Wenglor EtherCAT ZAC50CN0 Series User manual

Operating instructions
Available as PDF only
Status: 07.09.2016
www.wenglor.com
ZAC50CN0x
Ethernet Junctions
EN

2
EN
Index
1. Proper Use 3
2. Safety Precautions 3
3. Approvals and IP Protection 3
4. Technical Data 4
4.1. Connection table ZAC50CN0x 5
4.2. Housing Dimensions 6
4.2.1 ZAC5xxN01 6
4.2.2 ZAC50xN02 6
4.3. Complementary Products 7
5. Application Notes 11
6. Mounting Instructions 11
7. Initial Operation 11
7.1. System Structure 12
7.2. Power Cable 12
7.3. Functional Earth 13
7.4. Industrial Ethernet Cable 13
7.5. Industrial Ethernet Cable with Power over Ethernet 14
7.6. Connecting Digital Sensors and Actuators 14
7.7. Diagnosis 15
7.7.1 LED Display EtherCAT Device (ZAC50CN0x) 16
7.8. Operation on a Controller 18
9. Web-based Configuration 21
9.1. Call up the Administration Interface 21
9.2. Overview page 23
9.3. Device settings 24
9.4. Industrial Ethernet Ports Settings 26
9.5. Digital I/O Ports Settings 27
10. Maintenance Instructions 28
11. Proper Disposal 28
12. EU Declaration of Conformity 28

3
1. Proper Use
This wenglor product must be used in accordance with the following functional principle:
Junction
A Junction is an active network component which distributes data to the corresponding addresses within a
network in a targeted fashion. wenglor junctions are fitted optionally with additional Power over Ethernet tech-
nology. The power supply is integrated into existing network connection by means of Power over Ethernet. As
an addition to Industrial Ethernet, there are several digital inputs and outputs directly on the junction that 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
IND. CONT. EQ.
E480617
RoHS

4
EN
4. Technical Data
Order number ZAC50CN01 ZAC50CN02
Supply voltage 18...32 V DC 18...32 V DC
Max. Current Consumption Device * 0.3 A 0.25 A
Max. Current Consumption System ** 2.2 A 2 A
max. PoE Capacity 30 W 25 W
Temperature range –25...60 °C –25...60 °C
Voltage drop junctioning outputs < 2.5 V < 2.5 V
Max. junctioning current junctioning outputs 0.6 A 0.6 A
Max. total current of the
digital I/O ports 1A 1A
Digital I/O ports short-circuit protected Yes Yes
Digital I/O ports overload protected Yes Yes
Digital I/O ports reverse polarity protected Yes Yes
Number of digital I/O ports 2 2
Housing material Aluminum Aluminum
Protection class IP67 IP67
Type of connection power 7/8", 5-pin 7/8", 5-pin
Type of Connection Industrial
Ethernet Ports
M12×1, 4-pin,
D-coding
M12×1, 4-pin,
D-coding
Type of Connection PoE Ports M12×1, 8-pin, type x M12×1, 8-pin, type x
Type of Connection Digital I/O ports M12×1, 4-pin,
A-coding
M12×1, 4-pin,
A-coding
Number of PoE ports 5 2
Number of Industrial Ethernet Ports 2 2
Number of Digital I/O ports 2 2
PoE Standard IEEE802.3af IEEE802.3af
PoE Classes Class 0, 1, 2, 3 Class 0, 1, 2, 3
Baud Rate 100 Mbit/s 100 Mbit/s
Transmission Mode Full Duplex Full Duplex
EoE Ethernet over EtherCAT Yes Yes
Website Yes Yes
Junction Mode Store & Forward Store & Forward
VLAN Prioritization Yes Yes
Auto-Crossover Yes Yes
Auto-Negotiating Yes Yes
Auto-Polarity Yes Yes
* Maximum own power consumption of the product without additional loads
** Maximum own power consumption of the product with additional loads
Full assignment of all PoE ports (if available) without digital I/O ports

