g2-2 controlnet 2005/2012 series technical manual asset...
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LT2005/2012CNTECH-1 01/03 www.numatics.com Subject to change without notice
G2-2 ControlNet 2005/2012 Series
Technical Manual
2005/2012 Series ControlNet Technical Manual
LT2005/2012CNTECH-1 01/03 www.numatics.com Page 1 Subject to change without notice
Table of Contents PAGE
About ControlNet ............................................................................................................................................................................ 3 Overview....................................................................................................................................................................................... 3 G2-2 ControlNet Features ......................................................................................................................................................... 3 Segment lengths (as defined by ControlNet specification).................................................................................................. 3
2005/2012 and G2-2 Introduction.................................................................................................................................................. 4 Product Overview........................................................................................................................................................................ 4
2005/2012 and G2-2 Electronics Modularity................................................................................................................................ 5 Discrete I/O ................................................................................................................................................................................ 5 Pneumatic Valve Manifold......................................................................................................................................................... 6
Distributing I/O with G2-2 Electronics ....................................................................................................................................... 7 G2-2 ControlNet System Versatility......................................................................................................................................... 8
2005/2012 Valve Unit....................................................................................................................................................................... 9 Z-Board™ and Solenoid Coil Connections to Output Drivers............................................................................................ 9
Z-Board™ Connectors.........................................................................................................................................................10 Z-Board™ and Ribbon Cable Example: ...........................................................................................................................11 Z-Board™ and Ribbon Cable with Valve Side Sub-d Example:.....................................................................................12
Module Configurations and Pinouts ............................................................................................................................................13 ControlNet Communication Module (Node) .......................................................................................................................13
Connector Types...................................................................................................................................................................13 Auxiliary Power Connector Pin Out...................................................................................................................................14
Rotary Switches..........................................................................................................................................................................15 Rotary Switch Settings .........................................................................................................................................................15 Rotary Switch Settings Example ........................................................................................................................................16
Comm. Module...........................................................................................................................................................................17 Discrete I/O Modules...............................................................................................................................................................18
Rules........................................................................................................................................................................................18 Module Types........................................................................................................................................................................18 Input Modules: ......................................................................................................................................................................19 Output Modules.................................................................................................................................................................... 22
Electrical Connections .................................................................................................................................................................. 24 Power Supply Wiring Diagrams.............................................................................................................................................. 24 Power Consumption................................................................................................................................................................. 25
Auxiliary Power Connection .............................................................................................................................................. 25 Discrete I/O Module(s) Power Jumper............................................................................................................................ 25 Power Rating ........................................................................................................................................................................ 25 Recommended External Fuses: ......................................................................................................................................... 25 Discrete I/O Power Jumper ............................................................................................................................................... 26 Discrete Sub-D Output Power Jumper ............................................................................................................................. 27
Power Consumption and External Fuse Sizing Guide Chart............................................................................................. 28 I/O Module(s) Wiring Diagrams........................................................................................................................................... 29
Definitions............................................................................................................................................................................. 29 Sinking Description............................................................................................................................................................. 29 Sourcing Description........................................................................................................................................................... 29 Sinking (NPN) Input Connection .................................................................................................................................... 29 Sourcing (PNP) Input Connection ................................................................................................................................... 29 Sinking (NPN) Output Connection.................................................................................................................................. 30 Sourcing (PNP) Output Connection................................................................................................................................. 30
ControlNet Configuration and Mapping ....................................................................................................................................31 EDS File ......................................................................................................................................................................................31 I/O Setup ................................................................................................................................................................................... 32
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Outputs .................................................................................................................................................................................. 32 Inputs ..................................................................................................................................................................................... 32
I/O Sizes .................................................................................................................................................................................... 33 I/O Size - Manifold ............................................................................................................................................................. 33 I/O Size - Valve Side........................................................................................................................................................... 33 I/O Size - Discrete I/O Side ............................................................................................................................................. 33 Manifold I/O Sizing Worksheet........................................................................................................................................ 34 Bit Mapping Rules............................................................................................................................................................... 35 Valve Side .............................................................................................................................................................................. 35 Discrete I/O Side................................................................................................................................................................. 35
I/O Mapping............................................................................................................................................................................. 37 Example #1 ........................................................................................................................................................................... 37 Example #2........................................................................................................................................................................... 39 Example #3............................................................................................................................................................................41
Diagnostics – Comm. Module / Power Module....................................................................................................................... 43 LED Functions.......................................................................................................................................................................... 43 Internal Fuses ............................................................................................................................................................................ 44 Output Short Circuit Protection.............................................................................................................................................. 44
Status Bit Action During Fault Condition........................................................................................................................ 44 Appendix ......................................................................................................................................................................................... 45
System Specifications............................................................................................................................................................... 45 Factory Defaults Settings ......................................................................................................................................................... 46 Troubleshooting........................................................................................................................................................................ 47 Glossary of Terms ..................................................................................................................................................................... 48
Technical Support.......................................................................................................................................................................... 49
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About ControlNet
Overview
ControlNet is a serial communication protocol used to network devices that wish to exchange time-critical application information in a deterministic and predictable manner and also eliminate labor intensive and expensive point to point wiring schemes. Allen Bradley originally developed ControlNet, but it is now supported by a multitude of manufacturers. ControlNet International is an independent organization that governs the ControlNet specification and oversees conformance testing for products, which will be used in a ControlNet system. ControlNet uses a RG-6 quad shield coax cable and can have up to 99 nodes. The protocol can transfer a maximum of 510 bytes of data per node cycle with a communication (baud) rates of 5 Mbit/ sec.. Maximum distance is depended upon cable media type and number of nodes. Refer to the section below for details. More information about ControlNet International can be obtained from the web site http://www.controlnet.org
G2-2 ControlNet Features
Features Description Address Setting Via Rotary Switches Baud Rates Supported 5 Mbit/sec. Bus Topology Linear bus, Tree, Star, mix of all three CE CE compliant Connection Sizes 16 Words (32 Bytes) of Input Data and
16 Words (32 Bytes) of Output Data Minimum requested packet interval (RPI)
5ms
NAP Port Network Access Port allows a temporary network connection at the node. The NAP uses a standard 8-pin RJ-45 connector.
Physical Media Coax – RG-6 quad shield, Single or Dual – Redundant Media Redundant Media The node supports redundant media. Two coax connectors are
provided (Trunk Line A & B). Termination Resistor (external)
A 75 ohms resistor is required at each end of each segment.
Segment lengths (as defined by ControlNet specification)
0
250
500
750
1000
2 16 32 48
Seg
men
t len
gth
(m)
Number of taps
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2005/2012 and G2-2 Introduction
Product Overview
The 2005/2012 is a valve product line featuring a variety of valve configurations and electronic interface options. These include several Fieldbus communication protocols that can control up to 32 valve solenoid coils, on the valve side of the assembly, and up to 132 I/O points of I/O on the Discrete I/O side. This manual addresses the specifics of configuring and commissioning the Numatics 2005/2012 Series product line configured with the ControlNet communication interface. For more information relating to pneumatic valving and valve manifold assemblies, please refer to the Numatics 2005 & 2012 Series catalog, No. LT2005/2012-1.
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2005/2012 and G2-2 Electronics Modularity Discrete I/O
The 2005/ 2012 product line is a completely modular system. As shown below, all of the G2-2 electronic modules plug together, allowing easy assembly and field changes. Additionally, all the PC boards containing active electronics (i.e. communication, I/O and MCM) are also modular allowing changes to be made without the need to dismantle the manifold.
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Pneumatic Valve Manifold
The pneumatic valve manifold is also modular. The valve solenoid coil connections are made automatically 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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Distributing I/O with G2-2 Electronics
The G2-2 series fieldbus manifold allows its discrete I/O points to be distributed from the central manifold by using various I/O modules (see pages 18-23). This distribution capability can be made at any time, even after the manifold has been installed and commissioned, although, network or communication rack configurations may be affected depending on the new total number of I/O points configured. The distributed I/O points can be used for various input devices and loads with many different termination options, including additional manifolds with Sub-D connector option. Please refer to Figure 1 on the following page for a sample configuration layout.
