Wenglor ZAI02PN0 Series User manual

Operating instructions
Available as PDF only
Status: 12.09.2016
www.wenglor.com
ZAI02PN0x
Connection Boxes
EN

2
EN
Index
1. Use for Intended Purpose 3
2. Safety Precautions 3
3. Approvals and IP Protection 3
4. Technical Data 4
4.1. Connection table ZAI02PN0x 5
4.2. Housing Dimensions 6
4.3. Complementary Products 6
5. Application Notes 9
6. Mounting Instructions 9
7. Initial Operation 10
7.1. System Structure 10
7.2. Power Cable 11
7.3. Functional Earth 11
7.4. Industrial Ethernet Cable 12
7.5. Connecting Digital Sensors and Actuators 12
7.6. Diagnosis 13
7.6.1 LED Display PROFINET 14
7.7. Operation on a Controller 15
7.7.1 Overview of the modules for PROFINET 15
7.7.2 Detailed description of the modules for PROFINET devices 16
7.7.3 Diagnostic alarms 18
8. Web-based Configuration 20
8.1. Call up the Administration Interface 20
8.2. Overview Page 23
8.3. Device settings 24
8.4. Digital I/O Ports Settings 26
9. Maintenance Notes 27
10. Proper Disposal 27
11. EU Declaration of Conformity 27

3
1. Use for Intended Purpose
This wenglor product must be used in accordance with the following functional principle:
Connection Box
The connection box is used for reducing the cabling work involved when there are many Sensors/actuators
in a system and for connecting them to an industrial Ethernet network. The digital inputs and outputs can be
activated or evaluated via the network.
2. Safety Precautions
• This operating instruction is part of the product and must be kept during its entire service life.
• Read this operating instruction carefully before using the product.
• Installation, start-up and maintenance of this product has only to be carried out by trained personnel.
• Tampering with or modifying the product is not permissible.
• Protect the product against contamination during start-up.
• Not a safety component in accordance with the EU Machinery Directive.
3. Approvals and IP Protection
RoHS

4
EN
4. Technical Data
Order number ZAI02PN01 ZAI02PN02
Supply voltage 18...32 V DC
Power consumption of device max. * 0.1 A
Power consumption of system max. ** 1.8 A
Temperature range –25...60 °C
Voltage drop switching outputs < 2,5 V
Max. Switching current switching outputs 0.6 A 2 A
Max. total current of the I/O ports 9 A
Sensor Supply Voltage (Pin 1) 200 mA
Inputs according to DIN EN 61131-2:2003 Type 2
Digital I/O ports short-circuit protected yes
Digital I/O ports overload protected yes
Digital I/O ports reverse polarity protected yes
Number of standard I/O pins 16
Housing material Aluminum
Weight 1100 g
Protection class IP67
Type of connection power 7/8", 5-pin
Type of Connection Industrial Ethernet ports M12×1, 4-pin, D-coding
Type of Connection Digital I/O ports M12×1, 4-pin, A-coding
Number of Industrial Ethernet ports 2
Number of Digital I/O ports 8
Baud Rate 10 Mbit/s / 100 Mbit/s
Transmission Mode Full / Half Duplex
Webserver yes
Switch Mode Store & Forward
VLAN Prioritization ja
Default IP 192.168.100.1
Auto-Crossover yes
Auto-Negotiating yes
Auto-Polarity yes
Protection class III
* Maximum own power consumption of the product without additional loads
** Maximum own power consumption of the product with additional loads
Full assignment of all digital I/O ports with sensor supply (without outputs)

5
4.1. Connection table ZAI02PN0x
www.wenglor.com
2
FunctionPin
1 TxD (+)
2 RxD (+)
3
4
Socket 2
In/
Out
TxD (−)
RxD (−)
Out
In
Out
In
Function
Pin
1 +24 V DC
2 I/O
3
4
Socket 1
GND
I/O
Suitable Plug:
51
Suitable Plug:
Socket 3 7877
Suitable Plug:
5
Function
Pin
1 0 V DC
2 0 V DC
3
4+24 V DC USystem/Sensor
5 +24 V DC UDigital I/O
2
2
Socket 1
Socket 1
2
51
Socket 1
Socket 2
77
Socket 3
2
Socket 1
2
2
Socket 1
Socket 1
2
51
Socket 1
Socket 2
78
Socket 3
2
Socket 1
53

6
EN
4.2. Housing Dimensions
4.3. Complementary Products
wenglor offers Connection Technology providing field wiring means.
Connection plug, 7/8", 5-pin Order number: ZAT77NN01
Suitable Plug:
77
S82
Connection plug, 7/8", 5-pin Order number: ZAB78NN01
Suitable Plug:
78
S87

7
Connecting cable, 7/8", 5-pin Order number: ZAV78R201, Cable length: 2 m
Suitable Plug:
78
S76
Connecting line, 7/8", 5-pin Order number: ZAS78R601, Cable length: 10 m
Suitable Plug:
78
S75
Connector Plug RJ45; 8-pin Order number: ZAT45NN01
Suitable Plug:
45
S48
Connection plug, M12×1, 4-pin Order number: ZAT51NN01
Suitable Plug:
51
S08

8
EN
Connecting cable M12×1; 4-pin; D-coding Order number: ZAV51R201, Cable length: 2 m
Order number: ZAV51R601, Cable length: 10 m
Suitable Plug:
51
Order number: ZAV51R202, Cable length: 2 m
Order number. ZAV51R602, Cable length: 10 m
Suitable Plug:
51
2
Connection and power supply cables
M12×1; 4-pin, different lengths are available for connecting the Sensor/actuator.
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
PT

9
5. Application Notes
The Ethernet ports are fitted with overvoltage discharge protection. Internal varistors limit voltage surges to
approx. 70 V. The connecting cables of the Digital I/O ports must not be longer than 30 m.
6. Mounting Instructions
When mounting and operating the connection box, the corresponding electrical and mechanical regulations,
standards and safety rules must be observed. The connection box must be protected against mechanical influ-
ences. The connection box must be fastened in such a way that the mounting position cannot change. The
product is designed for use in the industrial sector. The industrial environment is characterized in that consum-
ers are not connected directly to the public low-voltage mains network. Additional measures must be taken for
use in the residential sector, business and commercial sectors.
The table below defines the tightening torques of the plugs and fastening options for ensuring compliant and
faultless operation.
Connection type Tightening torque in (Nm)
M12 0.4
7/8" plug 1.5
FE ground strap 2.2±0.2
Connection box mounting 4.0±0.2

10
EN
7. Initial Operation
Project planning, installation, start-up, maintenance and testing of the devices may only be carried out by quali-
fied electrical technicians familiar with the safety standards of automation technology.
Only cables and accessories that meet the standards and requirements for safety, electromagnetic compat-
ibility and, if necessary, telecommunications terminal equipment and the specifications. In case of damage, the
product must not be used further on. In the event of improper use, the guarantee and liability claim against the
manufacturer shall lapse.
Information concerning which cables and accessories are approved for installation can be found at
www.wenglor.com or are described in this manual.
7.1. System Structure
Industrial Ethernet
Digital
I/O Ports
Digital
I/O Ports
Power