Every machine.
Every minute.
AndonTap reads a machine's stack light, its 24 V machine signals and its spindle current, and serves its state, counts and runtime over Modbus TCP and EtherNet/IP. It works with Kepware, Ignition, a PLC or an MES. No gateway, no cloud and no DHCP are needed.
- 8 inputs in two groups. Inputs 1-4 take 24 VDC or 120 VAC, detected automatically, behind an isolation barrier. Inputs 5-8 take 24 VDC, sinking or sourcing, for door, feed-hold, part-count and M-code signals.IN5-8 firmware planned
- 2 current-transformer inputs. True-RMS, 16-bit. Spindle reported as stopped, turning or cutting. The second CT watches coolant, a conveyor, hydraulics or main power.
- Machine state on board. Up to 8 IF/THEN rules turn lamps and current into Running, Idle, Alarm, Setup and more, with time in each state.
- Plant-network safe. Static IP set over USB-C or Bluetooth. The unit sends nothing until an address is set. Network firmware updates roll back by themselves if the new version fails.
- Power from 24 VDC or PoE. An on-board 24 V output feeds dry contacts on inputs 5-8, even on PoE alone. Counters kept in FRAM through power loss.
- Room to grow. Optional on-board LoRaWAN module with an SMA jack in the end wall.Planned
On its own
Modbus TCP and EtherNet/IP. Kepware tag CSV and Studio 5000 UDT export, ready to import.
With FloorPulse
Live floor view out of the box. Runtime and OEE by shift, day and month.
How it works
Each of inputs 1-4 runs through its own bridge rectifier and a 2 mA constant-current stage into an optocoupler, so one circuit takes 24 VDC or 120 VAC with no jumpers. These four sit on the field side of an isolation barrier that only the optocouplers cross. Inputs 5-8 use bidirectional optocouplers with their own common, so they work as sinking or sourcing inputs, like a PLC input card. The processor samples every input at 1 kHz. It tells steady from flashing lamps, holds a 120 VAC input on through the zero crossings, and counts part pulses. CT signals are read as true RMS and divided by the number of wire passes, and the spindle level is decided with 10 % hysteresis.
Specifications
| DC supply | 24 VDC nominal, 3-pin plug +24V / 0V / PECircuit limits: the buck starts above about 8 V; the surge clamp's stand-off is 36 V. Working range to be confirmed in qualification. |
|---|---|
| Protection | Reverse-polarity diode, 0.5 A resettable fuse, TVS clamp |
| Protective earth | PE on the power plug · RJ45 shield to PE through 1 nF / 1 MΩ |
| Power over Ethernet | IEEE 802.3af, Class 0, mode A or BBuilt into every unit. 1500 V isolated PD module (Silvertel Ag9905). |
| USB-C power | 5 V, for bench setup |
| 24V OUT | 24 V from an on-board 5 V → 24 V boost, 0.1 A resettable fuseOn the inputs 5-8 plug, for dry contacts. Works on PoE-only installs. Full-load capability to be confirmed on V6 hardware. |
| Consumption | To be measured on V6 hardware |
| Channels | 4, one shared COM-AOne voltage per group: a 120 V lamp and a 24 V switch cannot share COM-A. |
|---|---|
| Input voltage | 24 VDC or 120 VAC 50/60 Hz, automaticEither polarity on DC. |
| Input current | About 2 mA, constant-current (1.3-2.8 mA)Design values, same circuit as V5. |
| On threshold | Above 9.3 V worst case (design value) |
| Isolation | Barrier between the field side and logic, crossed only by the optocouplersDesigned as reinforced insulation for 120 VAC: reinforced-rated optocouplers (5000 Vrms, maker's rating), layout target 6 mm creepage and no inner-layer copper within 3 mm of field copper. Not yet lab-evaluated. |
| Surge | Bidirectional TVS per channelMay be left off on 24 VDC-only units. |
