Emerson Aventics G3 Series User manual

G3 Series
EtherCATTM
Technical Manual

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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!

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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

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Table of Contents
About EtherCAT ............................................................................................................................1-6
Overview..............................................................................................................................1-6
G3 EtherCATTM Features .........................................................................................................1-6
G3 Introduction ............................................................................................................................2-7
G3 Electronics Modularity........................................................................................................2-8
500 Series Pneumatic Valve Manifold .......................................................................................2-9
500 Series Manifold Stations................................................................................................. 2-10
500 Series Z-Board™ Connectors........................................................................................... 2-11
2000 Series Pneumatic Valve Manifold.................................................................................... 2-12
2000 Series Z-Board™ Connectors......................................................................................... 2-13
2000 Series Z-Board™ and Ribbon Cable Example................................................................... 2-14
2000 Series Z-Board™ with Valve Side Sub-D Example ............................................................ 2-15
Zoned Power .............................................................................................................................. 3-16
503 Series Zoned Power application....................................................................................... 3-16
503 Series Zoned Power example .......................................................................................... 3-17
Communication Module................................................................................................................ 4-18
EtherCATTM Communication Module (Node)............................................................................. 4-18
Communication Module Description........................................................................................ 4-19
Connector Pin-Outs.............................................................................................................. 4-20
Electrical Connections........................................................................................................... 4-21
Ethernet Straight-Through Cabling Diagrams .......................................................................... 4-23
Ground Wiring..................................................................................................................... 4-24
Power Consumption ............................................................................................................. 4-25
Recommended External Fuses............................................................................................... 4-26
Diagnostics ......................................................................................................................... 4-27
Output Short Circuit Protection.............................................................................................. 4-28
G3 Graphic Display...................................................................................................................... 5-29
Main Menu Structure............................................................................................................ 5-30
EtherCATTM Operating States (Default Display)........................................................................ 5-31
Station Alias Sub-Menu ........................................................................................................ 5-32
IP Address.......................................................................................................................... 5-33
Subnet Mask....................................................................................................................... 5-33
Gateway IP......................................................................................................................... 5-34
Config Mode........................................................................................................................ 5-35
Web-Server ........................................................................................................................ 5-36
EtherCATTM communication ................................................................................................... 5-37
MAC Address....................................................................................................................... 5-38
Advanced Settings - I/O Diag. Menu ...................................................................................... 5-39
Advanced Settings - Diagnostic Word..................................................................................... 5-40
Advanced Settings – Comm. Fault ......................................................................................... 5-41
Advanced Settings – Brightness............................................................................................. 5-42
Advanced Settings – Flip Display ........................................................................................... 5-43
Advanced Settings – Parameters Lock .................................................................................... 5-44
Advanced Settings – Configuration Lock ................................................................................. 5-45
Factory Defaults .................................................................................................................. 5-46
Diagnostics - Self Test Mode ................................................................................................. 5-47
Diagnostics ......................................................................................................................... 5-48
Network and Sub-Network Error Codes................................................................................... 5-49
Error Messages.................................................................................................................... 5-50
ARM – Auto Recovery Module (Optional) ........................................................................................ 6-51
ARM process flowchart ......................................................................................................... 6-52
Distribution ................................................................................................................................ 7-53
Sub-Bus Distribution Modules................................................................................................ 7-54
580 Series Sub-Bus Valve Module.......................................................................................... 7-58
Sub-Bus Hub Module............................................................................................................ 7-59
Sub-Bus Cables ................................................................................................................... 7-60

