AndonTap
V6 user manual
How to mount, wire, power, connect and set up the AndonTap DIN-rail machine monitor, and how to read its data from Kepware, Ignition, a PLC or an MES.
Read section 1 (Safety) before you install. Inputs 1-4 can carry 120 VAC. Installation must be done by qualified personnel with the circuits switched off.
This manual covers V6 hardware with firmware 1.5. Items marked Planned or "to be confirmed" are not yet available or not yet verified on V6 hardware.
Safety
- Qualified personnel only. Installation, wiring and service must be done by a qualified electrician or a person trained for work in industrial control panels, following local electrical codes.
- De-energise before wiring. Switch off and lock out every circuit connected to the unit (the 24 VDC supply, the machine's 120 VAC stack-light circuit, the machine signals on inputs 5-8, and the PoE switch port) before you connect, disconnect, plug or unplug any terminal. Check with a meter that the circuit is dead.
- Inputs 1-4: one voltage per group. IN1-IN4 share one common, COM-A. All four inputs must be fed from the same circuit and the same voltage: either all 120 VAC from one source, or all 24 VDC from one source.
- Never mix 120 V and 24 V on the same COM. A 120 V lamp and a 24 V switch must never be wired to the same group. Never connect a 24 V signal to COM-A when another input of the group carries 120 VAC.
- Inputs 5-8 are 24 VDC only. Never connect 120 VAC, or any mains voltage, to the 7-pin IN5-8 plug (24V OUT, 0V, COM-B, IN5-IN8), to the CT plugs, to the power plug, or to USB-C. Doing so can destroy the unit and make exposed parts live.
- Mount inside a closed control panel. The unit is intended for use inside an enclosure that is only opened by qualified personnel (IP20 module). Do not operate it with the housing open.
- Isolation barrier not yet lab-evaluated. Inputs 1-4 sit on the field side of an internal isolation barrier that is designed as reinforced insulation for 120 VAC (reinforced-rated optocouplers, 6 mm creepage target). Its rating has not yet been confirmed by a test laboratory. As a precaution, switch off the 120 VAC circuit on IN1-4 before connecting a laptop to USB-C, or use Bluetooth setup instead.
- No approvals. The unit carries no safety or radio approvals at this time. The panel builder is responsible for the panel's compliance with local codes.
- CTs: voltage-output types only. Connect only split-core CTs with a 333 mV or 1 V AC output. Never connect a current-output CT (1 A or 5 A secondary): an open current-output CT can produce dangerous voltages, and it will damage the input.
- Branch protection. Protect the 24 VDC feed and the 120 VAC stack-light circuit that feeds IN1-4 with fuses or breakers sized per your panel design and local code. The unit has an internal 0.5 A resettable fuse on its 24 V input; it is not a substitute for branch protection.
- Monitoring only. The unit is a monitor. It must not be used as part of a safety function. A door switch or E-stop status wired to inputs 5-8 is read for information only; it does not replace the machine's safety circuit.
- Earth. Connect PE (pin 3 of the power plug) to the panel's protective earth.
Symbols in this manual: Danger marks a risk of electric shock or fire. Caution marks a risk of damage or wrong readings. Planned marks a function that is not available yet.
The unit at a glance
AndonTap is a 26.4 mm wide DIN-rail module that watches one machine. It reads the machine's stack light (inputs 1-4, 24 VDC or 120 VAC), up to four 24 VDC machine signals (inputs 5-8), and spindle and auxiliary current through two clip-on current transformers. From these it works out the machine state (Running, Idle, Alarm, Setup and more), counts and run times, and serves them over Ethernet as Modbus TCP and EtherNet/IP.
| J1 · Power | +24V · 0V · PE3-pin pluggable, 5.08 mm |
|---|---|
| J4 · Inputs 1-4 | COM-A · IN1-IN45-pin pluggable, 5.08 mm · 24 VDC or 120 VAC, any polarity · field side of the isolation barrier |
| J8 · Inputs 5-8 | 24V OUT · 0V · COM-B · IN5-IN87-pin pluggable, 3.5 mm · 24 VDC only, sinking or sourcingIN5-8 firmware planned |
| J6 · J7 · CT1 · CT2 | 2-pin pluggable, 3.5 mm each333 mV or 1 V AC split-core CTs |
| RJ45 | 10/100 Ethernet with PoE (802.3af) built inBottom end wall · green LED link, yellow LED activity |
| USB-C | Setup console, firmware loading, bench power |
| SMA | LoRaWAN antenna, top end wallPlannedKnock-out, closed on units without the option |
What the unit does
- Samples every input at 1 kHz; tells steady from flashing lamps and counts part pulses.
- Reads CT current as true RMS; spindle reported as stopped, turning or cutting.
- Up to 8 IF/THEN rules turn lamps and current into a machine state.
