Getting Started This is a brief document designed to quickly get you started setting up your valve manifold with integrated G2-2 series EtherNet/IP communication protocol. 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 Basics Below is an example of a 2005/2012 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 Valve Side and the I/O Side. The Valve Side supports a maximum of 32 solenoids coils and the I/O Side supports a maximum of 6 modules totaling 192 Outputs or 96 Inputs. The communication module has two connectors: a RJ45 communication connector and a 4- pin power connector. Pin outs for these, along with I/O connectors, are labeled on the side of the respective modules. TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 1
3) LED Functions The module is equipped with eight LEDs. The functions of the LEDs are described in the table below. LED Name Color Status Description Active Green FLASHING The LED flashes each time a packet is received or transmitted. IP address has been not been assigned to node. Or no power applied to unit. ON Connected. The module has established an Ethernet connection. Green No connection. There are no Ethernet connections established to FLASHING the module. Network Status Duplicate IP address. The module has detected that its IP address ON (Net. Stat.) is already being used elsewhere on the network Connection has timed out. One or more of the connections for Red which this module is the target has timed out. This flashing state is FLASHING changed only if all timed out connections are re-established or if the module is reset. Green Red FLASHING Self test. The module is performing a power on self-test. No power applied to module Module Status (Mod. Stat.) Link Fuse 1 +24V VLV / OUT Fuse 2 +24V NODE / IN Green ON Device operational. The module is operating correctly. FLASHING Standby. The module has not been configured. Red ON Major fault. A major internal error has been detected. FLASHING Minor fault. A minor recoverable fault has been detected. Green Red FLASHING Self test. The module is performing a power on self-test. Green No Ethernet connection is detected ON The module is connected to an EtherNet network Red Internal fuse F1 is open; No power is internally provided to valves ON or outputs. Communication NOT affected. 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. Green No DC Power present at +24V VLV / OUT pin on Aux. Power connector. Red Internal fuse F2 is open; No power is internally provided to node ON 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). ON DC Power applied to+24v NODE / IN pin on Aux. Power connector. Green No DC Power present at +24V NODE / IN pin on Aux. Power connector. TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 2
4) Self-Test Mode An internal diagnostic tool can also be enabled using the MCM module. This tool allows the user to confirm that all of the Inputs & 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. First, disconnect power and air from the manifold! Second, set the rotary switches to 99 (SW3 and SW4). Next, make sure that SW1-5, SW2-1, and SW2-7 are in the ON position. Then select the desired test mode with SW2-8 (see table below) Switch SW2-8 Testing Setting Description Mode Output Off Sequentially turns all the outputs ON and. Input/ Causes all of the odd outputs to come on and stay on until an input is On Output made. When an input is made, the outputs will toggle to the even outputs. Finally, make sure that all of the other switches are in the 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 of power up: First, put SW2-6 into the ON position. Second, put SW2-7 into the position. Once Self-Test Mode is enabled, the module status LED will flash red/green until Self-Test Mode is terminated by removing power to the unit.! Air should be disconnected to the manifold when attempting to run the Self-Test Mode. Communication lines should be disconnected before attempting to run the Self-Test Mode. TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 3
5) I/O Mapping Example: Here is just one example of the I/O mapping on a G2-2 Series EtherNet/IP manifold. Please note that the following configuration is assumed: Single Z-Boards are installed for single solenoid valves and double Z-Boards are installed for double solenoid valves. Valve outputs have 1 Status bit per output point; PNP discrete Output modules have 1 Status bit for every 4 Output points. PNP output modules have 1 Status bit for every 4 Output points, thus the first physical Input will begin at Byte 4, bit 0 in this example. Pos No. 1 2 3 Module Type 16O Sourcing (PNP) 8I Sinking (NPN) 4I Sinking (NPN) Part No. Input Size Value (Bytes) Output Size Value (Bytes) 239-1319 1 2 239-1308 1 0 239-1304 1 0 TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 4
