Numatics G3 Series EtherNet/IP User manual

TDG3DNTM1-1EN 05/09
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www.numatics.com/g3
G3Series
EtherNet/IPTM
TechnicalManual

G3SeriesEtherNet/IPTechnicalManual
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Table of Contents
PAGE
About EtherNet/IP................................................................................................................................................................3
Overview ............................................................................................................................................................................3
G3 EtherNet/IPTM Features..............................................................................................................................................3
G3 Introduction ......................................................................................................................................................................4
G3 Electronics Modularity.................................................................................................................................................5
Discrete I/O..................................................................................................................................................................5
Pneumatic Valve Manifold............................................................................................................................................6
Manifold Connectors .........................................................................................................................................................7
Solenoid Coil Connections using Z-Board™technology .............................................................................................7
Z-Board™ Connectors..................................................................................................................................................8
Z-Board™ and Ribbon Cable Example .......................................................................................................................9
Z-Board™ with Valve Side Sub-D Example .............................................................................................................. 10
Communication Module .......................................................................................................................................................11
EtherNet/IP Communication Module (Node) ...............................................................................................................11
Communication Module Description ............................................................................................................................. 12
Connector Pin-Outs......................................................................................................................................................... 13
Electrical Connections..................................................................................................................................................... 14
Power Connector Wiring Diagram ............................................................................................................................. 14
EtherNet/IPTM Straight-Through Cabling Diagrams............................................................................................... 15
EtherNet/IPTM Crossover Cabling Diagrams ........................................................................................................... 16
Power Consumption ........................................................................................................................................................ 17
External Fuse Sizing Chart ......................................................................................................................................... 18
Diagnostics ...................................................................................................................................................................... 19
Communication Module LED Functions .................................................................................................................. 19
Output Short Circuit Protection ................................................................................................................................. 20
G3 Graphic Display .............................................................................................................................................................. 21
IP Address Sub-Menu...................................................................................................................................................... 22
Subnet Mask Sub-Menu .................................................................................................................................................. 23
DHCP-BOOTP Sub-Menu ............................................................................................................................................. 24
MAC ADDR Menu .......................................................................................................................................................... 25
Advanced Settings - I/O Diag. Menu............................................................................................................................. 26
Advanced Settings - Diagnostic Word ............................................................................................................................ 27
Advanced Settings - Fault Action.................................................................................................................................... 28
Advanced Settings - Idle Action ...................................................................................................................................... 29
Advanced Settings - Brightness....................................................................................................................................... 30
Factory Defaults............................................................................................................................................................... 31
Diagnostics - Self Test Mode .......................................................................................................................................... 32
Diagnostics Cont. ............................................................................................................................................................ 33
Error Messages ................................................................................................................................................................ 34
MCM – Manual Configuration Module (Optional)............................................................................................................. 35
DIP Switch Settings......................................................................................................................................................... 36
ARM – Auto Recovery Module (Optional).......................................................................................................................... 37
Distribution .......................................................................................................................................................................... 38
Sub-Bus Distribution Modules........................................................................................................................................ 39
Sub-Bus OUT Module ................................................................................................................................................ 39
Sub-Bus Valve Module................................................................................................................................................ 42
Digital I/O Modules ............................................................................................................................................................ 42
Digital I/O Module Rules............................................................................................................................................... 43
I/O Module Descriptions and Menus ............................................................................................................................ 44
Menu ................................................................................................................................................................................ 44
Digital Input Modules ..................................................................................................................................................... 45
One Digital Input per Connector – M12 Female Modules ........................................................................................ 45
Two Digital Inputs per Connector – M12 Female Modules ...................................................................................... 46

