Zander Aachen ZX09 Series User manual

Operating Manual
FPGA-based High-Speed Industrial PLC
ZX09-Series
ZX20/ZX21-Series

H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aache • Germa y • Tel [phone]
Fax [phone] • i fo@za der-aache .de • www.za der-aache .de
2
Operating manual ZX09/20/21-Series
Zander GmbH & Co. KG
Am Gut Wolf 15
52070 Aachen, Germany
[e-mail]
www.zander-aachen.de
Item no.: E61-436-00
Version: N01
This document is the English translation.
Technical Changes reserved,
all information is subject to change.

H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aache • Germa y • Tel [phone]
Fax [phone] • i fo@za der-aache .de • www.za der-aache .de
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Operating manual ZX09/20/21-Series
1. About this document .................................................................................7
1.1 Validity ........................................................................................................7
1.2 Target group................................................................................................7
1.3 Explanation of symbols...............................................................................7
2. General safety instructions........................................................................8
3. About this device ........................................................................................9
3.1 Product information.....................................................................................9
3.2 Delivery content and supplies.....................................................................10
3.3 Intended usage ...........................................................................................11
3.4 Exclusion of liability and warranty...............................................................11
3.5 Function.......................................................................................................11
3.6 Device diagram ...........................................................................................12
3.6.1 ZX09.........................................................................................................12
3.6.2 ZX09A ......................................................................................................12
3.6.3 ZX09B / ZX09C / ZX09D / ZX09E ...........................................................13
3.6.4 ZX20T.......................................................................................................13
3.6.5 ZX21TP/TC ..............................................................................................14
4. Assembly .....................................................................................................14
4.1 Assembly on the mounting rail....................................................................14
4.2 Disassembly off the mounting rail...............................................................15
5. Electrical connection..................................................................................16
5.1 General rules for the electrical connection .................................................16
5.2 Connection terminals ..................................................................................17
5.2.1 ZX09 / ZX09A / ZX09B / ZX09C / ZX09D / ZX09E..................................17
5.2.2 ZX20T, ZX21TP/TC .................................................................................19
5.3 Failure safety...............................................................................................20
5.4 Electrical connection of the device..............................................................20
5.5 Inputs...........................................................................................................21
5.5.1 Digital Inputs.............................................................................................22
5.5.2 Connection of the digital Inputs................................................................23
5.5.3 Analog Inputs (only ZX09A/B/C/D/E).......................................................26
5.5.4 Connection of the analog inputs ..............................................................27

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Operating manual ZX09/20/21-Series
5.5.5 The SSI-Interface (only ZX09A, ZX09D and ZX09E)..............................28
5.5.6 Connection of an Encoder to the SSI-Interface.......................................29
5.5.7 TTL differential signal inputs (only ZX09A, ZX09D, ZX09E)...................30
5.5.8 TTL differential signal outputs (only ZX09A, ZX09D, ZX09E).................30
5.5.9 Connection of the In-/Outputs for the TTL differential signals.................30
5.6. Digital outputs.............................................................................................31
5.6.1 Connection of the digital outputs..............................................................32
6. Programming...............................................................................................34
7. Networking...................................................................................................35
7.1 Networking via Ethernet..............................................................................35
7.1.1 Modbus/TCP ............................................................................................35
7.1.2 ZanderNet ................................................................................................36
7.2 The RS 485-Interface (only ZX09A, ZX09D and ZX09E)...........................39
7.2.1 Modbus RTU............................................................................................39
7.2.2 Modbus RTU wiring..................................................................................40
7.2.3 ZanderLink ...............................................................................................41
7.2.4 ZanderLink wiring.....................................................................................42
7.3 Networking via Profinet (only ZX21TP).......................................................43
7.4 Networking via EtherCAT (only ZX21TC)...................................................44
8. Commissioning ...........................................................................................45
8.1 What happens at the start?.........................................................................45
8.2 Initial commissioning...................................................................................46
8.2.1 Step 1: Program creation in EX_PRESS 5..............................................46
8.2.2 Step 2: Connecting the power supply......................................................46
8.2.3 Step 3: Programming the PLC.................................................................46
8.2.4 Step 4: Connecting the inputs..................................................................46
8.2.5 Step 5: Connecting the encoder (ZX09A, ZX09D, ZX09E).....................47
8.2.6 Step 6: Controlling the function of the PLC via the LEDs........................47
8.2.7 Step 7: Connection to a network..............................................................47
8.2.8 Step 8: Connecting the outputs................................................................48
8.2.9 Step 9: Connecting the power supply of the digital outputs ....................48
9. Diagnosis .....................................................................................................48