- Keeps counters in non-volatile memory (FRAM) through power loss and firmware updates.
- Serves the data over Modbus TCP (port 502) and EtherNet/IP (port 44818).
- Sends nothing on the network until an address is set.
What's in the box
In the box To be confirmed
- AndonTap V6 module
- Mating plugs: 3-pin 5.08 mm (power), 5-pin 5.08 mm (inputs 1-4), 7-pin 3.5 mm (inputs 5-8), two 2-pin 3.5 mm (CT1, CT2)
- Quick Start Guide
The final box contents will be confirmed with the first production units.
Downloads (from andontap.com/downloads)
- Setup app (
cncmon_setup.html), a single file that runs in Chrome or Edge - EtherNet/IP EDS file
- Network firmware update tool and firmware files
- This manual and the datasheet
Not included
- Current transformers (333 mV or 1 V AC output, split-core)
- 24 VDC supply, PoE switch, Ethernet cable
- LoRaWAN antenna and coax (LoRaWAN builds)
Mounting
The module clips onto a standard TS35 × 7.5 DIN rail (EN 60715) and stands upright on it: the long, narrow front face with the terminals faces you, the USB-C end points up and the RJ45 end points down so the network cable drops into the wire duct.
To mount
- Hold the module with the USB-C end up.
- Hook the fixed hook at the back over the upper lip of the rail.
- Push the bottom of the module against the rail until the latch snaps over the lower lip.
- Check that the module is held firmly.
To remove
- Switch off and unplug all terminals.
- Put a flat screwdriver in the loop of the pull rod at the bottom (RJ45) end, at the back.
- Pull it down about 2.5 mm and tilt the module off the rail.
Space and placement
- Width on the rail: 26.4 mm. Modules can butt together; both cover screws stay reachable with neighbours on the rail.
- Depth: about 83 mm from the rail to the front face, plus the plugs and their wires.
- Cooling: passive, through vent slots in both end walls. Leave the top and bottom ends unobstructed, and keep wire duct clear of the vent slots.
- Bluetooth: a closed steel panel blocks most of the Bluetooth signal. For phone setup, open the panel door.
- Keep 120 V and 24 V wiring apart in the duct as your panel standard requires; route the IN1-4 wires away from the IN5-8 and CT wires.
Dimensions are from the current enclosure, which holds the same board. The V6 enclosure openings are being finalised; the outline is expected to stay but is to be confirmed.
Wiring
De-energise and lock out all circuits before connecting or unplugging any terminal. Wire each plug while it is out of the unit, then plug it in. Inputs 1-4 may carry 120 VAC.
General
- All field connections are pluggable screw terminals. Wire the plug off the unit, then push it in until it seats.
- Use ferrules on stranded wire. Wire size, strip length and screw torque: follow the plug maker's dataTo be confirmed. The power plug is Phoenix Contact MSTB 2,5/3-ST-5,08 (1757022) or equivalent.
- The plugs have different sizes and pin counts (3, 5 and 7 pins), so the power, 120 V and 24 V plugs cannot be swapped by accident. The two CT plugs are the same; check CT1 and CT2 against the front label.
- Pin 1 is the top pin of each plug when the module is mounted upright.
5.1J1 · Power: +24V / 0V / PE
| Pin | Name | Connect to |
|---|---|---|
| 1 | +24V | +24 VDC supply |
| 2 | 0V | Supply return (0 V) |
| 3 | PE | Panel protective earth |
- 24 VDC nominal. The working voltage range is to be confirmed in qualification.
- Protected inside by a reverse-polarity diode, a 0.5 A resettable fuse and a surge clamp. A reversed supply does not power the unit; the 24V LED stays off.
- PE is on pin 3 of this plug; there is no separate earth terminal. Inside, PE connects to the RJ45 cable shield through 1 nF / 1 MΩ. The unit's 0 V is not connected to PE.
- J1 may be left unconnected on PoE-powered units (section 6).
5.2J4 · Inputs 1-4 + COM-A (24 VDC or 120 VAC)
- One voltage per group: all four inputs and COM-A on the same circuit, either all 120 VAC or all 24 VDC.
- Never mix a 120 V signal and a 24 V signal on COM-A.
- Switch off the stack-light circuit before plugging or unplugging J4.
| Pin | Name | Typical use |
|---|---|---|
| 1 | COM-A | Common for IN1-IN4: the lamp return (neutral for 120 VAC; 0 V or +24 V for 24 VDC) |
| 2 | IN1 | Red lamp (factory setting) |
| 3 | IN2 | Amber lamp (factory setting) |
| 4 | IN3 | Green lamp (factory setting) |
| 5 | IN4 | 4th tier (blue / white), part counter or a signal; unused by default |
- Voltage: 24 VDC or 120 VAC 50/60 Hz, detected automatically, no jumpers. DC works in either polarity.