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G2-2 ControlNet System Versatility
Figure 1 Example of network to PLC/IPC with distributed valve manifolds and I/O devices.
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2005/2012 Valve Unit
Z-Board™ and Solenoid Coil Connections to Output Drivers
Z-Board™ plug together technology connects all valve solenoids to the valve coil output drivers, located in the communication node. The valve solenoid coil output drivers are divided into 2 separate 16 bit groups. Output group #1 is comprised of the first output word, bits 0-15, and output group #2 is comprised of the second output word, bits 16-31. Output group #1 connects directly to the Z-Boards™, while output group #2 is connected to Z-Boards™ via an internal ribbon cable or Valve Side Sub-D. The first output 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 #2. For the maximum capability of 32 solenoids, the 16th and 17th solenoid coils must NOT be on the same sub-base.
Single solenoid Double solenoid Z-Board™ Z-Board™
Plug-in Manifold with Integral “Z-Board™” Eliminates Wiring
Output Group #1 Connector
Output Group #2 Connector
Earth Ground Pin #3
Common Pin #4
14(A) Solenoid Pin #1
12(B) Solenoid Pin #2
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Z-Board™ Connectors The 2005/2012 valve series utilizes 2 different Z-Boards™ designs to achieve the single and double solenoid output functions that yield the possible 32 single, 16 double, or any combination of valve solenoid coil output capabilities.
Single Z-Board™ Double Z-Board™ Part # 256-640 (2012) Part # 256-151 (2005)
Part # 256-641 (2012) Part # 256-152 (2005)
Ribbon Connection Ribbon Connection Single Z-Board™ Double Z-Board™
Part # 256-642 (2012) Part # 256-742 (2005)
Part # 256-643 (2012) Part # 256-743 (2005)
single double
The 17th solenoid (output group #2’s first bit) must be accessed via either the valve side sub-d output module or a ribbon connector type Z-board.
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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 Bit # 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 # 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 n/a n/a n/a n/a n/a n/a
In the above example, Output Bits #15 and #26 thru #31 are allocated but not used.
S= Sgl. Sol. With Single Z-Board™ D= Dbl. Sol. With Double Z-Board™
Output Group #1 Connector to
Z-Board™
Output Group #2 Connector to Ribbon
Cable Output Group #2
Ribbon Connector Z-Board™
D S
15 16
17
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Z-Board™ and Ribbon Cable 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 ribbon cable, the following would be the valve side bit map:
Output Bit # 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 # 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
S= Sgl. Sol. With Single Z-Board™
Output Group #1 Connector to
Z-board™
Output Group #2 Connector to Ribbon Cable
Coil Outputs 17-32
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Module Configurations and Pinouts
ControlNet Communication Module (Node)
This module is the communication interface to the manifold. It contains communication electronics and short circuit protected solenoid coil output drivers Factory Defaults Settings
Type Value Description Baud Rate 5M bit/sec. Data Rate is 5 Mbit/s Node Address 00 Node Address value
Input/ Output Connection Sizes
8 In / 4 Out Bytes (4 In / 2 Out Words) + Discrete I/O
The Input and Output Connection Size of the manifold system. The total number of I/O that the manifold is configured for, including diagnostic Status Input bits and Run/Idle Header. (See Bit Mapping Section For Additional Information)
LED Display Connector Types
An Industry standard “mini” connector is used for auxiliary power. The Aux. Power is a single keyway 4 pin male connector. The two ControlNet communication connectors are BNC type connectors.
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Auxiliary Power Connector Pin Out
Pin # Function Description
1 +24VDC (Valves and Outputs)
Voltage used to power outputs (valve coils and discrete outputs)
2 Earth Ground Protective Earth (case) 3 0VDC Common 0VDC Common, for valve and I/O power
4 +24VDC (Node and Inputs)
Voltage used to power discrete inputs and node electronics
• Maximum current capacity on pin #3 (0VDC common) of auxiliary power connector is 8 Amps. The combined draw of Pin #1 (Valves & Outputs) and pin #4 (Node & Inputs) cannot exceed 8 Amps, at any given moment in time.
• Auxiliary power connector pin #4 supplies power to node electronics. This pin must be powered at all times for communication node to be functional.
ATTENTION
!
4 1
POWER
3 2
MALE
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Rotary Switches
The Rotary switches allow the user to set the node address.
Rotary Switch Settings
Network Address:
Switch Description
NA 01 Sets the Ones Digits
NA 10 Sets the Tens Digits
• Address is set to a default setting of 00 prior to shipment. • Rotary switch settings do not take effect until power is cycled (turned
OFF and ON).
ATTENTION
!
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Rotary Switch Settings Example
The example below shows the correct settings for the following requirements: Node Address = 73
Switch Settings:
Switch Setting Description
NA 01 3 Sets the Ones Digits of MAC ID to Three (3)
NA 01 7 Sets the Tens Digits of MAC ID to Two (2)
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Comm. Module Replacement and / or spare parts for the G2-2 ControlNet module can be purchased by ordering the entire module (communications and power module), 239-1841 or by specifying individual components (see chart below).
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Discrete I/O Modules
Rules
The maximum number of I/O modules that can be used on the Discrete I/O side of the manifold is 6. Modules can be connected in any combination and sequence of inputs and outputs up to the logical limitations of 132 I/O. Damage will occur if Discrete I/O and MCM Modules are inserted or removed with power applied. Module Types
Module Part #
Replacement I/O Board
Part # I/O Points
Module Size Connection Type I/O Type
Internal Status Bits
239-1304 256-646 Input 4 Narrow 4 x 12mm (1 input per conn.) Sinking (NPN) N/A 239-1305 256-648 Input 4 Narrow 4 x 12mm (1 input per conn.) Sourcing (PNP) N/A 239-1308 256-647 Input 8 Narrow 4 x 12mm (2 input per conn.) Sinking (NPN) N/A 239-1309 256-649 Input 8 Narrow 4 x 12mm (2 input per conn.) Sourcing (PNP) N/A 239-1312 256-654 Input 8 Wide 8 x 12mm (1 input per conn.) Sinking (NPN) N/A 239-1313 256-656 Input 8 Wide 8 x 12mm (1 input per conn.) Sourcing (PNP) N/A 239-1316 256-655 Input 16 Wide 8 x 12mm (2 input per conn.) Sinking (NPN) N/A 239-1317 256-657 Input 16 Wide 8 x 12mm (2 input per conn.) Sourcing (PNP) N/A 239-1868 256-796 Input 16 Narrow Dual 15 Pin Sub-D (8 inputs per Sub-D) Sinking (NPN) N/A 239-1870 256-798 Input 16 Narrow Dual 15 Pin Sub-D (8 inputs per Sub-D) Sourcing (PNP) N/A 239-1869 256-797 Input 16 Narrow 25 Pin Sub-D (16 inputs) Sinking (NPN) N/A 239-1871 256-799 Input 16 Narrow 25 Pin Sub-D (16 inputs) Sourcing (PNP) N/A 239-1306 256-650 Output 4 Narrow 4 x 12mm (1 input per conn.) Sinking (NPN) 4 239-1307 256-652 Output 4 Narrow 4 x 12mm (1 input per conn.) Sourcing (PNP) 1 239-1310 256-651 Output 8 Narrow 4 x 12mm (2 input per conn.) Sinking (NPN) 8 239-1311 256-653 Output 8 Narrow 4 x 12mm (2 input per conn.) Sourcing (PNP) 2 239-1314 256-658 Output 8 Wide 8 x 12mm (1 input per conn.) Sinking (NPN) 8 239-1315 256-660 Output 8 Wide 8 x 12mm (1 input per conn.) Sourcing (PNP) 2 239-1318 256-659 Output 16 Wide 8 x 12mm (2 input per conn.) Sinking (NPN) 16 239-1319 256-661 Output 16 Wide 8 x 12mm (2 input per conn.) Sourcing (PNP) 4
239-1460 256-722 Output 22 Wide 25 Pin Sub-D w/Aux Power (22 outputs) Sourcing (PNP) 6
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Input Modules:
Part # Description Part # Description
239-1304 4 Inputs (Sinking-NPN) - 1 Input/Connector 239-1312 8 Inputs (Sinking-NPN) - 1 Input/Connector
Part # Description Part # Description
239-1305 4 Inputs (Sourcing-PNP) - 1 Input/Connector 239-1313 8 Inputs (Sourcing-PNP) - 1 Input/Connector
Part # Description Part # Description
239-1308 8 Inputs (Sinking-NPN) – 2 Inputs/Connector 239-1316 16 Inputs (Sinking-NPN) - 2 Inputs/Connector
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Part # Description Part # Description
239-1309 8 Inputs (Sourcing-PNP) - 2 Inputs/Connector 239-1317 16 Inputs (Sourcing-PNP) - 2 Inputs/Connector
Part # Description
239-1868 16 Inputs (Sinking-NPN) – 8 Inputs/Connector
Part # Description
239-1870 16 Inputs (Sourcing-PNP) – 8 Inputs/Connector
Byte X
Byte X+1
Byte X
Byte X+1
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Part # Description
239-1869 16 Inputs (Sinking-NPN) – 16 Inputs/Connector
Part # Description
239-1871 16 Inputs (Sourcing-PNP) – 16 Inputs/Connector
ATTENTION
! Damage will occur if Discrete I/O and MCM Modules are inserted or removed with power applied.