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Operating manual ZX09/20/21-Series
10. Maintenance, repair and replacement ....................................................52
11. Dimensional drawing................................................................................53
12. Technical data ...........................................................................................54
12.1 ZX09 / ZX09A............................................................................................54
12.2 ZX09B / ZX09C / ZX09D / ZX09E.............................................................56
12.3 ZX20T, ZX21TP/TC ..................................................................................58
12.4 FPGA logic capacities...............................................................................59
13. Example 1...................................................................................................60
13.1 The process...............................................................................................60
13.2 Step 1: Program creation in EX_PRESS 5...............................................61
13.3 Step 2: Connecting the power supply.......................................................65
13.4 Step 3: Programming the PLC..................................................................65
13.5 Step 4: Connecting the inputs...................................................................65
13.6 Step 6: Controlling the function of the PLC via the LEDs.........................66
13.7 Step 8: Connecting the digital outputs......................................................66
13.8 Step 9: Connecting the power supply of the digital outputs .....................67
14. Example 2...................................................................................................68
14.1 The process...............................................................................................68
14.2 Step 1: Program creation in EX_PRESS 5...............................................69
14.3 Step 2: Connecting the power supply.......................................................72
14.4 Step 3: Programming the PLC..................................................................72
14.5 Step 4: Connecting the inputs...................................................................72
14.6 Step 6: Controlling the function of the PLC via the LEDs.........................73
14.7 Step 8: Connecting the digital outputs......................................................73
14.8 Step 9: Connecting the power supply of the digital outputs .....................74
15. Example 3...................................................................................................75
15.1 The Application .........................................................................................75
15.2 Step 1: Program creation in EX_PRESS 5...............................................76
15.3 Step 2: Connecting the power supply.......................................................79
15.4 Step 3: Programming the PLC..................................................................79
15.5 Step 4: Connecting the inputs...................................................................79
15.5 Step 7: Connecting the Ethernet interface................................................80

H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aache • Germa y • Tel [phone]
Fax [phone] • i fo@za der-aache .de • www.za der-aache .de
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Operating manual ZX09/20/21-Series
16. Declaration of conformity ........................................................................81
17. Service .......................................................................................................82

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Operating manual ZX09/20/21-Series
1. About this Document
1.1 Validity
This document ist valid for the programmable logic controllers
ZX09 (Item-no.: 589200), ZX09A (Item-no.: 589201), ZX09B (Item-no.: 589202),
ZX09C (Item-no.: 589203), ZX09D (Item-no.: 589204), ZX09E (Item-no.: 589205),
ZX20T (Item-no.: 589000), ZX21TP (Item-no.: 589052), ZX21TC (Item-no.: 589053).
1.2 Target group
This document is intended for electricians, installation-, commissioning– and service
personnel with appropriate knowledge in handling automation technology components.
1.3 Explanation of symbols
2. General safety instructions
Symbol / Illustration Meaning
Document in printed form
Document is available to download at
www.zander-aachen.de
Document on USB memory stick
Safety instruction
Warning: Possible dangers
Caution: Possibility of damage to life and property
Important information
HINT Tip / useful information

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Operating manual ZX09/20/21-Series
• Only authorised and qualified personnel may install the device and
put it into operation, i.e. personnel which
- is well-acquainted with correct technical handling of the
electrical machine equipment,
- is familiar with the applicable regulations concerning occu-
pational safety and accident prevention,
- has read and understood the operating manual and, if
applicable, the programming manual
• In case of incorrect connection or inappropriate use, the safe func-
tioning of the device during the machine operation will no longer be
guaranteed. This can result in fatal injuries or serious material loss.
• Please observe the national guidelines, which are valid for the com-
missioning of the device.
• The electrical connection of the device must take place only when
the voltage supply is switched off. This also applies to the connected
sensors and actuators.
• The wiring of the device must be done in conformance with the
instructions given in this operating manual.
• The person, who installs the device and puts it into operation, must
be adequately protected against electrostatic charge (earthing strap
or ESD shoes along with ESD flooring).
• Opening of the device and any manipulations to the device are not
allowed; and shall result in loss of warranty and warranty claims.
• Please observe all the relevant safety guidelines and standards.
• Non-observance of the safety guidelines may lead to death, severe
injuries and serious material damage.
• Please read the operating manual before use and preserve it care-
fully.
• Please ensure that the operating manual is always available at the
time of assembly, commissioning and maintenance work.

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Fax [phone] • i fo@za der-aache .de • www.za der-aache .de
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Operating manual ZX09/20/21-Series
3. About this device
3.1 Product information
The ZX09– and ZX20/21-series are high-speed industrial programmable logic control-
lers (PLCs). They can be used as stand-alone PLCs or in a network as decentralized
PLCs for parallel processing of signals in real time. This is made possible by the heart
of every ZX-control: A Field Programmable Gate Array (FPGA). This enables the
fastest possible and equally fast, reproducible processes without cycle time in absolute
parallelism.
The following table lists the type and number of inputs, outputs and communication
interfaces for all device types:
The programming is carried out via the programming software EX_PRESS 5
(Item.-no.: 589092 ) in structured text (ST) after IEC 61131-3.
ZX09 ZX09A ZX09B ZX09C ZX09D ZX09E ZX20T ZX21TC ZX21TP
Digital inputs 10 10 2 2 2 2 20 20 20
Digital outputs 4 4 4 4 4 4 16 16 16
Analog inputs
0..10V/4..20mA switchable - 1 2 2 2 2 - - -
Analog-inputs 0..10V - - 4 - 4 - - - -
Analog-inputs 4..20mA - - - 4 - 4 - - -
SSI (or second RS-485) - 1 - - 1 1 - - -
RS-485 (or second SSI) - 1 - - 1 1 - - -
Ethernet
(Modbus/TCP, ZanderNet) 1 1 1 1 1 1 1 1 1
PROFINET - - - - - - - - 2
(Switch)
EtherCAT - - - - - - - 2
(In/Out) -
TTL differential
inputs/outputs - 4 - - 4 4 - - -
ZanderLink - 2 - - 2 2 - - -