- Load: about 2 mA per input (constant current), so the unit can be connected in parallel with the lamps without affecting them.
- ON threshold: above 9.3 V worst case (design value).
- Each input lights up live on the setup app's Stack light page, so you can check the wiring lamp by lamp (section 8).
5.3J8 · Inputs 5-8 + COM-B + 24V OUT (24 VDC only)
| Pin | Name | Function |
|---|---|---|
| 1 | 24V OUT | 24 V output for dry contacts and small sensorsOn-board boost from the internal 5 V, 0.1 A resettable fuse. Available on PoE-only installs. |
| 2 | 0V | Return for 24V OUT (the unit's 0 V) |
| 3 | COM-B | Common for IN5-IN8 |
| 4 | IN5 | Door switch, feed hold, part count, lube / air / coolant switch, M-code relay, operator call |
| 5 | IN6 | |
| 6 | IN7 | |
| 7 | IN8 |
- 24 VDC only. Never 120 VAC.
- Sinking or sourcing, like a PLC input card, set by where COM-B goes:
- COM-B to 0V: sourcing signals (PNP sensors, dry contacts fed from +24 V).
- COM-B to +24V: sinking signals (NPN sensors).
- All four inputs share COM-B, so all four must be the same type: all sourcing or all sinking.
- ON at about 8 V (design value), about 4.8 mA at 24 V; 12 V machine signals switch with margin.
- The inputs are optically isolated, so COM-B can go to the machine's own 0 V or +24 V.
- 24V OUT is fused at 0.1 A for all loads together. A short trips the fuse; it resets by itself once the short is removed. Full-load capability is to be confirmed on V6 hardware, so keep sensor loads small.
Choosing COM-B
- Signal switches +24 V onto the input (PNP, dry contact from +24 V, PLC sourcing output): COM-B to 0 V.
- Signal pulls the input to 0 V (NPN, PLC sinking output): COM-B to +24 V.
- Use 24V OUT / 0V on the plug when the unit supplies the loop (A, B, C). Use the cabinet supply when the machine supplies the signal (D). Do not join 24V OUT to another 24 V supply.
5.4J6 / J7 · CT1 and CT2
| Plug | Pin | Connect |
|---|---|---|
| J6 CT1 | 1 · 2 | Spindle CT, the two output leads |
| J7 CT2 | 1 · 2 | Second CT: coolant pump, conveyor, hydraulics, main power or a second spindle |
- CT type: voltage-output split-core CT, 333 mV or 1 V AC at full scale. CT ratings from 1 to 5000 A are set in the setup app.
- One conductor only. Clamp the CT around a single phase conductor (for example L1 of the spindle motor or drive feed). Around a whole cable, the currents cancel and the reading is near zero.
- Orientation: the reading is true RMS, so the direction of the CT and which lead goes to pin 1 do not change it. For consistency, point the CT's arrow toward the load and put the same lead colour on pin 1 on every unit.
- Small currents: loop the conductor through the CT several times and set the number of wire passes (1-20) in the setup app; the reading is divided by it.
- On a VFD-driven spindle, put the CT on the drive's input or output consistently, and capture the thresholds live (section 8).
- Keep CT leads away from 120 V and motor wiring where possible; extend with twisted pair if needed.
5.5RJ45 · Ethernet and PoE
- Standard Cat5e or better patch cable to a 10/100 switch port. The jack is in the bottom end wall.
- An IEEE 802.3af switch port or injector can power the unit through the same cable (section 6).
- Jack LEDs: green = link, yellow = activity.
- The cable shield connects to PE (J1 pin 3) through 1 nF / 1 MΩ, so connect PE.
5.6USB-C
USB-C is for setup, diagnostics and firmware loading from a laptop, and it can power the unit on the bench. It is not meant as a permanent connection. See the caution in section 1 about using USB-C while 120 VAC is connected to IN1-4.
5.7SMA · LoRaWAN antenna optionPlanned
LoRaWAN builds have a bulkhead SMA jack in the top end wall; on other units this opening is a closed knock-out. In a metal cabinet, mount the antenna on the cabinet roof and run a short low-loss coax cable down to the SMA jack. A whip antenna screwed straight onto the jack is only suitable in plastic cabinets or open mounting. LoRaWAN firmware, frequency-plan variants and the antenna kit are to be confirmed.
Power options
| Source | How | Notes |
|---|---|---|
| 24 VDC | J1: +24V, 0V, PE | Standard. The 24V LED lights. Working range to be confirmed. |
| PoE | RJ45 from an IEEE 802.3af switch port or injector (Class 0, mode A or B) | Built into every unit. The PoE LED lights. Isolated PoE module. |
| 24 VDC and PoE | Both connected | Allowed. The two are combined internally; the unit keeps running if either one fails. |
| USB-C | 5 V from a laptop or USB supply | Bench setup and firmware loading only. |
- 24V OUT on J8 comes from an internal boost converter, so it is available with any of the sources above, including PoE alone.
