Emerson Aventics G3 Series User manual

G3 Series
PROFIBUSTM DP-V0 DP-V1
Technical Manual

G3 Series PROFIBUS-DPTM Technical Manual
2-2
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
Conditions for use of this product
(1) Aventics G3 Manifold ("the PRODUCT") shall be used in conditions;
i) Where any problem, fault or failure occurring in the PRODUCT, if any, shall not lead to any major or serious
accident.
ii) Where the backup and fail-safe function are systematically or automatically provided outside of the PRODUCT for
the case of any problem, fault or failure occurring in the PRODUCT.
(2) The PRODUCT has been designed and manufactured for the purpose of being used in general industries.
ASCO L.P. shall have no responsibility or liability including but not limited to any and all responsibility or liability based on
contract, warranty, tort, product liability for any injury or death to persons, loss or damage to property caused by the product
that are operated or used in application not intended or excluded by instructions, precautions or warnings contained in Aventics
Technical, User, Instruction, Safety manuals or bulletins.
Safety precautions
Before using this product, please read this manual and the relevant manuals carefully and pay attention to safety and product
application. The following symbols are used in the manual to identify important safety, installation and application information.
Caution symbol indicates a possible hazard which may cause injury or equipment damage.
Note symbol indicates important information regarding equipment installation and setup
NOTE!
CAUTION

G3 Series PROFIBUS-DPTM Technical Manual
2-3
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
Electrical installation and operational guidelines
•To be connected to Class 2 power source only
•All Aventics 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.
•All Aventics G3 Electronics Products to be installed or wired in accordance with Aventics’s published instructions and
applicable electrical codes.
•MULTIPLE CLASS 2 POWER SOURCES: When interconnects, class 2 sources shall be Listed and rated suitable for
parallel interconnection
•Sources shall be Listed and rated suitable for parallel interconnection
•CLASS 2 WIRING: All field wiring shall be suitable for Class 1, Electric Light and Power, or Class 2, 3 wirings are routed
separately and secured to maintain separation between 1) Class 2 wiring and all other class wiring, and 2) Limited
energy circuit conductors from unlimited energy circuit conductors
•Class 2 Device Wiring Only – Do Not Reclassify and Install as Class 1, 3 or Power and Lighting Wiring
•When using molded connector power cables, Do Not rely on wire colors for Pin-Out. Always use pin number
references.
•Wire connections shall be rated suitable for the wire size (lead and building wiring) employed
•MULTIPLE CLASS 2 POWER SOURCES: When interconnects, class 2 sources shall be Listed and rated suitable for
parallel interconnection
•Sources shall be Listed and rated suitable for parallel interconnection
CAUTION

