Wenglor EtherCAT ZAI02CN0x User manual

ZAI02CN0x

Connection Boxes

Operating Instructions

Available as PDF file only

Revision level: 14.07.2016

Version: 2.0.0

www.wenglor.com

2Table of Contents

Table of Contents

1. General ....................................................................................................................................................4

1.1 Information Concerning these Instructions .......................................................................................... 4

1.2 Explanations of Symbols ...................................................................................................................... 4

1.3 Limitation of Liability.............................................................................................................................. 5

1.4 Copyrights............................................................................................................................................. 5

2. For Your Safety.........................................................................................................................................6

2.1 Use for Intended Purpose..................................................................................................................... 6

2.2 Use for Other than the Intended Purpose ............................................................................................ 7

2.3 Personnel Qualiﬁcations ....................................................................................................................... 7

2.4 Modiﬁcation of Products ....................................................................................................................... 7

2.5 General Safety Precautions .................................................................................................................. 7

2.6 Approvals and IP Protection ................................................................................................................. 8

3. Technical Data..........................................................................................................................................8

3.1 Housing Dimensions............................................................................................................................. 9

3.2 Wiring Diagram ................................................................................................................................... 10

3.3 Accessory Products ............................................................................................................................ 11

3.4 System Layout..................................................................................................................................... 13

3.5 Scope of Delivery ................................................................................................................................ 14

4. Transport and Storage...........................................................................................................................14

4.1 Transport ............................................................................................................................................. 14

4.2 Storage................................................................................................................................................ 14

5. Installation and Electrical Connection .................................................................................................15

5.1 System Overview................................................................................................................................. 15

5.2 Installation ........................................................................................................................................... 16

5.3 Electrical Connection .......................................................................................................................... 17

5.3.1 Functional Earth....................................................................................................................... 18

5.4 Port Assignments ................................................................................................................................ 18

5.4.1 Industrial Ethernet Cable......................................................................................................... 18

5.4.2 Connecting Digital Sensors and Actuators............................................................................. 19

5.5 Diagnostics.......................................................................................................................................... 20

6. Initial Start-Up ........................................................................................................................................20

6.1 LED Display, EtherCAT........................................................................................................................ 21

6.2 Operation at a Controller.....................................................................................................................22

Connection Boxes

7. Detailed Description of the Object Directory for EtherCAT.................................................................23

7.1 Communication Proﬁle Area ............................................................................................................... 23

7.2 Device Proﬁle Area.............................................................................................................................. 24

7.3 Manufacturer-Speciﬁc Area................................................................................................................. 25

7.4 Device status....................................................................................................................................... 26

7.5 Port Allocation ..................................................................................................................................... 26

7.6 EtherCAT State, Machine.................................................................................................................... 26

8. Web-Based Conﬁguration .....................................................................................................................27

8.1 Accessing the Administration Interface .............................................................................................. 27

8.2 Overview Page .................................................................................................................................... 29

8.3 Page Layout ........................................................................................................................................ 30

8.4 Device, General................................................................................................................................... 31

8.5 Device Settings ................................................................................................................................... 32

8.6 Settings for Digital I/O Ports................................................................................................................ 34

9. Maintenance Instructions......................................................................................................................36

10. Proper Disposal .....................................................................................................................................36

11. Appendix ................................................................................................................................................37

11.1 List of Abbreviations............................................................................................................................ 37

11.2 Change Index, Operating Instructions................................................................................................ 37

11.3 EU Declaration of Conformity ............................................................................................................. 37

4General

1. General

1.1 Information Concerning these Instructions

• These instructions apply to products ZAI02CN01 and ZAI02CN02

• They make it possible to use the product safely and efficiently.

• These instructions are an integral part of the product and must be kept on hand for the entire duration of

its service life.

• Local accident prevention regulations and national work safety regulations must be complied with as well.

• The product is subject to further technical development, and thus the information contained in these oper-

ating instructions may also be subject to change. The current version can be found at www.wenglor.com in

the product’s separate download area.

NOTE:

The operating instructions must be read carefully before using the product and must be

kept on hand for later reference.

