Numatics G2-2 Series Instruction manual

G2-2 Series Profibus-DP 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 ith an integrated
Numatics’ G2-2 Series Profibus-DP communication node. Please note that this document is not intended to
replace the G2-2 Series Profibus-DP Technical Manual, hich includes more detailed technical information.
The full technical manual can be found on the Numatics ebsite at .numatics.com or may be ordered by
calling 248-887-4111.
1) Initial Unpacking and Inspection
1) Examine exterior of package for signs of damage. Report any damage to shipping carrier.
2) Remove rapped 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
Belo 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 vie ed as having t o 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 192 Outputs, 96 Inputs, or various combinations. The communication
module has t o connectors: a 5-pin communication connector and a 4-pin po er connector. The
communication connector either comes in a 12mm micro connector for 1.5 Mbps or a 12mm reverse key micro
connector for 1.5 thru 12 Mbps. Pin-outs for these, along ith I/O connectors, and are labeled on the side of
the respective modules.
FUSE 1
FUSE 2
BUS ERROR
MOD STATUS
+24V VLV/OUT
+24V NODE/IN
Profibus-DP
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/
Net ork
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
19 Pin Round
Connector Module
Analog Module
Dual 25 Pin Sub-D
/Aux Po er
Output Module

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3) MCM - Manual Configuration Module (Optional hen using Class 2 Profibus-DP Master)
The MCM is the module that allo s the user to manually set address and other user definable options. The
MCM consists of t o DIP s itch sets (SW1 and SW2) and t o rotary s itches (SW3 and SW4).
MCM Module Part Numbers
Description Part Number
Complete Module 239-1384
Replacement Board 256-684
(SW2)
(SW3) DIP S itch
(SW1)
DIP S itch
(SW4)
All DIP s itches sho n in the "OFF" position
Rotary S itch
Rotary S itch
14
3
256 7 8
ON
14
3
256 7 8
ON

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MCM Settings
DIP S itch Settings (SW1) – No Function
DIP S itch Settings (SW2)
Node Address – Hundreds Digit:
S itch Setting Description
SW2-1 Off Hundreds digit off
SW2-1 On* Hundreds digit on (add 100 to rotary s itch setting)
Manual or Soft are Configuration:
S itch Setting Description
SW2-2 Off* Address set manually using MCM Configuration
SW2-2 On Address set in soft are hen using Class 2 Profibus-DP Master
Node Address Reset:
S itch Setting Description
SW2-8 Off* No change to address retained in flash memory
SW2-8 On Node address in flash memory is set to 126 on next po er up cycle
Rotary S itch Settings (SW3 and SW4)
Node Address:
S itch Description
SW3 Sets the Ones Digits
SW4 Sets the Tens Digits
* Factory Default S
ettings
• All DIP and rotary s itch settings do not take effect until po er is cycled
(turned OFF and ON).
• Baud rate in Profibus-DP slaves is automatically configured.
• Node address may only be assigned once per net ork.
• GSD files may be do nloaded from our eb site at .numatics.com.

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4) Self-Test Mode
An internal diagnostic tool can also be enabled using the optional MCM module. This tool allo s the user to
confirm that all of the Inputs and Outputs on the manifold are fully functional ithout needing a net ork
connection or controller. There are t o 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 bet een even and odd values hen any input is made.
To use the Self-Test Mode, the user must first set some initial conditions using the MCM module. Follo
these steps to obtain the needed initial condition settings. Remember to remove po er from the manifold
before making changes to the MCM hen setting these initial conditions.
1) Disconnect po er and air from the manifold!
2) Record current MCM settings.
3) Set the rotary s itches to 99 (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 ith SW2-8 (see table belo )
S itch
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 ill toggle to
the even outputs.
6) Make sure that all of the other s itches are in the “OFF” position.
The initial conditions are no set. To enable the Self-Test Mode, apply po er to the manifold and make the
follo ing changes hile the module status LED is blinking ( ithin 5 to 10 seconds of po er up):
1) Set SW2-6 to the “ON” position.
2) Set SW2-7 to the “OFF” position.
Once Self-Test Mode is enabled, the Bus Error LED ill flash red/green until Self-Test Mode is terminated by
removing po er to the unit. Remember to return the MCM settings to their original settings to return the
communication node to normal operation.
!
• Air should be disconnected to the manifold hen attempting to run the
Self-Test Mode to prevent un anted motion.
• Communication lines should be disconnected before attempting to run the
Self-Test Mode.

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5) I/O Mapping Example
Example:
Discrete I/O Configuration
In Out Pos
No.
Module Type Part No.
Bytes
1 MCM 239-1384 -- --
2 8O Sourcing
(PNP) 239-1315 0 1
3 16O Sourcing
(PNP) 239-1319 0 2
4 4I Sinking
(NPN) 239-1304 1 0
5 8I Sinking
(NPN) 239-1308 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 0; Bits 0-7,
Byte 1; Bits 0-3
Allocated and
Reserved Inputs = 4 Byte 1; Bits 4-7
Total Inputs = 16
Assumed Settings
-Single Z-Boards
TM
used ith single solenoid
valves
-Double Z-Boards
TM
used ith double solenoid
valves
-Valve Output Configuration = 32 Coils
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. 9
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. 9 Discrete Output No. 8
Input Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Allocated &
Reserved
Discrete
Input No. 3
Discrete
Input No. 2
Discrete
Input No. 1
Discrete
Input No. 0
1 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

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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. Please refer to the table belo 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
7) 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 here the grounding guidelines can be found.
• Proper grounding ill alleviate and prevent many intermittent problems
ith net ork communication.
• When grounding to a machine frame, please ensure that the machine frame
itself is already properly grounded.
• Better grounding can be achieved hen larger diameter (lo er gauge) ire
is used.
!

