Emerson Aventics G3 Series Technical Manual
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Emerson Aventics G3 Series Technical Manual

Emerson Aventics G3 Series Technical Manual

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  • Page 1 G3 Series EtherCAT Technical Manual...
  • Page 2 G3 Series EtherCAT Technical Manual Conditions for use of this product (1) Aventics G3 Manifold ("the PRODUCT") shall be used in conditions; i) Where any problem, fault or failure occurring in the PRODUCT, if any, shall not lead to any major or serious accident. ii) Where the backup and fail-safe function are systematically or automatically provided outside of the PRODUCT for the case of any problem, fault or failure occurring in the PRODUCT.
  • Page 3 G3 Series EtherCAT Technical Manual Electrical installation and operational guidelines To be connected to Class 2 power source only • All Aventics communication nodes should be grounded during the installation process. These grounding guidelines can • be found in National Electrical code IEC 60204-1 or EN 60204-1. All Aventics G3 Electronics Products to be installed or wired in accordance with Aventics’s published instructions and •...

  • Page 4: Table Of Contents

    G3 Series EtherCAT Technical Manual Table of Contents About EtherCAT ..........................1-6 Overview ..........................1-6 G3 EtherCAT Features ......................1-6 G3 Introduction ..........................2-7 G3 Electronics Modularity......................2-8 500 Series Pneumatic Valve Manifold ..................2-9 500 Series Manifold Stations ....................2-10 500 Series Z-Board™...
  • Page 5 G3 Series EtherCAT Technical Manual G3 Sub-Bus Field Wiring Directions ..................7-61 Digital I/O Module ........................8-62 Digital I/O Module Usage ...................... 8-62 I/O Module Technical Data ....................8-63 I/O Module Descriptions and Menus ..................8-64 Digital Input Modules ......................8-65 Digital Output Modules ......................

  • Page 6: About Ethercat

    G3 Series EtherCAT Technical Manual About EtherCAT EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation (GmbH, Germany). Overview EtherCAT is an Ethernet-based networking solution for automation but has added benefits/features toward manufacturing applications. The EtherCAT Technology Group or ETG develops and promotes EtherCAT technology.

  • Page 7: G3 Introduction

    This manual details specific information for configuring and commissioning the Aventics G3 Series product line. For more information relating to pneumatic valves and valve manifold assemblies, please refer to the Aventics website at www.asco.com.

  • Page 8: G3 Electronics Modularity

    G3 Series EtherCAT Technical Manual G3 Electronics Modularity Discrete I/O The G3 Series product line is a completely modular and scalable system. As shown below, all of the G3 electronic modules plug together, via mechanical clips, allowing for easy assembly and field changes. TDG3ECM1-5EN 07/2020 Subject to change without notice...

  • Page 9: 500 Series Pneumatic Valve Manifold

    G3 Series EtherCAT Technical Manual 500 Series Pneumatic Valve Manifold The pneumatic valve manifold with internal circuit board technology is also modular. The valve solenoid coil connections are automatically made using Z-Board ™ technology (plug together PC boards), which allow internal connection from solenoid coils to output drivers without the use of wires).

  • Page 10: 500 Series Manifold Stations

    G3 Series EtherCAT Technical Manual 500 Series Manifold Stations Solenoid Coil Connections using Z-Board™ Technology for 50X valve series Z-Board ™ plug together technology connects all valve solenoids to the valve coil output driver board, located in the valve adapter. There is a maximum of 32 coil outputs available on the complete manifold assemblies. The 32 available outputs are accessed on the 501 series valves utilizing 4 station manifolds and on the 502 and 503 series utilizing 2 station manifolds.

  • Page 11: 500 Series Z-Board™ Connectors

    G3 Series EtherCAT Technical Manual 500 Series Z-Board™ Connectors The 501, 502 and 503 valve series utilize 2 different Z-Board ™ designs to achieve the single and double solenoid output functions. This yields the possible 32 single, 16 double, or various combinations of valve coil output capabilities.

  • Page 12: 2000 Series Pneumatic Valve Manifold

    G3 Series EtherCAT Technical Manual 2000 Series Pneumatic Valve Manifold The pneumatic valve manifold with internal circuit board technology is also modular. The valve solenoid coil connections are automatically made using Z-Board ™ technology (plug together PC boards), which allow internal connection from solenoid coils to output drivers without the use of wires).

  • Page 13: 2000 Series Z-Board™ Connectors

    G3 Series EtherCAT Technical Manual 2000 Series Z-Board™ Connectors The 2005/2012/2035 valve series utilize 2 different Z-Board ™ designs to achieve the single and double solenoid output functions. This yields the possible 32 single, 16 double, or various combinations of valve coil output capabilities.

  • Page 14: 2000 Series Z-Board™ And Ribbon Cable Example

    G3 Series EtherCAT Technical Manual 2000 Series Z-Board™ and Ribbon Cable Example If fourteen (14) single solenoid and one (1) double solenoid valves are connected directly to the communication node via their Z-Boards ™ , and one (1) single solenoid and four (4) double solenoid valves are connected to the communication node via the ribbon cable, the following would be the valve side bit map: Output Word Output Byte...

  • Page 15: 2000 Series Z-Board™ With Valve Side Sub-D Example

    G3 Series EtherCAT Technical Manual 2000 Series Z-Board™ with Valve Side Sub-D Example If sixteen (16) single solenoid valves are connected directly to the communication node via Z-Boards ™ and a valve side Sub-D connector is connected to the communication node via the output Group No. 2 connector then the following would be the valve side bit map: Output Word Output Byte...

  • Page 16: Zoned Power

    G3 Series EtherCAT Technical Manual Zoned Power 503 Series Zoned Power application The Zoned Power Manifold blocks can be incorporated into a 503 manifold assembly to isolate Power to a number of valve stations, independent from the main power of the manifold.

  • Page 17: 503 Series Zoned Power Example

    G3 Series EtherCAT Technical Manual 503 Series Zoned Power example In the example shown below there are two Zoned Power Manifold blocks used. One is a "W" wiring option and the other is a "V" wiring option. The first (5) stations of the manifold assembly get their power from the M12 4 Pin connector at station one.

  • Page 18: Communication Module

    G3 Series EtherCAT Technical Manual Communication Module EtherCAT Communication Module (Node) This module is the communication interface to the manifold. It contains communication electronics and internal short circuit protection for power. It can be configured via software and via the graphic display. Communication Module Kit Part Number EtherCAT Communication module...

  • Page 19: Communication Module Description

    G3 Series EtherCAT Technical Manual Communication Module Description Detail No. Description “Set” Button – used to navigate through user menus and to set parameters Status LEDs 4 Pin M12 D-Coded Female Communication Connectors Mounting Hole “Next” Button – used to navigate through user menus and to set parameters Graphic Display –...

  • Page 20: Connector Pin-Outs

    G3 Series EtherCAT Technical Manual Connector Pin-Outs Industry standard connectors are used for communication and auxiliary power. The communication connectors are a D-coded keyway 4 pin female M12 connector. The Power connector is a single keyway 5 pin male 7/8” MINI connector. Communication Connector Pin-Out Pin No.

  • Page 21: Electrical Connections

    G3 Series EtherCAT Technical Manual Electrical Connections Power Connector Wiring Diagram Power Supply Example (Non-isolated commons) Power Supply Example (Isolated commons) • Please see page 4-26 for external fuse sizing guide. When using molded connector power cables, Do Not rely on wire colors for Pin-Out. •...
  • Page 22 G3 Series EtherCAT Technical Manual • 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.

  • Page 23: Ethernet Straight-Through Cabling Diagrams

    G3 Series EtherCAT Technical Manual Ethernet Straight-Through Cabling Diagrams Straight-Through Ethernet cable is used when connecting an Ethernet node to any component (router, switch, hub, computer, etc.). Here are some basic wiring examples of Straight-Through cabling. RJ45 to M12 D Coded Cable M12 D Coded to M12 D Coded Cable Description Color...

