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Zander Aachen ZX20T Operating Manual

Fpga-based high-speed industrial plc
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ZX20T/TP/TC
Operating Manual
FPGA-based High-Speed Industrial PLC

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Summary of Contents for Zander Aachen ZX20T

  • Page 1 ZX20T/TP/TC Operating Manual FPGA-based High-Speed Industrial PLC...
  • Page 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...

  • Page 3: Table Of Contents

    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 ..............
  • Page 4 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 ..............

  • Page 5: About This Document

    Operating Manual ZX20T/TP/TC About this document Validity This document is valid for the programmable logic controllers ZX20T (order no.: 589000), ZX20TP (order no.: 589002) and ZX20TC (order no.: 589003). Target group Electricians, installation-, commissioning- and service personnel with appropriate knowledge in handling automation technology components.

  • Page 6: General Safety Instructions

    Operating Manual ZX20T/TP/TC General safety instructions  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, Warning, - is familiar with the applicable regulations concerning occu-...

  • Page 7: About This Device

    About this device 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).

  • Page 8: Appropriate Use

    Operating Manual ZX20T/TP/TC 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").

  • Page 9: Device Diagram

    FPGA Controller ZX20T Digital Inputs Fig. 1: Device diagram ZX20T 3.6.2 ZX20TP / ZX20TC Fig. 2: Device diagram ZX20TP / ZX20TC H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aachen • Germany • Phone +49 241 9105010...

  • Page 10: Assembly

    Operating Manual ZX20T/TP/TC 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.

  • Page 11: Removal From The Support Rail

    Operating Manual ZX20T/TP/TC 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.

  • Page 12: Electrical Connection

    Operating Manual ZX20T/TP/TC Electrical connection General basic rules for electrical connection 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".

  • Page 13: Connecting Terminals

    01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 Power Digital Output Link RX/TX RX/TX Link ZX20T / TP / TC BF / ERR SF / RUN PROFINET IO-Device EtherCAT Slave ZanderNet Digital Output Digital Input...

  • Page 14: Safety Against Failures

    Operating Manual ZX20T/TP/TC Safety against failures The operating voltage L+ / M is reverse polarity protected. All the digital outputs are short-circuit protected. 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.

  • Page 15: Inputs

    Operating Manual ZX20T/TP/TC 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").

  • Page 16: Digital Inputs

    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.
  • Page 17 Operating Manual ZX20T/TP/TC 24 V L+ M M Power Digital Output Digital Input Digital Input 11 12 13 14 15 16 17 18 19 20 01 02 03 04 05 06 07 08 09 10 18-30V Fig. 8 A: Connection of the digital inputs (unshielded)

  • Page 18: Outputs

    Operating Manual ZX20T/TP/TC Outputs All the device variants ZX20T, ZX20TP and ZX20TC provide 16 digital outputs. These are accessible via the upper two terminal blocks. 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", …...

  • Page 19: Digital Outputs

    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").

  • Page 20: Programming

    PDF file on the USB memory stick, enclosed within the program package. 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.

  • Page 21: Networking

    Networking Networking via Ethernet Several ZX20T, ZX20TP or ZX20TC controllers as well as other Zander controllers can be connected via the Ethernet interface and exchange data in the form of a distributed control system. In this network, all controllers are equivalent, which corre- sponds to multimaster operation.
  • Page 22 Operating Manual ZX20T/TP/TC ETHERNET- SWITCH Fig. 11: Networking via Ethernet 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...

  • Page 23: Zx20Tp: Networking Via Profinet

    PROFINET IO-Device PROFINET Controller RX/TX Link RX/TX Link ZX20T / TP / TC PROFINET IO-Device ZanderNet Digital Ou tput Digital Inp ut Fig. 12: Networking via PROFINET H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aachen • Germany • Phone +49 241 9105010...

  • Page 24: Zx20Tc: Networking Via Ethercat

    Note: The EDS file is provided as an XML file on the USB flash drive enclosed within the "EX_PRESS 5" software package EtherCat slave EtherCat master ZX20T / TP / TC EtherCAT slave ZanderNet Digital Ou tput Digital Inp ut Fig.

  • Page 25: Commissioning

    The ZX20T, ZX20TP and ZX20TC PLCs are not suitable for carrying out tasks pertaining to functional safety. One can not completely rule out the possibility of malfunctioning or unpredictable operating states.

  • Page 26: Initial Commissioning Procedure

    Operating Manual ZX20T/TP/TC Initial commissioning procedure 8.2.1 Step 1: Program creation in EX_PRESS 5 For an exact description of the program creation, please follow the instructions and information in the programming manual and chapter 7 "Program creation" of the installation manual EX_PRESS 5.

  • Page 27: Step 5: Control Of The Function Of The Plc Via Leds

    Operating Manual ZX20T/TP/TC 8.2.5 Step 5: Control of the function of the PLC via the LEDs Before connecting the network and the outputs, the functionality of the PLC should be checked via the LEDs. If the program does not correspond to the desired func- tion, it can be reprogrammed with connected digital inputs.

  • Page 28: Step 8: Connecting The Power Supply Of The Digital Outputs

    9. Diagnosis The ZX20T, ZX20TP and ZX20TC PLCs have LEDs on the front, which enable easy monitoring and are also useful for troubleshooting. A blue LED with the "Pwr" marking indicates the operating voltage supply (see fig.
  • Page 29 Operating Manual ZX20T/TP/TC ZX20TP: Color State Meaning green Bus module is ready green/ Flashing yellow green/yellow Bus module is booting yellow Device is deactivated or Bus module is defective No configuration; No / bad connection Flashing with No data exchange...
  • Page 30 Operating Manual ZX20T/TP/TC ZX20TC: Color State Meaning green Bus module is ready green/ Flashing yellow green/yellow Bus module is booting yellow Device is deactivated or Bus module is defective Flashing Invalid configuration Single Flash Local failure: The slave device application changed the EtherCAT status autonomously.

