Zander Aachen ZX09 Series Operating Manual Download

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Operating Manual

FPGA-based High-Speed Industrial PLC

ZX09-Series

ZX20/ZX21-Series

Summary of Contents for ZX09 Series

Page 1: ...Operating Manual FPGA based High Speed Industrial PLC ZX09 Series ZX20 ZX21 Series...

Page 2: ...er aachen de www zander aachen de 2 Operating manual ZX09 20 21 Series Zander GmbH Co KG Am Gut Wolf 15 52070 Aachen Germany info zander aachen de www zander aachen de Item no E61 436 00 Version M06 T...

Page 3: ...ction 10 3 6 Device diagram 11 3 6 1 ZX09 11 3 6 2 ZX09A 11 3 6 3 ZX09B ZX09C ZX09D ZX09E 12 3 6 4 ZX20T ZX21T 12 3 6 5 ZX20T TP TC ZX21T TP TC 13 4 Assembly 13 4 1 Assembly on the mounting rail 13 4...

Page 4: ...1 1 Modbus TCP 34 7 1 2 ZanderNet 36 7 2 The RS 485 Interface only ZX09A ZX09D and ZX09E 38 7 2 1 Modbus RTU 38 7 2 2 Modbus RTU wiring 39 7 2 3 ZanderLink 40 7 2 4 ZanderLink wiring 41 7 3 Networking...

Page 5: ...power supply 64 13 4 Step 3 Programming the PLC 64 13 5 Step 4 Connecting the inputs 64 13 6 Step 6 Controlling the function of the PLC via the LEDs 65 13 7 Step 8 Connecting the digital outputs 65 1...

Page 6: ...o 589000 ZX20TP Item no 589002 ZX20TC Item no 589003 ZX21T Item no 589051 ZX21TP Item no 589052 ZX21TC Item no 589053 1 2 Target group This document is intended for electricians installation commissio...

Page 7: ...rve 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...

Page 8: ...d 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 p...

Page 9: ...n 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 TP ZC ZX21T TP TC 4 x 10 pin This operating manual Required supplies Designation...

Page 10: ...ZanderNet via the Ethernet interface The controllers ZX20TP and ZX21TP can be integrated as slave PROFINET IO Device into a PROFINET network The controls ZX20TC and ZX21TC can be ad dressed as slave...

Page 11: ...6 2 ZX09A Power FPGA Controller ZX09 Digital Outputs Digital Inputs Ethernet 02 03 01 U L M M 04 02 03 01 04 06 07 05 08 10 09 Power Supply Fig 1 Device diagram ZX09 Fig 2 Device diagram ZX09A Power...

Page 12: ...M M 04 02 01 Power Supply 0V A5 Switchable Analog Inputs A1 0V A2 0V A3 0V A4 0V 0V A6 A D Conv A D Conv A D Conv A D Conv A D Conv Non switchable Analog Inputs A D Conv CK CK DT SSI DT 2 2 1 RS 485 1...

Page 13: ...f 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 el...

Page 14: ...9 20 21 Series 4 2 Disassembly off the mounting rail The two orange locking slides top and bottom are pulled out one after the other with a screwdriver blade width max 3 5 mm see Fig 8 The device is t...

Page 15: ...se shielded network cables of category Cat 7 for the network connection For connection to the SSI or RS 485 interface ZX09 series only a shielded twisted pair cable is required see Fig 15 Tighten the...

Page 16: ...tage and the voltage for the digital outputs and 0 V potential for digital and analog inputs M and 0V are connected internally U Connection for the positive voltage switched by the digital outputs can...

Page 17: ...05 06 07 08 09 10 1 1 2 2 Ck Ck D D RS 485 SSI Analog Input 20mA 10V A 0 V RUN OC 1 2 3 Fig 9 Connection terminals ZX09A Fig 10 Connection terminals ZX09B ZX09C ZX09D ZX09E U Power Supply L M M Digita...