  • Page 24: Ground Wiring

    G3 Series EtherCAT Technical Manual Ground Wiring All Aventics Inc. communication nodes should be grounded during the installation process. These grounding guidelines can be found in National Electrical code IEC 60204-1 or EN 60204-1. 500 Series CHASSIS GROUND CONNECTION POINT 2000 Series CHASSIS GROUND CONNECTION POINT...

  • Page 25: Power Consumption

    G3 Series EtherCAT Technical Manual Power Consumption Power Connection Pin No. Function Description 0 VDC Common 0 VDC Voltage used to power outputs (Valves and Outputs) (valve coils and discrete outputs) SW 0 VDC Common 0 VDC Voltage used to power (Node and Inputs) discrete inputs and node electronics UNSW Earth Ground...

  • Page 26: Recommended External Fuses

    G3 Series EtherCAT Technical Manual 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...

  • Page 27: Diagnostics

    G3 Series EtherCAT Technical Manual Diagnostics Communication Module LED Functions Upon power up, the LEDs indicate the status of the unit. There are three LEDs on the G3 EtherCAT node. These LEDs are described below. LED Name Color Status Description No Function Green No Function...

  • Page 28: Output Short Circuit Protection

    G3 Series EtherCAT Technical Manual Output Short Circuit Protection Status Bit Action during Fault Condition Output Status Output Type Fault Condition State No Fault Fault - Short Circuit, Over Temp/Over Current Valve Solenoid Coil Driver No Fault Fault - Open Load No Fault Discrete Outputs Fault - Short Circuit, Over Temp/Over Current...

  • Page 29: G3 Graphic Display

    G3 Series EtherCAT Technical Manual G3 Graphic Display The G3 Communication and I/O modules have an integrated graphic display that may be used to configure the parameters of the modules as well as showing diagnostic information. The following graphic displays represent the main menu selections of the G3 communication module (node). Use the NEXT button to scroll through the Main menu headings shown below.

  • Page 30: Main Menu Structure

    G3 Series EtherCAT Technical Manual Main Menu Structure Use the NEXT button to scroll through the Main menu headings shown below. At this level pressing the SET button allows access the Sub-Menus. Please see the appropriate pages referenced below for further details and descriptions of the Sub-Menus. Note that many of these settings can also be adjusted via software with GSD file parameters.

  • Page 31: Ethercat Tm Operating States (Default Display)

    G3 Series EtherCAT Technical Manual EtherCAT Operating States (Default Display) The default display identifies one of four possible operating states of the EtherCAT node. The node state display cannot be modified through the G3 menus. ETHERCAT Initialization- After power on the module is ready for INIT communication with the EtherCAT master.

  • Page 32: Station Alias Sub-Menu

    G3 Series EtherCAT Technical Manual Station Alias Sub-Menu Steps to Set Station Alias Press the SET button to enter the “Station Alias” sub-menu. STATION ALIAS STATION ALIAS Press the NEXT button to scroll through the choices for the tens digit of the node address. Press the SET button to select the tens digit and move into the ones digit selection.

  • Page 33: Ip Address

    G3 Series EtherCAT Technical Manual IP Address IP Address IP ADDRESS The IP address can only be modified from the module display 192.168.100.120 with EtherCat disabled (TCP IP only). • NOTE! Factory default address is 192.168.003.120 Subnet Mask Subnet Mask SUBNET MASK The Subnet Mask can only be modified from the module 255.255.255.0...

  • Page 34: Gateway Ip

    G3 Series EtherCAT Technical Manual Gateway IP Gateway IP Address GATEWAY IP The Gateway IP can only be modified from the module 0.0.0.0 display with EtherCat disabled (TCP IP only). • NOTE! Factory default gateway IP is 0.0.0.0 TDG3ECM1-5EN 07/2020 5-34 Subject to change without notice www.asco.com/g3...

  • Page 35: Config Mode

    G3 Series EtherCAT Technical Manual Config Mode Steps to Set Coil Configuration Press the SET button to enter the CONFIG MODE sub-menu. CONFIG MODE STANDARD Press the SET button and the NEXT button to change the number SELECT COILS 32=STANDARD of coils.

  • Page 36: Web-Server

    G3 Series EtherCAT Technical Manual Web-Server This will allow the enabling/disabling of the G3 Web Server. Web-Server Steps WEB-SERVER Press the SET button to enter the Web-Server sub-menu. ENABLED WEB-SERVER Press the NEXT button to scroll through the choices to DISABLED enable or disable the feature.

  • Page 37: Ethercat Tm Communication

    G3 Series EtherCAT Technical Manual EtherCAT communication This will disable EtherCAT communication to connect to the G3 webserver. EtherCAT Steps Press the SET button to enter the EtherCAT ETHERCAT ENABLED communication sub-menu. ETHERCAT Press the NEXT button to scroll through the choices to ENABLED enable or disable the feature.

  • Page 38: Mac Address

    G3 Series EtherCAT Technical Manual MAC Address MAC (Machine Access Control) Address MAC ADDR The MAC Address is a fixed unique value that cannot be 0.15.24.00.06.69 edited. The actual MAC ADDR has an extra leading zero. The actual number in the example shown is 00-15-24-00-06-69 The MAC ADDR cannot be modified •...

  • Page 39: Advanced Settings - I/O Diag. Menu

    G3 Series EtherCAT Technical Manual Advanced Settings - I/O Diag. Menu This will allow the enabling / disabling of the IO Status bits. The IO status bits include valve coil, discrete output, input short circuit and alarm status bits. The default condition is enabled. I/O Status Steps ADVANCED Press the SET button to enter the ADVANCED SETTINGS sub-menu.

  • Page 40: Advanced Settings - Diagnostic Word

    G3 Series EtherCAT Technical Manual Advanced Settings - Diagnostic Word This will allow the enabling / disabling of the Diagnostic Word Status bits. The Diagnostic word data includes power status and sub-bus related status bits. Detailed information regarding these bits can be found on page 15-178. The Diagnostic Word comes enabled from the factory.

  • Page 41: Advanced Settings - Comm. Fault

    G3 Series EtherCAT Technical Manual Advanced Settings – Comm. Fault This will allow the enabling / disabling of the Fault Action parameter. The Fault Action parameter determines the behavior of the outputs during a communication fault. Fault Action Settings ADVANCED Press the SET button to enter the ADVANCED SETTINGS SETTINGS menu.

  • Page 42: Advanced Settings - Brightness

    G3 Series EtherCAT Technical Manual Advanced Settings – Brightness Brightness Settings Brightness Settings Press the SET button to enter the ADVANCED SETTINGS ADVANCED Press the SET button to enter the ADVANCED SETTINGS menu. SETTINGS menu. Press the NEXT button to scroll to the option ADVANCED Press the NEXT button to scroll to the CONFIG MENU / SET “SET BRIGHTNESS”...

  • Page 43: Advanced Settings - Flip Display

    G3 Series EtherCAT Technical Manual Advanced Settings – Flip Display Flip Display Settings ADVANCED Press the SET button to enter the ADVANCED SETTINGS SETTINGS menu. ADVANCED MENU ADVANCED MENU Press the NEXT button to scroll to the CONFIG MENU / FLIP DISPLAY FLIP DISPLAY FLIP DISPLAY.

  • Page 44: Advanced Settings - Parameters Lock

    G3 Series EtherCAT Technical Manual Advanced Settings – Parameters Lock PARAMETER Steps PARAMETERS Press the SET button to enter the Parameters sub-menu. UNLOCKED PARAMETERS Press the NEXT button to scroll through the choices to UNLOCKED enable or disable the feature. UNLOCKED (Factory Default) LOCKED RETURN (this will return you to the main menu)

  • Page 45: Advanced Settings - Configuration Lock

    G3 Series EtherCAT Technical Manual Advanced Settings – Configuration Lock Configuration Lock Settings ADVANCED Press the SET button to enter the ADVANCED SETTINGS SETTINGS menu. Press the NEXT button to scroll to the CONFIG MENU / ADVNCED MENU ADVNCED MENU CONFIG LOCK CONFIG LOCK CONFIG.