- Power consumption is to be measured on V6 hardware.
- PoE-only units and the "Off" state. The factory state rules start with "no 24 V on J1 = machine Off". This lets a PoE-powered unit see whether the machine is powered: wire J1 +24V / 0V from the machine's control-power supply. If J1 is not connected on a PoE unit, change or delete that rule in the setup app, or the machine will always read Off.
- The unit reports the J1 voltage and the PoE supply voltage in its data (input registers 6 and 7), and whether each is present (status bits 8 and 9).
Network setup
A new unit has no IP address and sends nothing on the Ethernet port, not even DHCP requests or IPv6 traffic. This makes it safe to plug into a plant control network before it is set up. You give it an address over USB-C or Bluetooth.
Option A · Setup app (recommended)
- Open
cncmon_setup.htmlin Chrome or Edge on a laptop, or in Chrome on an Android phone. On an iPhone use the Bluefy browser. - Connect over USB-C (USB cable to the unit) or Bluetooth (pick
CNCMON-XXXXXXfrom the list). - Go to Network & security, choose Static, and enter the IP address, subnet mask and gateway from your network administrator (gateway 0.0.0.0 if the network has none).
- Click Write to unit. The unit checks the address, saves it and restarts on it.
Option B · Console commands
Any serial terminal on USB-C (any baud rate), or a "BLE UART" phone app (for example Serial Bluetooth Terminal, Bluefruit Connect or nRF Toolbox) on Bluetooth:
ip static 10.20.30.40 255.255.255.0 10.20.30.1
Replace the three addresses with yours. The unit saves and restarts. Type status to check.
Bluetooth setup window
- A unit with no address has Bluetooth on all the time; the blue BT LED blinks slowly.
- On a unit that already has an address, short-press CFG to turn Bluetooth on for 10 minutes.
- The unit advertises as
CNCMON-XXXXXX; the six characters are the end of its MAC address and match its host namecncmon-xxxxxx. - BT goes solid when a phone is connected. The radio turns off after the address is set and the unit restarts, 10 minutes after the last command, or with
bt off. - Range is short. A closed steel panel blocks most of the signal; open the door.
Other address options
- DHCP: choose DHCP in the setup app, or
ip dhcp. Find the unit in the DHCP server's lease table by its host namecncmon-xxxxxx. - Clear the address:
ip clear, or hold CFG for 10 s (section 9). The unit goes silent on the network and Bluetooth turns on. - The network settings can also be changed over Modbus when the unit is set to remote writes "full" (section 10).
For the IT / OT administrator
| TCP 502 | Modbus TCP server (up to 4 clients) |
|---|---|
| TCP/UDP 44818 | EtherNet/IP explicit messaging |
| UDP 2222 | EtherNet/IP class 1 I/O |
| TCP 80 | Only while a firmware update window is open (10 min) |
| Wi-Fi · IPv6 | Off |
First-time configuration
Everything is set in the setup app (cncmon_setup.html), over USB-C or Bluetooth. Changes collect in a Write to unit bar; the unit checks every write and applies all of it or none of it. The unit's clock is set from the laptop or phone each time the app connects. A Demo unit mode runs a simulated machine for training.
- Machine: enter the machine name and asset ID. They are served in the data, so Kepware and the PLC see which machine this is.
- Stack light: for each input choose a role (lamp, part counter, signal or unused), and for lamps the colour, tier position and label. Each row lights live, so with the machine running you can confirm red, amber and green one by one. With firmware 1.5 on V6, set inputs 5 and 6 to Unused (inputs 5-8 are read in a planned update).
- Spindle & CTs: set the number of CTs, the CT rating (A), output (333 mV or 1 V) and wire passes. Enter the spindle motor full-load amps to get suggested thresholds, or run the spindle and capture the idle-turning and cutting currents live. Choose what CT2 watches.
- State rules: check the rules that turn lamps and current into a machine state (below). The rule that matches right now glows.
- Network & security: address (section 7), Modbus and EtherNet/IP on or off, the setup PIN, and the remote-write level.
- Data map & export: export the Kepware tag CSV and the Studio 5000 UDT (.L5X), named with this machine's lamps and CTs.