Page 18: ...Positive voltage for the dig outputs can be different to operating voltage L Digital Input 01 20 Digital inputs Digital Output 01 16 Digital inputs Ethernet interface PROFINET IO Device PROFINET inte...

Page 19: ...27 5 V 24 V 15 see chapter 12 Technical data For wiring the positive voltage must be connected to terminal L and the corresponding 0 V potential to M The PE poten tial of the voltage source must be gr...

Page 20: ...indicated by a green LED on the PLC see Figs 14A and 14B The LEDs 01 02 03 20 are continuously assigned to the digital inputs 01 02 03 20 The ZX09 series do not have LEDs to indicate the input states...

Page 21: ...igital inputs These are accessible via the lower terminal blocks Digital Input 01 20 The digital inputs are not galvanically isolated from the supply voltage i e their 0 V reference potential is ident...

Page 22: ...see chapter 12 Technical data If a separate voltage source is used its 0 V output must be connected to the 0 V output of the operating voltage The signal cable of the sensors can be connected directly...

Page 23: ...ital inputs unshielded ZX20 21 series 108 0V 18 30V 24 V 0 V U Power L M M 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 M M Digi...

Page 24: ...ting manual ZX09 20 21 Series U Power Supply L M M Digital Input 01 02 03 04 05 06 07 08 09 10 RU Fig 15 A Connection of the digital inputs unshielded ZX09 series 0V 18 30V 24 V 0 V Fig 15 B Connectio...

Page 25: ...mA or a voltage value from 0 V to 10 V by means of the corresponding switch position The incoming current or voltage signal is connected to terminal A and the respective 0 V potential to 0V Note In t...

Page 26: ...ed cable Connect the cable screen on one side as close as possible to the terminals of the control system with low impedance to a screen rail which is at PE potential see fig 16 The cables must be lai...

Page 27: ...be connected via this interface Both Single Turn and Multi Turn versions are possible as well as the data formats binary code and gray code Both the SSI interface and the RS 485 interface can be confi...

Page 28: ...ded cable twisted in pairs Connect the cable shield at one end as close as possible to the terminals of the control with a low resistance shielding rail at PE potential see Fig 18 The data signal is c...

Page 29: ...signal outputs only ZX09A ZX09D ZX09E The SSI or RS 485 interfaces can also be used as differential outputs to connect actuators with TTL differential inputs Up to four TTL differential inputs are ava...

Page 30: ...sponds to output 1 LED 2 to output 2 etc If one of the outputs is activated it switches through the voltage applied to U otherwise the output is open ZX20 ZX21 or is actively pulled to 0 V ZX09 famil...

Page 31: ...Different actuators e g relays can be con nected to the terminals of the outputs Their 0 V potential is connected to the 0 V potential of the voltage source for the digital outputs terminal M A volta...

Page 32: ...32 Operating manual ZX09 20 21 Series 108 Fig 20 Connection of the outputs here e g relays ZX20 21 series 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 Fig 19 Con...

Page 33: ...interface In addition to the nameplate on the side each controller has a label with the corresponding MAC address see Fig 21 This label is located below the Ethernet interface on all ZX controllers T...

Page 34: ...gisters Function code 6 Write Single Register Function code 16 Write Multiple Registers The IP addresses of the Zander controllers are set in the user program using the reserved keywords IP_ADR and IP...

Page 35: ...X09A ETHERNET SWITCH ZX09A T R Lk RU OC 1 2 3 ZX09A T R Lk RU OC 1 2 3 ZX09A T R Lk RU OC 1 2 3 Example for Modbus TCP master Zander HMI series MVisio https www zander aachen de de automation hmi mvis...

Page 36: ...realized directly from controller to controller via an Ethernet cable No further devices are nec essary for this If more than two controllers should be connected with each other or controllers should...

Page 37: ...1050138 info zander aachen de www zander aachen de 37 Operating manual ZX09 20 21 Series Fig 23 Networking via ZanderNet e g with ZX09A ZX09A T R Lk RUN OC 1 2 3 4 ZX09A T R Lk RUN OC 1 2 3 4 A B ETHE...