  • Page 46: Factory Defaults

    G3 Series EtherCAT Technical Manual Factory Defaults Factory Default Settings Press the SET button to enter the FACTORY DEFAULTS FACTORY DEFAULTS sub-menu. SET DEFAULTS Press the SET button to change this parameter SET DEFAULTS Press the NEXT button to select Yes or No. Selecting No will bring you back to the main FACTORY DEFAULTS menu.

  • Page 47: Diagnostics - Self Test Mode

    G3 Series EtherCAT Technical Manual Diagnostics - Self Test Mode An internal diagnostic tool can be enabled on the communication module (node) using the graphic display. This tool allows the user to confirm that all of the inputs and outputs on the manifold and any of the distributed modules are fully functional without needing a network connection or controller.

  • Page 48: Diagnostics

    G3 Series EtherCAT Technical Manual Diagnostics All diagnostic information is read only DIAGNOSTICS Press the SET button to enter DIAGNOSTICS sub- menu. SET SELF TEST Press the NEXT button to scroll through the main diagnostic menu choices. SET SELF TEST USNW POWER 24.83...

  • Page 49: Network And Sub-Network Error Codes

    G3 Series EtherCAT Technical Manual Network and Sub-Network Error Codes Error Code Error Error Description Module No. Main Network Output power not present on communication module Comm. Node / Input power is below 19VDC Comm. Error associated with a sub-bus module (see sub-bus error) Comm.

  • Page 50: Error Messages

    G3 Series EtherCAT Technical Manual Error Messages The following are automatic error messages that are displayed when specific faults occur during operation: Displayed when a short circuit condition is SUB-BUS SHORT detected on the Sub-Bus power lines Displayed when a short circuit condition is SHORTED COIL detected on a valve coil NO.

  • Page 51: Arm - Auto Recovery Module (Optional)

    G3 Series EtherCAT Technical Manual ARM – Auto Recovery Module (Optional) ARM Module (Legacy) ARM-Clip Module The Auto Recovery Module (ARM) is an optional memory module that is installed between the node and the valve adapter module and is used to preserve the manifold system parameters even during catastrophic failure. During the power-up process it reads the configuration of the manifold, including any user settable parameters of I/O modules, and stores the information in its non-volatile memory.

  • Page 52: Arm Process Flowchart

    G3 Series EtherCAT Technical Manual ARM process flowchart TDG3ECM1-5EN 07/2020 6-52 Subject to change without notice www.asco.com/g3...

  • Page 53: Distribution

    G3 Series EtherCAT Technical Manual Distribution Distribution of I/O capability can be easily achieved with the G3 platform by means of Sub-Bus modules. I/O modules, valve manifolds and/or a combination of both can be simply separated from the main manifold and distributed via a sub-bus communication cable.

  • Page 54: Sub-Bus Distribution Modules

    G3 Series EtherCAT Technical Manual Sub-Bus Distribution Modules SUB-BUS OUT Module 1. Used only when distributing the Sub-Bus to another assembly is required. SUB-BUS OUT - 5 pin M12 female communication connector. Used to distribute the Sub-Bus to the next Sub-Bus assembly. Carries 24 VDC power for electronics of the next module.
  • Page 55 G3 Series EtherCAT Technical Manual SUB-BUS IN Modules • Used to distribute I/O assemblies that do not have valves Must be installed to the right of the I/O modules SUB-BUS IN - 5 pin M12 male communication connector. Must be connected to the Sub-Bus Out connector of the previous assembly Carries 24 VDC power for electronics of module AUX.
  • Page 56 G3 Series EtherCAT Technical Manual Terminator Module Used to terminate SUB-BUS connections. Must be installed on the left side of the last Sub-Bus module. Description Part Number Terminator Module with Din Rail Mounting 240-245 Terminator Module without Din Rail Mounting 240-184 •...
  • Page 57 G3 Series EtherCAT Technical Manual G3 Sub-Bus Valve Module COMM - 5 pin M12 male Sub-Bus input communication connector. Must be connected to the SUB-BUS OUT connector of the previous assembly Carries 24 VDC power for electronics of module POWER - 4 pin MINI male power connector. Power is required for Outputs Used to distribute Valves on the Sub-Bus.

  • Page 58: 580 Series Sub-Bus Valve Module

    G3 Series EtherCAT Technical Manual 580 Series Sub-Bus Valve Module 10. COMM - 5 pin M12 male Sub-Bus communication connector. Must be connected to the SUB-BUS OUT connector of the previous assembly Carries 24 VDC power for electronics of module 11.

  • Page 59: Sub-Bus Hub Module

    G3 Series EtherCAT Technical Manual Sub-Bus Hub Module The G3 HUB module allows for branch distribution from the I/O side of the G3 System and can be integrated into the existing G3 Series Sub-Bus configuration. Auto Addressing allows for trouble free set up and configuration.

  • Page 60: Sub-Bus Cables

    G3 Series EtherCAT Technical Manual Sub-Bus Cables TDG3ECM1-5EN 07/2020 7-60 Subject to change without notice www.asco.com/g3...

  • Page 61: G3 Sub-Bus Field Wiring Directions

    G3 Series EtherCAT Technical Manual G3 Sub-Bus Field Wiring Directions The purpose of this document is to instruct the end user of the proper wiring techniques required to make a G3 Sub-Bus cable from the available bulk cable and field wireable ends.

  • Page 62: Digital I/O Module

    G3 Series EtherCAT Technical Manual Digital I/O Module Digital I/O Module Usage The maximum number of modules that can be used on the Discrete I/O side of the manifold is 16. These modules can be centralized on the main fieldbus manifold, distributed or a combination of both. Modules can be connected in any combination of inputs, outputs and specialty up to the physical limitation of 16 modules.

  • Page 63: I/O Module Technical Data

    G3 Series EtherCAT Technical Manual I/O Module Technical Data Current Current Current Limitation for Module No. Description Connector Type Limitation for Limitation for connector Module manifold assy. 240-203 16 PNP Inputs .30A for each Terminal Strip +24VDC terminal 240-204 16 NPN Inputs 240-379 8 PNP Inputs 240-205...

  • Page 64: I/O Module Descriptions And Menus

    G3 Series EtherCAT Technical Manual I/O Module Descriptions and Menus Detail No. Description “Set” Button – used to navigate through user menus and set parameters Module Function (I/O Type) Alignment arrow for SPEEDCON connector Bit Designation for I/O “Next” Button – used to navigate through user menus and set parameters Graphic Display 5 Pin M12 female I/O connector Connector designation...