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Output Modules • 0.5 Amps per Output. (Consult factory for output loads greater than 0.5 Amps.) • Over current and short circuit protected • Status Bit for Short or Open Circuit
- Sinking Outputs utilize one status input for each output. - Sourcing Outputs utilize one status input for every four outputs
Part # Description Part # Description
239-1306 4 Outputs (Sinking-NPN) - 1 Output/Connector 239-1314 8 Outputs (Sinking-NPN) - 1 Output/Connector
Part # Description Part # Description
239-1307 4 Outputs (Sourcing-PNP) - 1 Output/Connector 239-1315 8 Outputs (Sourcing-PNP) - 1 Output/Connector
NOT FOR NEW APPLICATIONS
ATTENTION
! Damage will occur if Discrete I/O and MCM Modules are inserted or removed with power applied!
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Part # Description Part # Description
239-1310 8 Outputs (Sinking-NPN) – 2 Outputs/Connector 239-1318 16 Outputs (Sinking-NPN) - 2 Outputs/Connector
Part # Description Part # Description 239-1311 8 Outputs (Sourcing-PNP) - 2 Outputs/Connector 239-1319 16 Outputs (Sourcing-PNP) - 2 Outputs/Connector
Part # Description Part # Description
239-1460 22 Outputs (Sourcing-PNP) – 22 Outputs/Connector 239-1713 16 Outputs (Sinking-NPN)
– 16 Outputs/Connector (Valve side only)
25 PIN SUB-D CONNECTOR
4 PIN POWER CONNECTOR
NOT FOR NEW APPLICATIONS
PIN 1
PIN 25
Valve Side Sub-D
PIN 1
PIN 25
25 PIN SUB-D FEMALE
CONNECTOR
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Electrical Connections
Power Supply Wiring Diagrams
Single Power Supply Example (Male connector view)
• Please see page 28 for external fuse sizing guide. • When using molded connector power cables, Do Not rely on wire colors for
Pinout. Always use pin number references.
ATTENTION
!
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Power Consumption
Auxiliary Power Connection
Aux. Power Connector Pin # Description
1 24 VDC Power for Valves & Discrete Outputs 4 24 VDC Power for Inputs & Node Electronics
Discrete I/O Module(s) Power Jumper
All of Numatics, Inc., G2-2 I/O modules have a selectable power source jumper. This jumper determines which Aux. Power connector pin (1 or 4) will power these modules. This option allows the user to select how each specific module will be powered during different conditions (i.e. E-Stop). Each I/O module can be set-up independently allowing individual Output and/or Input modules to remain active if needed.
Power Rating
• Maximum system current capability is 8 amps. Care should be taken not to exceed 8 amp draw through pin #3 0VDC common (Current of pin #1 and pin #4 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 limitation.
• Loads should not draw more than 0.5 amps of current from any one individual discrete output point. (Contact factory for higher current capabilities)
Auxiliary Power Connector Volts Tolerance Current Power Pin 1 +24VDC (Valves & Outputs) Solenoid Valve Coil 2012 (Each) 24VDC +10%/-15% 0.105 A 2.5 Watts Solenoid Valve Coil 2005 (Each) 24VDC +10%/-15% 0.042A 1.0 Watts Discrete Output 24VDC - 0.5 A max. * 12 Watts max. * Pin 4 +24VDC (Node & Inputs) Node 24VDC +/- 10% 0.097 A 2.3 Watts Discrete I/O Module (Each) 24VDC - 0.006 A 0.14 Watts Discrete I/O Status LEDs (Each) 24VDC - 0.015 A 0.36 Watts
Recommended External Fuses:
External fuses should be chosen based upon the physical manifold configuration. Please refer to page 28 for the fuse sizing chart.
* Power consumption for each Discrete I/O point is dependent on the specific current draw of input sensor devices and output loads. Please consult the factory for output current requirements greater than 0.5 amps.
ATTENTION
!
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Discrete I/O Power Jumper
I/O Power from pin # 1 I/O Power from pin #4 of Aux. Power Connector of Aux. Power Connector
Please refer to the table below for jumper setting and description.
Jumper Jumpered Setting Pins Description
Jumper Pos 1 “SP”
"S" & "P"
Factory Default - Output power is supplied by Pin # 1 of Aux. Power Connector. This allows discrete outputs to be disabled without disabling power to communication node.
Output Module
Jumper Pos 2 “UP”
"U" & "P"
Output power is supplied by Pin # 4 of Aux Power Connector. This allows discrete outputs to be supplied by the same connection that powers the communication node.
Outputs will not be disabled separately from the communication node.
Jumper Pos 2 “UP”
"U" & "P"
Factory Default - Input power is supplied by Pin # 4 of Aux. Power Connector. This allows Input power to be supplied by the same connection which powers the communication node.
Input Module
Jumper Pos 1 “SP”
"S" & "P"
Input power is supplied by Pin # 1 of Aux Power connector. This allows Input power to be supplied by the same connection that powers the valve coils and discrete outputs.
Wide I/O Modules (Modules with eight 12mm connectors) contain two jumpers; one for each group of four connectors.
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Discrete Sub-D Output Power Jumper
Please refer to the table below for jumper setting and description.
Jumper Jumpered
Setting Pins Description
Jumper Pos 1 “SP”
"S" & "P"
Output power is supplied by Pin # 1 of Aux. Power Connector. This allows all valves and discrete outputs to be disabled without disabling power to communication node.
Jumper Pos 2 “UP”
"U" & "P"
Output power is supplied by Pin # 4 of Aux Power Connector. This allows all valves and discrete outputs to be supplied by the same connection that powers the communication node.
Outputs will not be disabled separately from the communication node.
Output Module
Jumper Pos 3 “XP”
“X” & “P” Factory Default - Output power is supplied by pin #1 of local 12mm Aux Power Connector. Outputs can be enabled/disabled via Local 12mm Aux Power Connector.
Local 12mm Aux. Power Connector (See Pg. 23 for Pin-Out)
Output Power from pin # 1 of Mini Aux. Power Connector
Output Power from pin #4 of Mini Aux. Power Connector
Output Power from pin #1 of local 12mm Aux. Power Connector
Fuse (4.0A)
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Power Consumption and External Fuse Sizing Guide Chart
Power Consumption - Aux. Power Connector Pin #1 – (Valves and Outputs)
Description Current Number of Solenoid Valve Coils Energized Simultaneously
___ X 0.105 A (2012 Series) = __________Amps
___ X 0.042 A (2005 Series) = __________Amps +
Total load current drawn by simultaneously energized Discrete Outputs = __________Amps with Discrete Outputs Power Jumper in "SP" Position (Factory Default).