5
4.1. Connection table ZAC50CN0x
Function
Pin
1 TxD (+)
2 RxD (+)
3
4
Socket 2
In/
Out
TxD (−)
RxD (−)
Function
Pin
1
2 TxD (−)
3
4
5
6
7
8
Socket 1
In/
Out
PoE (+)
In
Out
In
Out
In
Suitable Plug:
Out
In
Out
Out
Out
Out
Out
Out
Out
TxD (+)
RxD (−)
RxD (+)
PoE (+)
PoE (−)
PoE (−)
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77
50
Suitable Plug: 51
Suitable Plug: 2
Suitable Plug: 7877
50
50
Socket 1
Socket 1
51
2
Socket 2
Socket 3
77
Socket 4
51
2
Socket 2
Socket 3
78
Socket 4
50
50
Socket 1
Socket 1
50
Socket 1
Function
Pin
1 +24 V DC
2 I/O
3
4
Socket 3
In/
Out
GND
I/O
Socket 4
5
Function
Pin
1 0 V DC
2 0 V DC
3
4+24 V DC USystem
5 +24 V DC UDigital I/O / Sensor
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52
50
Socket 1
51
Socket 2
2
Socket 3
78
Socket 4
50
Socket 1
51
Socket 2
2
Socket 3
77
Socket 4

6
EN
4.2. Housing Dimensions
4.2.1 ZAC5xxN01
4.2.2 ZAC50xN02

7
4.3. Complementary Products
Connection plug, 7/8", 5-pin Order number: ZAT77NN01
Suitable Plug:
77
S82
Connection socket, 7/8", 5-pin Order number: ZAB78NN01
Suitable Plug:
78
Connecting cable, 7/8", 5-pin Order number: ZAV78R201,
Suitable Plug:
78
Cable length: 2 m
S76
S87

8
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Connecting line, 7/8", 5-pin Order number: ZAS78R601,
Suitable Plug:
78
Cable length: 10 m
S75
Connector Plug RJ45; 8-pin Order number: ZAT45NN01
Suitable Plug:
45
S48
Connection plug, M12×1; 8-pin Order number: ZAT50NN01
Suitable Plug:
50
S48

9
Connecting cable M12×1; 8-pin Order number: ZAV50R201,
Order number: ZAV50R501,
Suitable Plug:
50
Cable length: 2 m (ZAV50R201)
Cable length: 5 m (ZAV50R501)
S81
Order number: ZAV50R502,
Suitable Plug:
50
Cable length: 5 m
S85
Connecting line M12×1, 8-pin Order number: ZAS50R601
Suitable Plug:
50
Cable length: 10 m
S85
Connection plug, M12×1, 4-pin Order number: ZAT51NN01
Suitable Plug:
51
S08

10
EN
Connecting cable M12×1; 4-pin; D-coding Order number: ZAV51R201,
Order number: ZAV51R601,
Suitable Plug:
51
Cable length: 2 m (ZAV51R201)
Cable length: 10 m (ZAV51R601)
Order number: ZAV51R202,
Order number. ZAV51R602,
Suitable Plug:
51
Cable length: 2 m (ZAV51R202)
Cable length: 10 m (ZAV51R602)
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

11
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 junctions, the corresponding electrical and mechanical regulations, stan-
dards and safety rules must be observed. The junction must be protected against mechanical influences. The
product must be fastened in such a way that the mounting position cannot change. The junction is designed
for use in the industrial sector. The industrial environment is characterized in that consumers 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
Junction Mounting 4.0±0.2
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
compatibility 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.

12
EN
7.1. System Structure
* x1 designated the EtherCAT IN Port
7.2. Power Cable
1
2
34
5
1
2
3
4
5
Power In Power Out
0 V Pin 1 0 V Pin 1
0 V Pin 2 0 V Pin 2
Pin 3 Pin 3
24 V max. 9 A Pin 4 System 24 V max. 9 A Pin 4
24 V max. 9 A Pin 5 Digital I/O / Sensor 24 V max. 9 A Pin 5
The 7/8" plug is designed for a maximum current of 9 A per pin. This must be taken into account when looping
the supply voltage.
The junction must be connected to a power supply of 18 to 32 V DC. The System/sensor supplies the connec-
tion with voltage and the Digital I/O provides the power supply of the digital I/O ports.
The voltage of the System must not be junctioned off during ongoing operation and hence must not be con-
ducted via emergency stop circuits, since otherwise the junction and all connected Ethernet products will not
be able to participate in the communication.
Industrial Ethernet
Power
Digital
I/O-Ports
Digital
I/O-Port
Digital
I/O-Port
x1* x1*
x1*

