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
EN

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

3
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.

5
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

7
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)

9
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
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
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
Connection Boxes
3.3 Accessory Products
wenglor can provide you with suitable connector technology for your Connection Box.
Plug connector, 7/8", 5-pin Order number: ZAT77NN01
Suitable plug:
77
S82
Plug connector, 7/8", 5-pin Order number: ZAB78NN01
Suitable plug:
78
S87
Connecting cable, 7/8", 5-pin Order number: ZAV78R201, cable length: 2 m
Suitable plug:
78
S76

12 Technical Data
Connecting cable, 7/8", 5-pin Order number: ZAS78R601, cable length: 10 m
Suitable plug:
78
S75
RJ45 Plug connector, 8-pin Order number: ZAT45NN01
Suitable plug:
45
S48
Plug connector, M12×1, 4-pin Order number: ZAT51NN01
Suitable plug:
51
S08

13
Connection Boxes
Connecting cable, M12×1, 4-pin, D coded 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 cables
M12×1, 4-pin, available in various lengths for connecting sensors/actuators.
3.4 System Layout
* x1 designates the EtherCAT IN port
Industrial Ethernet
Digital
I/O Ports
Digital
I/O Ports
Power
x1*

14 Transport and Storage
3.5 Scope of Delivery
• ZAI02CN0x
• Quick-start guide
• Mounting kit consisting of mounting screws, FE ground strap, washers, 7/8" and M12 cover caps and
name plates for the ports
4. Transport and Storage
4.1 Transport
Upon receipt of shipment, inspect the goods for damage in transit. In the case of damage, conditionally
accept the package and notify the manufacturer of the damage. Then return the device making reference to
damage in transit.
4.2 Storage
The following points must be taken into condition with regard to storage:
• Do not store the product outdoors
• Store the product in a dry, dust-free place
• Protect the product against mechanical impacts
• Protect the product against exposure to direct sunlight
ATTENTION!
Risk of property damage in case of improper storage!
The product may be damaged.
• Comply with storage instructions.

15
Connection Boxes
5. Installation and Electrical Connection
5.1 System Overview
ZAI02CN0x
Ethernet
Connection Box
e.g. Inductive
Sensors
PLC
24 V
Order
Number Description Cable Length
Plug
Pattern
ZAV51R201
ZAV51R601
Connection cable
4-pin M12×1 plug on both ends
2 m
10 m
34 34
ZAV51R202
ZAV51R602
Connection cable
M12×1 plug, 4-pin, RJ45 plug
2 m
10 m
34
12345 8
67
ZAT51NN01 Plug connector
M12×1, 4-pin, field wireable —
34
ZAT45NN01 Plug connector
RJ45, 8-pin, field wireable —
12345 8
67

16 Installation and Electrical Connection
Order Number Description Cable
Length
Plug
Pattern
ZAV78R201 Connection cable
7/8" plug, socket, 5-pin 2 m
1
2
5
3
4
1
2
5
3
4
ZAS78R601 Connector Cable
7/8", socket, 5-pin 10 m
1
2
5
3
4
ZAT77NN01 Plug connector
7/8", 5-pin, field wireable —
1
2
5
3
4
ZAB78NN01 Socket connector
7/8", 5-pin, field wireable —
1
2
5
3
4
Description Cable
Length
Plug
Pattern
Standard cable Connection cables
M12×1, 4-pin
Various
lengths
available
34
2
1
34
21
5.2 Installation
• Protect the product against contamination during installation
• Observe all applicable electrical and mechanical regulations, standards, and safety rules
• Protect the product against mechanical influences
• Make sure that the Connection Box is mounted in a mechanically secure fashion.
• Specified torque values must be complied with (see “3. Technical Data” on page 8).
• The product is laid out for use in industrial applications. Industrial environments are distinguished by the
fact that power consumers are not connected directly to the public low-voltage mains. Additional measures
must be implemented for use in residential, business and commercial environments.
ATTENTION!
Risk of property damage in case of improper installation!
The product may be damaged.
• Comply with installation instructions.
CAUTION!
Risk of personal injury or property damage during installation!
Personal injury and damage to the product may occur.
• Ensure a safe installation environment.

17
Connection Boxes
5.3 Electrical Connection
• The Connection Box must be connected to 18 to 32 V DC (see “3.2 Wiring Diagram” on page 10).
1
2
3
4
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 USystem/Sensor 24 V max. 9 A Pin 4
24 V max. 9 A Pin 5 UDigital I/O 24 V max. 9 A Pin 5
The 7/8" plug is laid out for a maximum current value of 9 A per pin. This must be taken into consideration when
looping supply power through.
The Connection Box must be connected to supply voltage within a range of 18 to 32 V DC.
USystem/Sensor supplies the Connection Box and all connected sensors with voltage, and UDigital I/O is used to
supply voltage to the digital I/O ports.
Voltage from USystem/Sensor must not be switched off during operation, and thus may not be connected via the
emergency off circuit, because the Connection Box would otherwise no longer be able to participate in com-
munication.
In any event, it must be assured that supply voltage – measured at the most distant user – is no less than
18 V DC from a system power supply standpoint.
To be observed in the feedback mode:
If digital I/O power supply is combined with power supply for the Connection Box, there’s a risk that
communication could be interrupted in the event of a short-circuit at the I/O devices.