Total load current drawn by Sensor Devices from Discrete Inputs source = +
__________Amps with Discrete Input Power Jumper in "SP" Position.
Total: __________Amps Surge Compensation: X 1.25
Suggested External Pin #1 Fuse Value: __________Amps
Power Consumption - Aux. Power Connector Pin #4 – (Node and Inputs) Description Current
Communication Node Power Consumption = 0.097 Amps +
Total load current drawn by simultaneously energized Discrete Outputs = __________Amps with Discrete Outputs Power Jumper in "UP" Position. +
Total load current drawn by Sensor Devices from Discrete Inputs source = __________Amps with Discrete Inputs Power Jumper in "UP" Position (Factory Default). +
Number of I/O modules installed ___ X 0.006 A = __________Amps +
Number of Discrete I/O Status LEDs simultaneously on ___ X 0.015 A = __________Amps
Total: __________Amps Surge Compensation: X 1.25
Suggested External Pin #4 Fuse Value: __________Amps
• The standard power jumper configuration for all Output Modules is “SP”.
• The standard power jumper configuration for all Input Modules is “UP”.
• At any given moment in time, the combined current draw through pin #1 (Valves & Outputs) and pin #4 (Node & Inputs) cannot exceed 8 amperes. Therefore, the combined value of the two fuses on pin #1 and pin #4 should not exceed 10 amperes (8 ampere max by 1.25 surge compensation).
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FEMALE
PIN 3=COMMON PIN 1=+24VDC
PIN 4=INPUT OVDC
(SINKING)
1
INPUT MODULE
3 4 Input/Signal
(SINKING) PIN 4=INPUT PIN 1=+24VDC PIN 3=COMMON
FEMALE
OVDC
MODULE INPUT 3
1
4
(NPN)
LOAD
I/O Module(s) Wiring Diagrams
Definitions
Sinking Description • NPN • Switching Negative • Positive Common
Sourcing Description • PNP • Switching Positive • Negative Common
Sinking (NPN) Input Connection Electronic Sensor Type Mechanical Sensor Type Sourcing (PNP) Input Connection Electronic Sensor Type Mechanical Sensor Type
LOAD
LOAD
FEMALE
PIN 3=COMMON PIN 1=+24VDC
PIN 4=INPUT OVDC
(SOURCING)
INPUT MODULE
3 4
1 FEMALE
PIN 3=COMMON PIN 4=INPUT
(SOURCING)
PIN 1=+24VDC OVDC
MODULE INPUT 3
1
4 Input/Signal
(PNP)
LOAD
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Sinking (NPN) Output Connection
Sourcing (PNP) Output Connection
(COMM)
PIN 4=OUTPUT
PIN 3=NOT
.5A MAX.
(SINKING)
USED
MODULE
PIN 1=+24VDC
FEMALE
3
1
4
OUTPUT
OVDC
+24VDC
LOAD
PIN 3=COMMON
.5A MAX.
(SOURCING)
PIN 4=OUTPUT
OVDC
USED
MODULE
FEMALE
PIN 1=NOT
3
1
4
OUTPUT
OVDC
LOAD
+24VDC
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ControlNet Configuration and Mapping
Configuration with RSLOGIX 5000
When setting up your node, specific values must be entered for the assembly instance with regards to Inputs, Outputs and Configuration (these values will remain constant for all Numatics’ G2-2 ControlNet nodes). The minimum “Size” values are determined from the actual physical configuration of the manifold. Please see the diagram below for an example taken from Allen Bradley’s RSLogix 5000 programming software.
Connection Parameters
Assembly Instance values:
Sizes:
Comm Format:
Description Decimal Hexadecimal
Input 100 64 Output 150 96
Configuration 1 1
Description Size (16 bits=1 word)
Input
Total Input Size value (in words) from manifold configuration (including status Input bits) + 2 Words of ControlNet Run/Idle Header (overhead). This is a minimum value; larger values may be specified for future expansion purposes.
Output Total Output Size value (in words) from manifold configuration. This is a minimum value; larger values may be specified for future expansion purposes.
Configuration 0 (8 bits)
Description Data
Comm. Format “Data – INT”
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EDS File
The EDS file contains configuration information required to establish communication to a node on a ControlNet network. The EDS file is available on the Numatics, Inc., website at www.numatics.com.
I/O Setup
Outputs
Outputs are defined as any valve solenoid coil and/or any output point from a discrete Output module. The Output connection size depends upon the physical configuration of the manifold. Please reference the following pages for a detailed explanation for calculating the Output connection size.
Inputs
Inputs are defined as discrete (points from discrete Input modules) and internal (Status Input bits produced by Output drivers). Thus, the Input connection size will include discrete Input points, internal Inputs (Status Input bits), and 4 bytes of Run/Idle Header. Please reference the following pages for a detailed explanation for calculating the Input connection size. If you want to mask off the run/idle header for clarity, create a user defined type with 2 members – HEADER, type DINT; and DATA type INT <input assembly size –2>]. Copy the data from the actual input tag to a tag of this structure, and then you can reference the structure’s DATA member using the element numbers
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I/O Sizes
I/O Size - Manifold
The overall size of the Input/Output data for the manifold consists of the valve side size plus the Discrete I/O side size. In the G2-2 Series ControlNet node, the Input/Output size can vary from 8 to 32 bytes (4 to 16 words). Due to the many physical configuration possibilities of the G2-2 series, the worksheet on page 34 will allow accurate sizing of the Input/Output byte requirements.
I/O Size - Valve Side
The Connection size for the valve side of the manifold consists of an output bit for each valve solenoid coil driver and an input bit for the corresponding Status Input bit. The value for the valve side connection size is 4 bytes (2 words) of inputs and outputs. I/O Size - Discrete I/O Side
The connection size for the Discrete I/O side is automatically configured based on the I/O modules installed. The output connection size will consist of an output bit for each output point. The input connection size will consist of an input bit for each input point plus Status Input bits for corresponding outputs. Sinking (NPN) outputs will return one Status bit for each output bit. Sourcing (PNP) outputs will return one Status bit for every four output bits.
• Sinking (NPN) output modules return one Status bit for each output bit.
• Sourcing (PNP) output modules return one Status bit for every four output bits.
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Manifold I/O Sizing Worksheet 1 : Choose up to six modules that you want to include on the Discrete I/O side of the manifold and place the sum of
the corresponding Input bytes and Output bytes in the boxes labeled, “Discrete I/O Byte Requirements” at the bottom of the page.
2 : Total the Input byte and Output byte values from the boxes labeled “Discrete I/O Byte Requirements”, “Run /Idle Header (Required)” and “Valve Byte Requirements”. This is the total Input / Output byte values required for the configured manifold
2
Narrow Module (4 Connector - 4/8 Points)Module # I/O Board # Description Input Bytes Output Bytes
239-1304 256-646 4 Inputs (Sinking-NPN) 1 0239-1305 256-648 4 Inputs (Sourcing-PNP) 1 0239-1308 256-647 8 Inputs (Sinking-NPN) 1 0239-1309 256-649 8 Inputs (Sourcing-PNP) 1 0239-1306 256-650 4 Outputs (Sinking-NPN) 1 1239-1307 256-652 4 Outputs (Sourcing-PNP) 1 1239-1310 256-651 8 Outputs (Sinking-NPN) 1 1239-1311 256-653 8 Outputs (Sourcing-PNP) 1 1
Wide Module (8 Connector - 8/16 Points)Module # I/O Board # Description Input Bytes Output Bytes
239-1312 256-654 8 Inputs (Sinking-NPN) 1 0239-1313 256-656 8 Inputs (Sourcing-PNP) 1 0239-1316 256-655 16 Inputs (Sinking-NPN) 2 0239-1317 256-657 16 Inputs (Sourcing-PNP) 2 0239-1314 256-658 8 Outputs (Sinking-NPN) 1 1239-1315 256-660 8 Outputs (Sourcing-PNP) 1 1239-1318 256-659 16 Outputs (Sinking-NPN) 1 2239-1319 256-6561 16 Outputs (Sourcing-PNP) 1 2
Sub -D I/O ModulesModule # I/O Board # Description Input Bytes Output Bytes
239-1868 256-796 16 Inputs - Dual 15 Pin Sub-D (Sinking-NPN) 2 0239-1870 256-798 16 Inputs - Dual 15 Pin Sub-D (Sourcing-PNP) 2 0239-1869 256-797 16 Inputs - 25 Pin Sub-D (Sinking-NPN) 2 0239-1871 256-799 16 Inputs - 25 Pin Sub-D (Sourcing-PNP) 2 0239-1460 256-722 22 Outputs - 25 Pin Sub-D (Sourcing-PNP) 1 3
Input Bytes Output Bytes
Discrete I/O Byte RequirementsValve Byte Requirements 4 4
Run Idle Header (Required) 4 0Total Input/Output Bytes for Manifold
Station #123456
Module #
1
2 Bytes = 1 Word
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Bit Mapping Rules
The bit mapping for a G2-2 manifold varies with the physical configuration of the manifold. The following is a breakdown of the bit mapping rules associated with the 2005/2012 valve manifold.