G3 Series PROFIBUS-DPTM Technical Manual
2-4
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
Table of Contents
1. About PROFIBUS-DPTM ................................................................................................................ 2-6
1.1 Overview........................................................................................................................... 2-6
1.2 G3 PROFIBUS-DPTM Features................................................................................................ 2-6
1.3 Cabling and Drop Line Lengths (as defined by PROFIBUS specification) ..................................... 2-6
2. G3 Introduction ......................................................................................................................... 2-7
2.1 G3 Electronics Modularity..................................................................................................... 2-8
2.2 Pneumatic Valve Manifold – 500 Series.................................................................................. 2-9
2.3 Manifold Connectors.......................................................................................................... 2-10
2.4 500 Series Z-Board™ Connectors........................................................................................ 2-11
2.5 2000 Series Pneumatic Valve Manifold................................................................................. 2-12
2.6 2000 Series Z-Board™ Connectors...................................................................................... 2-13
2.7 2000 Series Z-Board™ and Ribbon Cable Example................................................................ 2-14
2.8 2000 Series Z-Board™ and Valve Side Sub-D Example.......................................................... 2-15
3. Zoned Power ............................................................................................................................3-16
3.1 503 Series Zoned Power application.................................................................................... 3-16
3.2 503 Series Zoned Power example ....................................................................................... 3-17
4. Communication Module..............................................................................................................4-18
4.1 PROFIBUS-DPTM Communication Module (Node).................................................................... 4-18
4.2 Communication Module Description..................................................................................... 4-19
4.3 Connector Pin-Outs........................................................................................................... 4-20
4.4 Electrical Connections........................................................................................................ 4-21
4.5 Ground Wiring.................................................................................................................. 4-22
4.6 Power Consumption .......................................................................................................... 4-23
4.7 Recommended External Fuses............................................................................................ 4-24
4.8 Diagnostics - Communication Module LED Functions.............................................................. 4-25
5. G3 Graphic Display....................................................................................................................5-26
5.1 Main Menu Structure......................................................................................................... 5-27
5.2 Network Address Sub-Menu ............................................................................................... 5-28
5.3 SSA Lock Sub-Menu.......................................................................................................... 5-29
5.4 Config Mode Sub-Menu...................................................................................................... 5-30
5.5 Profibus Mode .................................................................................................................. 5-31
5.6 Advanced Settings - Brightness.......................................................................................... 5-32
5.7 Advanced Settings – Flip Display ........................................................................................ 5-33
5.8 Advanced Settings - Extended Diagnostics........................................................................... 5-34
5.9 Advanced Settings - Parameters......................................................................................... 5-35
5.10 Factory Defaults ............................................................................................................... 5-36
5.11 Diagnostics...................................................................................................................... 5-37
5.12 Diagnostics - Self Test Mode .............................................................................................. 5-38
5.13 Network and Sub-Network Error Codes................................................................................ 5-39
5.14 Error Messages................................................................................................................. 5-40
6. ARM – Auto Recovery Module .....................................................................................................6-41
6.1 ARM process flowchart ...................................................................................................... 6-42
7. Distribution ..............................................................................................................................7-43
7.1 Sub-Bus Distribution Modules............................................................................................. 7-44
7.2 Sub-Bus Cables................................................................................................................ 7-50
8. Digital I/O Modules..................................................................................................................8-52
8.1 Digital I/O Module Rules.................................................................................................... 8-52
8.2 I/O Module Technical Data................................................................................................. 8-53
8.4 Digital Input Modules ........................................................................................................ 8-55
8.5 Digital Output Modules...................................................................................................... 8-64
8.6 Digital Input/Output Modules ............................................................................................. 8-68
9. Valve Interface Modules.............................................................................................................9-69
9.1 2000 Series & 500 Series Valve Driver ................................................................................ 9-69
9.2 Sub-bus Valve Module....................................................................................................... 9-71
9.3 Sub-bus Valve Module without Distribution and I/O............................................................... 9-73
9.4 Valve Side Output Module.................................................................................................. 9-75

G3 Series PROFIBUS-DPTM Technical Manual
2-5
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
9.5 500 Series Extended Coil Capability .................................................................................... 9-76
9.6 Extended Coil Configuration ............................................................................................... 9-76
9.7 Extended Coil Valve driver IO Mapping................................................................................ 9-77
9.8 501 Series, up to 64 solenoid coils...................................................................................... 9-78
9.9 501 Series, up to 128 solenoid coils.................................................................................... 9-79
9.10 502 and 503 Series, up to 80 coils...................................................................................... 9-80
10. Analog I/O Modules.................................................................................................................10-81
10.1 Analog I/O Module Rules ..................................................................................................10-81
11.2 Analog Graphic Display.....................................................................................................10-88
10.3 Analog Module / Self Test Mode.........................................................................................10-91
10.4 Analog Module / Factory Defaults.......................................................................................10-92
11. Specialty Modules ...................................................................................................................11-93
11.1 G3 RTD Temperature Module ............................................................................................11-93
12.2 Sub-Bus Hub Module......................................................................................................11-104
12. I/O Module(s) Wiring Diagrams...............................................................................................12-112
12.1 NPN/PNP Definitions.......................................................................................................12-112
13. PROFIBUS-DPTM Configuration and Commissioning ....................................................................13-114
13.1 Parameters...................................................................................................................13-114
13.2 Communication Fault/Idle Mode Parameter.......................................................................13-115
13.3 Profibus GSD File/Mode Selection.....................................................................................13-116
13.4 Commissioning G3 Profibus with Siemens TIA Portal Software.............................................13-117
13.5 Profibus and G3 Diagnostics............................................................................................13-121
13.6 Commissioning DeltaV for G3 Profibus (DPV1) with AMS Suite.............................................13-126
14. PROFIBUS-DPTM Mapping........................................................................................................14-140
14.1 I/O Sizes ......................................................................................................................14-140
14.2 Manifold and I/O Data Sizing Worksheet...........................................................................14-141
14.3 Bit Mapping Rules..........................................................................................................14-142
14.4 Example No. 1...............................................................................................................14-143
14.5 Example No. 2...............................................................................................................14-145
14.6 Example No. 3...............................................................................................................14-147
14.7 Example No. 4...............................................................................................................14-149
14.9 Extended Diagnostics.....................................................................................................14-151
14.10 Diagnostic Telegram Example..........................................................................................14-152
15. Appendix..............................................................................................................................15-153
15.1 System Specifications.....................................................................................................15-153
15.2 Factory Default Settings .................................................................................................15-154
15.3 Troubleshooting.............................................................................................................15-154
15.4 Glossary of Terms..........................................................................................................15-155
15.5 Technical Support..........................................................................................................15-156