- Save: save a setup file. To set up the next identical machine, load and clone it; cloning keeps the new unit's own name and IP address.
| Network | No address (silent) |
|---|---|
| Inputs | IN1 red, IN2 amber, IN3 green lamp; others unused |
| Debounce / flash window | 100 ms / 1500 ms |
| CT | 1 CT, 100 A : 333 mV, 1 pass |
| Spindle thresholds | On 2.00 A, cutting 5.00 A |
| Modbus · EtherNet/IP | On · On |
| Remote writes | Basic |
| Setup PIN | None |
| J1 wired to the machine's 24 V | Off (PoE-only units do not report Off) |
| # | If | Then |
|---|---|---|
| 1 | No 24 V on J1 (counts only when "J1 is wired to the machine's 24 V supply" is on) | Off |
| 2 | Red on or flashing | Alarm |
| 3 | Green flashing | Setup |
| 4 | Green on | Running |
| 5 | Amber on or flashing | Warning |
| – | None of the above | Idle |
Up to 8 rules, each with up to 3 conditions on lamp colours, single inputs, spindle level, CT2 and 24 V power. States: Unknown, Off, Idle, Running, Alarm, Setup, Warning, Maintenance.
Setup app over the plant networkPlanned
A later firmware lets you reach the setup app over Ethernet once the unit has its IP address. On any PC on the same plant network, open http://<unit IP> in Chrome or Edge: the unit serves the app from its own memory, with the same live screens (lamps, states, counts, spindle current) and the same settings. Changes need the setup PIN, with the same lockout after wrong guesses. Giving a new unit its first address is still done at the unit, over USB-C or Bluetooth (section 7). Firmware 1.5 does not have this yet.
Setup PIN and security
- A 4-6 digit setup PIN can be set in Network & security. When set, it is required for changes over Bluetooth, and optionally over USB-C as well. Five wrong PINs block PIN entry on that port for 5 minutes.
- Bluetooth is only on when no address is set or after a CFG press, so setup needs physical access to the unit.
- Forgot the PIN: hold CFG for 10 s. This clears the PIN and the IP address; counters are kept.
- Factory reset (setup app Device page, or
factoryon the console) returns all settings to the factory values, including the network address (the unit goes off the network), and sets all counters to zero.
Console commands
| Command | Does |
|---|---|
| status | Live values, network settings, supply voltages, which internal chips answered |
| ip static IP MASK GW [DNS] | Fixed address; saves and restarts |
| ip dhcp · ip clear | DHCP, or no address; saves and restarts |
| time UNIX_SECONDS | Set the clock (UTC) |
| unlock PIN | Unlock when a setup PIN is set |
| bt off | Close the Bluetooth window now |
| remote off|basic|full | What Modbus / EtherNet/IP clients may change |
| update arm | Open the 10-minute network firmware update window |
| diag | Firmware version and update state, reset reason, memory |
| reset counters · identify · reboot · factory | Zero counters · flash the blue LED 10 s · restart · factory reset |
Lamps, CTs, rules and names are set in the setup app, not on the console.
LEDs and buttons
| LED | State | Meaning |
|---|---|---|
| 24V | On | DC supply present on J1 (correct polarity) |
| Off | No DC supply, or reversed. Normal on PoE-only units. | |
| PoE | On | PoE power present |
| STATUS | Blinking (1 s) | Running, but no network yet: no cable / link, no address set, or waiting for DHCP |
| On | Link up and IP address set | |
| Off | No power, or firmware not running | |
| BT | Off | Bluetooth off |
| Slow blink | Bluetooth setup open, waiting for a connection | |
| On | Phone / app connected, or CFG being held | |
| Fast flash | Identify command (10 s), or CFG held past 10 s (clearing, then restart) | |
| FAULT | On | An internal chip did not answer: memory (FRAM), CT converter or Ethernet controller. status shows which. |
| Button | Action | Result |
|---|---|---|
| CFG | Short press (< 2 s) | Bluetooth setup on for 10 minutes |
| Hold 10 s | Clears the IP address and the setup PIN, then restarts with no address and Bluetooth on. Counters and other settings are kept. | |
| RST | Press | Restart (counters are kept) |
| BOOT | Hold while pressing RST | Firmware load mode, for USB-C firmware loading only |
CFG has a captive push key in the bezel. RST and BOOT are recessed: press them with a straightened paper clip.
| New unit, powered | 24V (or PoE) on · STATUS blinking · BT slow blink |
|---|---|
| Address set, cable in | STATUS on · BT off · jack link LED on |
| Running normally | 24V / PoE on · STATUS on · FAULT off |
Data and protocols
The same data is served over Modbus TCP (port 502, any unit ID, up to 4 clients) and EtherNet/IP (adapter, explicit messaging and class 1 I/O). The register layout is fixed and identical on every unit, so one Kepware template or one Logix UDT covers a whole floor. This section is a summary; the full table is in the Register Map document and on the setup app's Data map & export page, which also exports ready-to-import Kepware and Studio 5000 files.