Page 38: ...us func tion codes to access the network variables declared in the EX_PRESS 5 user program under VAR_GLOBAL and VAR_EXTERNAL Function code 3 Read Holding Registers Function code 6 Write Single Registe...

Page 39: ...via the connections 2 and 2 of the RS 485 interface using a shielded twisted pair two wire cable see Fig 24 The shield must be connected to a shielding rail at one end with low impedance as close as...

Page 40: ...nk is designed for the exchange of relatively little user data but this data is transferred very quickly For example the cyclic exchange of 32 bit user data master to slave slave to master is possible...

Page 41: ...ance A terminating resistor of 120 Ohm must be connected to terminals 1 and 1 or 2 and 2 Alternatively the SSI port of the controllers can be used for ZanderLink Here the terminals Ck and Ck as well a...

Page 42: ...ET IO Device The GSDML file must be included in the PROFINET IO Controller configuration software In the software the input and output data which are exchanged with the PROFINET IO Controller must be...

Page 43: ...the chain it has to be connected to the left RJ45 socket OUT The EDS file must be included in the EtherCAT Master configuration software The input and output data that are exchanged with the master ca...

Page 44: ...verall system a risk assessment must be carried out in accordance with the Machinery Directive If additional measures are to be taken with regard to functional safety approved safety components such a...

Page 45: ...ed by the green RUN LED ZX09 series or the blue Pwr LED ZX20 21 series 8 2 3 Step 3 Programming the PLC For program transfer the PLC must be connected to an existing network to which the PC is connect...

Page 46: ...ction to a network If it is intended to use the controller within a data transmission network Modbus TCP or ZanderNet connect the controller to the network using an Ethernet cable Proceed as described...

Page 47: ...here are various LEDs on the controllers which allow easy diagnosis and are helpful in the event of any necessary troubleshooting A green LED labelled RUN ZX09 series see Fig 28 or a blue LED labelled...

Page 48: ...M 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 Digital Output 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 RX TX RX TX Link Link ZanderNet L A OUT L...

Page 49: ...Status Meaning SYS Green On Bus module ready for operation Green Yellow Flashing Green Yellow Bus module moves up Yellow On Off Device is switched off or bus module is defective BF Red On No configur...

Page 50: ...defective ERR Red Flashing Invalid configuration Red Single flash Local error The slave device application has changed the EtherCAT state independently Red Double flash Process data watchdog timeout O...

Page 51: ...f 15 52070 Aachen Germany Tel 49 241 9105010 Fax 49 241 91050138 info zander aachen de www zander aachen de 51 Operating manual ZX09 20 21 Series 11 Dimensional drawing Fig 30 Dimensional drawing exem...

Page 52: ...nd replacement Assuming correct installation maintenance work is not required Repairs to the device may only be carried out by the manufacturer Opening the device by the user will result in the loss o...

Page 53: ...hort circuit protection Yes electronic self resetting Digital inputs Quantity 10 Input voltage 18 30 V Input current at 24 V 6 5 mA Input resistance 3 7 k Galvanic separation No Low level 5 V High lev...

Page 54: ...quency TP 2nd order 110 kHz Dielectric strength switch position 10 V 35 V Current resistance Switch position 20 mA 38 mA Processing time Internal processing time FPGA 20 ns Interfaces RS 485 422 only...

Page 55: ...ut voltage 18 30 V Input current at 24 V 6 5 mA Input resistance 3 7 k Galvanic separation No Low level 5 V High level 18 V Pulse suppression Configurable 1 s 1073 s see programming manual Max switch...

Page 56: ...frequency TP 2nd order 110 kHz Dielectric strength switch position 10 V 35 V Current resistance Switch position 20 mA 38 mA Processing time Internal processing time FPGA 20 ns Interfaces RS 485 SSI on...