18 Installation and Electrical Connection
5.3.1 Functional Earth
The FE terminal is located at the bottom front edge of the Connection Box. In order to assure proper functioning
in accordance with the EMC requirements specified in the data sheet, we recommend using our ground strap,
which is included in the scope of delivery (see “3. Technical Data” on page 8 regarding tightening torque).
5.4 Port Assignments
Pin and port assignments for the network and the digital I/O ports are described below.
5.4.1 Industrial Ethernet Cable
wenglor offers a range of preassembled Industrial Ethernet cables.
In order to assure simple and reliable wiring, we recommend using out preassembled Industrial Ethernet
cables.
Pin assignments for Industrial Ethernet connection (D coded):
1
2
3
4
Pin Function
1 TxD (+)
2 RxD (+)
3 TxD (–)
4 RxD (–)
NOTE!
• For connection to the controller, the connection cable from the controller must be con-
nected to the Connection Box via EtherCAT port x1. Please also note that the respective
downstream Connection Box must be operated via EtherCAT in port (x1). The field wire-
able ZAT50NN01 plug or suitable connection cables (see “6. Initial Start-Up” on page
20) can, for example, be used for these connections.

19
Connection Boxes
5.4.2 Connecting Digital Sensors and Actuators
1 2
34
Pin Function
1 24 V
2Freely programmable
input/output
3 0 V
4Freely programmable
input/output
Unused sockets must be sealed with blanking caps (included in scope of delivery). IP 67 protection cannot
otherwise be assured.
Any short-circuiting at the IO pins is displayed via the website, as well as in the controller via EtherCAT. This
message, which can be enabled via the device parameters, indicates that short-circuiting to ground or UDigital
I/O has occurred. In the event of a short-circuit at the digital I/O ports, communication is maintained with the
Connection Box via PROFINET. The inputs can still be read in as well, although separate power supply for UDigi-
tal I/O and USystem/Sensor is required to this end.
ZAI02CN01 and ZAI02CN02 Connection Boxes are equipped with a mechanism which protects the electronics
from overheating. Both of these Connection Boxes switch the digital outputs off in the case of overtemperature,
for example due to excessive current output or operation outside of the specified ambient temperature range.
After a cool-down phase, the Connection Boxes are started back up again automatically. The current status can
be read out via the “PROFINET” Status module
Individual output pin monitoring and overall current monitoring for digital UDigital I/O has also been integrated
into the ZAI02CN02. The individual pin monitoring function detects overloading of greater that 2 A at the output
pins and attempts to restart the components after a short period of time. Overall current monitoring is neces-
sary because current of up to 4 A can be made available at each port. However, the utilized power plug has a
rating of max. 9 A. This total may not be exceeded by the sum of all digital outputs. If the limit value is neverthe-
less violated, the Connection Box is switched to an error status and all outputs are deactivated. The Connection
Box then has to be reset in order to start it back up again. Supply power must be briefly interrupted to this end.
Looping through to the power out socket is not monitored in this case, and adherence to the specified maxi-
mum current values for the power in plug must be assured by the user.
NOTE!
• The Ethernet ports are equipped with overvoltage discharge protection. Internal varistors
limit overvoltage to roughly 70 V.
The connection cables for the digital I/O ports may not exceed a length of 30 meters.

20 Initial Start-Up
5.5 Diagnostics
Conduct in case of fault:
NOTE:
• Shut down the machine.
• With the help of the diagnostics information, analyze and eliminate the cause of error.
• If the error cannot be eliminated, please contact wenglor’s support department.
• Do not operate in case of indeterminate malfunctioning.
• The machine must be shut down if the error cannot be unequivocally clarified or reliably
eliminated.
DANGER!
Risk of personal injury or property damage in case of non-compliance!
The system’s safety function is disabled. Personal injury and damage to equipment.
• Conduct in case of fault as specified..
6. Initial Start-Up
Project engineering, installation, initial start-up, maintenance and testing of the devices may only be carried
out by electricians with recognized training, who are familiar with safety standards for automation technology.
All cables and accessories installed to the setup must comply with applicable safety and electromagnetic
compatibility requirements and regulations, and if applicable correspond with any telecommunication terminal
devices and their specifications. If damage has occurred, the product may no longer be used. The guarantee
and any liability claims against the manufacturer are rendered null and void in the event of improper use.
Information regarding which cables and accessories are approved for installation is available from
www.wenglor.com or is included in this manual.