  • Page 65: Digital Input Modules

    G3 Series EtherCAT Technical Manual Digital Input Modules One Digital Input per Connector – M8 Female Modules Module Short Circuit I/O Type Short Circuit Protection Input Points Part No. Protection Status Bits YES – Visual YES – Optional 240-379 PNP (Sourcing) Input Mapping BYTE Bit 7...
  • Page 66 G3 Series EtherCAT Technical Manual One Digital Input per Connector – M12 Female Modules Module Short Circuit I/O Type Short Circuit Protection Input Points Part No. Protection Status Bits 240-210 NPN (Sinking) 240-206 PNP (Sourcing) Input Mapping BYTE Bit 7 Bit 6 Bit 5 Bit 4...
  • Page 67 G3 Series EtherCAT Technical Manual Two Digital Inputs per Connector – M12 Female Modules Module Short Circuit I/O Type Short Circuit Protection Input Points Part No. Protection Status Bits 240-209 NPN (Sinking) 240-205 PNP (Sourcing) Input Mapping BYTE Bit 7 Bit 6 Bit 5 Bit 4...
  • Page 68 G3 Series EtherCAT Technical Manual Sixteen Digital Inputs – Terminal Strip Modules Specifications Wire Range: 12 to 24 AWG Strip Length: 7mm Tightening Torque: 0.5 Nm Module Short Circuit Protection I/O Type Short Circuit Protection Input Points Part No. Status Bits 240-203 PNP (Sourcing) 240-204...
  • Page 69 G3 Series EtherCAT Technical Manual Intrinsically safe [Ex ia] NAMUR Compatible Input Module One Digital Input per Connector – M12 Female Input module is for use with NAMUR certified intrinsically safe (IS) sensors. The module can be placed in any G3 I/O position available but must be used in conjunction with appropriate clips with partition plates (see picture on page 8-71).
  • Page 70 G3 Series EtherCAT Technical Manual Intrinsically safe [Ex ia] NAMUR Compatible Input terminal strip module Module Short Circuit /Open Circuit Short Circuit /Open Circuit I/O Type Input Points Part No. Protection Present Status Bits 240-322 NAMUR YES - Visual YES - Optional Input Mapping BYTE Bit 7...
  • Page 71 G3 Series EtherCAT Technical Manual Intrinsically safe [Ex ia] Support Modules Mechanical isolation between standard and [Ex ia] modules is mandatory to fulfill ATEX certification. Clips with Partition Plates are available to achieve the required isolation. G3 [Ex ia] Clip 240-317 G3 [Ex ia] Sub-Bus Out 240-318 G3 [Ex ia] Sub-Bus In 240-319 TDG3ECM1-5EN...
  • Page 72 G3 Series EtherCAT Technical Manual 19 Pin M23 Input Module The 19 Pin M23 Input module is for use with any Input block available from Phoenix Contact, Turck, Brad Harrison, etc. It can also be used with a single ended 19 Pin Cable. Part Numbers and Mapping Module Short Circuit /Open Circuit...

  • Page 73: Digital Output Modules

    G3 Series EtherCAT Technical Manual Digital Output Modules One Digital Output per Connector - M12 Female Modules Module Short Circuit I/O Type Short Circuit Protection Output Points Part No. Protection Status Bits 240-208 PNP (Sourcing) Output Mapping BYTE Bit 7 Bit 6 Bit 5 Bit 4...
  • Page 74 G3 Series EtherCAT Technical Manual Two Digital Outputs per Connector - M12 Female Modules Module Short Circuit I/O Type Short Circuit Protection Output Points Part No. Protection Status Bits 240-207 PNP (Sourcing) Output Mapping BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2...
  • Page 75 G3 Series EtherCAT Technical Manual Sixteen Digital Outputs – Terminal Strip Modules Specifications Wire Range: 12 to 24 AWG Strip Length: 7mm Tightening Torque: 0.5 Nm Module Short Circuit Protection I/O Type Short Circuit Protection Output Points Part No. Status Bits 240-330 PNP (Sourcing) Output Mapping...
  • Page 76 G3 Series EtherCAT Technical Manual Two Digital High Current Outputs per Connector - M12 Female Modules The high current output module is to be used with output devices requiring between 0.5 and 1.0 Amps. Each connector incorporates two outputs that are capable of sourcing 1.0 Amp per output.

  • Page 77: Digital Input/Output Modules

    G3 Series EtherCAT Technical Manual Digital Input/Output Modules Two Digital I/O per Connector – M12 Female Modules Short Circuit Output Short Circuit Input Module Part No. I/O Type Protection Status Points Protection Points Bits 240-211 PNP (Sourcing) Output Mapping BYTE Bit 7 Bit 6 Bit 5...

  • Page 78: Valve Interface Modules

    G3 Series EtherCAT Technical Manual Valve Interface Modules 2000 Series & 500 Series Valve Driver Output Data Mapping Interface to control valves from a G3 communication module. Module Short Circuit I/O Type Short Circuit Protection Output Points Part No. Protection Status Bits 219-828 NPN (Sinking) 2000 Series YES –...
  • Page 79 G3 Series EtherCAT Technical Manual Diagnostic Data Mapping Module Short Circuit I/O Type Short Circuit Protection Output Points Part No. Protection Status Bits 219-828 NPN (Sinking) 2000 Series YES – Visual YES (32) – Optional P599AE42518801 NPN (Sinking) 500 Series YES –...

  • Page 80: Sub-Bus Valve Module

    G3 Series EtherCAT Technical Manual Sub-bus Valve Module Output Data Mapping Used to control a distributed valve manifold through the Sub-Bus. Module I/O Type Short Circuit Protection Status Bit Data Output Points Part No. 240-241 NPN (Sinking) YES – Visual YES (128) –...
  • Page 81 G3 Series EtherCAT Technical Manual Diagnostic Data Mapping Module I/O Type Short Circuit Protection Status Bit Data Output Points Part No. YES (128) – 240-241 NPN (Sinking) YES – Visual Optional Diagnostics BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1...

  • Page 82: Sub-Bus Valve Module Without Distribution

    G3 Series EtherCAT Technical Manual Sub-bus Valve Module without Distribution Used to control a distributed valve manifold through the Sub-Bus. Module I/O Type Short Circuit Protection Status Bit Data Output Points Part No. YES (128) – P580AEDS4010A00 NPN (Sinking) YES – Visual Optional Output Mapping BYTE...
  • Page 83 G3 Series EtherCAT Technical Manual Used to control a distributed valve manifold through the Sub-Bus. Module I/O Type Short Circuit Protection Status Bit Data Output Points Part No. YES (128) – P580AEDS4010A00 NPN (Sinking) YES – Visual Optional Diagnostics BYTE Bit 7 Bit 6 Bit 5...

  • Page 84: Valve Side Output Module

    G3 Series EtherCAT Technical Manual Valve Side Output Module The valve side output module is used to distribute available valve side output points (i.e. when valves are located away from the rest of the electronics). These modules go to the right of the G3 valve adapter. The 16 bit output module utilizes the last 16 output bits on the valve side of the manifold (bits 16-31).

  • Page 85: 500 Series Extended Coil Capability

    G3 Series EtherCAT Technical Manual 500 Series Extended Coil Capability The Extended Coil manifolds must be connected to a G3 Electronics Node to operate. Not all G3 supported protocols will support the Extended Coil Manifolds. Below is a list of the hardware and minimum firmware levels that support the Extended Coil Manifolds.
  • Page 86 G3 Series EtherCAT Technical Manual The following example of the G3 diagnostic webpage “Node Configuration” identifies the details of a manifold configured for 64 possible coils. Number of Maximum Coils should only be adjusted if 1 or more additional extended coil valve driver(s) has been physically added.
  • Page 87 G3 Series EtherCAT Technical Manual The following is an example of the G3 diagnostic webpage “Diagnostics” which identifies the details of the valve driver’s control of 64 possible coils TDG3ECM1-5EN 07/2020 9-87 Subject to change without notice www.asco.com/g3...

  • Page 88: Extended Coil Valve Driver Mapping

    G3 Series EtherCAT Technical Manual Extended Coil Valve Driver Mapping IO Mapping for each additional 501 series 32 coil valve driver added to the manifold assembly Input Mapping BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Coil 7...

  • Page 89: 501 Series, Up To 64 Solenoid Coils

    G3 Series EtherCAT Technical Manual 501 Series, up to 64 solenoid coils 501 series, 4 station manifold block with an integrated 32 coil valve driver • To be used with 501 series valves on valve manifold assemblies with 33-64 coils. •...