Page 57: ...pprox 60 mA approx 160 mA Power consumption at UB for ZX20T ZX21T for ZX20TP TC ZX21TP TC all inputs activated without load approx 1 5 W approx 3 9 W Digital inputs Quantity 20 Input voltage 18 30 V I...

Page 58: ...stress 93 r m at 40 C dewless Vibrations according to EN 61131 2 Frequency 5 8 4 Hz 3 5 mm amplitude Frequency 8 4 150 Hz 1 0 g acc Shock according to EN 61131 2 Acceleration 15 g Mechanical data Pro...

Page 59: ...ould stop and therefore not transport a new container to the plant In the plant the empty container should be transported under the filling hopper via a further conveyor belt A proximity switch should...

Page 60: ...variables for the four sensors are declared for this purpose The variables Light barrier1 and Light barrier2 correspond to the respective light barriers proximity switch to the proximity switch and pu...

Page 61: ...hese variables are all initialized with 0 Finally the internal clock of the controller is declared under VAR_TIMER The actual program is written in the logic part marked by LOGIC PART Via various IF E...

Page 62: ...hat no further container is conveyed into the system ELSIF Lightbarrier1 1 THEN Belt1 0 As soon as light barrier 2 is activated belt 1 is reactivated so that a new container is conveyed to the plant E...

Page 63: ...0 filled 1 END_IF If the container is filled and is still at the filling position conveyor 2 is started again The full con tainer is then transported away ELSIF Belt2 0 AND Proxswitch 1 AND filled 1...

Page 64: ...3 Programming the PLC For programming the controller is connected to a computer via the Ethernet interface The PLC is programmed using the EX_PRESS 5 software After successfully compil ing and fittin...

Page 65: ...ication does not provide an encoder 13 6 Step 6 Controlling the function of the PLC via the LEDs After successful programming and connection of the inputs the function is controlled via the LEDs next...

Page 66: ...nal 2 the control of volume 2 to terminal 3 and the error status display to terminal 4 The connection is made as described in chapter 5 6 1 Connection of the digital outputs 13 8 Step 9 Connecting the...

Page 67: ...vered via a conveyor belt At position 1 these parts are to be checked for their maximum height For this purpose a light barrier is to be used to check whether the individual components exceed the spec...

Page 68: ...erminals namely 1 2 3 and 4 via the command AT The output signals are declared under VAR_OUTPUT This is the control of trap door 1 and 2 Door1Open and Door2Open If these are active the components are...

Page 69: ...ail2 is set to 1 otherwise Fail2 is set to 0 Finally the output signals are assigned For this the outputs are switched over a defined period of time In the last part of the program marked by TIMERS th...

Page 70: ...nd 2 the component had the wrong colour Fail2 is set IF Light2 1 AND timerColor 1 THEN Fail2 1 ELSE Fail2 0 END_IF Door1Open timerDoor1 Door2Open timerDoor2 TIMERS As soon as Fail1 is active timerDoor...

Page 71: ...er supply is connected to the controller 14 4 Step 3 Programming the PLC For programming the controller is connected to a computer via the Ethernet interface The PLC is programmed using the EX_PRESS 5...

Page 72: ...provided in the application 14 7 Step 8 Connecting the digital outputs Fig 36 shows the connection of the digital outputs As with the connection of the in puts make sure that the cabling is connected...

Page 73: ...tal outputs Finally the power supply of the digital outputs is connected The voltage supply of the outputs is connected as described in chapter 5 6 1 Connection of the digital outputs Fig 36 Connectio...

Page 74: ...ZANDER GmbH Co KG Am Gut Wolf 15 52070 Aachen Germany Tel 49 241 9105010 Fax 49 241 91050138 info zander aachen de www zander aachen de 74 Operating manual ZX09 20 21 Series 15 Declaration of conformi...

Page 75: ...ander aachen de www zander aachen de 75 Operating manual ZX09 20 21 Series 16 Service Contact us in case of service H Zander GmbH Co KG Am Gut Wolf 15 52070 Aachen Germany Service phone Within Germany...

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