Solenoid Outputs Total I/O Bytes from manifold configuration. Total I/O Words (6 bits) from manifold configuration. Input Size Value Bytes Output Size Value Bytes ( Word) (2 Words) (2 Words) 4 (2 Words) Valve Station # Valve Station #2 Valve Station #3 Valve Station #4 Valve Station #5 Valve Station #6 Valve Station #7 LT2005/202CNTECH- 0/03 Page 37

39 I/O Mapping Tables Example # WORD BYTE Output Table No. 8 (Pos. No.) No. 6 (Pos. No.) No. 7 (Pos. No.) No. 5 (Pos. No.) No. 6 (Pos. No. ) No. 4 (Pos. No.) No. 5 (Pos. No.) No. 3 (Pos. No.) No. 4 (Pos. No.) No. 2 (Pos. No.) No. 3 (Pos. No.) No. (Pos. No.) No.2 (Pos. No.) No. 0 (Pos. No.) No. (Pos. No. ) No. 9 (Pos. No. ) WORD 0 BYTE Input Table Coil No. 8 Coil No. 6 Coil No. 7 Coil No. 5 Coil No. 6 Coil No. 4 Coil No. 5 Coil No. 3 Coil No. 4 Coil No. 2 Coil No. 3 Coil No. Coil No. 2 Coil No. 0 Coil No. Coil No Coil No. 24 Coil No. 32 Coil No. 23 Coil No. 3 Coil No. 22 Coil No. 30 Coil No. 2 Coil No. 29 Coil No. 20 Coil No. 28 Coil No. 9 Coil No. 27 Coil No. 8 Coil No. 26 Coil No. 7 Coil No No. 8 No. 7 No. 6 No. 5 (Pos. No.2) Status for s No.3-6 (Pos. No. ) No. 4 No. 2 Status for s No. 9-2 (Pos. No. ) No. 3 No. Status for s No. 5-8 (Pos. No. ) No. 2 No. 0 Status for s No. -4 (Pos. No. ) No. No. 9 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. LT2005/202CNTECH- 0/03 Page 38

40 I/O Mapping Example #2 Assumed Settings Double Z-Boards are installed for all valves. will always take up the first two words of the Input map. Status Input s are mapped after the two words of and every output device thus the first physical Input will begin at NODE6:I.DATA[5].0 in this example. Valve outputs have Status bit per output point; PNP discrete Output modules have Status bit for every 4 Output points Sample address scheme: NODE6:X.DATA[Y].Z I/O Station #4 I/O Station #3 I/O Station #2 I/O Station # (4I) NODE6:O.DATA[6].0-3 Allocated (4I) NODE6:O.DATA[6].4-7 (6I) NODE6:O.DATA[5].0-5 (22O) NODE6:O.DATA[2].8-5 NODE6:O.DATA[3].0-3 Allocated (2 O): NODE6:O.DATA[3].4-5 (8O) NODE6:O.DATA[2].0-7 Node Address or Module Tag X = (O) Output or (I) Input Y = Word No. Z = No. Pos No Module Type 8O Sourcing (PNP) 22O Sourcing (PNP) 6I Sinking (NPN) 4I Sinking (NPN) Part No. Valve Side Solenoid Outputs Total I/O Bytes from manifold configuration. Total I/O Words (6 bits) from manifold configuration. Input Size Value Bytes Output Size Value Bytes (2 Words) ( Word) (2 Words) (2 Words) 0 4 (2 Words) NODE6:O.DATA[0].0-5 NODE6:O.DATA[].0-5 Valve Station # Valve Station #2 Valve Station #3 Valve Station #4 Valve Station #5 Valve Station #6 Valve Station #7 Valve Station #8 Valve Station #9 LT2005/202CNTECH- 0/03 Page 39

41 I/O Mapping Tables Example #2 WORD BYTE Output Table No. 8 (Pos. No.) No. 6 (Pos. No.2) No. 24 (Pos. No.2) No. 7 (Pos. No.) No. 5 (Pos. No.2) No. 23 (Pos. No.2) No. 6 (Pos. No. ) No. 4 (Pos. No.2) No. 22 No. 30 (Pos. No.2) 2 29 No. 5 (Pos. No.) No. 3 (Pos. No.2) No. 2 (Pos. No.2) No. 29 (Pos. No.2) No. 4 (Pos. No.) No. 2 (Pos. No.2) No. 20 (Pos. No.2) No. 28 (Pos. No.2) No. 3 Pos. No.) No. (Pos. No.2) No. 9 (Pos. No.2) No. 27 (Pos. No.2) 26 No.2 (Pos. No.) No. 0 (Pos. No.2) No.8 (Pos. No.2) No. 26 (Pos. No.2) 25 No. (Pos. No. ) No. 9 No. 7 No. 25 WORD 0 BYTE Input Table Coil No. 8 Coil No. 6 Coil No. 7 Coil No. 5 Coil No. 6 Coil No. 4 Coil No. 5 Coil No. 3 Coil No. 4 Coil No. 2 Coil No. 3 Coil No. Coil No. 2 Coil No. 0 Coil No. Coil No Coil No. 24 Coil No. 32 Coil No. 23 Coil No. 3 Coil No. 22 Coil No. 30 Coil No. 2 Coil No. 29 Coil No. 20 Coil No. 28 Coil No. 9 Coil No. 27 Coil No. 8 Coil No. 26 Coil No. 7 Coil No No. 8 No. 6 No. 7 No. 5 Status for s No No. 6 No. 4 Status for s No No. 5 No. 3 Status for s No.2-24 No. 4 No. 2 No. 20 (Pos. No. 4) Status for s No No. 3 No. No. 9 (Pos. No. 4) Status for s No. 5-8 (Pos. No. ) Status for s No. 3-6 No. 2 No. 0 No. 8 (Pos. No. 4) Status for s No. -4 (Pos. No. ) Status for s No. 9-2 No. No. 9 No. 7 (Pos. No. 4) 3 LT2005/202CNTECH- 0/03 Page 40