  • Page 90: 501 Series, Up To 128 Solenoid Coils

    G3 Series EtherCAT Technical Manual 501 Series, up to 128 solenoid coils 501 series, 8 station manifold with integrated 32 coil valve driver, auxiliary power connector and mid-station supply and exhaust ports • To be used with 501 series valves on valve manifold assemblies with 33-128 coils. •...

  • Page 91: 502 And 503 Series, Up To 80 Solenoid Coils

    G3 Series EtherCAT Technical Manual 502 and 503 Series, up to 80 solenoid coils 502 and 503 series, 4 station manifold with integrated 16 coil valve driver, power connector and mid-station supply and exhaust ports • To be used with 502 and 503 series valves on valve manifold assemblies with 33-80 coils. •...

  • Page 92: Analog I/O Modules

    G3 Series EtherCAT Technical Manual Analog I/O Modules Analog I/O Module Rules The analog I/O modules follow the same rules as the digital I/O modules. The maximum total number of modules on the Sub-Bus is 16. The analog boards allow the user to control devices using an analog signal. The analog modules also allow the user to relay analog information from input devices.
  • Page 93 G3 Series EtherCAT Technical Manual One Analog Input per Connector – M12 Female Modules Short Circuit Module Short Circuit Input Signal Type Protection Status Part No. Protection Points Bits 240-212 0-10 VDC YES (4) – YES – Visual 240-214 4-20 mA Selectable Input Mapping BYTE...
  • Page 94 G3 Series EtherCAT Technical Manual One Analog I/O per Connector – M12 Female Modules Short Circuit Output Module Short Circuit Signal Type Protection Status Points Input Points Part No. Protection Bits 240-213 0-10 VDC 240-215 4-20 mA Output Mapping BYTE Bit 7 Bit 6 Bit 5...
  • Page 95 G3 Series EtherCAT Technical Manual One High Current Analog I/O per Connector – M12 Female Modules Short Circuit Module Short Circuit Signal Type Protection Status Output Points Input Points Part No. Protection Bits 240-307 0-10 VDC Output Mapping BYTE Bit 7 Bit 6 Bit 5 Bit 4...
  • Page 96 G3 Series EtherCAT Technical Manual One Analog Input + One Analog Output per Connector – M12 Female Modules Module Short Circuit Short Circuit / Power Signal Type Input Channels Output Channels Part No. Protection Present Status Bits 240-363 4-20 mA YES (4) –...
  • Page 97 G3 Series EtherCAT Technical Manual One 4-20ma Analog Input + One 4-20 Analog Output per Connector – M12 Female Modules Module Short Circuit Short Circuit / Power Signal Type Input Channels Output Channels Part No. Protection Present Status Bits 240-363 4-20 mA YES (4) –...
  • Page 98 G3 Series EtherCAT Technical Manual Internal or Aux. Power Select (240-363 Only) Analog devices connected to the 240-363 can be powered from the Aux. Power supply port (Internal Power Disabled) or from the module backplane (Internal Power Enabled). This is selected through the “Internal Power Menu”...

  • Page 99: Analog Graphic Display

    G3 Series EtherCAT Technical Manual Analog Graphic Display The G3 Analog I/O modules have an integrated graphic display that may be used to configure the parameters of the modules as well as show diagnostic information. Please see the following pages for detailed information regarding these displays. I/O MAPPING INPUT BYTE XX I/O MAPPING...
  • Page 100 G3 Series EtherCAT Technical Manual Analog Module / I/O Mapping Displays the starting Input and Output byte address for the module I/O MAPPING INPUT BYTE XX I/O MAPPING OUTPUT BYTE XX Analog Module / Module Number Displays the module number; identifying its position in the G3 I/O system. MODULE NUMBER Analog Module / Alarm Settings Allows the setting of low and high alarms for analog inputs and outputs...
  • Page 101 G3 Series EtherCAT Technical Manual Analog Module / Description Displays the quantity and type of I/O on the module Ex. 2 analog Inputs and 2 analog outputs DESCRIPTION 2AI / 2AO Analog Module / Part number Displays the replacement part number of the module PART NUMBER 240-XXX Analog Module / Firmware...

  • Page 102: Analog Module / Self Test Mode

    G3 Series EtherCAT Technical Manual Analog Module / Self Test Mode Self test mode is an internal diagnostic tool that can be enabled on the analog module using the graphic display. This tool allows the user to confirm that all of the outputs on the module are fully functional without needing a network connection or controller.

  • Page 103: Analog Module / Factory Defaults

    G3 Series EtherCAT Technical Manual Analog Module / Factory Defaults Factory Default Settings FACTORY Press the SET button to enter the FACTORY DEFAULTS DEFAULTS sub-menu. SET DEFAULTS Press the NEXT button to select Yes or No. Selecting No will bring you back to the main FACTORY DEFAULTS menu.

  • Page 104: Specialty Modules

    G3 Series EtherCAT Technical Manual Specialty Modules RTD Module The G3 RTD Temperature module is used with Resistive Temperature Detectors (RTDs) and can support up to 4 RTD devices simultaneously. This module supports various RTD types including: Pt100, Pt200, Pt500, Pt1000, Ni100 and Ni1000. Standard M12 single key connector types are used;...
  • Page 105 G3 Series EtherCAT Technical Manual Sensor Wiring Diagrams 2 Wire Sensor Type 3 Wire Sensor Type 4 Wire Sensor Type 2 Wire Cable (Fig 1) 3 Wire Cable (Fig 2 4 Wire Cable (Fig 4) 2 Wire 3 Wire 4 Wire Sensor Type Sensor Type Sensor Type...
  • Page 106 G3 Series EtherCAT Technical Manual Part Numbers and Mapping Module I/O Type Alarms Diagnostics Input Points Part No. 240-311 Hi/Low Temp for each Channel Open/Short, Out of Range Input Mapping BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0...
  • Page 107 G3 Series EtherCAT Technical Manual RTD Module Graphic display RTD Module / Temperature Monitoring Press the NEXT button to scroll through the TEMP AT CH0 Temperature Monitoring display options. Pressing the SET button while in one of the Temperature Monitoring displays, will return the TEMP AT CH1 display back to the home screen.
  • Page 108 G3 Series EtherCAT Technical Manual RTD Module / Sensor Type Select (Channel Enable) Allows the sensor type for each channel to be selected, and, enable the channel selected Press the SET button to enter the SELECT CHAN CHANNEL 0 Sensor Type Select sub menu. Press the NEXT button to scroll SELECT CHAN through the channels.
  • Page 109 G3 Series EtherCAT Technical Manual RTD Module / Temperature Scale Allows the temperature scale for each channel to be set to Celsius or Fahrenheit. Press the SET button to enter the Temp Scale sub menu. TEMP SCALE TEMP SCALE CHANNEL 0 CHANNEL 0 Press the NEXT button to scroll through the channels.
  • Page 110 G3 Series EtherCAT Technical Manual RTD Module / Alarm Settings Allows the Low and High alarms of each RTD Input channel to be set. This parameter generates a visual and logical (bit) when set value is achieved. Press the SET button to enter the SET ALARM ALARM CHANNEL CH0...
  • Page 111 G3 Series EtherCAT Technical Manual RTD Module / Advanced Setting Allows the Update Filters for each channel to be set. Press the SET button to enter the UPDATE FILTER ADVANCED Advance Settings sub-menu. SETTINGS Press the NEXT button to choose the option;...
  • Page 112 G3 Series EtherCAT Technical Manual RTD Module / I/O Mapping Input Byte I/O MAPPING INPUT BYTE 4 RTD Module / Module Number (Position) MODULE NUMBER 2 RTD Module / Module Description DESCRIPTION 4 CHAN RTD RTD Module / Part Number PART NUMBER 240-311 RTD Module / Firmware Revision...
  • Page 113 G3 Series EtherCAT Technical Manual RTD Module / Set Display Brightness Allows the Brightness of the display to be changed press the SET button to enter the Set BRIGHTNESS MEDIUM BRIGHTNESS Brightness sub menu. Press the NEXT button to scroll BRIGHTNESS HIGH through the brightness options...
  • Page 114 G3 Series EtherCAT Technical Manual RTD Module / Factory Defaults Set all parameter settings to default values. Press the SET button to enter the Factory Defaults sub menu. FACTORY SET DEFAULT DEFAULTS Presss the NEXT button to choose Yes or No. Press the SET button to confirm.