I/O Mapping Table Output Table BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Valve Coil #8 Valve Coil #7 Valve Coil #6 Valve Coil #5 Valve Coil #4 Valve Coil #3 Valve Coil #2 Valve Coil #1 1 Valve Coil #16 Valve Coil #15 Valve Coil #14 Valve Coil #13 Valve Coil #12 Valve Coil #11 Valve Coil #10 Valve Coil #9 2 Valve Coil #24 Valve Coil #23 Valve Coil #22 Valve Coil #21 Valve Coil #20 Valve Coil #19 Valve Coil #18 Valve Coil #17 3 Valve Coil #32 Valve Coil #31 Valve Coil #30 Valve Coil #29 Valve Coil #28 Valve Coil #27 Valve Coil #26 Valve Coil #25 4 Output #8 Output #7 Output #6 Output #5 Output #4 Output #3 Output #2 Output #1 5 Output #16 Output #15 Output #14 Output #13 Output #12 Output #11 Output #10 Output #9 Input Table BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Status for Status for Status for Status for Status for Status for Status for Status for Valve Coil #8 Valve Coil #7 Valve Coil #6 Valve Coil #5 Valve Coil #4 Valve Coil #3 Valve Coil #2 Valve Coil #1 1 Status for Status for Status for Status for Status for Status for Status for Status for Valve Coil #16 Valve Coil #15 Valve Coil #14 Valve Coil #13 Valve Coil #12 Valve Coil #11 Valve Coil #10 Valve Coil #9 2 Status for Status for Status for Status for Status for Status for Status for Status for Valve Coil #24 Valve Coil #23 Valve Coil #22 Valve Coil #21 Valve Coil #20 Valve Coil #19 Valve Coil #18 Valve Coil #17 3 Status for Status for Status for Status for Status for Status for Status for Status for Valve Coil #32 Valve Coil #31 Valve Coil #30 Valve Coil #29 Valve Coil #28 Valve Coil #27 Valve Coil #26 Valve Coil #25 4 Status for Status for Status for Status for Allocated & Allocated & Allocated & Allocated & Reserved Reserved Reserved Reserved Outputs #13-16 Outputs #9-12 Outputs #5-8 Outputs #1-4 5 Input Input Input Input Input Input Input Input #8 #7 #6 #5 #4 #3 #2 #1 6 Allocated & Reserved Allocated & Reserved Allocated & Reserved Allocated & Reserved Input #12 Input #11 Input #10 Input #9 TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 5
6) 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 (see pg. 8). Please refer to the table below for Status Input Bit action during fault condition: Output Type Valve Solenoid Coil Driver or Sinking (NPN) Outputs Valve Solenoid Coil Driver or Sinking (NPN) Outputs Sourcing (PNP) Outputs Output State ON ON Fault Condition Status Bit No Fault 0 Fault - Short Circuit, Over Temp/Over Current 1 No Fault 0 Fault - Open Load 1 No Fault 0 Fault - Short Circuit, Over Temp/Over Current 1 7) Auxiliary Power Connector Pin Out Pin # Function Description 1 +24VDC (Valves and Outputs) Voltage Used to Power Outputs (Valves and 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 Inputs and Node Electronics! ATTENTION Maximum current capacity on pin No. 3 (0VDC common) of auxiliary power connector is 8 Amps. The combined current draw of Pin No. 1 (Valves & Outputs) and pin No. 4 (Node & Inputs) cannot exceed 8 Amps, at any given moment in time. Auxiliary power connector pin No. 4 supplies power to node electronics. This pin must be powered at all times for communication node to be functional. TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 6
8) IP Address Configuration The IP address of the Numatics G2-2 Ethernet node may be configured via several different methods: DHCP/ BootP ARP command Configuration page on the node s imbedded Web Server Manual Configuration DIP switch A.) DHCP/ BootP The node is shipped from the factory with DHCP/BootP enabled. This allows a DHCP server to automatically set the IP address to the node when connected to the network, or a BootP server to establish communication to the node and set the IP address. These methods require that the unique MAC ADDRESS of the node is known. The MAC ADDRESS can be found on the label of the DIP switch located on the node cover (see below). It will be different for every node. If DHCP/BootP is enabled and a DHCP/BootP server is found, (and the configuration switch is set to 0) the IP address, Subnet mask, and gateway are automatically configured by the DHCP/ BootP server. The DHCP/ BootP setting can be enabled or disabled via the nodes integrated web server. Simply log on to the node with any web browser and go to the configuration page (see Web Server configuration below). B.) Manual Configuration DIP switch The manual configuration DIP switch provides an easy way to configure the node s IP address. The switch represents the binary value of the last octet in the IP address. When all switches are set to, it is disabled and other means of setting the address must be used (see above). DIP switch configuration settings require power to be cycled before changes take effect. IP address: 192.168.0.X Subnet Mask 255.255.255.0 Gateway address: 0.0.0.0 (no gateway set) 8 7 6 5 4 3 2 1 MAC = 00-11-03-0D-12-00 ON X = DIP switch setting per the table below Bit 8 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Octet Value (decimal) DIP Switch Disabled ON 1 ON 2 ON ON 3 ON 4 ON ON ON ON 120 ON ON ON ON ON ON ON 253 ON ON ON ON ON ON ON 254 ON ON ON ON ON ON ON ON Not allowed TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 7