Valve Side
1) Solenoid coil outputs are distributed to the valve coils using the Z-Boards™. 2) The valve solenoid coil output portion for the total output connection size is 4 bytes (2 words). 3) Each solenoid coil output has an associated Status Input bit (refer to “Output Short Circuit Protection”
section page 44 for functional details). This will affect the overall input connection size. 4) Solenoid coil output addressing begins at the 1st valve sub base nearest the node and continues in ascending
order away from the communication node. 5) Each sub base is allocated 1 or 2 output bits, depending on the Z-Board™ type installed. Single Z-Board™
allocates 1 output bit, double Z-Board™ allocate 2 output bits. 6) Z-Boards™ can be used in any arrangement (all singles, all doubles, or any combination) as long as output
group #1 and output group #2 bits do not overlap (i.e. combinations of Z-Boards™ could exist where the physical configuration of the manifold could exceed the output quantity capacity, see page 9).
7) When using valve side sub-d module the 1st output available will always be bit 16. Single solenoid valves can be used with double Z-BoardsTM. However, one of the
2 available outputs will remain unused.
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Discrete I/O Side Outputs 1) The discrete output connection size portion is self-configuring in byte increments once an output module is plugged into back plane and power is applied.
2) Discrete output bits are mapped, in ascending order (away from the communication node), starting at Word No.2 (third word). 3) All discrete output modules have an associated internal Status Input bit, which will affect the total value of the input connection size. Sinking (NPN) output modules allocate one internal Status Input bit per output point. Sourcing (PNP) output modules allocate one internal Status Input bit for every 4 output points. 4) Output bits are always configured in byte increments, thus four point output modules will always use a
full byte (8 bits) when mapped. Although not used, the additional four bits in that byte are reserved. Inputs 1) The discrete input connection size portion is self-configuring in byte increments once an input module
is plugged into back plane and power is applied. 2) Internal Status Input bits, associated with the valve side output drivers, are always mapped before any physical input points. 3) All internal Status Input bits associated with any discrete output module are mapped in byte increments and in ascending order following any existing physical or internal Status Input bits. Refer to pages 37-42 for sample I/O mapping.
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Assumed Settings
• Single Z-Boards™ are installed for single solenoid valves and double Z-Boards™ are installed for double solenoid valves.
• Run/Idle Header (Overhead) will always take up the first two words of the Input map.
• Status Input Bits are mapped after the two words of Run/Idle Header (Overhead) and every output device thus the first physical Input will begin at “NODE6:I.DATA[4].8” in this example.
• Valve outputs have 1 Status bit per output point; PNP discrete Output modules have 1 Status bit for every 4 Output points
Sample address scheme: NODE6:X.DATA[Y].Z
X = (O) Output or (I) Input Y = Word No. Z = Bit No.
I/O Mapping
Example #1
PosNo.
Module Type Part No.
Input Size
Value Bytes
Output Size
Value Bytes
1 16O Sourcing (PNP)
239-1319 1 2 (1 Word)
2 8I Sourcing (PNP)
239-1309 1 0
3 4I Sinking (NPN)
239-1304 1 0
Valve Side Solenoid Outputs
---- 4 (2 Words)
4 (2 Words)
Run/Idle Header (Overhead)
---- 4 (2 Words)
0
Total I/O Bytes from manifold configuration.
11 6
Total I/O Words (16 bits) from manifold
configuration. 6 3
Node Address or Module Tag
I/O Station #3
I/O Station #2
I/O Station #1 Discrete Output (16O) NODE6:I.DATA[2].0-15
Discrete Input (4I) NODE6:I.DATA[5].0-3
Allocated (4I): NODE6:I.DATA[5].4-7
Discrete Input (8I) NODE6:I.DATA[4].8-15
25 Pin Valve Side Sub-D Output
(16O) NODE6:O.DATA[1].0-15
NODE6:O.DATA[0].0-15
Valve Station #1
Valve Station #2
Valve Station #3
Valve Station #4
Valve Station #5
Valve Station #6
Valve Station #7
0
1
2
3 4
6 5
7
8
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I/O Mapping Tables
Example #1
Output Table
WORD BYTE Bit 15
Bit 7 Bit 14
Bit 6 Bit 13
Bit 5 Bit 12
Bit 4 Bit 11
Bit 3 Bit 10
Bit 2 Bit 9
Bit 1 Bit 8
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
0 1
Valve Coil No. 16
Valve Coil No. 15
Valve Coil No. 14 Valve Coil No. 13 Valve Coil No. 12 Valve Coil No. 11 Valve Coil No. 10 Valve Coil No. 9
2 Valve Coil No.
24 Valve Coil No.
23 Valve Coil No.
22 Valve Coil No. 21
Valve Coil No. 20
Valve Coil No.19 Valve Coil No. 18 Valve Coil No. 17
1
3 Valve Coil No.
32 Valve Coil No.
31 Valve Coil No.
30 Valve Coil No.
29 Valve Coil No.
28 Valve Coil No.
27 Valve Coil No.
26 Valve Coil No.
25
4 Discrete Output
No. 8 (Pos. No.1)
Discrete Output No. 7 (Pos.
No.1)
Discrete Output No. 6 (Pos. No.
1)
Discrete Output No. 5 (Pos.
No.1)
Discrete Output No. 4 (Pos.
No.1)
Discrete Output No. 3 (Pos.
No.1)
Discrete Output No.2 (Pos. No.1)
Discrete Output No. 1 (Pos. No.
1) 2
5 Discrete Output
No. 16 (Pos. No.1)
Discrete Output No. 15 (Pos.
No.1)
Discrete Output No. 14 (Pos.
No.1)
Discrete Output No. 13 (Pos.
No.1)
Discrete Output No. 12 (Pos.
No.1)
Discrete Output No. 11 (Pos.
No.1)
Discrete Output No. 10 (Pos.
No.1)
Discrete Output No. 9 (Pos. No.
1)
Input Table
WORD BYTE Bit 15
Bit 7 Bit 14
Bit 6 Bit 13
Bit 5 Bit 12
Bit 4 Bit 11
Bit 3 Bit 10
Bit 2 Bit 9
Bit 1 Bit 8
Bit 0
0 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead) 0
1 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
2 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead) 1
3 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
4 Status for Valve
Coil No. 8 Status for Valve
Coil No. 7 Status for Valve
Coil No. 6 Status for Valve
Coil No. 5 Status for Valve
Coil No. 4 Status for Valve
Coil No. 3 Status for Valve
Coil No. 2 Status for Valve
Coil No. 1 2
5 Status for Valve
Coil No. 16 Status for Valve
Coil No. 15 Status for Valve
Coil No. 14 Status for Valve
Coil No. 13 Status for Valve
Coil No. 12 Status for Valve
Coil No. 11 Status for Valve
Coil No. 10 Status for Valve
Coil No. 9
6 Status for Valve
Coil No. 24 Status for Valve
Coil No. 23 Status for Valve
Coil No. 22 Status for Valve
Coil No. 21 Status fo r Valve
Coil No. 20 Status for Valve
Coil No. 19 Status for Valve
Coil No. 18 Status for Valve
Coil No. 17 3
7 Status for Valve
Coil No. 32 Status for Valve
Coil No. 31 Status for Valve
Coil No. 30 Status for Valve
Coil No. 29 Status for Valve
Coil No. 28 Status for Valve
Coil No. 27 Status for Valve
Coil No. 26 Status for Valve
Coil No. 25
8 Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved
Status for Discrete Outputs
No.13-16 (Pos. No. 1)
Status for Discrete Outputs
No. 9-12 (Pos. No. 1)
Status for Discrete Outputs
No. 5-8 (Pos. No. 1)
Status for Discrete Outputs
No. 1-4 (Pos. No. 1) 4
9 Discrete Input
No. 8 (Pos. No. 2)
Discrete Input No. 7
(Pos. No. 2)
Discrete Input No. 6
(Pos. No. 2)
Discrete Input No. 5
(Pos. No.2)
Discrete Input No. 4
(Pos. No. 2)
Discrete Input No. 3
(Pos. No. 2)
Discrete Input No. 2
(Pos. No. 2)
Discrete Input No. 1
(Pos. No. 2)
10 Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved
Discrete Input No. 12
(Pos. No. 3)
Discrete Input No. 11
(Pos. No. 3)
Discrete Input No. 10
(Pos. No. 3)
Discrete Input No. 9
(Pos. No. 3) 5
11
The Status Input bits report the health of a corresponding output bit. To review the status bit action during a fault condition see page 43.