| Reg | Data |
|---|---|
| 0 | Status bits: inputs, spindle, 24 V, PoE, link, clock, FAULT |
| 1 | Firmware version (0x0105 = 1.5) |
| 2-7 | Uptime, UTC time, 24 V and PoE supply voltages |
| 8 | Machine state |
| 9 | Spindle level: 0 stopped, 1 turning, 2 cutting |
| 10-15 | Input states: 0 off, 1 on, 2 flashing |
| 16-19 | Spindle and CT2 current, 0.01 A RMS |
| 20-55 | Per input: count (or parts), on time, flashing time |
| 56-65 | Spindle on / cut time, starts; CT2 run time, starts |
| 66-83 | Seconds in each machine state; state changes |
| 84-98 | Boot count, powered time, clients, diagnostics, remote-write level |
| 100-123 | Machine name and asset ID (ASCII) |
| 0 | Unknown | 4 | Alarm |
| 1 | Off | 5 | Setup |
| 2 | Idle | 6 | Warning |
| 3 | Running | 7 | Maintenance |
- Addresses are 0-based. In Kepware with zero-based addressing on, input register 0 is
300001. - 32-bit values use two registers, low word first (Kepware DWord default), and start on an even register.
- Holding registers 1000-1123 mirror input registers 0-123 for clients that only read FC 03.
- Counters are saved every second and survive power loss and firmware updates.
- V6 inputs: registers 10-55 carry inputs 1-6 in firmware 1.5; on V6 only inputs 1-4 are wired to these slots today. Inputs 5-8 of the V6 board are planned: slots 5-6 for inputs 5-6, and inputs 7-8 added after register 123 so existing clients do not move.
Writing to the unit
Holding registers 0-31 accept settings and commands. What a client may change is set by the remote-write level; USB-C and Bluetooth setup are not affected by it.
| Level | Modbus / EtherNet/IP clients may |
|---|---|
| off | Read only |
| basic factory | Also set the spindle / CT2 thresholds, debounce and clock; identify; reset counters |
| full | Also change network settings, restart, factory reset, and open the firmware update window |
A write that is not allowed is refused with Modbus exception 01 and changes nothing. Names, lamps, CTs, rules and the PIN can only be set in the setup app.
MQTT
Firmware 1.5 does not include MQTT. Data is available over Modbus TCP and EtherNet/IP; a gateway such as Kepware or Ignition can publish it to MQTT.
PLC and SCADA integration
Kepware (Modbus TCP/IP Ethernet driver)
- Add a Modbus TCP/IP Ethernet device with the unit's IP address (port 502, any device ID).
- In the setup app, Data map & export, export the Kepware tag CSV and import it into the device.
- Keep zero-based addressing on and first-word-low for 32-bit values (the driver defaults).
Ignition, MES and other Modbus clients
Read input registers 0-123 (FC 04), or holding registers 1000-1123 (FC 03). Use the register map for names and types.
Allen-Bradley Logix (Studio 5000)
- Add a Generic Ethernet Module, comm format Data - INT.
- Input assembly 100, size 100. Output assembly 150, size 2. Configuration assembly 151, size 0. RPI 10 ms or slower.
- Import the UDT exported by the setup app, then copy the input data into it:
COP(Module:I.Data[0], MyTag, 1). - Output INT 0 is a command (same codes and remote-write rules as Modbus register 30); output INT 1 is a counter-reset mask.
Input-only and listen-only connections are supported for a second PLC or HMI. An EDS file is supplied. The machine name and asset ID are in assembly 101, read with an explicit message (Get Attribute Single, class 4, instance 101, attribute 3).
AutomationDirect CLICK and Rockwell Micro800
These controllers can read the unit as Modbus TCP clients. Read holding registers 1000-1123 (FC 03), which mirror the live data; the CLICK cannot address input registers. 32-bit values are low word first.
Holding registers 0-3 (thresholds, debounce) and 30-31 (command, counter-reset mask) take writes, subject to the remote-write level.
One template for all. A client template that reads FC 03 from 1000 works for every unit.
PLC program template. For sites that want to run the same state logic and register map on a CLICK or Micro800 PLC instead of the AndonTap, a program template is in preparation. It has not yet been run on a controller.Planned
EtherNet/IP note
EtherNet/IP conformance has not been tested, and the vendor ID is a placeholder until one is assigned. The adapter is built on the open-source OpENer stack; its licence notice is supplied with the product documentation.
FloorPulse
With FloorPulse, units on the network appear in a live floor view with runtime and OEE by shift, day and month.
Firmware updates
Settings and counters are kept over firmware updates. The installed version is shown by status and diag, in the setup app, and in input register 1.
Over the network (firmware 1.5 and later)
- Open the update window on the unit. It stays open 10 minutes, and only then does the unit listen on port 80.
- At the machine:
update armon the console, or the update command in the setup app. - From the network: Modbus holding register 30 = 5, or EtherNet/IP command 5. Needs remote writes "full".