G3 Series PROFIBUS-DPTM Technical Manual
2-6
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
1. About PROFIBUS-DPTM
1.1 Overview
PROFIBUS-DPTM is a communication protocol used to network industrial devices to eliminate labor intensive and
expensive point to point wiring schemes. Siemens originally developed PROFIBUS DP, but it is now supported by a
multitude of manufacturers and the protocol standard governed by the PROFIBUS Trade Organization (PTO).
The G3 Series PROFIBUS-DPTM product is designed to conform to the PROFIBUS standard EN50170 and is certified by
PROFIBUS Interface Center (PIC) according to the guidelines determined by the PROFIBUS Trade Organization (PTO).
The certification process ensures interoperability for all PROFIBUS-DP devices. This product supports PROFIBUS DP-V0
and DP-V1
PROFIBUS-DPTM uses a 2-wire (plus shield) network and can have up to 126 nodes. The protocol can transfer a
maximum of 244 bytes of data per node cycle with nine selectable communication (baud) rates of 9.6 Kbps, 19.2
Kbps, 45.45 Kbps, 93.75 Kbps, 187.5 Kbps, 500 Kbps, 1.5 Mbps, 3 Mbps, 6 Mbps and 12 Mbps. Maximum distance is
depended upon baud rate and cable media type. Refer to the section below for details.
More information about PROFIBUS can be obtained from the PROFIBUS web site www.PROFIBUS.com
1.2 G3 PROFIBUS-DPTM Features
Features
Description
Bus Topology
Linear bus, active bus termination on both ends. Stub lines permitted
only for <= 1.5Mbit/sec baud rates.
Baud Rates Supported
9.6 Kbps, 19.2 Kbps, 45.45 Kbps, 93.75 Kbps, 187.5 Kbps, 500 Kbps,
1.5Mbps, 3 Mbps, 6 Mbps and 12 Mbps
Duplicate address detection
Node address must match address in Master configuration software,
before node will enter the data exchange mode
Error Correction If error detected, sender is requested to repeat the message
Address Setting options
Via Software (with Profibus-DPTM Class 2 Master), with standard Manual
Configuration Module (MCM), or graphic display
1.3 Cabling and Drop Line Lengths (as defined by PROFIBUS specification)
Maximum Cable Length
Baud
Rate 9.6Kbps
19.2Kbps 93.75Kbps 187.5Kbps 500Kbps 1.5Mbps 12Mbps
Range/
Segment
1200M 1200M 1200M 1000M 400M 200M 100M

G3 Series PROFIBUS-DPTM Technical Manual
2-7
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
2. G3 Introduction
The G3 Series is an electronic product platform that features an integrated graphic display for simple commissioning
and displaying of diagnostic information. In addition it has an innovative distribution capability which allows the same
I/O components that make up a centralized manifold configuration to be used as the distribution components as well,
decreasing the need for duplicate components on centralized and distributed applications. The G3 platform interfaces
to a variety of valve series and fieldbus interface protocols and is capable of addressing a total of 1200 I/O points (150
bytes). With proper assembly and termination, the G3 modules will have an IP65 rating.
The manifold can be viewed as having two sections to it, the Valve Side and the Discrete I/O Side. The Valve Side
supports a maximum of 128 solenoid coils and the Discrete I/O Side supports a maximum of 16 modules capable of
addressing up to 1200 outputs, 1200 inputs or various combinations.
Various discrete modules with integrated graphic display are available. They include digital I/O, analog I/O, and
specialty modules which cover various application needs. Pin-outs for all connectors are labeled on the side of the
respective modules and are also detailed in the module section of this document.
This manual details specific information for configuring and commissioning the Aventics G3 Series product line. For
more information relating to pneumatic valving and valve manifold assemblies, please refer to the appropriate valve
series catalog at www.asco.com.
Discrete I/O Side
Accepts up to 16 modules in
centralized or distributed
configuration
Communication Module (Node)
Available with various
Industrial protocols
Sub-Bus OUT
Used to distribute
additional I/O and
manifolds
Valve Side
Drives up to 128 coils
Clips
Allows easy field changes of
electronic modules.
Graphic Display
Allows Easy
Configuration &
Diagnostic reporting
ARM
(Auto Recovery Module)
Automatically stores &
reprograms configuration
information

G3 Series PROFIBUS-DPTM Technical Manual
2-8
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
2.1 G3 Electronics Modularity
The G3 Series product line is a completely modular and scalable system. As shown below, all of the G3 electronic
modules plug together, via mechanical clips, allowing easy assembly and field changes.