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I/O Mapping
Example #2
PosNo.
Module Type Part No.
Input Size
Value Bytes
Output Size
Value Bytes
1 8O Sourcing (PNP)
239-1315 1 1
2 22O Sourcing (PNP)
239-1460 1 3 (2 Words)
3 16I Sinking (NPN)
239-1869 2 (1 Word) 0
4 4I Sinking (NPN)
239-1304 1 0
Valve Side Solenoid Outputs
---- 4 (2 Words)
4 (2 Words)
Run/Idle Header (Overhead)
---- 4 (2 Words) 0
Total I/O Bytes from manifold configuration.
13 8
Total I/O Words (16 bits) from manifold
configuration. 7 4
Assumed Settings • Double Z-Boards™ are installed for all valves. • Run/Idle Header (Overhead) will always take
up the first two words of the Input map. • Status Input Bits are mapped after the two
words of Run/Idle Header (Overhead) and every output device thus the first physical Input will begin at “NODE6:I.DATA[5].0” in this example.
• Valve outputs have 1 Status bit per output point; PNP discrete Output modules have 1 Status bit for every 4 Output points
Sample address scheme: NODE6:X.DATA[Y].Z
X = (O) Output or (I) Input Y = Word No. Z = Bit No.
Node Address or Module Tag
Discrete Output (8O) NODE6:O.DATA[2].0-7
Discrete Output (22O) NODE6:O.DATA[2].8-15 NODE6:O.DATA[3].0-13
Allocated (2 O): NODE6:O.DATA[3].14-15
Discrete Input (4I) NODE6:O.DATA[6].0-3
Allocated (4I) NODE6:O.DATA[6].4-7
Discrete Input (16I) NODE6:O.DATA[5].0-15
I/O Station #4
I/O Station #1
I/O Station #2
I/O Station #3
0
11
15
10
12 13
14
17 16
1
3 2
5 4
7 6
8
9
NODE6:O.DATA[0].0-15 NODE6:O.DATA[1].0-15
Valve Station #1
Valve Station #2
Valve Station #3
Valve Station #4
Valve Station #5
Valve Station #6
Valve Station #7
Valve Station #8
Valve Station #9
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I/O Mapping Tables
Example #2
Output Table
WORD BYTE Bit 15
Bit 7 Bit 14
Bit 6 Bit 13
Bit 5 Bit 12
Bit 4 Bit 11
Bit 3 Bit 10
Bit 2 Bit 9
Bit 1 Bit 8
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
0 1
Valve Coil No. 16
Valve Coil No. 15
Valve Coil No. 14 Valve Coil No. 13 Valve Coil No. 12 Valve Coil No. 11 Valve Coil No. 10 Valve Coil No. 9
2 Valve Coil No.
24 Valve Coil No.
23 Valve Coil No.
22 Valve Coil No. 21
Valve Coil No. 20
Valve Coil No.19 Valve Coil No. 18 Valve Coil No. 17 1
3 Valve Coil No.
32 Valve Coil No.
31 Valve Coil No.
30 Valve Coil No.
29 Valve Coil No.
28 Valve Coil No.
27 Valve Coil No.
26 Valve Coil No.
25
4 Discrete Output
No. 8 (Pos. No.1)
Discrete Output No. 7
(Pos. No.1)
Discrete Output No. 6
(Pos. No. 1)
Discrete Output No. 5
(Pos. No.1)
Discrete Output No. 4
(Pos. No.1)
Discrete Output No. 3
Pos. No.1)
Discrete Output No.2
(Pos. No.1)
Discrete Output No. 1
(Pos. No. 1) 2
5 Discrete Output
No. 16 (Pos. No.2)
Discrete Output No. 15
(Pos. No.2)
Discrete Output No. 14
(Pos. No.2)
Discrete Output No. 13
(Pos. No.2)
Discrete Output No. 12
(Pos. No.2)
Discrete Output No. 11
(Pos. No.2)
Discrete Output No. 10
(Pos. No.2)
Discrete Output No. 9
(Pos. No. 2)
6 Discrete Output
No. 24 (Pos. No.2)
Discrete Output No. 23
(Pos. No.2)
Discrete Output No. 22
(Pos. No. 2)
Discrete Output No. 21
(Pos. No.2)
Discrete Output No. 20
(Pos. No.2)
Discrete Output No. 19
(Pos. No.2)
Discrete Output No.18
(Pos. No.2)
Discrete Output No. 17
(Pos. No. 2) 3
7 Allocated &
Reserved Allocated &
Reserved
Discrete Output No. 30
(Pos. No.2)
Discrete Output No. 29
(Pos. No.2)
Discrete Output No. 28
(Pos. No.2)
Discrete Output No. 27
(Pos. No.2)
Discrete Output No. 26
(Pos. No.2)
Discrete Output No. 25
(Pos. No. 2)
Input Table
WORD BYTE Bit 15
Bit 7 Bit 14
Bit 6 Bit 13
Bit 5 Bit 12
Bit 4 Bit 11
Bit 3 Bit 10
Bit 2 Bit 9
Bit 1 Bit 8
Bit 0
0 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead) 0
1 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/I dle Header
(Overhead)
2 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead) 1
3 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
4 Status for Valve
Coil No. 8 Status for Valve
Coil No. 7 Status for Valve
Coil No. 6 Status for Valve
Coil No. 5 Status for Valve
Coil No. 4 Status for Valve
Coil No. 3 Status for Valve
Coil No. 2 Status for Valve
Coil No. 1 2
5 Status for Valve
Coil No. 16 Status for Valve
Coil No. 15 Status for Valve
Coil No. 14 Status for Valve
Coil No. 13 Status for Valve
Coil No. 12 Status for Valve
Coil No. 11 Status for Valve
Coil No. 10 Status for Valve
Coil No. 9
6 Status for Valve
Coil No. 24 Status for Valve
Coil No. 23 Status for Valve
Coil No. 22 Status for Valve
Coil No. 21 Status for Valve
Coil No. 20 Status for Valve
Coil No. 19 Status for Valve
Coil No. 18 Status for Valve
Coil No. 17 3
7 Status for Valve
Coil No. 32 Status for Valve
Coil No. 31 Status for Valve
Coil No. 30 Status for Valve
Coil No. 29 Status for Valve
Coil No. 28 Status for Valve
Coil No. 27 Status for Valve
Coil No. 26 Status for Valve
Coil No. 25
8 Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved
Status for Discrete Outputs
No. 5-8 (Pos. No. 1)
Status for Discrete Outputs
No. 1-4 (Pos. No. 1)
4
9 Allocated &
Reserved Allocated &
Reserved
Status for Discrete Outputs
No. 29-32 (Pos. No. 2)
Status for Discrete Outputs
No. 25-28 (Pos. No. 2)
Status for Discrete Outputs
No.21-24 (Pos. No. 2)
Status for Discrete Outputs
No. 17-20 (Pos. No. 2)
Status for Discrete Outputs
No. 13-16 (Pos. No. 2)
Status for Discrete Outputs
No. 9-12 (Pos. No. 2)
10 Discrete Input
No. 8 (Pos. No. 3)
Discrete Input No. 7
(Pos. No. 3)
Discrete Input No. 6
(Pos. No. 3)
Discrete Input No. 5
(Pos. No. 3)
Discrete Input No. 4
(Pos. No. 3)
Discrete Input No. 3
(Pos. No. 3)
Discrete Input No. 2
(Pos. No. 3)
Discrete Input No. 1
(Pos. No. 3) 5
11 Discrete Input
No. 16 (Pos. No. 3)
Discrete Input No. 15
(Pos. No. 3)
Discrete Input No. 14
(Pos. No. 3)
Discrete Input No. 13
(Pos. No. 3)
Discrete Input No. 12
(Pos. No. 3)
Discrete Input No. 11
(Pos. No. 3)
Discrete Input No. 10
(Pos. No. 3)
Discrete Input No. 9
(Pos. No. 3)
12 Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved
Discrete Input No. 20
(Pos. No. 4)
Discrete Input No. 19
(Pos. No. 4)
Discrete Input No. 18
(Pos. No. 4)
Discrete Input No. 17
(Pos. No. 4) 6
13
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I/O Mapping
Example #3
PosNo.