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Sixteen Digital Inputs – Terminal Strip Modules ...................................................................................................... 47
Digital Output Modules .................................................................................................................................................. 48
One Digital Output per Connector - M12 Female Modules ...................................................................................... 48
Two Digital Outputs per Connector - M12 Female Modules .................................................................................... 49
Sub-Bus Valve Module................................................................................................................................................ 50
Digital Input/Output Modules ....................................................................................................................................... 51
Two Digital I/O per Connector - 12mm Female Modules........................................................................................ 51
Valve Side Digital Output Modules ................................................................................................................................ 52
Sixteen Outputs per Connector - Sub-D 25 Pin Female Module............................................................................... 52
Analog I/O Modules............................................................................................................................................................ 53
Analog I/O Module Rules............................................................................................................................................... 53
Four I/O - 12mm Female Modules ............................................................................................................................ 53
One Analog Input per Connector – M12 Female Modules........................................................................................ 54
One Analog I/O per Connector – M12 Female Modules .......................................................................................... 55
I/O Module(s) Wiring Diagrams ........................................................................................................................................ 56
EtherNet/IPTM Configuration and Mapping...................................................................................................................... 58
EDS File........................................................................................................................................................................... 58
Connecting to a G3 Series EtherNet/IPTM Node........................................................................................................... 59
Using the Functionality of the G3 Series EtherNet/IPTM Web Server .......................................................................... 63
Home........................................................................................................................................................................... 63
Node Configuration .................................................................................................................................................... 64
I/O Force and Test..................................................................................................................................................... 65
Diagnostics.................................................................................................................................................................. 66
Numatics.com............................................................................................................................................................. 66
IP Address Configuration................................................................................................................................................ 67
DHCP / BOOTP........................................................................................................................................................ 67
Integrated Web Page Configuration........................................................................................................................... 68
Configuration with RSLogix 5000 ................................................................................................................................... 70
Module Properties....................................................................................................................................................... 70
User Configurable Device Parameters ............................................................................................................................ 71
Communication Fault/Idle Mode Parameter................................................................................................................. 72
Communication Fault / Idle Mode Sequence ........................................................................................................... 72
EtherNet/IPTM Mapping..................................................................................................................................................... 73
I/O Sizes.......................................................................................................................................................................... 73
Manifold and I/O Data Sizing Worksheet...................................................................................................................... 74
Discrete I/O Side........................................................................................................................................................ 75
Appendix............................................................................................................................................................................... 86
System Specifications ...................................................................................................................................................... 86
Factory Default Settings .................................................................................................................................................. 87
Troubleshooting .............................................................................................................................................................. 88
Glossary of Terms ............................................................................................................................................................ 89
Technical Support............................................................................................................................................................ 91

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About EtherNet/IP
Overview
EtherNet/IPTM is a communication protocol that uses the same network technology that can be found in
commercial and domestic operations worldwide, but has added benefits/features toward manufacturing
applications. It is a CIP (common industrial protocol) Network that follows the Open Systems
Interconnection (OSI) model.
The ODVA (Open DeviceNet Vendor Association) is an independent organization that governs the
EtherNet/IPTM specification and oversees conformance testing for products.
EtherNet/IPTM uses industrial M12 IP67-rated connectors. The protocol can transfer data at two interface
speeds of 10 Mbps and 100 Mbps. Maximum network cabling distance is limited to 100m segments at 20º C.
More information about EtherNet/IPTM and ODVA can be obtained from the ODVA web site www.odva.org
G3 EtherNet/IPTM Features
Features Description
EtherNet/IPTM Spec.
Supported Designed to EtherNet/IPTM Specification
Bus Topology Star and Multi-Star
Baud Rates Supported 10/100 Mbps and Autobaud
CE CE Compliant
Duplicate Address
Detection
If a duplicate address is detected on power up, duplicates will not
progress to run mode
Address Setting Via DHCP/BOOTP, Web Page Configuration, Graphical Display or
optional Manual Configuration Module (MCM)
Duplex Half and Full supported
Conformance Tested Tested by ODVA for conformance.
Connection Type Multicast

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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 / IP67 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 32 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 Numatics G3 Series product
line. For more information relating to pneumatic valving and valve manifold assemblies, please refer to the
Numatics
In Control Catalog at www.numatics.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 32 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 easy assembly and field changes.