1.2 Explanations of Symbols

• Safety precautions and warnings are emphasized by means of symbols and attention-getting words

• Safe use of the product is only possible if these safety precautions and warnings are adhered to

• The safety precautions and warnings are laid out in accordance with the following principle:

ATTENTION-GETTING WORD!

Type and Source of Danger!

Possible consequences in the event that the hazard is disregarded.

• Measures for averting the hazard.

The meanings of the attention-getting words, as well as the scope of the associated hazards, are listed below.

DANGER!

This word indicates a hazard with a high degree of risk which, if not avoided, results in

death or severe injury.

WARNING!

This word indicates a hazard with a medium degree of risk which, if not avoided, may result

in death or severe injury.

CAUTION!

This word indicates a hazard with a low degree of risk which, if not avoided, may result in

minor or moderate injury.

Connection Boxes

ATTENTION!

This word draws attention to a potentially hazardous situation which, if not avoided, may

result in property damage.

NOTE:

A note draws attention to useful tips and suggestions, as well as information regarding

efﬁcient, error-free use.

1.3 Limitation of Liability

• The product has been developed in consideration of the current state-of-the-art and applicable standards

and guidelines. Subject to change without notice. A valid declaration of conformity can be accessed at

www.wenglor.com in the product’s separate download area.

• wenglor sensoric elektronische Geräte GmbH (hereinafter referred to as “wenglor”) excludes all liability in

the event of:

• Non-compliance with the instructions

• Use of the product for purposes other than those intended

• Use by untrained personnel

• Use of unapproved replacement parts

• Unapproved modification of products

• These operating instructions do not include any guarantees from wenglor with regard to the described

procedures or specific product characteristics.

• wenglor assumes no liability for printing errors or other inaccuracies contained in these operating instruc-

tions, unless wenglor was verifiably aware of such errors at the point in time at which the operating instruc-

tions were prepared.

1.4 Copyrights

• The contents of these instructions are protected by copyright law.

• All rights are reserved by wenglor

• Commercial reproduction or any other commercial use of the provided content and information, in particu-

lar graphics and images, is not permitted without previous written consent from wenglor.

6For Your Safety

2. For Your Safety

2.1 Use for Intended Purpose

Connection Boxes

Connection Boxes are used to reduce wiring effort in systems with many sensors/actuators, and to link them

to an Industrial Ethernet network. The digital inputs and outputs can be

addressed and evaluated directly via the network.

This product can be used in the following industry sectors:

• Special machinery manufacturing

• Heavy machinery manufacturing

• Logistics

• Automotive industry

• Food industry

• Packaging industry

• Pharmaceuticals industry

• Clothing industry

• Plastics industry

• Woodworking industry

• Consumer goods industry

• Paper industry

• Electronics industry

• Glass industry

• Steel industry

• Printing industry

• Aviation industry

• Construction industry

• Chemicals industry

• Agriculture industry

• Alternative energy

• Raw materials extraction

Connection Boxes

2.2 Use for Other than the Intended Purpose

• Not a safety component in accordance with 2006/42/EC (Machinery Directive)

• The product is not suitable for use in potentially explosive atmospheres.

• The product may only be used with accessories supplied or approved by wenglor, or combined with

approved products. A list of approved accessories and combination products can be accessed at www.

wenglor.com on the product detail page.

DANGER!

Risk of personal injury or property damage in case of use for other than the intended

purpose!

Use for other than the intended purpose may lead to hazardous situations.

• Observe instructions regarding use for intended purpose.

2.3 Personnel Qualifications

• Suitable technical training is a prerequisite.

• In-house electronics training is required.

• Trained personnel who use the product must have uninterrupted access to the operating instructions.

DANGER!

Risk of personal injury or property damage in case of incorrect initial start-up and

maintenance!

Personal injury and damage to equipment may occur.

• Adequate training and qualification of personnel.

2.4 Modification of Products

DANGER!

Risk of personal injury or property damage if the product is modiﬁed!

Personal injury and damage to equipment may occur. Non-observance may result in loss of

the CE marking and the guarantee may be rendered null and void.

• Modification of the product is impermissible.

2.5 General Safety Precautions

NOTE!

• These instructions are an integral part of the product and must be kept on hand for the

entire duration of its service life.