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8) Communication Module Connector Pin-Outs
Profibus-DP Communication Connector Pin-Out
Pin No. Function Description
1 +5 VDC +5 volt output from node, used for termination of net ork or
auxiliary devices.
2 Data Line A Profibus-DP 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-DP cable.
Auxiliary Po er Connector Pin-Out
Pin No. Function Description
1 +24VDC
(Valves and Outputs)
Voltage Used to Po er Outputs
(Valve Coils and Discrete Outputs)
2 Earth Ground Protective Earth (Case Ground)
3 0VDC Common 0VDC Common, for Valves, I/O, and Node Po er
4 +24VDC
(Node and Inputs) Voltage Used to Po er Discrete Inputs and Node Electronics
!
• Maximum current capacity on the 0VDC common pin of the auxiliary
po er connector is 8 Amps. The combined dra of the +24VDC Valves and
Outputs and +24VDC Node and Inputs pins cannot exceed 8 Amps, at any
given moment in time.
• The auxiliary po er +24VDC Node and Inputs pin supplies po er to the
node electronics. This pin must be po ered at all times for communication
node to be functional.
• Internal node electronics support all Profibus-DP communication baud
rates of 9.6kBit/s thru 12Mbit/s. Only Comm. Connector types differ.
Profibus DP (1.5 Mbps)
AUX MALE
MALE
PIN 5= EARTH GROUND
AUX MALE
Profibus DP (12 Mbps)
PIN 1= +5VDC
PIN 2= DATA LINE A
PIN 3= COMMON 0VDC
PIN 4= DATA LINE B
FEMALE
43
5
1 2
4
3
1
2
2
1
14
32
4
5
3
PIN 5= EARTH GROUND
PIN 1= +5VDC
PIN 2= DATA LINE A
PIN 3= COMMON 0VDC
PIN 4= DATA LINE B

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9) LED Functions
Upon po er up, the LEDs indicate the status of the unit. There are six LEDs on the G2-2 Profibus-DP node;
one for Bus Error, one for Mod Status, t o for internal fuse integrity, and t o for Aux. Po er status.
LED Name Color Status Description
Green ON
Normal operation. The bus link is OK. Baud rate detected,
parameterization and configuration OK; Unit is in data exchange
mode.
Red ON Bus Error. Bus connection failed or off-line; Invalid
parameterization or configuration.
BUS ERROR
Green Red FLASHING
The module configuration (I/O and valves) in the user application
is different than the physical configuration of the manifold (If
manifold is online).
Module is in self-test mode (If manifold is Offline).
Green ON Normal operation. Node hard are OK. MOD STATUS
(Module Status) Red ON Critical hard are fault. The microprocessor is not running.
OFF Internal fuse
F1 is OK (valid only hen po er is applied to
+24V
VLV / OUT
pin on Aux. Po er connector).
FUSE 1 Red
ON Internal fuse
F1 is open; No po er is internally provided to valves or
outputs. Communication NOT affected.
OFF No DC Po er present at
+24V
VLV / OUT
pin on Aux. Po er
connector. +24V VLV/OUT Green
ON DC Po er applied to +24V
VLV / OUT
pin on Aux. Po er Connector.
OFF Internal fuse
F2 is OK (valid only hen po er is applied to
+24V
NODE / IN
pin on Aux. Po er connector.
FUSE 2 Red
ON Internal fuse
F2 is open; No po er is internally provided to node
electronics or inputs. Communication Node ill not function.
OFF No DC Po er present at
+24V
NODE / IN
pin on Aux. Po er
connector. +24V NODE/IN Green
ON DC Po er applied to +24V
NODE / IN
pin on Aux. Po er connector.

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10) Factory Default Settings
Unless other ise requested, all standard G2-2 Series Profibus-DP manifolds ship ith specific factory default
settings. Belo is a list of the factory default settings:
Description Default Settings
Node Address 126
Address Reset No change to address retained in flash memory
Manual or Soft are Configuration Node address set manually ith MCM
Input Module Po er Jumper PU
(Input sensor po er supplied by
+24VDC Node and Inputs pin on the Aux. po er connector)
Output Module Po er Jumper SP
(Output module po er supplied by
+24VDC Valves and Outputs pin on the Aux. po er connector)
Valve Side Output Bytes 4 Bytes (32 Allocated Valve Coil Outputs)
Discrete I/O Side - I/O Bytes Self-Configuring based on the I/O modules installed.
11) Technical Support
For technical support, contact your local Numatics distributor. If further information is required,
please call Numatics Inc. at [phone] and ask for Technical Support.
Issues relating to net ork set-up, PLC programming, sequencing, soft are related functions, etc…
should be handled ith the appropriate product vendor.
Information on device files, technical manuals, local distributors, and other Numatics, Inc. products
and support issues can be found on the Numatics, Inc’s. WEB site at .numatics.com