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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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Manifold Connectors
Solenoid Coil Connections using Z-Board™technology
Z-Board™plug together technology connects all valve solenoids to the valve coil output driver board,
located in the valve adapter. The 32 available coil outputs are divided into 2 separate connector groups.
Output group No. 1 is comprised of the first output word, bits 0-15, and output group No. 2 is comprised
of the second output word, bits 16-31. Output group No. 1 connects directly to the Z-Boards™. Output
group No. 2 is connected to the Z-Boards™via an internal ribbon cable or valve side Sub-D. The first
output (bit 0) connects to the “14” (A) solenoid on the valve closest to the communication node. The 17th
– 32nd solenoids interconnect via the Z-Boards™to output group No. 2. For the maximum capability of 32
solenoids on the same manifold, the 16th and 17th solenoid coils must NOT be on the same sub-base.
DOUBLE
"Z-BOAR D"
SINGLE
"Z-BOARD" DOUBLE
"Z-BOARD"
SINGLE
"Z-BOARD"
14(A) Solenoid Pin No. 1
Earth Ground Pin No. 3
12(B) Solenoid Pin No. 2
Common Pin No. 4
A single solenoid valve’s coil is always on the “14” end.
NOTE!
Plug-in Manifold with
Intergral "Z-Board"
Eliminates Wiring
Output Group
No. 1
Output Group
No. 2

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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 17
th
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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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
In the above example, Output Bits No. 25 thru No. 31 are allocated but
not used. Allocation may be changed by configuration changes in the
communic
a
tion module
(
node
)
. Refer to
p
a
g
e 2
3
in this manual.
NOTE!

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Z-Board™ with Valve Side Sub-D Example
If sixteen (16) single solenoid valves are connected directly to the communication node via their 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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Communication Module
EtherNet/IP 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).
Communication Module Kit Part Number
EtherNet/IP Communication module 240-181

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Communication Module Description
Detail No. Description
1 “Set” Button – used to navigate through user menus and to set parameters
2 Activity/Link Status LED
3 4 Pin M12 D-Coded Female Communication Connector
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 Network Status LED
8 Slot for text ID tags
9 Keying for preventing I/O module insertion
10 4 Pin MINI Male Power Connector
6
9
8
7
3
10
4
1
2
5

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Connector Pin-Outs
Industry standard connectors are used for communication and auxiliary power. The EtherNet communication
connector is a D-coded keyway 4 pin female M12 connector. The Power connector is a single keyway
4 pin male 7/8” MINI connector.
EtherNet/IP Communication Connector Pin-Out
Pin No. Function Description
1 TX+ Positive Transmit Line
2 RX+ Positive Receive Line
3 TX- Negative Transmit Line
4 RX- Negative Receive Line
Power Connector with Cenelec Pin-Out
Cenelec
Pin No. Function Description
1 +24 VDC
(Valves and Outputs)
Voltage used to power outputs
(valve coils and discrete outputs) SW
2 +24 VDC
(Node and Inputs)
Voltage used to power discrete inputs and
node electronics UNSW
3 0 VDC
(Node and Inputs)
0 VDC Voltage used to power discrete inputs and
node electronics UNSW
4 0 VDC
(Valves and Outputs)
0 VDC Voltage used to power outputs
(valve coils and discrete outputs) SW
!
 Power common (0 VDC) pins 3 and 4 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.

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Electrical Connections
Power Connector Wiring Diagram
Power Supply Example (Non-isolated commons)
Power Supply Example (Isolated commons)
 Please see page 17 for external fuse sizing guide.

When using molded connector power cables, Do Not rely on wire colors for
Pin-Out. Always use pin number references.
!