• In the event of possible changes, the respectively current version of the operating

instructions can be accessed at www.wenglor.com in the product’s separate download

area.

• Read the operating instructions carefully before using the product.

• Protect the Connection Box against contamination and mechanical influences.

8Technical Data

2.6 Approvals and IP Protection

IND. CONT. EQ.

E480617

RoHS

3. Technical Data

Article Number ZAI02CN01 ZAI02CN02

Supply power 18 to 32 V DC

Max. device current consumption * 0.1 A

Max. system current consumption ** 1.8 A

Temperature range -25 to 60° C

Voltage drop, switching outputs < 2.5 V

Max. Switching current, switching outputs 0.6 A 2 A

Max. total current, I/O ports 9 A

Sensor supply voltage (pin 1) 200 mA

Inputs per DIN EN 61131-2:2003 Type 2

Digital I/O ports short-circuit proof Yes

Digital I/O ports overload proof Yes

Digital I/O ports reverse polarity protected Yes

Number of standard I/O pins 16

Housing material Aluminum

Weight 1100 g

Protection IP 67

Connector type, power ⅞", 5-pin

Connector type, Industrial Ethernet ports M12×1, 4-pin, D coded

Connector type, I/O ports M12×1, 4-pin, A coded

Number of Industrial Ethernet ports 2

Number of I/O ports 8

Transmission speed 100 Mbit/s

Transmission mode Full duplex

Webserver Yes

EoE – Ethernet over EtherCAT Yes Yes

Auto-crossover Yes

Auto-negotiating Yes

Auto-polarity Yes

Protection class III

Interface EtherCAT

* Maximum intrinsic current consumption of the product without additional consuming devices

** Maximum intrinsic current consumption of the product with additional consuming devices

Fully allocation of all digital I/O ports with sensor supply power (without outputs)

Connection Boxes

The following table speciﬁes the tightening torques of the plugs and mounting options in order to assure

compliant, error-free operation:

Connector Type Tightening Torque (Nm)

M12 0.4

7/8" plug 1.5

FE ground strap 2.2 ± 0.2

Connection Box mounting 4.0 ± 0.2

3.1 Housing Dimensions

10 Technical Data

3.2 Wiring Diagram

www.wenglor.com

FunctionPin

1 TxD (+)

2 RxD (+)

Socket 2

In/

Out

TxD (−)

RxD (−)

Out

Function

1 +24 V DC

2 I/O

Socket 1

GND

I/O

Suitable Plug:

Socket 3

7877

Suitable Plug:

Function

1 0 V DC

2 0 V DC

4+24 V DC USystem/Sensor

5 +24 V DC UDigital I/O

Socket 1

Socket 2

Socket 3

Socket 1

Socket 2

Socket 3

Socket 1

Legend

Wire Colors according to

DIN IEC 757

Platinum measuring resistor

not connected

Test Input

Test Input inverted

Trigger Input

Analog Output

Ground for the Analog Output

Block Discharge

Valve Output

Valve Control Output +

Valve Control Output 0 V

Synchronization

Receiver-Line

Emitter-Line

Grounding

Switching Distance Reduction

Ethernet Receive Path

Ethernet Send Path

Interfaces-Bus A(+)/B(–)

Emitted Light disengageable

Magnet activation

Input confirmation

Contactor Monitoring

Encoder A/A (TTL)

Encoder B/B (TTL)

Black

Brown

Red

Orange

Yellow

Green

Blue

Violet

Grey

White

Pink

Green/Yellow

Supply Voltage +

Supply Voltage 0 V

Supply Voltage (AC Voltage)

Switching Output (NO)

Switching Output (NC)

Contamination/Error Output (NO)

Contamination/Error Output (NC)

Input (analog or digital)

Teach Input

Time Delay (activation)

Shielding

Interface Receive Path

Interface Send Path

Ready

Ground

Clock

Output/Input programmable

Power over Ethernet

Safety Input

Safety Output

Signal Output

Ethernet Gigabit bidirect. data line (A-D)

Encoder 0-pulse 0-0 (TTL)

Encoder A

Encoder B

Digital output MIN

Digital output MAX

Digital output OK

Synchronization In

Synchronization OUT

Brightness output

Maintenance

Table of contents

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