13
Measures must be taken in all cases to ensure that the supply voltage, measured at the remotest partici-
pant, does not fall short of the system supply voltage of 18 V DC.
To be complied with in reactive operation:
If the power supply of the digital I/O ports is merged with the voltage supply of the junction, there will
then be the risk of a communication disruption in the event of a short-circuit on the I/O devices.
7.3. Functional Earth
The FE connection is on the lower front edge of the junction. To ensure proper functioning in accordance with
the EMC regulations specified in the data sheet, we recommend using our ground strap, which is included in
the scope of delivery (for tightening torque see “Housing Dimensions” on page 13).
7.4. Industrial Ethernet Cable
wenglor provides a variety of preassembled industrial Ethernet cables.
To ensure cabling as simple and reliable as possible, we recommend using our preassembled industrial
Ethernet cables.
Assignment of the Industrial Ethernet connection:
1
2
3
4
Pin Function
1 TxD (+)
2 RxD (+)
3 TxD (–)
4 RxD (–)

14
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7.5. Industrial Ethernet Cable with Power over Ethernet
To ensure cabling as simple and reliable as possible, we recommend using our preassembled industrial Ether-
net cables. In addition, several branches can be connected. The PoE ports (x2 – x6) can also be used for this
purpose. Please note that the next branch must always be operated via the EtherCAT in port (x1). ZAT50NN01
field-assembly connectors see chapter “4.3. Supplementary products” on page 7) must be used for these con-
nections.
Assignment of the Industrial Ethernet connection with PoE:
1
2
3
45
6
8
7
Pin Function
1 TxD (+)
2 TxD (–)
3 RxD (+)
4RxD(–)
5 PoE (+)
6 PoE (+)
7 PoE (–)
8 PoE (–)
7.6. Connecting Digital Sensors and Actuators
1 2
34
Pin Function
1 24 V
2Freely programmable
input/output
3 0 V
4Freely programmable
input/output
Sockets that are not used must be provided with caps, which are included in the scope of supply. Otherwise,
the protection class IP67 cannot be guaranteed.

15
7.7. Diagnosis
Assignment example:
Status
X2
X4 X5
X6
X3
X1 X7
01
MS PoE max
PoE
L/A
PoE
L/A
PoE
L/A
PoE
L/A
PoE
L/A
IO
0.0
Power
IN
IO
1.0
IO
0.1
IO
1.1
L/A L/A
OUT
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Status
X2 X3
X1 X4
01
MS PoE max
PoE
L/A
PoE
L/A
IO
0.0
Power
IO
1.0
IO
0.1
IO
1.1
L/A L/A
IN OUT
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ZAC50CN01 ZAC50CN02

16
EN
7.7.1 LED Display EtherCAT Device (ZAC50CN0x)
Status MS PoE max
The status displays for the communication are marked on the junction with status and MS.
Designation Condition Function
Status
Green off ESM state: Initialisation
Green flashing ESM state: PRE - Operational
Flashing green once ESM state: SAFE - Operational
Green on ESM state: Operational
Red off No Error
Red on Application controller failure
Flashing red once Local Error
Flashing red twice Process Data Watchdog Timeout/
EtherCAT Watchdog Timeout
Red flashing Red blinking Invalid Configuration
MS (Module Status)
Off —
Green Operate Status
Red Device Error
Red flashing —
PoE max Red Maximum PoE performance reached
Red flashing PoE performance monitoring was junctioned off
The LED display on the M12 sockets displays the diagnosis for the corresponding socket.
X2 PoE
L/A
Designation Condition Function
PoE Yellow PoE in operation
Yellow flashing PoE function junctioned off
L/A
Off No Ethernet device is connected to the port
Green An Ethernet device is connected to the port
Green flashing An Ethernet device which is currently communicating
is connected to the port

17
The LED display on the M12 sockets displays the diagnosis for the corresponding socket.
L/A
X1
Designation Condition Function
L/A
Off No Ethernet device is connected to the port
Green An Ethernet device is connected to the port
Green flashing An Ethernet device which is currently communicating
is connected to the port
0IO
0.0
IO
1.0
Designation Condition Function
IO 0.0/IO 1.0 Yellow Input UB at Pin 2/4
Output Junctioning output at UB Pin 2/4
Red Output Short circuit at Pin 2/4