  • Page 115: Sub-Bus Hub Module

    G3 Series EtherCAT Technical Manual Sub-Bus Hub Module The G3 HUB module allows for branch distribution from the I/O side of the G3 System and can be integrated into the existing G3 Series Sub-Bus configuration. Auto Addressing allows for trouble free set up and configuration.
  • Page 116 G3 Series EtherCAT Technical Manual 240-205 240-205 The Sub-bus hub module does not produce mapped diagnostics. The data table in this example represents what is physically attached to the HUB module. This will change as modules are added NOTE! or removed. Example I/O Mapping of Attached Modules BYTE Bit 7...
  • Page 117 G3 Series EtherCAT Technical Manual Hub Module / Identification Identifies HUB module in G3 System. SUB-BUS HUB Hub Module / Description Identifies Module type. DESCRIPTION SUB-BUS HUB Hub Module / Advanced Settings Allows the user to set/configure module parameters. ADVANCED SETTINGS Press the SET button to advance to the first parameter/setting.
  • Page 118 G3 Series EtherCAT Technical Manual Branch Reserve I/O BRANCH RESERVE IO Press the SET button to enter the Branch Reserve IO sub-menu. BRANCH 1 NO RESERVE Press the NEXT button to select the desired Branch to reserve I/O bytes. BRANCH 2 NO RESERVE I/O data bytes can be reserved on each branch for future expansion within the G3 system.
  • Page 119 G3 Series EtherCAT Technical Manual Factory Defaults Allows all parameter settings to be set back to default values. FACTORY DEFAULTS Press the SET button to enter the Factory SET DEFAULTS Defaults sub menu. Press the NEXT button to choose Yes or No. Press the SET button to confirm.
  • Page 120 G3 Series EtherCAT Technical Manual Diagnostics Allows the user to refernce Part No., Firmware Rev., and Branch Connections. DIAGNOSTICS Press the NEXT button to enter the PART NUMBER Part Number Diagnostics sub-menu. 240-326 The Part Number screen is displayed (reference only). Press the NEXT button to advance to Firmware Rev.
  • Page 121 G3 Series EtherCAT Technical Manual Error/Event Messages The following are error messages that are displayed when specific faults/events occur during operation: Displayed when a Sub-Bus module that had been MISSING MODULE NUMBER XX previously installed becomes absent from the configuration SUB-BUS Displayed when a Sub-Bus power short circuit SHORT CIRCUIT...
  • Page 122 G3 Series EtherCAT Technical Manual HUB Integration - Example TDG3ECM1-5EN 07/2020 11-122 Subject to change without notice www.asco.com/g3...

  • Page 123: I/O Module(S) Wiring Diagrams

    G3 Series EtherCAT Technical Manual I/O Module(s) Wiring Diagrams 12.1 NPN/PNP Definitions NPN Descriptions LOAD Sinking • • Switching Negative Positive Common • PNP Descriptions Sourcing • Switching Positive • • Negative Common LOAD NPN (Sinking) Input Connection PNP (Sourcing) Input Connection TDG3ECM1-5EN 07/2020 12-123...
  • Page 124 G3 Series EtherCAT Technical Manual I/O Module(s) Wiring Diagrams Continued PNP (Sourcing) Output Connection TDG3ECM1-5EN 07/2020 12-124 Subject to change without notice www.asco.com/g3...

  • Page 125: Connecting To A G3 Series Ethercat

    G3 Series EtherCAT Technical Manual G3 EtherCAT Web Server Connecting to a G3 Series EtherCAT node Note: To access the G3 Node’s diagnostic Web Page the G3 EtherCAT node must be set to EtherCAT disabled (TCP ONLY mode). EtherCAT Steps ETHERCAT Press the SET button to enter the Web-Server sub-menu.

  • Page 126: Tm Node (Windows 7)

    G3 Series EtherCAT Technical Manual Connecting to a G3 Series EtherCAT Node (Windows 7) This section will discuss how to connect a computer to a G3 Series EtherCAT node. There are multiple ways to complete this task, so only two will be discussed. Connect a 24VDC power supply to the valve manifold.
  • Page 127 G3 Series EtherCAT Technical Manual The “Network and Sharing Center” window will open. Double click on “Change adapter settings”. The “Network Connections” window opens. Double click the “Local Area Connection Icon” TDG3ECM1-5EN 07/2020 13-127 Subject to change without notice www.asco.com/g3...
  • Page 128 G3 Series EtherCAT Technical Manual Click on “Internet Protocol Version 4 (TCP/IPv4)” the properties window will open Choose the option marked “Use the following IP address” and type in an IP address that has the same first three octets as the address as you the manifold you are connected with. For the last octet you may choose any number from 0-255, just make sure that it is not the same number as the IP address that the manifold will have.
  • Page 129 G3 Series EtherCAT Technical Manual 10. Left click “OK” in the “Internet Protocol (TCP/IP) Properties” and “Local Area Connection” windows for the changes to take effect on the computer. Close out of any open windows. Once the IP address for the computer is known, you can set the IP address of the Aventics manifold using one of the methods described on page 5-33.
  • Page 130 G3 Series EtherCAT Technical Manual 13. Open a web browser on the computer and type the IP address of the manifold. Ex. http://192.168.3.120. The Aventics G3 webpage should load after several seconds. TDG3ECM1-5EN 07/2020 13-130 Subject to change without notice www.asco.com/g3...
  • Page 131 G3 Series EtherCAT Technical Manual Connecting to a G3 Series EtherCAT Node (Windows 10) This section will discuss how to connect a computer to a G3 Series EtherNet/IP node. There are multiple ways to complete this task, so only two will be discussed. All computer commands are shown in Windows 10. Connect a 24VDC power supply to the valve manifold.
  • Page 132 G3 Series EtherCAT Technical Manual Next, left click on “Ethernet” on the left-hand side of the window, and then “Network and Sharing Center”. The “Network and Sharing Center” window will open. Double click on “Change adapter settings”. TDG3ECM1-5EN 07/2020 13-132 Subject to change without notice www.asco.com/g3...
  • Page 133 G3 Series EtherCAT Technical Manual The “Network Connections” window opens. Double click the “Local Area Connection Icon” lick on “Internet Protocol Version 4 (TCP/IPv4)” the properties window will open TDG3ECM1-5EN 07/2020 13-133 Subject to change without notice www.asco.com/g3...
  • Page 134 G3 Series EtherCAT Technical Manual 10. Choose the option marked “Use the following IP address” and type in an IP address that has the same first three octets as the address that you will set the manifold to. For the last octet you may choose any number from 0-255, just make sure that it is not the same number as the IP address that the manifold will have.
  • Page 135 G3 Series EtherCAT Technical Manual Type, “Ping, and then the IP address of the manifold, you can view the address on the graphical display. For example, if the IP address is 192.168.3.120, “ping 192.168.3.120” would be typed. You will get a message stating, “Reply from 192.168.3.120: bytes=32 time<1ms TTL=128”, if the manifold responds.
  • Page 136 G3 Series EtherCAT Technical Manual Using the Functionality of the G3 Series EtherCAT Web Server This section will discuss the functionality of the built in Ethernet server. Every Aventics EtherCAT node has this feature. Through this server you can configure the node, force I/O, check diagnostics, etc. Each Aventics’ web page will be explained.
  • Page 137 G3 Series EtherCAT Technical Manual Node Configuration The “Node Configuration” window can be used to control different parameters within the manifold. These parameters include, “Station Alias”, “Max Coils”, “Node Configuration Parameters (lock)” and “I/O Configuration (lock)”. Once the changes have been made, left click on the “Update Configuration” button. The “Configuration Successfully Updated”...
  • Page 138 G3 Series EtherCAT Technical Manual Password The “Password” window allows the user to set a password that will prevent unwanted access to the I/O Force and Test functionality. The password comes disabled from the factory. To set the initial password, leave the “Enter Current Password”...
  • Page 139 G3 Series EtherCAT Technical Manual Diagnostics The “Diagnostics” window allows the user to monitor different values. These values include, “MAC Address”, “Serial Number”, “Firmware Revision”, and “Valve Diagnostic Table”. The “Valve Diagnostic Table” enables the user to check the status of the valve side outputs. Actual Configuration of modules with...
  • Page 140 G3 Series EtherCAT Technical Manual Relevant node information including firmware revision Graphic of module “Diagnostic word” data Valve coil forcing capability. Can be disabled with password Shows diagnostic status of whether coils are shorted or open. *Note The G3 node must be switched to Pre-Operational mode via the Twincat system manager software to allow forcing output states from the G3 webpage.
  • Page 141 G3 Series EtherCAT Technical Manual Show Details: Shows Input & Output signal status Shows diagnostic status of source power to sensor, “Connector E shorted” Shows input signal status TDG3ECM1-5EN 07/2020 13-141 Subject to change without notice www.asco.com/g3...
  • Page 142 G3 Series EtherCAT Technical Manual Error / Event Log: Allow user to clear Keeps a running count of 50 Allows user to add events. comments First in First out (FIFO) Reboot events are shown in red TDG3ECM1-5EN 07/2020 13-142 Subject to change without notice www.asco.com/g3...
  • Page 143 G3 Series EtherCAT Technical Manual Help: The “Help” tab is a quick link to Aventics’ website. The computer must have internet access for this tab to be functional. TDG3ECM1-5EN 07/2020 13-143 Subject to change without notice www.asco.com/g3...

