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

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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

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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)

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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