Numatics G2-2 Series Instruction manual

G2-2 Series Modbus/TCP Quick Start Manual
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Getting Started
This is a brief document designed to quickly get you started setting up your valve manifold with an integrated
Numatics’ G2-2 Series Modbus/TCP communication node.
1) Initial Unpacking and Inspection
1) Examine exterior of package for signs of damage. Report any damage to shipping carrier.
2) Remove wrapped manifold assembly from box.
a) Remove manifold assembly from anti-static packaging
b) Retain documentation for installation and configuration
3) Examine manifold assembly for any shipping damage such as:
a) Bent pins or connectors
b) Report any damage to shipping carrier immediately
4) Examine manifold assembly for proper ordered configuration. (Valves, I/O, Protocol, etc.)
2) G2-2 Introduction
Below is an example of a 2012 series valve manifold. This fieldbus manifold series is capable of addressing a
total of 224 I/O. The manifold can be viewed as having two sections to it, the Valve Side and the Discrete I/O
Side
. The Valve Side supports a maximum of 32 solenoid coils and the Discrete I/O Side supports a
maximum of 6 modules totaling 1 2 Outputs, 6 Inputs, or various combinations. The communication
module has two connectors: a 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.
Valve
I/O Point
LED Status
Indicator(s)
Discrete I/O
Connectors
Discrete I/O Side
(Maximum of 6 Modules)
Valve Side
(Maximum of 32 Solenoids)
Module/
Network
Status LED's
Chassis Ground
Connection
Valve
End Plates
Manual
Override
Solenoid LED
Status Indicator
Valve Side
Sub-D Output
Module
Communications
Module (Node)
Manual Configuration
Module (MCM)
Terminal Strip Module
8 Connector I/O Module
1 Pin Round
Connector Module
Analog Module
Dual 25 Pin Sub-D
w/Aux Power
Output Module
IP
EtherNet
MAC ADDRESS

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3) Modbus/TCP Communication Module Part Numbers
Modbus/TCP Communication Replacement Part Numbers
Connector Type Description Part Number
Complete Module 240-163
Communication Board with Cover 240-167
M12 D Coded
Valve Driver Board 256-680
Complete Module 240-164
Communication Board with Cover 240-168
IP67 RJ45
Valve Driver Board 256-680

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4) MCM - Manual Configuration Module (Optional)
The MCM is the module that allows the user to manually set the IP address, fault conditions, and other user
definable options, without the need for software configuration. If software configuration is preferred, this
module is not necessary. The MCM consists of two DIP switch sets (SW1 and SW2) and two rotary switches
(SW3 and SW4).
MCM Module Part Numbers
Description Part Number
Complete Module 23 -1384
Replacement Board 256-684
(SW2)
(SW3) DIP Switch
(SW1)
DIP Switch
(SW4)
All DIP switches shown in the "OFF" position
Rotary Switch
Rotary Switch
14
3
25678
ON
14
3
25678
ON