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G3 Sub-Bus Field Wiring Directions........................................................................................ 7-61
Digital I/O Module....................................................................................................................... 8-62
Digital I/O Module Usage...................................................................................................... 8-62
8.2 I/O Module Technical Data.................................................................................................... 8-63
I/O Module Descriptions and Menus ....................................................................................... 8-64
Digital Input Modules ........................................................................................................... 8-65
Digital Output Modules......................................................................................................... 8-73
Digital Input/Output Modules ................................................................................................ 8-77
Valve Interface Modules............................................................................................................... 9-78
2000 Series & 500 Series Valve Driver ................................................................................... 9-78
Sub-bus Valve Module.......................................................................................................... 9-80
Sub-bus Valve Module without Distribution ............................................................................. 9-82
Valve Side Output Module..................................................................................................... 9-84
500 Series Extended Coil Capability ....................................................................................... 9-85
Extended Coil Configuration .................................................................................................. 9-85
Extended Coil Valve Driver Mapping....................................................................................... 9-88
501 Series, up to 64 solenoid coils......................................................................................... 9-89
501 Series, up to 128 solenoid coils....................................................................................... 9-90
502 and 503 Series, up to 80 solenoid coils ............................................................................ 9-91
Analog I/O Modules............................................................................................................ 10-92
Analog I/O Module Rules .................................................................................................... 10-92
Analog Graphic Display....................................................................................................... 10-99
Analog Module / Self Test Mode..........................................................................................10-102
Analog Module / Factory Defaults........................................................................................10-103
Specialty Modules.............................................................................................................11-104
RTD Module .....................................................................................................................11-104
Sub-Bus Hub Module.........................................................................................................11-115
I/O Module(s) Wiring Diagrams ..........................................................................................12-123
12.1 NPN/PNP Definitions ..................................................................................................12-123
G3 EtherCATTM Web Server................................................................................................13-125
Connecting to a G3 Series EtherCATTM node.........................................................................13-125
Connecting to a G3 Series EtherCATTM Node (Windows 7) ......................................................13-126
Connecting to a G3 Series EtherCATTM Node (Windows 10) ....................................................13-131
Using the Functionality of the G3 Series EtherCATTM Web Server ............................................13-136
IP Address Configuration ...................................................................................................13-144
User Configurable Device Parameters..................................................................................13-145
Parameters Lock...............................................................................................................13-145
I/O Configuration Lock ......................................................................................................13-145
Communication Fault Mode Parameter.................................................................................13-145
G3 EtherCATTM PLC Configuration........................................................................................14-147
Create Aventics G3 EtherCATTM configuration (Beckhoff PLC)..................................................14-147
Twincat configuration for IP communication over EtherCATTM (Beckhoff PLC)............................14-152
Configure IP communication with G3 over EtherCATTM (Beckhoff PLC) .....................................14-155
Create Aventics G3 EtherCATTM configuration (Lenze PLC)......................................................14-156
Create Aventics G3 EtherCATTM configuration (Omron PLC) ....................................................14-163
EtherCATTM Mapping..........................................................................................................15-167
I/O Sizes .........................................................................................................................15-167
Manifold and I/O Data Sizing Worksheet..............................................................................15-168
Bit Mapping Rules.............................................................................................................15-169
I/O Mapped Diagnostic Word..............................................................................................15-178
Appendix.........................................................................................................................16-180
System Specifications........................................................................................................16-180
Factory Default Settings ....................................................................................................16-181
G3 EtherCATTM Process Data Map........................................................................................16-182
Troubleshooting................................................................................................................16-183
Glossary of Terms.............................................................................................................16-184
Technical Support.............................................................................................................16-186

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About EtherCAT
EtherCATTM is a registered trademark and patented technology, licensed by Beckhoff Automation (GmbH, Germany).
Overview
EtherCATTM is an Ethernet-based networking solution for automation but has added benefits/features toward
manufacturing applications.
The EtherCATTM Technology Group or ETG develops and promotes EtherCATTM technology.
G3 EtherCATTM uses industrial M12 IP67-rated connectors. The protocol transfers data at a fixed speed of 100 Mbps.
The maximum network cabling distance is limited to 100m segments at 20º C.
More information about EtherCATTM can be obtained at the web site http://www.EtherCAT.org.
G3 EtherCATTM Features
Features
Description
Spec. Supported
Designed by the EtherCATTM Technology Group (ETG)
Bus Topology
Star, Tree, Ring or Daisy Chain
Baud Rates Supported
100 Mbps
CE
CE Compliant
Duplicate Address Detection
If a duplicate address is detected on power up, duplicates will not
progress to run mode
Address Setting
Web Page Configuration, Graphical Display
Conformance Tested
ETG proof of conformity

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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 valves and valve manifold assemblies, please refer to the Aventics website 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

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G3 Electronics Modularity
Discrete I/O
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 for easy assembly and field changes.

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500 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.

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500 Series Manifold Stations
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 4 station manifolds and on the 502 and 503 series utilizing 2 station manifolds.
NOTE!
A single solenoid valve’s coil is always on the “14” end.
14 Solenoid,
Pin No. 1
Not Used,
Pin No. 3
Common,
Pin No. 4
12 Solenoid,
Pin No. 2

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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

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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.

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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!

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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

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2000 Series Z-Board™ with 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

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Zoned Power
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

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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.
S+
S
NC
S+
S-
NC
S+
S-
NC
24 VDC
V Wiring Option
W Wiring Option
N
o
d
e
&
I
n
p
u
t
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!

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Communication Module
EtherCATTM 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 and via the graphic display.
Communication Module Kit Part Number
EtherCATTM Communication module 240-310

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Communication Module Description
Detail No.
Description
1
“Set” Button – used to navigate through user menus and to set parameters
2
Status LEDs
3
4 Pin M12 D-Coded Female Communication Connectors
4
Mounting Hole
5
“Next” Button – used to navigate through user menus and to set parameters
6
Graphic Display – used to display parameter information
7
Slot for text ID tags
8
Keying for preventing I/O module insertion
9
5 Pin MINI Male Power Connector
6
8
7
3
9
4
1
2
5

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Connector Pin-Outs
Industry standard connectors are used for communication and auxiliary power.
The communication connectors are a D-coded keyway 4 pin female M12 connector.
The Power connector is a single keyway 5 pin male 7/8” MINI connector.
Communication Connector Pin-Out
Pin No. Function Description
1 TD+ Positive Transmit Line
2 RD+ Positive Receive Line
3 TD- Negative Transmit Line
4 RD- Negative Receive Line
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.
CAUTION