G3 Series PROFIBUS-DPTM Technical Manual
2-9
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
2.2 Pneumatic Valve Manifold – 500 Series
The pneumatic valve manifold with internal circuit board technology is also modular. The valve solenoid coil
connections are automatically made 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.

G3 Series PROFIBUS-DPTM Technical Manual
2-10
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
2.3 Manifold Connectors
Solenoid Coil Connections using Z-Board™ Technology for 50x valve series
Z-Board™ plug together technology connects all valve solenoids to the valve coil output driver board, located in the
valve adapter. There is a maximum of 32 coil outputs available on the complete manifold assemblies. The 32 available
outputs are accessed on the 501 series valves utilizing 3 and 4 station manifolds and on the 502 and 503 series
utilizing 2 station manifolds.
14 Solenoid,
Pin No. 1
Not Used,
Pin No. 3
Common,
Pin No. 4
12 Solenoid,
Pin No. 2
NOTE!
•A single solenoid valve’s coil is always on the “14” end.

G3 Series PROFIBUS-DPTM Technical Manual
2-11
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
2.4 500 Series Z-Board™ Connectors
The 501, 502 and 503 valve series utilize 2 different Z-Board™designs to achieve the single and double solenoid
output functions. This yields the possible 32 single, 16 double, or various combinations of valve coil output
capabilities.
501 Series 502 Series
503 Series

G3 Series PROFIBUS-DPTM Technical Manual
2-12
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
2.5 2000 Series Pneumatic Valve Manifold
The pneumatic valve manifold with internal circuit board technology is also modular. The valve solenoid coil
connections are automatically made 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.

G3 Series PROFIBUS-DPTM Technical Manual
2-13
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
2.6 2000 Series Z-Board™ Connectors
The 2005/2012/2035 valve series utilize 2 different Z-Board™designs to achieve the single and double solenoid output
functions. This yields the possible 32 single, 16 double, or various combinations of valve coil output capabilities.
Single Z-Board™Double Z-Board™
Ribbon Connection
Single Z-Board™Ribbon Connection Double Z-Board™
single
double
The 17th solenoid (output group No. 2’s first bit) must be accessed via either
the valve side Sub-D output module or a ribbon connector type Z-board.
NOTE!

G3 Series PROFIBUS-DPTM Technical Manual
2-14
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
2.7 2000 Series Z-Board™ and Ribbon Cable Example
If fourteen (14) single solenoid and one (1) double solenoid valves are connected directly to the communication node
via their Z-Boards™, and one (1) single solenoid and four (4) double solenoid valves are connected to the
communication node via the ribbon cable, the following would be the valve side bit map:
Output Word
0
1
Output Byte
0
1
2
3
Output Bit No.
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Solenoid Coil
Output No.
1 2 3 4 5 6 7 8 9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
n/a

G3 Series PROFIBUS-DPTM Technical Manual
2-15
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
2.8 2000 Series Z-Board™ and Valve Side Sub-D Example
If sixteen (16) single solenoid valves are connected directly to the communication node via Z-Boards™and a valve side
Sub-D connector is connected to the communication node via the output Group No. 2 connector then the following
would be the valve side bit map:
Output Word
0
1
Output Byte
0
1
2
3
Output Bit No.
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Solenoid Coil
Output No.
1 2 3 4 5 6 7 8 9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27 28 29 30
31
32

G3 Series PROFIBUS-DPTM Technical Manual
3-16
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
3. Zoned Power
3.1 503 Series Zoned Power application
The Zoned Power Manifold blocks can be incorporated into a 503 manifold assembly
to isolate Power to a number of valve stations, independent from the main power of
the manifold. This is achieved by the integral 4 Pin M12 connector along with the
modified manifold board. The total number of Zoned Power Manifold blocks is
determined by the maximum solenoid outputs as defined by the type of interface
(e.g. G3 Electronics, Terminal Strip, D-Sub). For user flexibility, the Zoned Power
Manifold blocks are available in both "proprietary" and "ISO" versions and can be
ordered with the M12 connector starting at the first or second station.
Technical Data:
Electrical Data:
Voltage:
24 VDC (0 VDC must be common with main power)
Connection:
4 Pin M12 Single Key Male
Environmental:
IP65 (with proper connection)
V Wiring Option
W Wiring Option
V
W
W & V Connector Pin Out