18
EN
7.8. Operation on a Controller
If you want to commission the device when connected to a control system, please perform the following steps:
• Connect the branch to the supply voltage and to the control system via the EtherCAT in port (x1). You will find
the matching connection equipment on the wenglor homepage.
• You will need the EtherCAT XML Device Description File (ESI-File EtherCAT Slave Information) which is
available at www.wenglor.com › Product World › Product search (Order number) › Download › Product
Description Files.
• The files should always be stored in the ESI directory of the respective master. If the Twin-CAT software is
used, it should be stored in the folder “...\IO\EtherCAT\” in the installation folder.
• The following example shows the steps that have to be carried out (example based on the TwinCat System
Manager by Beckhoff):
• First, the list “Echtzeit Ethernet kompatible Geräte” (list of all real-time Ethernet-compatible devices) must be
requested.
• Once the correct network card has been installed, new slave devices can be searched for in “E/A Geräte” (I/O
devices). If all configurations are correct, the slave devices are now listed in the TwinCAT tree.
• The assemblies can now be switched into “Free Run” mode so that the local cycle runs independently of the
pre-set master cycle.
• In the next step, the process data of the individual devices can be configured.
For a more detailed description of the different control systems and the installation of files or the network de-
sign, please refer to the help files of the corresponding control system.

19
8. Detailed description of the object directory for EtherCAT
8.1 I/O Direction Register (0x2010)
Index Name Default Value
0x2010:00 Highest sub-index supported 1
0x2010:01 I/O Direction 0x00
0x2010:01 Value range 1 Byte
Bit 7 6 5 4 3 2 1 0
Port – – – – 1, Pin 4 0, Pin 4 1, Pin 2 0, Pin 2
Bit value ––––01010101
Event – – – – Input Output Input Output Input Output Input Output
Bit 4-7 invalid = „0“
8.2 I/O Status Register (0x2020)
Index Name Default Value
0x2020:00 Highest sub-index supported 2
0x2020:01 I/O Error Status 0x00
0x2020:02 I/O Error Info 0x00
0x2020:01 Value range 1 Byte
Bit 7 6 5 4 3 2 1 0
Port – – – – 1, Pin 4 0, Pin 4 1, Pin 2 0, Pin 2
Bit value ––––01010101
Event – – – – no error error no error error no error error no error error
Bit 4-7 invalid = „0“
0x2020:02 Value range 1 Byte
Bit 7 6 5 4 3 2 1 0
Port – – – – 1, Pin 4 0, Pin 4 1, Pin 2 0, Pin 2
Bit value ––––01010101
Event ––––
Short-
circuit to
GND
Short-
circuit to
VCC
Short-
circuit to
GND
Short-
circuit to
VCC
Short-
circuit to
GND
Short-
circuit to
VCC
Short-
circuit to
GND
Short-
circuit to
VCC
Bit 4-7 invalid = „0“

20
EN
8.3 PoE Control (0x2030)
Index Name Default Value
0x2030:00 Highest sub-index supported 2
0x2030:01 Power Monitoring Control FALSE (enabled)
0x2030:02 PoE Port Control 0x1f (ZAC50CN01) bzw. 0x03 (ZAC50CN02)
0x2020:01 Value range 1 Byte
Bit 7654321 0
Monitoring – – – – – – – on/off
Bit value –––––––01
Event – – – – – – – on off
Bit 1-7 invalid = „0“
0x2030:02 Value range 1 Byte
Bit 7 6 5 4 3 2 1 0
PoE-Port – – – X6 X5 X4 X3 X2
Bit value –––0101010101
Event – – – off on off on off on off on off on
Bit 5-7 invalid = „0“
8.4 Webserver Access Control (0x2040)
Index Name Default Value
0x2040:00 Highest sub-index supported 1
0x2040:01 Highest sub-index supported FALSE (enabled)
0x2040:01 Value range 1 Byte
Bit 7654321 0
Monitoring – – – – – – – lock/unlock
Bit value –––––––01
Event – – – – – – – unlock lock
Bit 1-7 invalid = „0“