  • Page 31: Maintenance, Repair And Replacement

    Operating Manual ZX20T/TP/TC Maintenance, repair and replacement Provided the device has been commissioned properly, maintenance work is not required. Only the manufacturer is allowed to carry out repairs on the device. If the user opens the device, it will result in loss of warranty and warranty claims.

  • Page 32: Dimensional Drawing

    Operating Manual ZX20T/TP/TC Dimensional drawing 90 mm Fig. 15: Connection terminals 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...

  • Page 33: Technical Data

    (terminals „L+“ and „M“) DC 24 V Voltage tolerance ± 15 % Current consumption at U ZX20T / ZX20TP, ZX20TC Approx. 60 mA / approx. 160 mA (all inputs enabled / no load) Power consumption at U ZX20T / ZX20TP, ZX20TC Approx.
  • Page 34 Operating Manual ZX20T/TP/TC Environmental Data Ambient temperature 0 °C to 50 °C Storage temperature -20 °C to 80 °C Humidity rating 93 % r.F. at +40 °C, non-bedewing Vibrations acc. to EN 61131-2 Frequency: 5 - 8.4 Hz, 3.5 mm amplitude Frequency: 8.4 - 150 Hz, accel.: 1.0 g...

  • Page 35: An Example

    Operating Manual ZX20T/TP/TC An Example In this example, the initial commissioning steps are performed for a specific example. Starting with the development of a program in step 1, the individual steps are performed until the system is fully operational after completing step 8.

  • Page 36: Step 1: Program Creation In Ex_Press 5

    Operating Manual ZX20T/TP/TC Pos. 4 Pos. 1 Pos. 2 Pos. 5 Pos. 3 Height control Color sensor Light barrier Light barrier Abb. 16: Principle diagram of good / bad part sorting 13.2 Step 1: Program Creation in EX_PRESS 5 The program for the application is shown below. In the first part of the program, identified by "DECLARATION", all the necessary variables are declared.
  • Page 37 Operating Manual ZX20T/TP/TC In the logic part of the program, marked by "LOGIC-PART", the actual program is written. Here, the signals of the light barriers are debounced with 200 ms first. This ensures that only passing components activate the light barrier.
  • Page 38 Operating Manual ZX20T/TP/TC Fail1; Fail2; END_VAR; VAR_TIMER timerHigh; timerColor; timerDoor1; timerDoor2; END_VAR; (*************************LOGIC-PART*******************) (*Debouncing of the input signals of the light barriers*) Licht1.TDB:=200ms; Licht2.TDB:=200ms; (*If 1. light barrier 2 is activated and 2. the component is detected as too high, Fail1 is set*) IF Licht1=1 AND timerHigh=1 THEN Fail1:=1;...
  • Page 39 Operating Manual ZX20T/TP/TC END_IF; Door1Open:=timerDoor1; Door2Open:=timerDoor2; (*************************TAKTUNG*******************) (*As soon as Fail1 is active, „timerDoor1“ is restarted and delivers a high signal for 1200 ms.*) timerDoor1.ENABLE:=1; timerDoor1.RESET:=Fail1; timerDoor1.POL:=HIGH; timerDoor1.MODE:=SINGLE_SHOT; timerDoor1:=1200ms; (*As soon as Fail2 is active, "timerDoor2" is restarted and delivers a high signal for 1200 ms.*) timerDoor2.ENABLE:=1;...

  • Page 40: Step 2: Connecting The Power Supply

    Operating Manual ZX20T/TP/TC (*If the component is recognized as being wrongly colored, "timerColor" starts and keeps the value until the light barrier 2 is reached*) timerColor.ENABLE:=1; timerColor.RESET:= Color; timerColor.POL:=HIGH; timerColor.MODE:=SINGLE_SHOT_SE; timerColor:=1s; END_PROGRAM; 13.3 Step 2: Connecting the power supply As described in chapter 5.4 "Connecting the Power Supply", the power supply is connected to the controller.

  • Page 41: Step 5: Control Of The Function Via Leds Of The Plc

    Operating Manual ZX20T/TP/TC 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 L M M Power Digital Output Digital Output Digital Input Digital Input 01 02 03 04 05 06 07 08 09 10...

  • Page 42: Step 8: Connecting The Power Supply Of The Digital Outputs

    Operating Manual ZX20T/TP/TC Trap door 2 Trap door 1 01 02 03 04 05 06 L M M 07 08 09 10 11 12 13 14 15 16 Power Digital Output Digital Output Digital Input Digital Input 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 Abb.

  • Page 43: Declaration Of Conformity

    Operating Manual ZX20T/TP/TC Declaration of Conformity 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...

  • Page 44: Service

    Operating Manual ZX20T/TP/TC Service For service requirements, please contact: H. Zander GmbH & Co. KG Am Gut Wolf 15 52070 Aachen Germany Service line: Within Germany: (0241) 910501-16 Other countries: +49 241 910501-16 E-Mail: info@zander-aachen.de Internet: www.zander-aachen.de H. ZANDER GmbH & Co. KG • Am Gut Wolf 15 • 52070 Aachen • Germany • Phone +49 241 9105010...

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