G3 Series PROFIBUS-DPTM Technical Manual
3-17
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
3.2 503 Series Zoned Power example
In the example shown below there are two Zoned Power Manifold blocks used. One is a "W" wiring option
and the other is a "V" wiring option. The first (5) stations of the manifold assembly get their power from
the M12 4 Pin connector at station one. The next (5) stations get their power from the M12 4 Pin
connector at station six. Each of these "Zones" can be individually switched of if the machine or process
requires. This example is considered a manifold with (2) Power Zones. The Main Power (7/8" MINI) cannot
be considered or used as a Power Zone; Switched Power (Solenoid/Output Power) MUST be present for
control to the solenoids
24 VDC
V Wiring Option
W Wiring Option
V
a
l
v
e
&
O
u
t
p
u
t
The 0 VDC reference for the +24 VDC applied to Pin 4 of the M12 connector MUST be the same
as the one used on G3/580/Terminal Strip/25 or 37 Pin Sub-D/19 or 26 Pin Round Connector.
If multiple 24 VDC power supplies are used the 0 VDC references of each supply MUST be
common.
NOTE!
N
o
d
e
&
I
n
p
u
t

G3 Series PROFIBUS-DPTM Technical Manual
4-18
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
4. Communication Module
4.1 PROFIBUS-DPTM Communication Module (Node)
This module is the communication interface to the manifold. It contains communication electronics and internal short
circuit protection for power. It can be configured via software, via the graphic display, or manually via DIP switches
through the optional Manual Configuration Module (MCM).
The Aventics G3 PROFIBUS-DPTM node is tested by the PIC to ensure compatibility and interoperability.
Communication Module
Part Number
PROFIBUS-DP
TM
Communication module
240-239

G3 Series PROFIBUS-DPTM Technical Manual
4-19
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
4.2 Communication Module Description
Detail No. Description
1
“Set” Button – used to navigate through user menus and to set parameters
2
Module Status LED
3
5 Pin M12 Reverse Key Male Communication Connector
4
5 Pin M12 Reverse Key Female Communication Connector
5
Mounting Hole
6
“Next” Button – used to navigate through user menus and to set parameters
7
Graphic Display – used to display parameter information
8
Network Status LED
9
Slot for text ID tags
10
Keying for preventing I/O module insertion
11
5 Pin MINI Male Power Connector
7
10
9
8
3
11
5
1
2
6
4

G3 Series PROFIBUS-DPTM Technical Manual
4-20
TDG3PTTM1-11EN 07/2020
Subject to change without notice
www.asco.com
4.3 Connector Pin-Outs
Industry standard connectors are used for communication and power. The PROFIBUS-DPTM communication connectors
are a M12 reverse key 5 pin male connector and a M12 reverse key 5 pin female connector. The Power connector is a
7/8” MINI 5 pin male connector.
PROFIBUS Communication Connector Pin-Out
Pin No. Function Description
1 +5 VDC
+5 volt output from node, used for termination of network or
auxiliary devices.
2 Data Line A Profibus-DPTM Communication Line A (Green)
3 0VDC Common Common for +5V output and Data Lines A & B
4
Data Line B
Profibus-DP Communication Line B (Red)
5 Earth Ground
Internally connected to earth ground (case). Connect to shield
of Profibus-DPTM cable.
Power Connector Pin-Out
Pin No. Function Description
1
0 VDC Common
(Valves and Outputs)
0 VDC Voltage used to power outputs
(valve coils and discrete outputs) SW
2
0 VDC Common
(Node and Inputs)
0 VDC Voltage used to power
discrete inputs and node electronics UNSW
3
Earth Ground
Protective Earth
4
+24 VDC
(Node and Inputs)
Voltage used to power
discrete inputs and node electronics UNSW
5 +24 VDC
(Valves and Outputs)
Voltage used to power outputs
(valve coils and discrete outputs) SW
!
•Power common (0 VDC) pins 1 and 2 are isolated from each other to allow separate
(isolated) power supply connection if required. However, they can be tied together if a
single common, non-isolated, application is preferred.
•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 Node and Inputs pin supplies power to the node electronics. This pin must be
powered at all times for communication node to be functional.
•To be connected to Class 2 power source only