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Operating manual ZX09/20/21-Series
3.2 Delivery content and supplies
Delivery content
• High-Speed-PLC ZX09 (Item.-no.: 589200), ZX09A (Item-no.: 589201),
ZX09B (Item-no.: 589202), ZX09C (Item.-no.: 589203), ZX09D (Item.-
no.: 589204),
ZX09E (Item.-no.: 589205) or ZX20T (Item.-no.: 589000),
ZX21TP (Item.-no.: 589052)
or ZX21TC (Item.-no.: 589053)
• Pluggable screw terminals (plugged into the device when delivered):
♦ ZX09: 1 x 10-pin and 2 x 4-pin
♦ ZX09A: 2 x 10-pin and 2 x 4-pin
♦ ZX09B/C: 1 x 10-pin and 3 x 4-pin
♦ ZX09D/E: 1 x 10-pin and 5 x 4-pin
♦ ZX20T, ZX21TP/TC: 4 x 10-pin
• This operating manual
Required supplies
3.6 Device diagram
Designation Execution Item-no.:
EX_PRESS 5 USB memory stick 589092
Note!
For the program creation and programming of the High-Speed-PLC
you need the software package EX_PRESS 5 in the latest version,
which is separately available.
Designation Item-no.:
Set of plug terminals with cable exits for ZX09 on the side 589270
Set of plug terminals with cable exits for ZX09A on the side 589271
Set of plug terminals with cable exits for ZX09B/C on the side 589272
Set of plug terminals with cable exits for ZX09D/E on the side 589273
Set of plug terminals with cable exits for ZX20/ZX21 on the side 589070

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Operating manual ZX09/20/21-Series
3.3 Intended usage
The ZX09- und ZX20/21-Series have been designed for the use in machines and
plants for industrial use. They must be installed in switch cabinets or appropriate hous-
ings with minimum degree of protection IP54. The approved operating parameters for
use must be complied with (see chapter 12 “Technical data”).
The inputs and outputs have to be connected accordingly.
The controls can be integrated as slaves into an existing Modbus TCP/IP network or
build an existing network with the Multimaster protocol “ZanderNet“ via the
Ethernet-interface.
The controller ZX21TP can be integrated as slave (PROFINET IO-Device) into a
PROFINET-network. The controller ZX21TC can be addressed as slave in an EtherCat
-network.
3.4 Exclusion of liability and warranty
If the conditions above are not complied for the intended use, the safety instructions
are not followed, or maintenance work is not performed as required, it will lead to a
disclaimer or loss of warranty.
3.5 Function
The function of the device depends upon the loaded user program. The logic stored in
this program determines how the input signals are evaluated and the outputs switch.
Note!
The user is responsible for the integration of the device into the overall
system. For this, the correct electrical installation and the correct pro-
gramming of the ZX09, ZX09A, ZX09B, ZX09C, ZX09D, ZX09E,
ZX20T or ZX21TP/TC must be verified.

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Operating manual ZX09/20/21-Series
3.6.1 ZX09
3.6.2 ZX09A
Fig. 1: Device diagram ZX09
Fig. 2: Device diagram ZX09A

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Operating manual ZX09/20/21-Series
3.6.3 ZX09B / ZX09C / ZX09D / ZX09E
3.6.4 ZX20T / ZX21T
Fig. 3: Device diagram ZX09B / ZX09C / ZX09D / ZX09E
Fig. 4: Device diagram ZX20T / ZX21T
ZX20T
ZX21T

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Operating manual ZX09/20/21-Series
3.6.5 ZX21TP / ZX21TC
4. Assembly
Please note:
The device must be installed in a switch cabinet or suitable housing with a minimum
degree of protection of IP54
• Mount the controller on a 35 mm mounting rail according to EN 60715
• Maintain a mounting distance of minimum 5 mm from the adjacent devices
• Ensure that there is sufficient heat dissipation in the switch cabinet.
• Keep the PLC away from devices or components, which carry high voltage or cause
strong electrical interference.
4.1 Assembly on the support rail
The black underside of the device is placed flat on the mounting rail (see Fig. 6). Then
press the unit firmly onto the mounting rail with your palms (see Fig. 7) until both or-
ange locking slides, which are located at the bottom, in the middle, on the long outer
sides and on the underside of the control unit, are engaged.
Fig. 5: Device diagram ZX21TP / ZX21TC