Zander Aachen ZX20T User manual

Operating Manual
FPGA-based High-Speed Industrial PLC
ZX20T/TP/TC

H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aachen • Germany • Phone +49 241 9105010
Fax +49 241 91050138 • info@zander-aachen.de • www.zander-aachen.de
2
Operating Manual ZX20T/TP/TC
H. Zander GmbH & Co. KG
Am Gut Wolf 15
52070 Aachen, Germany
info@zander-aachen.de
www.zander-aachen.de
Part No.: E61-335-10
Edition: L06
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 Aachen • Germany • Phone +49 241 9105010
Fax +49 241 91050138 • info@zander-aachen.de • www.zander-aachen.de 3
Operating Manual ZX20T/TP/TC
1. About this document .................................................................................. 5
1.1 Validity ....................................................................................................... 5
1.2 Target group ............................ .................................................................. 5
1.3 Legend ....................................................................................................... 5
2. General safety instructions ....................................................................... 6
3. About this device ........................................................................................ 7
3.1 Product information ..................................................................................... 7
3.2 Scope of delivery and accessories ............................................................ 7
3.3 Appropriate use........................................................................................... 8
3.4 Disclaimer and warranty ............................................................................. 8
3.5 Function ...................................................................................................... 8
3.6 Device diagram .......................................................................................... 9
3.6.1 ZX20T....................................................................................................... 9
3.6.2 ZX20TP / ZX20TC.................................................................................... 9
4. Assembly .................................................................................................... 10
4.1 Assembly on the support rail....................................................................... 10
4.2 Removal from the support rail ..................................................................... 11
5. Electrical connection ................................................................................. 12
5.1 General basic rules for electrical connection .............................................. 12
5.2 Connecting terminals .................................................................................. 13
5.3 Safety against failures ................................................................................ 14
5.4 Electrical connection of the device ............................................................ 14
5.5 Inputs .......................................................................................................... 15
5.5.1 Digital inputs ............................................................................................ 16
5.6 Outputs ........................................................................................................ 18
5.6.1 Digital outputs ......................................................................................... 19
6. Programming ............................................................................................... 20
7. Networking .................................................................................................. 21
7.1 Networking via Ethernet ............................................................................. 21
7.2 ZX20TP: Networking via PROFINET .......................................................... 23
7.3 ZX20TC: Networking via EtherCAT ............................................................ 24

H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aachen • Germany • Phone +49 241 9105010
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Operating Manual ZX20T/TP/TC
8. Commissioning ........................................................................................... 25
8.1 What happens at the start? ......................................................................... 25
8.2 Initial commissioning procedure.................................................................. 26
8.2.1 Step 1: Program creation in EX_PRESS 5 .............................................. 26
8.2.2 Step 2: Connecting the power supply ...................................................... 26
8.2.3 Step 3: Programming the PLC ................................................................. 26
8.2.4 Step 4: Connecting the inputs .................................................................. 26
8.2.5 Step 5: Control of the function of the PLC via LEDs................................ 27
8.2.6 Step 6: Connection to a network.............................................................. 27
8.2.7 Step 7: Connecting the digital outputs ..................................................... 27
8.2.8 Step 8: Connecting the power supply of the digital outputs .................... 28
9. Diagnosis ..................................................................................................... 28
10. Maintenance, repair and replacement .................................................... 31
11. Dimensional drawing ................................................................................ 32
12. Technical data ........................................................................................... 33
13. An example ................................................................................................ 35
13.1 The process............................................................................................... 35
13.2 Step 1: Program creation in EX_PRESS 5 ............................................... 36
13.3 Step 2: Connecting the power supply ...................................................... 40
13.4 Step 3: Programming the PLC .................................................................. 40
13.5 Step 4: Connecting the inputs ................................................................... 40
13.6 Step 5: Control of the function via LEDs of the PLC ................................ 41
13.7 Step 7: Connecting the digital outputs ...................................................... 41
13.8 Step 8: Connecting the power supply of the digital outputs ..................... 42
14. Declaration of Conformity........................................................................ 43
15. Service ....................................................................................................... 44

H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aachen • Germany • Phone +49 241 9105010
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Operating Manual ZX20T/TP/TC
1. About this document
1.1 Validity
This document is valid for the programmable logic controllers ZX20T (order no.:
589000), ZX20TP (order no.: 589002) and ZX20TC (order no.: 589003).
1.2 Target group
Electricians, installation-, commissioning- and service personnel with appropriate
knowledge in handling automation technology components.
1.3 Legend
Symbol / Illustration Meaning
Document in printed form
Document is available to download at
www.zander-aachen.de
Document on USB memory stick
Warning, Caution
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 ZX20T/TP/TC
2. General safety instructions
Warning,
Caution
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.