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DIP Switch Settings (SW1 and SW2)
IP Address:
The SW1 and SW2 DIP switches provide a manual way to configure the node’s IP address. The values of
the first and second octets are factory set to 1 2.168, respectively. The switches set the binary value of the
last two octets in the IP address. SW1 sets the fourth octet, while SW2 sets the third octet. When all DIP
switches are set to OFF, manual configuration is disabled and other means of setting the IP address must
be used. DIP switch configuration settings require power to be cycled before any changes will take effect.
IP address: 1 2.168.XXX.XXX (1 2.168.SW2.SW1)
Subnet Mask 255.255.255.0
Gateway address: 0.0.0.0 (no gateway set)
XXX = DIP switch setting per the table below
Address Example:
To configure the IP address, 1 2.168.6.35, the DIP switches must be set accordingly:
Rotary Switch Settings (SW3 and SW4)
The rotary switches, SW3 and SW4, control several features of the node including the state of the outputs
during a communication fault. If the Modbus/TCP node loses communication to the controller, the
outputs can be set to a predetermined state. There are two states to choose from: “All Outputs Off” or
“Hold Last State”. The rotary switches also are used to enable Self-Test mode (see next page) and register
byte reversal.
SW3 SW4 Description
0** 0** Turn Off All Outputs, Register Byte Reversal Off
1 0 Hold Last Output State, Register Byte Reversal Off
0 1 Turn Off All Outputs, Register Byte Reversal On
1 1 Hold Last Output State, Register Byte Reversal On
2-8 2-8 MCM Disabled/Future Expansion
Self-Test Mode **Factory Default Settings
2
7
=128
SW-8
2
6
=64
SW-7
2
5
=32
SW-6
2
4
=16
SW-5
2
3
=8
SW-4
2
2
=4
SW-3
2
1
=2
SW-2
2
0
=1
SW-1
Octet Value
(Decimal)
OFF OFF OFF OFF OFF OFF OFF OFF 0*
OFF OFF OFF OFF OFF OFF OFF ON 1
OFF OFF OFF OFF OFF OFF ON OFF 2
OFF OFF OFF OFF OFF OFF ON ON 3
OFF OFF OFF OFF OFF ON OFF OFF 4
OFF ON ON ON ON OFF OFF OFF 120
ON ON ON ON ON ON OFF ON 253
ON ON ON ON ON ON ON OFF 254
ON ON ON ON ON ON ON ON 255*
*Not valid for fourth octet
14
3
25678
ON
All switches shown in
the "OFF" position.
14
3
25678
ON
14
3
256 7 8
ON
Rotary Switch
(SW3)
Rotary Switch
(SW4)
DIP Switch
(SW2)
DIP Switch
(SW1)
(Third Octet)
6
(Fourth Octet)
35

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5) Self-Test Mode
An internal diagnostic tool can also be enabled using the optional MCM module. This tool allows the user to
confirm that all of the Inputs and Outputs on the manifold are fully functional without needing a network
connection or controller. There are two test modes that the user can choose using SW2-8. The “Output” test
mode tests all the outputs by sequentially turning them ON one at a time. The “Input/Output” test mode
tests the inputs by causing all of the outputs to toggle between even and odd values when any input is made.
To use the Self-Test Mode, the user must first set some initial conditions using the MCM module. Follow
these steps to obtain the needed initial condition settings. Remember to remove power from the manifold
before making changes to the MCM when setting these initial conditions.
1) Disconnect power and air from the manifold!
2) Record current MCM settings.
3) Set the rotary switches to (SW3 and SW4).
4) Make sure that SW1-5, SW2-1, and SW2-7 are in the “ON” position.
5) Select the desired test mode with SW2-8 (see table below)
Switch
Testing
Mode
Setting Description
Output Off Sequentially turns all the outputs ON and OFF.
SW2-8
Input/
Output
On
Causes all of the odd outputs to come on and stay on until an
input is made. When an input is made, the outputs will toggle to
the even outputs.
6) Make sure that all of the other switches are in the “OFF” position.
The initial conditions are now set. To enable the Self-Test Mode, apply power to the manifold and make the
following changes while the module status LED is blinking green (within 2 to 5 seconds of power up):
1) Set SW2-6 to the “ON” position.
2) Set SW2-7 to the “OFF” 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. Remember to return the MCM settings to their original settings to
return the communication node to normal operation.
An error during initialization during self-test mode will result in a blinking red module status LED.
!
• Air should be disconnected to the manifold when attempting to run the
Self-Test Mode to prevent unwanted motion.
• Communication lines should be disconnected before attempting to run the
Self-Test Mode.

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6) I/O Mapping Example
Example:
Discrete I/O Configuration
In Out Pos
No.
Module Type Part No.
Bytes
1 MCM 23 -1384 -- --
2 8O Sourcing
(PNP) 23 -1315 1 1
3 16O Sourcing
(PNP) 23 -131 1 2
4 4I Sinking
(NPN) 23 -1304 1 0
5 8I Sinking
(NPN) 23 -1308 1 0
Manifold I/O Configuration
Outputs and Mapping Location
Valve Outputs = 12 Byte 0; Bits 0-7
Byte 1; Bits 0-3
Allocated Unused
Valve Outputs = 20
Byte 1; Bits 4-7
Bytes 2 - 3; Bits 0-7
Discrete Outputs = 24 Bytes 4,5 and 6;
Bits 0-7
Total Outputs = 56
Inputs and Mapping Location
Discrete Inputs = 12 Byte 6; Bits 0-3,
Byte 7; Bits 0-7
Allocated and
Reserved Inputs = 4 Byte 6; Bits 4-7
Total Inputs = 16
Assumed Settings
-Single Z-Boards
TM
used with single solenoid
valves
-Double Z-Boards
TM
used with double solenoid
valves
When the 14 End
Solenoid is
energized, the 4 port
is pressurized.
When the 12 End
Solenoid is
energized, the 2 port
is pressurized.