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EtherNet/IPTM Straight-Through Cabling Diagrams
Straight-Through Ethernet cable is used when connecting an Ethernet node to a basic media component
(router, switch, hub, etc.). Here are some basic wiring examples of Straight-Through cabling.
 These are examples only. For appropriate network cabling information,
please see the ODVA document titled, “EtherNet/IP
TM
: Media
Planning and Installation Manual”.
 RJ45 shown as T-568B standard.
NOTE!
STRAIGHT-THROUGH
CABLE MALE
2
3
41
RJ45 to M12 D Coded Cable
RX- (GREEN)
TX+
(WHITE/ORANGE)
RX+ (WHITE/GREEN)
TX- (ORANGE)
STRAIGHT-THROUGH
CABLE
M12 D Coded to M12 D Coded Cable
RX- (GREEN)
6
3
2
1
RX- (GREEN)
RX+ (WHITE/GREEN)
TX- (ORANGE)
TX+ (WHITE/ORANGE)
MALE
RX+ (WHITE/GREEN)
TX- (ORANGE)
RX- (GREEN)
TX+ (WHITE/ORANGE)
MALE
2
3
41
RX+ (WHITE/GREEN)
TX- (ORANGE)
RX- (GREEN)
TX+ (WHITE/ORANGE)
2
3
41
MALE

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EtherNet/IPTM Crossover Cabling Diagrams
A Crossover Ethernet cable is used when connecting two Ethernet nodes directly together. For example, when
you connect a computer directly to a Numatics’ valve manifold, a Crossover cable would be used. Here are
some basic wiring examples of Crossover cabling.
CROSSOVER CABLE MALE
2
3
41
RJ45 to M12 D Coded Cable
TX- (ORANGE)
RX+
(WHITE/GREEN)
TX+ (WHITE/ORANGE)
RX- (GREEN)
CROSSOVER CABLE
M12 D Coded to M12 D Coded Cable
6
3
2
1
TX- (ORANGE)
TX+ (WHITE/ORANGE)
RX- (GREEN)
RX+ (WHITE/GREEN)
MALE
RX+ (WHITE/GREEN)
TX- (ORANGE)
RX- (GREEN)
TX+ (WHITE/ORANGE)
MALE
2
3
41
RX+ (WHITE/GREEN)
TX- (ORANGE)
RX- (GREEN)
TX+ (WHITE/ORANGE)
2
3
41
MALE
 These are examples only. For appropriate network cabling information,
please see the ODVA document titled, “EtherNet/IP
TM
: Media
Planning and Installation Manual”.
 RJ45 shown as T-568B standard.
NOTE!

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Power Consumption
Power Connection
CENELEC
Pin No. Function Description
1 +24 VDC
(Valves and Outputs)
Voltage used to power outputs
(valve coils and discrete outputs) SW
2 +24 VDC
(Node and Inputs)
Voltage used to power discrete inputs and
node electronics UNSW
3 0 VDC Common
(Node and Inputs)
0 VDC (-V) Voltage used to power discrete inputs and
node electronics UNSW
4 0 VDC Common
(Valves and Outputs)
0 VDC (-V) Voltage used to power outputs
(valve coils and discrete outputs) SW
Power Rating
The maximum system current capability is 8 Amps. Care should be taken not to exceed 8 Amp draw
through the 0VDC common pin (Current through both +24 VDC Pins combined).
Discrete I/O current draw is dependent on the device(s) connected. It is critical to know what these
values are in order to remain safely within the 8 Amp limitations.
Loads should not draw more than 0.5 Amps of current from any one individual discrete output point
(Contact factory for higher current capability requirements).
Component Voltage Tolerance
+24VDC
(Valves and Outputs)
Pins 1 & 4
+24VDC
(Node and Inputs)
Pins 2 & 3
Current Power Current Power
Solenoid Valve Coil 2002 (Each) 24 VDC +10%/-15% 0.021 A 0.5 W 0 A 0 W
Solenoid Valve Coil 2005 (Each) 24 VDC +10%/-15% 0.056 A 1.35 W 0 A 0 W
Solenoid Valve Coil 2012 (Each) 24 VDC +10%/-15% 0.105 A 2.5 W 0 A 0 W
Solenoid Valve Coil 2035 (Each) 24 VDC +10%/-15% 0.105 A 2.5 W 0 A 0 W
Solenoid Valve Coil ISO - SPA 24 VDC +10%/-15% 0.167 A 4.0 W 0 A 0 W
V
alve Adapter (Driver) 24 VDC +/- 10% .134 A 3.22 W 0 A 0 W
Discrete Digital Input Module 24 VDC +/- 10% .012 A .29 W .085 A*2.04 W*
Discrete Digital Output Module 24 VDC +/- 10% .051 A 1.2 W .060 A*1.44 W*
Discrete Digital I/O Module 24 VDC +/- 10% .035 A 0.84 W .076 A*1.82 W*
Discrete Analog Input Module (V & C) 24 VDC +/- 10% .012 A 0.288 W .077 A*1.85 W*
Discrete Analog I/O Module (V & C) 24 VDC +/- 10% .018 A 0.432 W .087 A*2.08 W*
Communication Module (Node) 24 VDC +/- 10% .006 A 0.144 W .091 A*1.7 W*
Sub-Bus Valve Module 24 VDC +/- 10% .012 A 0.288 W .066 A*1.58 W*
A
uto Recovery Module (ARM) 24 VDC +/- 10% 0A 0 W .022 A .53 W
Manual Configuration Module (MCM) 24 VDC +/- 10% 0 A 0 W .022 A .53 W
* Current depends on graphic display brightness setting. Max. value shown with high brightness.
Values decrease by approx. 12% for Medium and 25% for Low brightness settings.
 Total power consumption for each Discrete I/O point is dependent on
the specific current draw of input sensor devices and output loads.
NOTE!