H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aachen • Germany • Phone +49 241 9105010
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Operating Manual ZX20T/TP/TC
3. About this device
3.1 Product information
ZX20T, ZX20TP and ZX20TC 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 ZX20T, ZX20TP and ZX20TC controllers provide 20 digital
inputs and 16 digital outputs. All controllers also offer an Ethernet network connec-
tion. This allows a connection to a computer for programming and configuration, as
well as connecting with another device or in a network. The programming is carried
out via the programming system EX_PRESS 5 (order no.: 589092) in the program-
ming language Structured Text (ST), specified in IEC 61131-3. Additionally, the
ZX20TP controller has two PROFINET interfaces and the ZX20TC controller one
EtherCAT input as well as one EtherCAT output.
3.2 Scope of delivery and accessories
Scope of delivery
High-Speed Industrial PLC ZX20T (Order No. 589000), ZX20TP (Order No.
589002) or ZX20TC (order no. 589003)
4 plug-in terminal blocks (inserted into the device at delivery)
This operating manual
Required Accessories
Description Item Order Number
EX_PRESS 5 USB memory stick 589092
Note:
For the program evaluation and programming of the High-Speed PLC,
you will need the EX_PRESS 5 software package, which is available
separately.

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Operating Manual ZX20T/TP/TC
3.3 Appropriate use
The ZX20T, ZX20TP and ZX20TC PLCs have been designed for the use in ma-
chines and plants for industrial use. They must be installed in switch cabinets or
appropriate housings with minimum protection class of IP54. The approved operating
parameters for use must be complied with (see paragraph 12 "Technical Data").
The controllers can be integrated into an existing network or build a new network via
the Ethernet port. Within the network all controllers operate with equal rights
(multimaster).
With PROFINET the controller ZX20TP can be connected as a slave.
With EtherCat the controller ZX20TC can be connected as a slave.
3.4 Disclaimer 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 on 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 ZX20T, ZX20TP or ZX20TC must be verified.

H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aachen • Germany • Phone +49 241 9105010
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Operating Manual ZX20T/TP/TC
3.6 Device diagram
3.6.1 ZX20T
3.6.2 ZX20TP / ZX20TC
Fig. 1: Device diagram ZX20T
Power FPGA Controller
ZX20T
Digital Outputs
Digital Inputs
Ethernet
02 0301U+
L+ MM04 06 0705 08 10 1109 12 14 1513 16
02 0301 04 06 0705 08 10 1109 12 14 1513 16 18 1917 20
Power Supply
Fig. 2: Device diagram ZX20TP / ZX20TC

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Operating Manual ZX20T/TP/TC
4. Assembly
The ZX20T, ZX20TP and ZX20TC devices are specially designed so they can be
installed easily.
Please note:
The device must be installed in a switch cabinet or a suitable housing with a
minimum degree of protection of IP54.
Mount on a mounting rail 35mm in conformance with EN 60715 (profile rail).
Maintain a mounting distance of minimum 5 mm from the adjacent devices, which
generate heat.
Ensure that there is sufficient heat dissipation in the switch cabinet.
Keep enough place for the wiring.
Keep the ZX20T, ZX20TP or ZX20TC away from devices or components, which
carry high voltage or cause strong electrical interference.
4.1 Assembly on the support rail
Place the device straight on the support rail (see fig. 3). Then press the device with
the ball of the thumb onto the support rail (see fig. 4) until both of the orange slide
locks are latched into place (above and below).
Fig. 3: Placing the device on the support rail Fig. 4: Pressing the device onto the support
rail

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Operating Manual ZX20T/TP/TC
4.2 Removal from the support rail
Pull out both orange slide locks (above and below) one after the other using a
screwdriver (blade width max. 3.5 mm) (see fig. 5). By doing this, the device gets
detached from the support rail and can be removed.
Fig. 5: Pulling out the slide locks

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Operating Manual ZX20T/TP/TC
5. Electrical connection
5.1 General basic rules for electrical connection
Also note that:
All electrical connections must be insulated from the mains either using safety
transformers (SELV/PELV) in conformance with IEC 61558-2-6 with limited volt-
age output in the event of error, or using equivalent insulation measures.
Under inductive loads, all outputs must have a sufficiently effective protection
circuit. The outputs must be protected with a free-wheeling diode.
Do not install the signal and communication lines in the same cable track as the
AC supply voltage lines or lines subject to severe interference. Maintain a mini-
mum distance of 20 cm from such cable tracks.
It is recommended to use Ethernet-cable of Category 7 for networking.
Tighten the screws of the connecting terminals with 0.6 … 0.8 Nm tightening
torque.
Warning
The operating voltage must correspond to the specifications given in the
chapter "Technical Data".
The voltages at the digital inputs must correspond to the specifications
given in the chapter "Technical Data".
The voltage connected to the voltage input for the digital outputs ("U+")
must correspond to the specifications given in the chapter "Technical
Data".
Do not connect any external voltage to the digital outputs.
At the time of wiring, the supply voltage of the device must be discon-
nected. The supply voltage to all the sensors and actuators must also
be disconnected.
Non-compliance of these specifications can cause severe damage to
the electronic components of the device! This will result in loss of
warranty and warranty claims.