42 I/O Mapping Example #3 Assumed Settings will always take up the first two words of the Input map. Status Input s are mapped after the two words of and every output device thus the first physical Input will begin at NODE6:I.DATA[5].0 in this example. Valve outputs have Status bit per output point; PNP discrete Output modules have Status bit for every 4 Output points Sample address scheme: NODE6:X.DATA[Y].Z Node Address or Module Tag X = (O) Output or (I) Input Y = Word No. Z = No. I/O Station #4 I/O Station #3 I/O Station #2 I/O Station # (4I) NODE6:I.DATA[5].8- Allocated (4I) NODE6:I.DATA[5].2-5 (8I) NODE6:I.DATA[5].0-7 (6O) NODE6:O.DATA[2].8-5 NODE6:O.DATA[3].0-7 (8O) NODE6:O.DATA[2].0-7 Pos No Module Type 8O Sourcing (PNP) 6O Sourcing (PNP) 8I Sinking (NPN) 4I Sinking (NPN) Part No. Valve Side Solenoid Outputs Total I/O Bytes from manifold configuration. Total I/O Words (6 bits) from manifold configuration. Input Size Value Bytes Output Size Value Bytes ( Word) (2 Words) (2 Words) 4 (2 Words) NODE6:O.DATA[0].0-5 NODE6:O.DATA[].0-5 LT2005/202CNTECH- 0/03 Page 4

43 I/O Mapping Tables WORD Example #3 BYTE /202 Series ControlNet Technical Manual 6 3 Output Table No. 8 (Pos. No. ) No. 6 No. 24 (Pos. No.2) No. 7 (Pos. No. ) No. 5 No. 23 (Pos. No.2) No. 6 (Pos. No. ) No. 4 No No. 5 (Pos. No. ) No. 3 No. 2 (Pos. No.2) No. 4 (Pos. No. ) No. 2 No. 20 (Pos. No.2) No. 3 (Pos. No. ) No. No. 9 (Pos. No.2) 26 No. 2 (Pos. No. ) No. 0 No. 8 (Pos. No.2) 25 No. (Pos. No. ) No. 9 No. 7 WORD 0 BYTE Input Table Coil No. 8 Coil No. 6 Coil No. 7 Coil No. 5 Coil No. 6 Coil No. 4 Coil No. 5 Coil No. 3 Coil No. 4 Coil No. 2 Coil No. 3 Coil No. Coil No. 2 Coil No. 0 Coil No. Coil No Coil No. 24 Coil No. 32 Coil No. 23 Coil No. 3 Coil No. 22 Coil No. 30 Coil No. 2 Coil No. 29 Coil No. 20 Coil No. 28 Coil No. 9 Coil No. 27 Coil No. 8 Coil No. 26 Coil No. 7 Coil No No. 8 No. 7 No. 6 No. 5 Status for s No.2-24 No. 4 No. 20 (Pos. No. 4) Status for s No No. 3 No. 9 (Pos. No. 4) Status for s No. 5-8 (Pos. No. ) Status for s No. 3-6 No. 2 No. 8 (Pos. No. 4) Status for s No. -4 (Pos. No. ) Status for s No. 9-2 No. No. 7 (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. LT2005/202CNTECH- 0/03 Page 42