- At the machine:
- On any PC on the plant network with Python 3, run the update tool with the firmware file and the unit's address, or a list of units:
python cncmon_update.py <firmware>_app_ota.bin 10.20.30.40 python cncmon_update.py <firmware>_app_ota.bin @units.txt --parallel 4 --pin 1234
- The tool skips units already up to date, sends the file, waits for the restart and for the unit to confirm the new firmware, and reports each unit as done or FAILED.
Automatic rollback
New firmware must run healthily for 60 seconds, and reach the network if the unit has an address, before the unit keeps it. If it crashes, hangs, loses power or restarts in that time, or is not healthy within 3 minutes, the unit goes back to the previous firmware by itself. Input register 95 bit 6 then shows "last update rolled back".
The unit refuses
- firmware older than 1.5 (use USB-C for those);
- a file that is not AndonTap firmware, or is damaged or incomplete (checksum);
- a second upload before it has restarted on the first;
- an upload without the PIN, when a setup PIN is set.
Over USB-C
Used for units on firmware older than 1.5, or for recovery. Support will supply the full firmware image and instructions; the image is loaded from Chrome or Edge with a browser-based flasher, nothing to install. If the unit is not detected, hold BOOT, tap RST, release BOOT and try again. See the USB-C caution in section 1.
Security note. Firmware images are not yet cryptographically signed. Until they are, keep the remote-write level at basic (so the network cannot open the update window) and set a setup PIN.
Planned firmware: inputs 5-8 and LoRaWAN.Planned
Troubleshooting
First step for most problems: connect the setup app or a console and run status. It shows the supply voltages, which internal chips answered, the inputs, the CTs and the network settings.
| Symptom | Likely cause | What to do |
|---|---|---|
| No LEDs at all | No power; 24 V reversed; PoE switch port not 802.3af / PoE disabled on the port | Measure 24 V at J1 pins 1-2 (pin 1 positive). Check the panel fuse. On PoE, check the switch port supplies power. |
| 24V LED off, unit running on PoE | Normal: no DC on J1 | If the machine always reads Off, see section 6 (rule 1). |
| Unit restarts or 24V LED drops out | Supply overloaded, internal 0.5 A fuse tripped, or supply below the working range | Switch off, wait a minute (the fuse resets), check the supply and wiring. diag shows the last reset reason. |
| STATUS keeps blinking, BT blinking | No IP address set | Set the address (section 7). |
| STATUS keeps blinking, BT off | No link (cable, switch port), or no DHCP answer | Check the jack's green link LED and the cable. On DHCP, check the server; or set a static address. |
| STATUS on, but the client cannot connect | Wrong subnet / gateway; Modbus or EtherNet/IP turned off; 4 Modbus clients already connected; firewall | Check with status. Ping the unit. Check ports 502 / 44818 / 2222 are open between the networks. |
| FAULT LED on | Memory, CT converter or Ethernet chip not answering | Run status to see which. Restart with RST. If it stays on, contact support. |
| An IN1-4 input never shows ON | COM-A not on the return of the same circuit; voltage below the ON threshold; input set to Unused | Check COM-A goes to the lamp common (neutral or 0 V). Measure the voltage between the input and COM-A with the lamp on. Check the role in the setup app. |
| A steady lamp reads "flashing", or a flashing lamp reads "on" | Flash window does not suit the lamp's blink rate | Adjust the flash window in the setup app (Machine, signal timing). |
| IN5-8 do not change in the data | Firmware 1.5 does not read inputs 5-8 yet | Planned in a firmware update. Wiring can be done now. |
| Dry contacts or sensors on IN5-8 dead (after the update) | COM-B not connected; 24V OUT fuse tripped by a short; wrong COM-B for the sensor type | Check the COM-B jumper (section 5.3). Remove the short; the fuse resets. Measure 24V OUT to 0V. |
| Spindle current reads zero | CT count set to 0; CT around the whole cable; CT on the wrong plug | Clamp around one conductor. Check the CT setup and CT1 / CT2 plugs. |
| Current reads too high or too low | CT rating, output (333 mV / 1 V) or wire passes set wrong | Correct the CT settings to match the CT's label. |
| Spindle level wrong (turning vs cutting) | Thresholds do not suit the machine | Capture the thresholds live in the setup app with the spindle idling, then cutting. |
Cannot find CNCMON-XXXXXX on Bluetooth | Window closed; steel panel; browser without Web Bluetooth | Short-press CFG (BT blinks). Open the panel door. Use Chrome / Edge, or Bluefy on iPhone. |
| Setup app says "locked" | A setup PIN is set | Enter the PIN. If forgotten, hold CFG 10 s (clears PIN and IP address). |
| A Modbus write is refused (exception 01) | Remote-write level too low | Raise it in the setup app (Network & security) if that change should be allowed. |
| Network update reports FAILED | The new firmware did not confirm, and the unit rolled back | The unit is running its previous firmware. Note the unit and contact support. |
| Update refused | Window not open; unit older than 1.5; PIN missing | Open the window (update arm); use USB-C for older firmware; pass the PIN. |
| Clock wrong after a power cut | RTC backup cell empty | Replace the CR1220 cell (section 15). The setup app sets the clock when it connects. |
Specifications
Summary. Values are design values from the V6 circuit, not yet measured on V6 hardware, and may change after first-article testing. See the datasheet for details.