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Operating Manual ZX20T/TP/TC
5.2 Connecting Terminals
Terminal Description
L+ Positive voltage supply UB
M (2 equivalent terminals)
0 V connection of the supply voltage
and the voltage for the digital outputs
as well as 0 V potential for digital inputs
U+ Positive voltage for the digital outputs
Digital Input 01..20 Digital inputs
Digital Output 01..16 Digital outputs
ZanderNet Ethernet interface
PROFINET IO-Device PROFINET interface (only ZX20TP)
EtherCAT Slave EtherCAT interface (only ZX20TC)
Fig 6: Connection terminals
108
ZX20T / TP / TC
BF / ERR
SF / RUN
SYS
Digital Input
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
U+
Power
L+ MM
Digital Output
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
PROFINET IO-Device
EtherCAT Slave
RX/TX RX/TX
Link Link
ZanderNet
IN OUT
L/A L/A
Pwr
Digital Output
Digital Input

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Operating Manual ZX20T/TP/TC
5.3 Safety against failures
The operating voltage L+ / M is reverse polarity protected.
All the digital outputs are short-circuit protected.
5.4 Electrical connection of the device
The electrical connection of the device is shown in fig. 7. The power supply is con-
nected to the device via the terminals L+ and M on the upper left terminal block. The
maximum permissible voltage at the terminals is approx. 27.5 V (24 V + 15%, see
chapter 12 "Technical data"). The positive voltage must be connected to terminal L+
and 0 V to M for wiring. The PE potential of the voltage supply must be grounded
according to the requirements of the system. The control itself must not be grounded
additionally. Do not connect terminal M to the PE connection of the voltage supply. If
the voltage supply is properly connected and in operation, the blue Pwr LED on the
controller will light up (see fig. 6 and fig. 15).
108
Fig. 7: Connection of the voltage supply
U+
Power
L+ MM
24 V
0 V
Warning:
The switching capacity specifications given in chapter 12 „Technical data“
must be observed. In case of overload, the output drivers could be de-
stroyed.

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Operating Manual ZX20T/TP/TC
5.5 Inputs
All the device variants "ZX20T", “ZX20TP” and "ZX20TC" have 20 digital inputs.
These are accessible via the lower two terminal blocks „Digital Input 01..20“.
The inputs do not have a galvanic isolation to the voltage supply, which means their
0 V reference potential is identical with the 0 V potential of the voltage supply
(terminal "M").
To generate the input signals, a voltage supply other than the operating voltage
supply can be used. In this case, the 0 V potential of this voltage source must be
connected at low-resistance to the 0 V potential of the operating voltage. A SELV /
PELV voltage supply according to IEC 61558-2-6 with output voltage limitation in
case of failure must be used.
If a signal is applied to one of the inputs, it will be indicated by a green LED on the
PLC (see fig. 8 A, 8 B and fig. 14). Here the LED Digital Input 01 corresponds to the
terminal Digital Input 01 etc.
Note:
Please observe the permissible voltage range for the digital inputs
(18 - 30 V) "Technical data".
Note:
In "Structured Text", input variables for digital inputs can be assigned to
the connecting terminals mentioned above via the keyword "AT", using the
"In_01", "In_02", … , "In_20" designations. You can find further infor-
mation in the programming manual in chapter 2.2.5.1 „VAR_INPUT /
VAR_OUTPUT“, which is also available as a PDF file on the USB memory
stick enclosed with the "EX_PRESS 5" software package (order no.:
589092).

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Operating Manual ZX20T/TP/TC
5.5.1 Digital Inputs
The connection of the digital inputs is shown in fig. 8 A and 8 B.
Sensors which generate a digital signal, can be connected to the terminals "Digital
Input 01..20", demonstrated here by simple switches. These can be supplied either
by the operating voltage supply or by a separate voltage supply. A voltage range of
18-30 V applies to the input voltage (see chapter 12 "Technical Data").
If another voltage supply than the operating voltage supply is used for generating
input signals, the 0 V potential of this voltage source must be connected with the 0 V
potential of the operating voltage supply. For processing very fast input signals, it is
recommended that they should be connected via shielded cables installed away from
other cables because of possible interference. Here, connect the cable shield one-
sidedly to a shield rail as close as possible to the terminals of the PLC (low-
resistance connection).
For input signals which are not time-sensitive, the interference in the corresponding
inputs can be suppressed with software technology, where these are allotted a
"debouncing time" in the user program.
Note:
Precise information for programming the debouncing time is given in the
programming manual in chapter 2.3.1.1 „VAR_INPUT, which is also avail-
able as a PDF file on the USB flash drive enclosed with the "EX_PRESS
5" software package (order no.: 589092).