Module Type Part No.
Input Size
Value Bytes
Output Size
Value Bytes
1 8O Sourcing (PNP)
239-1315 1 1
2 16O Sourcing (PNP)
239-1319 1 2 (1 Word)
3 8I Sinking (NPN)
239-1308 1 0
4 4I Sinking (NPN)
239-1304 1 0
Valve Side Solenoid Outputs
---- 4 (2 Words)
4 (2 Words)
Run/Idle Header (Overhead)
---- 4 (2 Words) 0
Total I/O Bytes from manifold configuration.
12 7
Total I/O Words (16 bits) from manifold
configuration. 6 4
Assumed Settings • Run/Idle Header (Overhead) will always
take up the first two words of the Input map.
• Status Input Bits are mapped after the two words of Run/Idle Header (Overhead) and every output device thus the first physical Input will begin at “NODE6:I.DATA[5].0” in this example.
• Valve outputs have 1 Status bit per output point; PNP discrete Output modules have 1 Status bit for every 4 Output points
Sample address scheme: NODE6:X.DATA[Y].Z
X = (O) Output or (I) Input Y = Word No. Z = Bit No.
I/O Station #4
I/O Station #1
I/O Station #2
I/O Station #3
Discrete Input (4I) NODE6:I.DATA[5].8-11 Allocated (4I) NODE6:I.DATA[5].12-15
Discrete Input (8I) NODE6:I.DATA[5].0-7
Discrete Output (16O) NODE6:O.DATA[2].8-15 NODE6:O.DATA[3].0-7
Discrete Output (8O) NODE6:O.DATA[2].0-7
Node Address or Module Tag
NODE6:O.DATA[0].0-15 NODE6:O.DATA[1].0-15
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I/O Mapping Tables
Example #3
Output Table
WORD BYTE Bit 15
Bit 7 Bit 14
Bit 6 Bit 13
Bit 5 Bit 12
Bit 4 Bit 11
Bit 3 Bit 10
Bit 2 Bit 9
Bit 1 Bit 8
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
0 1
Valve Coil No. 16
Valve Coil No. 15
Valve Coil No. 14 Valve Coil No. 13 Valve Coil No. 12 Valve Coil No. 11 Valve Coil No. 10 Valve Coil No. 9
2 Valve Coil No.
24 Valve Coil No.
23 Valve Coil No.
22 Valve Coil No. 21
Valve Coil No. 20
Valve Coil No.19 Valve Coil No. 18 Valve Coil No. 17 1
3 Valve Coil No.
32 Valve Coil No.
31 Valve Coil No.
30 Valve Coil No.
29 Valve Coil No.
28 Valve Coil No.
27 Valve Coil No.
26 Valve Coil No.
25
4 Discrete Output
No. 8 (Pos. No. 1)
Discrete Output No. 7
(Pos. No. 1)
Discrete Output No. 6
(Pos. No. 1)
Discrete Output No. 5
(Pos. No. 1)
Discrete Output No. 4
(Pos. No. 1)
Discrete Output No. 3
(Pos. No. 1)
Discrete Output No. 2
(Pos. No. 1)
Discrete Output No. 1
(Pos. No. 1) 2
5 Discrete Output
No. 16 (Pos. No. 2)
Discrete Output No. 15
(Pos. No. 2)
Discrete Output No. 14
(Pos. No. 2)
Discrete Output No. 13
(Pos. No. 2)
Discrete Output No. 12
(Pos. No. 2)
Discrete Output No. 11
(Pos. No. 2)
Discrete Output No. 10
(Pos. No. 2)
Discrete Output No. 9
(Pos. No. 2)
6 Discrete Output
No. 24 (Pos. No.2)
Discrete Output No. 23
(Pos. No.2)
Discrete Output No. 22
(Pos. No. 2)
Discrete Output No. 21
(Pos. No.2)
Discrete Output No. 20
(Pos. No.2)
Discrete Output No. 19
(Pos. No.2)
Discrete Output No. 18
(Pos. No.2)
Discrete Output No. 17
(Pos. No. 2) 3
7
Input Table
WORD BYTE Bit 15
Bit 7 Bit 14
Bit 6 Bit 13
Bit 5 Bit 12
Bit 4 Bit 11
Bit 3 Bit 10
Bit 2 Bit 9
Bit 1 Bit 8
Bit 0
0 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead) 0
1 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
2 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead) 1
3 Run/Idle
Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header (Overhead)
Run/Idle Header
(Overhead)
Run/Idle Header
(Overhead)
4 Status for Valve
Coil No. 8 Status for Valve
Coil No. 7 Status for Valve
Coil No. 6 Status for Valve
Coil No. 5 Status for Valve
Coil No. 4 Status for Valve
Coil No. 3 Status for Valve
Coil No. 2 Status for Valve
Coil No. 1 2
5 Status for Valve
Coil No. 16 Status for Valve
Coil No. 15 Status for Valve
Coil No. 14 Status for Valve
Coil No. 13 Status for Valve
Coil No. 12 Status for Valve
Coil No. 11 Status for Valve
Coil No. 10 Status for Valve
Coil No. 9
6 Status for Valve
Coil No. 24 Status for Valve
Coil No. 23 Status for Valve
Coil No. 22 Status for Valve
Coil No. 21 Status for Valve
Coil No. 20 Status for Valve
Coil No. 19 Status for Valve
Coil No. 18 Status for Valve
Coil No. 17 3
7 Status for Valve
Coil No. 32 Status for Valve
Coil No. 31 Status for Valve
Coil No. 30 Status for Valve
Coil No. 29 Status for Valve
Coil No. 28 Status for Valve
Coil No. 27 Status for Valve
Coil No. 26 Status for Valve
Coil No. 25
8 Allocated &
Reserved Allocated & Reserved Allocated &
Reserved Allocated & Reserved Allocated &
Reserved Allocated & Reserved
Status for Discrete Outputs
No. 5-8 (Pos. No. 1)
Status for Discrete Outputs
No. 1-4 (Pos. No. 1)
4
9 Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved
Status for Discrete Outputs
No.21-24 (Pos. No. 2)
Status for Discrete Outputs
No. 17-20 (Pos. No. 2)
Status for Discrete Outputs
No. 13-16 (Pos. No. 2)
Status for Discrete Outputs
No. 9-12 (Pos. No. 2)
10 Discrete Input
No. 8 (Pos. No. 3)
Discrete Input No. 7
(Pos. No. 3)
Discrete Input No. 6
(Pos. No. 3)
Discrete Input No. 5
(Pos. No. 3)
Discrete Input No. 4
(Pos. No. 3)
Discrete Input No. 3
(Pos. No. 3)
Discrete Input No. 2
(Pos. No. 3)
Discrete Input No. 1
(Pos. No. 3) 5
11 Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved Allocated &
Reserved
Discrete Input No. 20
(Pos. No. 4)
Discrete Input No. 19
(Pos. No. 4)
Discrete Input No. 18
(Pos. No. 4)
Discrete Input No. 17
(Pos. No. 4)
The Status Input bits report the health of a corresponding output bit. To review the status bit action during a fault condition see page 43.