44 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 Power Module LED Name Color Status Description Fuse Communication Module LED Name Color Status Description Channel & Channel or Module Status (MS) Module Owned (OWNED) Red +24V VLV / OUT Green Fuse 2 Red +24V NODE / IN Green ON OFF ON OFF ON OFF ON OFF Internal fuse F is open; No power is internally provided to valves or outputs. Communication NOT affected. Internal fuse F is OK (valid only when power is applied to +24V VLV / OUT pin on Aux. Power connector. DC Power applied to +24V VLV / OUT pin on Aux. Power Connector. No DC Power present at +24V VLV / OUT pin on Aux. Power connector. Internal fuse F2 is open; No power is internally provided to node electronics or inputs. Communication Node will not function. Internal fuse F2 is OK (valid only when power is applied to +24V NODE / IN pin on Aux. Power connector. DC Power applied to+24v NODE / IN pin on Aux. Power connector. No DC Power present at +24V NODE / IN pin on Aux. Power connector. -- OFF Module is not initialized Green/Red ALTERNATING Self test of bus controller Red ON Faulted unit, must be restarted FLASHING Incorrect node configuration; i.e. duplicate MAC ID -- OFF Channel is disabled, depending on the network configuration ON Normal operation of channel Green Temporary errors (node will self correct) or node is not configured to go FLASHING online Red FLASHING Media Fault or no other nodes on the network Green/Red FLASHING Incorrect network configuration Green ON Module is initialized FLASHING Module is waiting for initialization Red ON Major fault, module must be restarted FLASHING Minor fault, MAC ID has been changed after initialization, etc. Green OFF No connection is opened ON A connection is opened to the module LT2005/202CNTECH- 0/03 Page 43

45 Internal Fuses Fuse (F) Fuse (F2) Fuse Function and Description Fuse # Description Size Part Number Type F Fuse for Aux. Power connector Pin # (Valves & Outputs). 0 A max. fast acting Mini ATO F2 Fuse for Aux. Power connector Pin #4 (Node & Inputs). 4A max. fast acting 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 Action During Fault Condition Output Status Output Type Fault Condition State Valve Solenoid Coil Driver or No Fault 0 ON Sinking (NPN) s Fault - Short Circuit, Over Temp/Over Current Valve Solenoid Coil Driver or No Fault 0 OFF Sinking (NPN) s Fault - Open Load Sourcing (PNP) No Fault 0 ON s Fault - Short Circuit, Over Temp/Over Current LT2005/202CNTECH- 0/03 Page 44

46 Appendix System Specifications Supply Voltage Current Internal Fuses Recommended External Fuse Spike Suppression s (Sinking (NPN) or Sourcing (PNP)) Valve Solenoid Coil Output Drivers Operating Temperature for Electronic Components Electrical Valves: 24 VDC + 0%, -5% Node and Discrete I/O: 24 VDC +/- 0% Total current on the Aux. Power Connector (Pin - Valves & Outputs and Pin 4 - Node & Inputs ) must not exceed 8 amperes. Pins # and #4 on the Auxiliary Power Connector are each internally fused with a 4 and 0 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 information. Output spike suppression is internally provided for both discrete and valve outputs. 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. Maximum 0.5 amperes per output. All output points are short circuit protected and have internal spike supression. 23 to 4 F (-5 to 46 C) LT2005/202CNTECH- 0/03 Page 45

47 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 I/O Connection Size 4/0 Bytes (2/0 Words) LT2005/202CNTECH- 0/03 Page 46

48 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. All LEDs off Fuse LEDs displays red The wrong valve solenoid coils are being energized. Valve outputs do not energize. All node LEDs normal. Power not properly applied Blown internal fuses Z-Board TM type mismatch. Single Z-Board TM present where double Z-Board TM expected or vice versa. Output power not present or connected in properly on Aux. Power connector. 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 3 for Details Check for external shorts to Input connector from external sensor devices or cable and repair. Replace internal fuse. If problem persists contact factory. Check that correct Z-Board TM types are installed. Check that ribbon cable (output group #2) is connected to appropriate valve station. See page 35 for bit mapping rules Check for 24VDC on pin # of Aux. Power connector of Comm. module. Check for 24VDC on Pin # of 2mm local Aux Power connector of 25 Pin Sub-D Module, if applicable LT2005/202CNTECH- 0/03 Page 47

49 Glossary of Terms The following is a list and description of common terms and symbols used throughout this document: Smallest unit of digital information either a 0 or mapping Byte Change of State Comm. Fault Cyclic Discrete I / O EDS file Chart showing which bit is connected to which physical input or output point 8 bits (/2 word) I/O message type in which either the expiration of the transmission timer or a change in input state triggers data production. One or more of the I/O connections have timed out. I/O message type in which data production is triggered by the expiration of the transmission timer. The Inputs / Outputs that are available via the Discrete I/O side of manifold 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 Idle MAC ID Maximum Scheduled Node NEMA NUT Polled RPI RS NetWorx Sinking (NPN) Sourcing (PNP) Status Input bit Word Z-Board TM Any combination of Inputs and Outputs A zero (0) length poll massage (i.e.: scanner in program mode) Media Access Connection Identification (00-99) Node (network drop) address Node with highest MAC ID that can use scheduled time on a link. National Electrical Manufacturers Association Network Update Time. Repetitive time interval in which data can be sent on the link, 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. Requested Packet Interval. The measure of how frequently the node requires the transmission of data from the target application (scanner). Allen-Bradley s ControlNet configuration software Method of connecting electrical circuits in which the zero (0) volt DC side is switched and the common is positive Method of connecting electrical circuits in which the positive side is switched and the common is zero (0) volts DC. A bit in the input table that reports the health of a corresponding output. Indicates short circuit or open coil (load) diagnostics 2 Bytes (6 bits) 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. LT2005/202CNTECH- 0/03 Page 48