  • Page 144: Tm Node (Windows 10)

    G3 Series EtherCAT Technical Manual IP Address Configuration EtherCAT fieldbus devices do not communicate using a standard IP address. The Aventics G3 node’s IP address is only used to access the nodes integrated web server for configuration and diagnostic information via a personal computer’s web browser.

  • Page 145: User Configurable Device Parameters

    G3 Series EtherCAT Technical Manual User Configurable Device Parameters The Aventics’ G3 EtherCAT node allows the user to set many user options which define how the manifold behaves in certain instances. The following is a description of these device parameters. Settable Via Name Description...
  • Page 146 G3 Series EtherCAT Technical Manual Communication Fault Sequence The Communication Fault parameter determines the output state if the device encounters a communication fault. A Communication Fault is defined as an inability for the master node to communicate with a slave node on a network. The process for determining the output state during a Communication Fault/Idle Mode is as follows: The device receives a Communication Fault event.

  • Page 147: G3 Ethercat Tm Plc Configuration

    G3 Series EtherCAT Technical Manual G3 EtherCAT PLC Configuration Create Aventics G3 EtherCAT configuration (Beckhoff PLC) The following example illustrates the necessary steps to add a Aventics G3 EtherCAT Manifold to an existing Beckhoff PLC configuration. This includes how to install the Aventics EtherCAT XML file and how to select the various software components to configure a G3 Manifold (GSD and XML files are available at www.asco/g3.com).
  • Page 148 G3 Series EtherCAT Technical Manual Add the G3 EtherCAT node Launch TwinCAT “System Manager” Select I/O Configuration Expand I/O Devices Right Click I/O Devices Select Append Box TDG3ECM1-5EN 07/2020 14-148 Subject to change without notice www.asco.com/g3...
  • Page 149 G3 Series EtherCAT Technical Manual The “Insert EtherCAT Device” Dialogue Box Appears Select the “Numatics Inc.” Device Folder Double Click Numatics G3 TDG3ECM1-5EN 07/2020 14-149 Subject to change without notice www.asco.com/g3...
  • Page 150 G3 Series EtherCAT Technical Manual Create the G3 I/O mapping Expand the “Numatics G3” Box (device) Press the “Linked to” button to select an input variable (byte) to map to the G3 manifold Note- the I/O variables must already exist within the associated PLC Control Project TDG3ECM1-5EN 07/2020 14-150...
  • Page 151 G3 Series EtherCAT Technical Manual Select the Variable tag(s) from the PLC program to associate with the G3 Input Byte(s) Expand the Numatics G3 Outputs list Press the “Linked to” button to select an output variable (byte) to map to the G3 manifold Select the Variable tag(s) from the PLC program to associate with the G3 Output Byte(s) TDG3ECM1-5EN 07/2020...

  • Page 152: Twincat Configuration For Ip Communication Over Ethercat

    G3 Series EtherCAT Technical Manual Twincat configuration for IP communication over EtherCAT (Beckhoff PLC) This configuration is required for a PC to communicate with the G3 node web page through the EtherCAT master device. Expand the “Numatics G3” Box (device) Select the EtherCAT Click advanced settings TDG3ECM1-5EN...
  • Page 153 G3 Series EtherCAT Technical Manual Expand the mailbox item Select EOE (Ethernet over EtherCAT Check “Virtual Ethernet Port” Select “IP Port” TDG3ECM1-5EN 07/2020 14-153 Subject to change without notice www.asco.com/g3...
  • Page 154 G3 Series EtherCAT Technical Manual Select the box for IP Address Enter an IP address of the G3 EtherCAT node Enter the Subnet mask Enter the default Gateway (The gateway must be the same as the Beckhoff controller’s virtual port address) Enter the DNS name “netx”...

  • Page 155: Configure Ip Communication With G3 Over Ethercat

    G3 Series EtherCAT Technical Manual Configure IP communication with G3 over EtherCAT (Beckhoff PLC) The Beckhoff PLC must be specifically configured to allow ethernet communications with the G3 node to access the G3 web page. This is accomplished by connecting a PC to the EtherCAT master device’s ethernet port and connecting to the G3 node via ethernet over Ethercat (EoE) using the PLC’s virtual Ethernet port.

  • Page 156: Create Aventics G3 Ethercat Tm Configuration (Lenze Plc)

    G3 Series EtherCAT Technical Manual Create Aventics G3 EtherCAT configuration (Lenze PLC) The following example illustrates the necessary steps to add a Aventics G3 EtherCAT Manifold to an existing Lenze PLC configuration. This includes how to install the Aventics EtherCAT XML file and how to select the various software components to configure a G3 Manifold (GSD and XML files are available at www.asco.com/g3).
  • Page 157 G3 Series EtherCAT Technical Manual Configure the location of the Aventics G3 XML file Select Install Select the XML file TDG3ECM1-5EN 07/2020 14-157 Subject to change without notice www.asco.com/g3...
  • Page 158 G3 Series EtherCAT Technical Manual Add the G3 EtherCAT node PLC Designer V3.8 Select the EtherCAT Master from the Project Tree Right Click and Select Add Device TDG3ECM1-5EN 07/2020 14-158 Subject to change without notice www.asco.com/g3...
  • Page 159 G3 Series EtherCAT Technical Manual Select the Numatics G3 Select Add Device Double Click Numatics G3 TDG3ECM1-5EN 07/2020 14-159 Subject to change without notice www.asco.com/g3...
  • Page 160 G3 Series EtherCAT Technical Manual Select the PLC Program Tab Create the G3 I/O Program (Byte) Variables that will connect to the G3 I/O map Example Outputs – OutB0, OutB1, OutB2 etc. Example Inputs – InB0, InB1, InB2 etc. TDG3ECM1-5EN 07/2020 14-160 Subject to change without notice...
  • Page 161 G3 Series EtherCAT Technical Manual Map the G3 I/O data to program variables Select the Mapping reference for %QB0 (byte 0 Output data) Press the Radio button to launch the Input Assistant (PLC variables table) Select the Variable that will reference Byte 0 of G3 Outputs TDG3ECM1-5EN 07/2020 14-161...
  • Page 162 G3 Series EtherCAT Technical Manual Complete Mapping all necessary G3 Output Data to PLC variables Complete Mapping all necessary G3 Input Data to PLC variables TDG3ECM1-5EN 07/2020 14-162 Subject to change without notice www.asco.com/g3...