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I/O Mapping Table Example Continued
Output Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 Valve Coil
No. 8
Valve Coil
No. 7
Valve Coil
No. 6
Valve Coil
No. 5
Valve Coil
No. 4
Valve Coil
No. 3
Valve Coil
No. 2
Valve Coil
No. 1
1 Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Valve Coil
No. 12
Valve Coil
No. 11
Valve Coil
No. 10
Valve Coil
No.
2 Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
3 Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
4 Discrete
Output No. 7 Discrete Output No. 6 Discrete Output No. 5 Discrete Output No. 4 Discrete Output No. 3 Discrete Output No. 2 Discrete Output No. 1 Discrete Output No. 0
5 Discrete
Output No. 7 Discrete Output No. 6 Discrete Output No. 5 Discrete Output No. 4 Discrete Output No. 3 Discrete Output No. 2 Discrete Output No. 1 Discrete Output No. 0
6 Discrete
Output No. 15 Discrete Output No. 14 Discrete Output No. 13 Discrete Output No. 12 Discrete Output No. 11 Discrete Output No. 10 Discrete Output No. Discrete Output No. 8
Input Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 Coil No. 8
Status
Coil No. 7
Status
Coil No. 6
Status
Coil No. 5
Status
Coil No. 4
Status
Coil No. 3
Status
Coil No. 2
Status
Coil No. 1
Status
1 Coil No. 16
Status
Coil No. 15
Status
Coil No. 14
Status
Coil No. 13
Status
Coil No. 12
Status
Coil No. 11
Status
Coil No. 10
Status
Coil No.
Status
2 Coil No. 24
Status
Coil No. 23
Status
Coil No. 22
Status
Coil No. 21
Status
Coil No. 20
Status
Coil No. 1
Status
Coil No. 18
Status
Coil No. 17
Status
3 Coil No. 32
Status
Coil No. 31
Status
Coil No. 30
Status
Coil No. 2
Status
Coil No. 28
Status
Coil No. 27
Status
Coil No. 26
Status
Coil No. 25
Status
4 Allocated &
Reserved Allocated & Reserved Allocated & Reserved Allocated & Reserved Allocated & Reserved Allocated & Reserved
Status for
Discrete
Outputs
No. 4-7
Status for
Discrete
Outputs
No. 0-3
5 Allocated &
Reserved Allocated & Reserved Allocated & Reserved Allocated & Reserved
Status for
Discrete
Outputs
No. 12-15
Status for
Discrete
Outputs
No. 8-11
Status for
Discrete
Outputs
No. 4-7
Status for
Discrete
Outputs
No. 0-3
6 Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Input No. 3
Discrete
Input No. 2
Discrete
Input No. 1
Discrete
Input No. 0
7 Discrete
Input No. 7
Discrete
Input No. 6
Discrete
Input No. 5
Discrete
Input No. 4
Discrete
Input No. 3
Discrete
Input No. 2
Discrete
Input No. 1
Discrete
Input No. 0
• Remember, when enabling “Discrete/coil bit swap”, “Register bit swap”,
or “Register byte swap”, this mapping table example will change. If the
mapping does not seem to match the mapping example, make sure the
swap configurations are disabled.
!