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Recommended External Fuses
External fuses should be chosen based upon the physical manifold configuration. Please refer to the
table below for the fuse sizing chart.
External Fuse Sizing Chart
Power Consumption - Power Connector Pin for Valves and Outputs
Description Current
Number of Solenoid Valve Coils Energized Simultaneously
___ X 0.167 A (ISO - SPA Series) = __________Amps
___ X 0.105 A (2012 and 2035
Series) = __________Amps
___ X 0.056 A (2005 Series) = __________Amps
___ X 0.021 A (2002 Series) = __________Amps
+
Total load current drawn by simultaneously energized Discrete Outputs = __________Amps
+
Number of I/O modules installed ___ X 0.008 A = __________Amps
+
Valve Adapter = .134 Amps
+
Communication Node Power Consumption = .006 Amps
+
Total: __________Amps
Surge Compensation: X 1.25
Suggested External +24 VDC (Valves and Outputs) Fuse Value: __________Amps
Power Consumption – Power Connector Pin for Node and Inputs
Description Current
Communication Node Power Consumption = .091 Amps
+
Total load current drawn by Sensor Devices from Discrete Inputs source = __________Amps
+
Number of I/O modules installed ___ X 0.080 A = __________Amps
+
Total: __________Amps
Surge Compensation: X 1.25
Suggested External Pin +24 VDC (Node and Inputs) Fuse Value: __________Amps
*Factory Default Settings
 The Node and Inputs Aux Power pins supply power to the node electronics. These pins must
be powered at all times for communication node and Inputs to be functional.

The internal electronic fuses exist to protect against damage due to catastrophic failure of
internal components. External fuses are always recommended for protection against power
supply failure, over-current conditions, etc…
NOTE!

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Diagnostics
Communication Module LED Functions
Upon power up, the LEDs indicate the status of the unit. There are three LEDs on the G3 EtherNet
node. These LEDs are described below.
LED Name Color Status Description
MODULE
STATUS
Off OFF No power applied to
+24V
N
ODE/ 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.
Self -Test Mode - An error has occurred in the initialization process.
Green Red FLASHING Self -Test Mode.
NETWORK
STATUS
Off OFF
IP address has been not been assigned to node or no power applied to
+24V
N
ODE/ IN
.
Green
ON Connected. The module has established an EtherNet/IP connection.
FLASHING No connection. There are no EtherNet/IP connections established to the
module.
Red
ON Duplicate IP address. The module has detected that its IP address is already
being used elsewhere on the network
FLASHING EtherNet/IP connection has timed out. One or more of the connections for
which this module is the target has timed out.
ACTIVITY/LINK Green
OFF No EtherNet connection is detected
ON The module is connected to an EtherNet network
FLASHING The LED flashes each time a packet is received or transmitted.