  • Page 163: Create Aventics G3 Ethercat Tm Configuration (Omron Plc)

    G3 Series EtherCAT Technical Manual Create Aventics G3 EtherCAT configuration (Omron PLC) The following example illustrates the necessary steps to add an Aventics G3 EtherCAT Manifold to an existing Omron PLC configuration. This includes how to install the Aventics EtherCAT XML file and how to select the various software components to configure a G3 Manifold (XML files are available at www.asco.com/g3).
  • Page 164 G3 Series EtherCAT Technical Manual Add the G3 EtherCAT node Open the Sysmac Studio project Double click EtherCAT Scroll through the devices under the toolbox list at the right to find the Numatics G3 Drag the Numatics G3 to the EtherCat master TDG3ECM1-5EN 07/2020...
  • Page 165 G3 Series EtherCAT Technical Manual Configure the G3 EtherCat Node Address Set the G3 Station Alias to match the Omron Node Address setting For more information on setting Station Alias; see page 5-32 Station Alias TDG3ECM1-5EN 07/2020 14-165 Subject to change without notice www.asco.com/g3...
  • Page 166 G3 Series EtherCAT Technical Manual Assign Variables to the G3 I/O map data for the PLC program Build the Controller project and Transfer to controller TDG3ECM1-5EN 07/2020 14-166 Subject to change without notice www.asco.com/g3...

  • Page 167: Ethercat Tm Mapping

    G3 Series EtherCAT Technical Manual EtherCAT Mapping I/O Sizes Manifold utputs Outputs are defined as any valve solenoid coil and/or any discrete output point from any output module. The output size depends upon the physical configuration of the manifold (i.e. module type and how many are used). Please reference the following pages for a detailed explanation for calculating the output size.

  • Page 168: Manifold And I/O Data Sizing Worksheet

    G3 Series EtherCAT Technical Manual Manifold and I/O Data Sizing Worksheet : Choose appropriate value and place the corresponding Input and Output values in the boxes labeled, “Valve Byte Requirements” at the bottom of the page : Choose up to sixteen modules to be included on the discrete I/O side of the manifold and place sum of the corresponding input bytes and output bytes in the boxes labeled, “Sub-Bus Byte Requirements”...

  • Page 169: Bit Mapping Rules

    G3 Series EtherCAT Technical Manual Bit Mapping Rules The bit mapping for a G3 manifold varies with the physical configuration of the manifold. The following is a breakdown of the bit mapping rules associated with the Aventics valve manifold. Valve Side Solenoid coil outputs are connected to the valve coils using the Z-Boards ™...
  • Page 170 G3 Series EtherCAT Technical Manual I/O Mapping Examples Assumed Settings Example No. 1 Double Z-Boards used with all valves I/O Modules and mapping schemes are identified by their corresponding color. I/O Status bits are enabled Diagnostic Word is enabled Manifold I/O Configuration Module Type Part No.
  • Page 171 G3 Series EtherCAT Technical Manual Example No. 1 Table Output Table BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil No.
  • Page 172 G3 Series EtherCAT Technical Manual Assumed Settings Example No. 2 Double Z-Boards used with all valves I/O Modules and mapping schemes are identified by their corresponding color. I/O Status bits are enabled Diagnostic Word is enabled Manifold I/O Configuration Pos. Module Type Part No.
  • Page 173 G3 Series EtherCAT Technical Manual Example No. 2 Table Output Table BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil No.
  • Page 174 G3 Series EtherCAT Technical Manual Assumed Settings Example No. 3 Double Z-Boards used with all valves I/O Modules and mapping schemes are identified by their corresponding color. I/O Status bits are enabled Diagnostic Word is enabled Manifold I/O Configuration Module Type Part No.
  • Page 175 G3 Series EtherCAT Technical Manual Example No. 3 Table Output Table BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil No.
  • Page 176 G3 Series EtherCAT Technical Manual Assumed Settings Example No. 4 Double Z-Boards used with all valves I/O Modules and mapping schemes are identified by their corresponding color. I/O Status bits are enabled Diagnostic Word is enabled Manifold I/O Configuration Module Type Part No.
  • Page 177 G3 Series EtherCAT Technical Manual Example No. 4 Table Output Table BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil Valve Coil No.

  • Page 178: I/O Mapped Diagnostic Word

    G3 Series EtherCAT Technical Manual I/O Mapped Diagnostic Word Diagnostic Word Format BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Sub-Bus Sub-Bus Un-Switched Switched Reserved Reserved Reserved Reserved Short Circuit Error Power Status Power Status (Comm.
  • Page 179 G3 Series EtherCAT Technical Manual I/O Mapped Diagnostic Word Continued Byte 1 (Sub-Bus Status) Module Address Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Description No error Communication Module I/O module No. 1 I/O module No. 2 I/O module No. 3 I/O module No.

  • Page 180: Appendix

    G3 Series EtherCAT Technical Manual Appendix System Specifications Electrical Valves (2005, 2012, 2035): 24 VDC + 10%, -15% Supply Voltage Valves (501, 502, 503): 24 VDC +/- 10% Node and Discrete I/O: 24 VDC ± 10% Total current on the Auxiliary Power Connector (“Valves and Outputs” and Current “Node and Inputs”...

  • Page 181: Factory Default Settings

    G3 Series EtherCAT Technical Manual Factory Default Settings FACTORY DEFAULT SETTINGS Description Default IP Address 193.168.003.120 Subnet Mask 255.255.255.0 Gateway IP 0.0.0.0 I/O Status Enabled Diag. Word Enabled Fault Action Brightness Medium Parameters Unlocked I/O configuration Unlocked TDG3ECM1-5EN 07/2020 16-181 Subject to change without notice www.asco.com/g3...
  • Page 182 G3 Series EtherCAT Technical Manual G3 EtherCAT Process Data Map The following process data map is available from the G3 node over EtherCat communications to controllers capable of reading the manifold configuration and building an internal mapping and diagnostic table. Object Index:SubIndex Description...

  • Page 183: Troubleshooting

    G3 Series EtherCAT Technical Manual Troubleshooting Communication Node Symptom Possible Cause Solution Check that correct Z-Board types are Z-Board type mismatch. The wrong valve solenoid coils installed. Check that ribbon cable Single Z-Board present are being energized. (Output group No. 2) is connected to where double Z-Board appropriate valve station.

  • Page 184: Glossary Of Terms

    G3 Series EtherCAT Technical Manual Glossary of Terms The following is a list and description of common terms and symbols used throughout this document: Term Description Address A protocol used to set an IP address using a MAC Address hardware address. This can be done in the Resolution command prompt window.
  • Page 185 G3 Series EtherCAT Technical Manual Glossary of Terms Continued Term Description NEMA National Electrical Manufacturers Association Network A group of nodes connected by a communication medium through repeaters, router, and gateways. Node A device on the network that contains a single MAC Address, which can communicate over a subnet. Octet 8 bits of information.

  • Page 186: Technical Support

    G3 Series EtherCAT Technical Manual Technical Support For technical support, contact your local Aventics distributor. If further information is required, please call the Technical Support Department at (248) 596-3337. Issues relating to network setup, PLC programming, sequencing, software related functions, etc. should be handled with the appropriate product vendor.

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