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Diagnostics – Comm. Module / Power Module
LED Functions
Upon power up, the LEDs indicate the status of the unit. The Power Module of the G2-2 ControlNet node has four LEDs; two for internal fuse integrity and two for Aux. Power status. The Communication module also has four status LEDs
Communication Module LED Name Color Status Description
-- OFF Module is not initialized
Green/Red ALTERNATING Self test of bus controller ON Faulted unit, must be restarted
Channel
& Red
FLASHING Incorrect node configuration; i.e. duplicate MAC ID -- OFF Channel is disabled, depending on the network configuration
ON Normal operation of channel Green
FLASHING Temporary errors (node will self correct) or node is not configured to go online
Red FLASHING Media Fault or no other nodes on the network
Channel or
Green/Red FLASHING Incorrect network configuration ON Module is initialized Green
FLASHING Module is waiting for initialization ON Major fault, module must be restarted
Module Status (MS)
Red FLASHING Minor fault, MAC ID has been changed after initialization, etc.
OFF No connection is opened Module Owned (OWNED)
Green ON A connection is opened to the module
Power Module LED Name Color Status Description
ON Internal fuse F1 is open; No power is internally provided to valves or outputs. Communication NOT affected. Fuse 1 Red
OFF Internal fuse F1 is OK (valid only when power is applied to +24V VLV / OUT pin on Aux. Power connector.
ON DC Power applied to +24V VLV / OUT pin on Aux. Power Connector. +24V VLV / OUT Green OFF No DC Power present at +24V VLV / OUT pin on Aux. Power connector.
ON Internal fuse F2 is open; No power is internally provided to node electronics or inputs. Communication Node will not function. Fuse 2 Red
OFF Internal fuse F2 is OK (valid only when power is applied to +24V NODE / IN pin on Aux. Power connector.
ON DC Power applied to+24V NODE / IN pin on Aux. Power connector. +24V NODE / IN Green OFF No DC Power present at +24V NODE / IN pin on Aux. Power connector.
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Internal Fuses
Fuse Function and Description
Fuse # Description Size Part Number Type
F1 Fuse for Aux. Power connector Pin #1 (Valves & Outputs).
10 A max. fast acting 140-934 Mini ATO
F2 Fuse for Aux. Power connector Pin #4 (Node & Inputs).
4A max. fast acting 140-933 Mini ATO
Fuse Status LED - Indicates the internal fuse integrity
Status Indication Description Off Internal Fuse is Intact Condition normal.
Red Internal Fuse is Blown Electrical Overload / Over Current Condition
Output Short Circuit Protection Status Bit Action During Fault Condition
Output Type Output State
Fault Condition Status Bit
No Fault 0 Valve Solenoid Coil Driver or Sinking (NPN) Discrete Outputs 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
Fuse (F2)
Fuse (F1)
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Appendix
System Specifications
Electrical Valves: 24 VDC + 10%, -15% Node and Discrete I/O: 24 VDC +/- 10% Supply Voltage
Current Total current on the Aux. Power Connector (Pin 1 - “Valves & Outputs” and Pin 4 - “Node & Inputs”) must not exceed 8 amperes.
Internal Fuses Pins #1 and #4 on the Auxiliary Power Connector are each internally fused with a 4 and 10 ampere (maximum) MINI ATO type fuses. External fuses should be chosen depending upon manifold configuration. Please refer to power consumption chart on page 28 for additional fuse sizing
Recommended External Fuse
information. Spike Suppression Output spike suppression is internally provided for both discrete and valve outputs.
Discrete Outputs (Sinking (NPN) or Sourcing (PNP))
Maximum 0.5 amperes per output (Sinking (NPN) or Sourcing (PNP)). All outputs are short circuit protected and have internal spike supression. Contact factory for higher current requirements.
Valve Solenoid Coil Output Drivers
Maximum 0.5 amperes per output. All output points are short circuit protected and have internal spike supression.
Operating Temperature for Electronic Components
23 to 114°F (-5 to 46°C)
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Factory Defaults Settings
Description Default Node Address 00
Baud Rate 5 M bit/sec. Input Module Power Jumper UP
Output Module Power Jumper SP Valve Side - I/O Connection Size 4/4 Bytes (2/2 Words) I/O Side - I/O Connection Size Self-Configuring. See Page 35
Run/Idle Header – I/O Connection Size 4/0 Bytes (2/0 Words)
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Troubleshooting
Symptom Possible Cause Solution
Power must be present between pin #2 and pin #3 on the communication connector and between pin #4 and pin #3 on the auxiliary power connector for the node to function properly.
24VDC must be present between pin #4 and pin #3 of the auxiliary power connector even if Discrete I/O modules are not installed See page 13 for Details
All LEDs off
Power not properly applied
Fuse LEDs displays red Blown internal fuses
Check for external shorts to Input connector from external sensor devices or cable and repair. Replace internal fuse. If problem persists contact factory.
The wrong valve solenoid coils are being energized.
Z-BoardTM type mismatch. Single Z-BoardTM present where double Z-BoardTM expected or vice versa.
Check that correct Z-BoardTM types are installed. Check that ribbon cable (output group #2) is connected to appropriate valve station. See page 35 for bit mapping rules
Valve outputs do not energize. All node LEDs normal.
Output power not present or connected in properly on Aux. Power connector.
Check for 24VDC on pin #1 of Aux. Power connector of Comm. module. Check for 24VDC on Pin #1 of 12mm local Aux Power connector of 25 Pin Sub-D Discrete Output Module, if applicable
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Glossary of Terms
The following is a list and description of common terms and symbols used throughout this document:
Bit Smallest unit of digital information either a “0” or “1”
Bit mapping Chart showing which bit is connected to which physical input or output point
Byte 8 bits (1/2 word)
Change of State I/O message type in which either the expiration of the transmission timer or a change in input state triggers data production.
Comm. Fault One or more of the I/O connections have timed out.
Cyclic I/O message type in which data production is triggered by the expiration of the transmission timer.
Discrete I / O The Inputs / Outputs that are available via the “Discrete I/O” side of manifold
EDS file Electronic Data Sheet. A text file, which contains specific product information, definitions of product capabilities and configurable parameters necessary for operation on a ControlNet network.
G2-2 A Numatics product series of electronics which features modular backplane technology that allows various Discrete I/O components and Communication modules to be added, removed or changed in the field
Ground This term is used to indicate an earth ground
I/O Any combination of Inputs and Outputs
Idle A zero (0) length poll massage (i.e.: scanner in program mode)
MAC ID Media Access Connection Identification (00-99) – Node (network drop) address
Maximum Scheduled Node
Node with highest MAC ID that can use scheduled time on a link.
NEMA National Electrical Manufacturers Association
NUT Network Update Time. Repetitive time interval in which data can be sent on the link,
Polled I/O message type in which the devise consumes I/O data from its master and produces I/O data when the master requests it.
RPI Requested Packet Interval. The measure of how frequently the node requires the transmission of data from the target application (scanner).
RS NetWorx Allen-Bradley’s ControlNet configuration software
Sinking (NPN) Method of connecting electrical circuits in which the zero (0) volt DC side is switched and the common is positive
Sourcing (PNP) Method of connecting electrical circuits in which the positive side is switched and the common is zero (0) volts DC.
Status Input bit A bit in the input table that reports the health of a corresponding output. Indicates short circuit or open coil (load) diagnostics
Word 2 Bytes (16 bits)
Z-BoardTM Circuit board installed in the valve sub-base which electrically connects the valve solenoid to the electrical /electronics interface. Available in single or double solenoid versions.
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Technical Support
For technical support, contact your local Numatics distributor. Additional assistance is available from Numatics Inc. at (248) 887-4111 and ask for Technical Support. Issues relating to network set-up, PLC programming, sequencing, software related functions, etc… should be handled with the appropriate product vendor. Information on EDS files, local distributors, and other Numatics, Inc. products and support issues can be found on the Numatics, Inc. WEB site at: http://www.numatics.com