C.) Web Page Configuration The Numatics G2-2 Ethernet node has an imbedded web server. This server can be accessed via any standard web browser program. If the IP address of the node is known, the Node Configuration Page for the node can be called up and the configuration parameters updated. If the IP address of the node is not known, it can be set using any of the previously described methods. Please note that the PC, where the web browser is installed, must be correctly configured for operation with the appropriate network IP ranges and Subnet settings that match the G2-2 Ethernet node. Consult appropriate personnel before changing your computer s network settings and always record previous settings before attempting changes! Below is a representation of the Node Configuration Page which is stored in the Ethernet node. IP address, Subnet Mask, Gateway Address, SMTP server address and DHCP/BootP enabled selections can all be configured from this page. These parameters will be programmed in the node s non-volatile FLASH memory once UPDATE CONFIG. is clicked. Modifications to the Configuration Page settings require power to be cycled before changes take effect. D.) ARP & PING Commands G2-2 Series EtherNet 10/100 Mbit/s Node Configuration Page IP Address: 192.168.3.120 Subnet Mask: 255.255.255.0 Gateway Address: 0.0.0.0. SMTP server: 0.0.0.0. DHCP/BOOTP enabled: UPDATE CONFIG ARP (Address Resolution Protocol) and PING are DOS commands that can be used to set an IP address. This will require a PC equipped with an Ethernet Network Interface Card (NIC). The IP address will be stored in the node s non-volatile FLASH memory after it is set. No power cycle is necessary. The following is an example of how to configure the IP address using the ARP command from a DOS window. where: ARP -s <IP address> <MAC address> <IP address> is the IP address that the node is to be set to <MAC address> is the unique MAC ADDRESS of the node where the IP address is to be set (see label on DIP switch) Also a PING command must be executed after the ARP -s command so the IP address can be sent to the node. PING <IP address> where: <IP address> is the IP address that was previously used in the ARP -s command.! ATTENTION The ARP command automatically configures the subnet mask to 255.255.255.0 thus the first three octets of the IP address must be the same as the PC executing the command. The module will use the configuration stored in FLASH memory if the configuration switch is set to 0 and the DHCP/BootP server is disabled. The parameters set in the node are programmed in non-volatile FLASH memory. They will NOT be lost during loss of power. TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 8
9) EtherNet/IP Configuration with RSLOGIX 5000 When commissioning your Ethernet/IP network, 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 are sample screen shots taken from Allen Bradley s RSLogix 5000 programming software, they show where the appropriate values for the IP Address, Assembly Instance, Size and Configuration must be entered. Connection Parameters Assembly Instance values: Sizes: Comm. Format: Description Decimal Format Hexadecimal Format Input 100 64 Output 150 96 Configuration 1 1 Description Size (8 bits=1 byte) Total Input Bytes value (in bytes) from manifold configuration (including status Input bits). This is a Input minimum value; larger values may be specified for future expansion purposes. Total Output Bytes value (in bytes) from manifold Output configuration. This is a minimum value; larger values may be specified for future expansion purposes. Configuration 0 Description Comm. Format Data Data SINT TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 9
10) Factory Defaults Settings Unless otherwise requested, all standard G2-2 Series Ethernet manifolds ship with specific factory default settings. Below is a list of the factory default settings: Description Baud Rate I/O Side Allocated I/O IP address MAC ID DHCP/BootP Input Module Power Jumper Output Module Power Jumper Default 10/100 Mbit per sec. (Autobaud) Self configuring DHCP/ BootP Enabled (192.168.3.120 in FLASH) A unique alpha-numeric code for each node. Located on the configuration DIP switch label (Not user configurable) Enabled PU (Input sensor power supplied by auxiliary power connector pin No. 4) SP (Output module power supplied by auxiliary power connector pin No. 1) 11) 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 technical manuals, local distributors, and other Numatics, Inc. products and support issues can be found on the Numatics, Inc s WEB site at http://www.numatics.com/fieldbus For general help or more information regarding Industrial Ethernet protocol, please see the following appropriate web pages: EtherNet/IP International http://www.ethernet-ip.org TDG2-2ENIPQS-1.3 07/06 http://www.numatics.com/fieldbus Page 10