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7) Output Short Circuit Protection (Status Input Bits)
Status Input Bits report the integrity of the load being driven by the output driver. They must be mapped to the
scanner as part of the Input Size Value. Please refer to the table below for Status Input Bit action during fault
condition:
Output Type Output State Fault Condition Status Bit
No Fault 0
ON Fault -
Short Circuit, Over Temp/Over Current 1
No Fault 0
Valve Solenoid Coil Driver or
Sinking (NPN)
Discrete Outputs OFF Fault -
Open Load 1
No Fault 0 Sourcing (PNP)
Discrete Outputs ON Fault -
Short Circuit, Over Temp/Over Current 1
8) Ground Wiring
All Numatics Inc. communication nodes should be grounded during the installation process. These grounding
guidelines can be found in National Electrical code IEC 60204-1 or EN 60204-1. There also is a,
“ATTENTION: CONNECT TO EARTH GROUND FOR PROPER GROUNDING OF UNIT”, label
attached to the chassis ground connection point on the G2-2 series communication node housing. This label
also points out where the grounding guidelines can be found.
• Proper grounding will alleviate and prevent many intermittent problems
with network communication.
• When grounding to a machine frame, please ensure that the machine frame
itself is already properly grounded.
• Better grounding can be achieved when larger diameter (lower gauge) wire
is used.
!

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) Auxiliary Power Connector Pin-Out
Pin No. Function Description
1 +24VDC
(Valves and Outputs)
Voltage Used to Power Outputs
(Valve Coils and Discrete Outputs)
2 Earth Ground Protective Earth (Case Ground)
3 0VDC Common 0VDC Common, for Valves, I/O, and Node Power
4 +24VDC
(Node and Inputs) Voltage Used to Power Discrete Inputs and Node Electronics
!
• Maximum current capacity on the 0VDC common pin of the auxiliary
power connector is 8 Amps. The combined draw of the +24VDC Valves and
Outputs and +24VDC Node and Inputs pins cannot exceed 8 Amps, at any
given moment in time.
• The auxiliary power +24VDC Node and Inputs pin supplies power to the
node electronics. This pin must be powered at all times for communication
node to be functional.
4
1 3
2
Modbus TCP
23
14
Pin-Out
(M12 D Coded)
Com. - M12 D Coded
Aux. - MINI
4
13
2
Modbus TCP
Pin-Out
(IP67 RJ45)
Com. - IP67 RJ45
Aux. - MINI

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10) LED Functions
Upon power up, the LEDs indicate the status of the unit. There are seven LEDs on the G2-2 Modbus/TCP
node, which are described below.
LED Name Color Status Description
Off OFF No power applied to module
ON Device operational. The module is operating correctly.
Green FLASHING Standby. The module has not been configured.
ON Major fault. A major internal error has been detected.
Red FLASHING Minor fault. A minor recoverable fault has been detected.
Self -Test Mode - An error has occurred in the initialization process.
MOD STATUS
(Module Status)
Green Red FLASHING Self -Test Mode.
Off OFF IP address has been not been assigned to node. Or no power applied to
unit.
ON Connected. The module has established a Modbus/TCP connection.
Green FLASHING No connection. There are no Modbus/TCP connections established to
the module.
ON Duplicate IP address. The module has detected that its IP address is
already being used elsewhere on the network
NET STATUS
(Network Status)
Red
FLASHING Modbus/TCP connection has timed out. One or more of the connections
for which this module is the target has timed out.
OFF No EtherNet connection is detected
ON The module is connected to an EtherNet network
ACTIVITY/LINK Green
FLASHING The LED flashes each time a packet is received or transmitted.
OFF
The electronically resettable fuse is OK (valid only when power is applied
to +24V
VLV / OUT
pin on Auxiliary Power connector). No short circuit
conditions are present.
VLV/OUT FLT
(Valve/Output
Fault)
Red
ON
The electronically resettable fuse has detected a short circuit; No power is
internally provided to valves or outputs. Communication is NOT affected.
When the short circuit condition is removed, the LED will turn off.
OFF No DC Power present at +24V
VLV / OUT
pin on Aux. Power connector. +24V VLV/OUT
(Valve/Output) Green ON DC Power applied to
+24V
VLV / OUT
pin on Aux. Power Connector.
OFF
The electronically resettable fuse is OK (valid only when power is applied
to +24V
NODE / IN
pin on Auxiliary Power connector). No short circuit
conditions are present.
NODE/IN FLT
(Node/Input
Fault)
Red
ON
The electronically resettable fuse has detected a short circuit; No power is
internally provided to node electronics or inputs. Communication Node
will not function. When the short circuit condition is removed, the LED
will turn off.
OFF No DC Power present at +24V
NODE / IN
pin on Aux. Power connector. +24V NODE/IN
(Node/Input) Green ON DC Power applied to
+24V
NODE / IN
pin on Aux. Power connector.