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Operating Manual ZX20T/TP/TC
Fig. 8 A: Connection of the digital inputs (unshielded)
108
0V
18-30V
24 V
0 V
U+
Power
L+ MM
...
Digital Input
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
Pwr
Digital Output
Digital Input
U+
Power
L+ MM
Digital Input
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
shield rail
(PE)
...
Fig. 8 B: Connection of the digital inputs (shielded)
0V
18-30V
24 V
0 V
108
Pwr
Digital Output
Digital Input

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Operating Manual ZX20T/TP/TC
5.6 Outputs
All the device variants ZX20T, ZX20TP and ZX20TC provide 16 digital outputs.
These are accessible via the upper two terminal blocks.
The outputs do not have a galvanic isolation from the supply voltage, which means
their 0 V reference potential is identical with the 0 V potential of the voltage supply
(connecting terminal "M").
If one of the outputs is used by the programmed logic of the user program, it will be
indicated by green LEDs on the top of the controller (see fig. 9 and fig. 14). Here, the
LED Digital Output 01 corresponds to the terminal Digital Output 01 etc. If one of the
outputs switches, the voltage applied to U+ is connected through, otherwise 0 V is
applied.
All digital outputs are permanently short-circuit proofed.
When controlling inductive loads, a protective circuit in the form of a freewheeling
diode or a varistor must be used.
It is possible to connect the voltage supply of the outputs without the operating volt-
age supply being connected. In this case, there is no switching of the outputs.
Note:
In "Structured Text", output variables for digital outputs can be assigned to
the abovementioned connecting terminals via the keyword "AT" using the
"Out_01", "Out_02", … , "Out_16" designations. Further information on the
issue you will find in the programming manual in chapter 2.2.4.1
VAR_INPUT / VAR_OUTPUT, which is also available as a PDF file on the
USB stick enclosed with the "EX_PRESS 5" software package (order no.:
Note:
Please observe the permissible voltage range for the digital outputs
in chapter 12 "Technical Data".
Warning:
The switching capacity specifications given in chapter 12 „Technical data“
must be observed. In case of overload, the output drivers could be de-
stroyed.

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Operating Manual ZX20T/TP/TC
5.6.1 Digital Outputs
The connection of digital outputs is shown in fig. 9. Various actuators (e.g. relays)
can be connected to the terminals of the outputs. Their 0 V potential is connected to
the 0 V potential of the voltage supply (terminal "M").
If the outputs are enabled, the voltage generated at the connecting terminals "U+"
and "M" are connected through to the outputs. The voltage at "U+" and "M" can
deviate from the supply voltage UB; For the permitted voltage range see chapter 12
"Technical Data". If a separate voltage source is used, an additional connection of
the 0 V output of the voltage source with the 0 V output of the operating voltage
source is not necessary, since the terminals "M" are internally connected in the
device.
108
Fig. 9: Connection of digital outputs (here: relays)
10-30 V
24 V
0 V
0 V
...
Digital Output
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16

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Operating Manual ZX20T/TP/TC
Note:
The programming manual, in which the "EX_PRESS 5" programming
system is described in detail, is available in the form of a PDF file on the
USB memory stick, enclosed within the program package.
Important information:
The download of the final program into the PLC is only possible, if there is
no exchange of data via the PROFINET or EtherCAT interface at that
same time.
6. Programming
The "EX_PRESS 5" programming system, which is separately available, is required
for the evaluation of the program and for downloads to the PLC. The program is
created in the PLC programming language "Structured Text".
You can download the final program via the Ethernet interface, which is marked on
the device with the symbol . The connection with a computer can take place either
as a point-to-point connection or in a bigger network, connected to one another via
switches or hubs. Several PLCs of the same type may be found in this network. In
both cases the computer must be connected via the Ethernet interface.
Every ZX20T, ZX20TP or ZX20TC PLC has got a label with the corresponding MAC
address (see fig. 10). This label can be found right beneath the voltage supply. With
the MAC address the PLC can be identified within the network. This ensures that
every PLC contains the program meant for it.
Programming of Zander PLCs via internet is not possible.
Fig. 10: Type label and MAC address
Type
label
MAC address
This manual suits for next models
2
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