| Sampling | 1 kHz · debounce, flash window and count debounce set per unit |
| Roles | Stack-light lamp, part counter, signal, unused |
| Channels | 4, one shared COM-B |
|---|---|
| Input voltage | 24 VDC onlyLow-voltage group. Never connect 120 VAC to this plug. |
| Wiring | Sinking or sourcing, bidirectional optocouplerCOM-B to 0V: sourcing (PNP, or dry contacts fed from 24V OUT). COM-B to +24V: sinking (NPN). |
| On threshold | About 8 V (design value)12 V machine signals switch with margin. |
| Input current | About 4.8 mA at 24 V (design value) |
| Protection | TVS clamp per input · RC filter on the logic side |
| Uses | Door switch, feed hold, part count, lube / air / coolant switches, M-code relays, operator call |
| Firmware | PlannedFirmware 1.5 does not read inputs 5-8 on V6 hardware yet. |
| Channels | 2 (CT1 spindle, CT2 auxiliary) |
|---|---|
| CT type | Voltage-output split-core, 333 mV or 1 V AC full scale |
| CT rating | 1-5000 A, set in setup · 1-20 wire passes |
| Measurement | True RMS, 16-bit ADC, 0.01 A resolution |
| Spindle levels | Stopped · turning · cutting, 10 % hysteresisThresholds suggested from motor FLA or captured live. |
| Ethernet | 10/100BASE-TX (W5500), RJ45 PoE magjack with link and activity LEDs |
|---|---|
| Addressing | Static IP (default) or DHCP · no traffic until set · IPv6 off |
| Modbus TCP | Server, port 502, any unit ID, 4 clients |
| EtherNet/IP | Adapter, explicit and class 1 I/O · EDS file supplied1 |
| Remote writes | Off, basic (default) or fullSets what Modbus and EtherNet/IP clients may change. |
| Setup | USB-C console and Bluetooth LE, same commandsWeb setup app in Chrome or Edge; Bluetooth from a phone. Over the plant network: open http://<unit IP> in a browser and the unit serves the same app, PIN-protectedPlanned |
| Security | Optional setup PIN, required over Bluetooth when set · radio on only after a CONFIG press, or when no IP is set |
| LoRaWAN | Optional RAK3172 module, fitted by hand on LoRa buildsPlannedu.FL pigtail to a bulkhead SMA jack in the top end wall; no RF copper on the main board. Firmware support and frequency-plan variants to be confirmed. |
|---|---|
| Antenna | Metal cabinet: roof-mounted antenna, coax down to the SMA jackA whip straight on the jack only in plastic cabinets or open mounting. Antenna kit to be specified. |
| Wi-Fi | Not used (off in firmware) |
| MCU | ESP32-S3, dual core 240 MHz, BLE 5 |
|---|---|
| Non-volatile counters | FRAM, written every second |
| Clock | Battery-backed RTC, CR1220 cell |
| Settings | Flash with a FRAM backup copy · kept over firmware updates |
| Firmware update | USB-C from a browser, or over the network with automatic rollbackNetwork updates only while an update window is open. Update images are not signed yet. |
| Mounting | TS35 × 7.5 DIN rail (EN 60715), screwdriver release |
|---|---|
| Board | 135 × 70 mm, 6 layers |
| Size (W × H × D) | 26.4 × 153.6 × 83.2 mmCurrent enclosure. The V6 front-face openings are being updated; final size to be confirmed. |
| Housing | PA12 nylon, dyed black · 2 × M3 screws |
| Cooling | Passive, vent slots in both end faces |
| Indicators | 5 LEDs through light pipes on the front bezel |
| Operating temperature | Pending qualification |
| Approvals | None at this time · for use inside an IP20 control panel |
Data the unit serves
The register layout is fixed. It is the same on every unit, so one Kepware template or one Logix UDT covers a whole floor. The setup app writes both files with the machine's own lamp and CT names. The map below is firmware 1.5. Inputs 5-8 of the V6 board are not in it yet: their firmware is planned, with new data added after the current map so existing clients do not move.