| DC supply | 24 VDC nominal on J1 (+24V / 0V / PE)Working range to be confirmed |
|---|---|
| Protection | Reverse-polarity diode, 0.5 A resettable fuse, surge clamp |
| PoE (option) | IEEE 802.3af, Class 0, mode A or B, isolated module |
| USB-C | 5 V, bench setup |
| 24V OUT | 24 V from an on-board boost, 0.1 A resettable fuseFull-load capability to be confirmed |
| Consumption | To be measured on V6 hardware |
| Channels | 4, shared COM-A |
|---|---|
| Voltage | 24 VDC (either polarity) or 120 VAC 50/60 Hz, automatic |
| Current | About 2 mA, constant current |
| ON threshold | Above 9.3 V worst case |
| Isolation | Field side of an internal barrierDesigned as reinforced for 120 VAC; not yet lab-evaluated |
| Channels | 4, shared COM-B, optically isolated |
|---|---|
| Voltage | 24 VDC only, sinking or sourcing |
| ON threshold | About 8 V |
| Current | About 4.8 mA at 24 V |
| Firmware | Planned (not read by firmware 1.5) |
| Channels | 2 (CT1 spindle, CT2 auxiliary) |
|---|---|
| CT type | Split-core, 333 mV or 1 V AC output |
| CT rating | 1-5000 A, 1-20 wire passes |
| Measurement | True RMS, 16-bit, 0.01 A resolution |
| Ethernet | 10/100BASE-TX, RJ45 |
|---|---|
| Protocols | Modbus TCP server (502, 4 clients) · EtherNet/IP adapter (44818, I/O on 2222) |
| Addressing | Static (factory: none) or DHCP · IPv6 off |
| Setup | USB-C and Bluetooth LE · setup app in Chrome / Edge |
| LoRaWAN | Option, SMA in the top end wallPlanned; firmware to be confirmed |
| Mounting | TS35 × 7.5 DIN rail |
|---|---|
| Size (W × H × D) | 26.4 × 153.6 × 83.2 mmCurrent enclosure; V6 to be confirmed |
| Housing | PA12 nylon, black |
| Memory | Counters in FRAM (saved every second) · RTC with CR1220 backup cell |
| Operating temperature | To be confirmed (pending qualification) |
| Approvals | None at this time · for use inside a control panel |
Maintenance
The unit needs no routine maintenance apart from the clock backup cell. Keep the vent slots clear of dust. Clean the housing with a dry cloth only.
RTC backup cell (CR1220)
A CR1220 lithium coin cell keeps the real-time clock running while the unit is unpowered. Counters and settings do not depend on it; they are kept in non-volatile memory. The design estimate for cell life is about 6 years; actual life is to be confirmed. Replace it if the clock is lost after a power cut (status bit 11 "clock set" clears, status shows "clock NOT SET").
Opening the housing exposes the field side of inputs 1-4. Switch off and disconnect all power and signal sources, unplug every terminal and the network cable, and remove the unit from the panel before opening it.
- Switch off, unplug all terminals and the RJ45 cable, and take the unit off the rail (section 4).
- Remove the two M3 screws in the front face.
- Swing the cover off about its back edge.
- Replace the CR1220 cell, observing the polarity marked on the holder. Do not bend the holder contacts.Cell access to be confirmed
- Close the cover: hook the back edge first, then press the front down. Refit the two screws without over-tightening.
- Mount, reconnect and power up. Connect the setup app once; it sets the clock. Or use
timeon the console.
Disposal
- Do not dispose of the unit with household waste. Take it to a collection point for electronic equipment, according to local regulations.
- Remove the CR1220 lithium coin cell first (section 15) and recycle it separately as a battery.
- Before passing a unit on or disposing of it, run a factory reset to remove the machine name, network settings and PIN.
Support
| Manufacturer | Altitude AP LLC |
|---|---|
| Support email | support@altitudeap.com |
| Website and downloads | andontap.com · andontap.com/downloads |
When you contact support, please have ready:
- the serial number from the unit's label;
- the firmware version (
statusordiag); - the output of
statusanddiag, copied from the console; - what the LEDs are doing.
Preliminary document. V6 hardware is in development. The information in this manual comes from the V6 design and from firmware 1.5 testing, and may change after first-article testing. Check andontap.com/downloads for the current revision.