| Modbus input reg. | Data | Type |
|---|---|---|
| 0 | Status bits: inputs, spindle, 24 V, PoE, link, FAULT | U16 |
| 8 · 9 | Machine state · spindle level | U16 |
| 10-15 | Input 1-6 state: off, on, flashingV6: inputs 1-4 today; slots 5-6 for V6 inputs 5-6 once their firmware is done. | U16 |
| 16-19 | Spindle and CT2 current, 0.01 A RMS | U32 |
| 20-55 | Per input: count (or parts), on time, flashing time | U32 |
| 56-65 | Spindle on time, cut time, starts · CT2 run time, starts | U32 |
| 66-83 | Seconds in each machine state · state changes | U32 |
| 84-98 | Boot count, powered time, clients, time in current state, CT setup, reset reason, diagnostic flags, free memory, FRAM errors, remote-write level | U16 / U32 |
| 100-123 | Machine name and asset ID, ASCII | String |
| after 123 | Inputs 7-8: state, count, on time, flashing time (planned) | U16 / U32 |
Holding registers 1000-1123 mirror input registers 0-123 for clients that only read FC 03. EtherNet/IP: input assembly 100 carries the same 200 bytes; output assembly 150 (4 bytes) takes commands; assembly 101 holds the name. 32-bit values are low word first and start on an even register, so the data copies straight into a UDT.
Front face
| USB | USB-C · setup console, firmware, bench power |
|---|---|
| +24V · 0V · PE | 3-pos pluggable, 5.08 mm · DC supply and protective earth |
| COM-A · 1-4 | 5-pos pluggable, 5.08 mm · universal inputs, 24 VDC or 120 VAC |
| 24V OUT · 0V · COM-B · 5-8 | 7-pos pluggable, 3.5 mm · 24 VDC inputs |
| CT1 · CT2 | 2-pos pluggable, 3.5 mm each |
| RJ45 | Bottom end face, cable drops into the wire duct |
| SMA | Top end face, LoRaWAN builds only · knock-out, closed otherwise |
| 24V | DC supply present |
|---|---|
| PoE | PoE power present |
| STATUS | Blinks until link and IP, then solid |
| BT | Slow blink: setup radio on · solid: connected |
| FAULT | A memory, CT converter or Ethernet chip did not answer |
| CFG | Press: Bluetooth on for 10 min · hold 10 s: clear IP and PIN |
| RST · BOOT | Restart · firmware load modeRecessed; press with a paper clip. CFG has a captive key in the cover. |
Dimensions
Millimetres, from the current enclosure, which holds the same 135 × 70 mm board. The V6 front-face openings and the SMA knock-out are being added; the outline is expected to stay but will be confirmed when the V6 enclosure is made. Connector positions on the front view are schematic. Depth is measured from the rail hook tips to the front face; add the mating plugs and their wires. Modules butt together at 26.4 mm pitch, and both cover screws stay reachable with neighbours on the rail.
Ordering and notes
| Standard | PoE (802.3af) built in, or 24 VDC; Ethernet, 8 inputs, 2 CTs |
|---|---|
| LoRaWAN option | Adds the RAK3172 module, pigtail and SMA jackPlanned |
| 24 VDC-only inputs 1-4 | Input surge TVS can be omitted |
| Included | EDS file · web setup app · Kepware and Studio 5000 export · network update tool |
Preliminary. V6 is in layout. Values come from the V6 circuit design and from firmware 1.5 tests in emulation. They are not yet measured on V6 hardware and may change after first-article testing.
Planned items. Firmware for inputs 5-8 and the LoRaWAN module is not written yet. Radio approvals for the LoRaWAN option have not been assessed.
1 · EtherNet/IP. Conformance has not been tested, and the vendor ID is a placeholder until ODVA assigns one. The adapter is built on OpENer; its license notice ships with the product documentation.