Device manual

AS-i PowerSwitch
ZB0028 – ZB0040

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 Device manual
POWERSWITCH ZB0028 – ZB0040 Date: 04/02/02

Contents
1. Views........................................................................................................................... 3
1.1 Top view............................................................................................................... 3
1.2 Front view............................................................................................................. 4
1.3 Bottom view.......................................................................................................... 5
1.4 Secondary view.................................................................................................... 6
1.5 Hand-held operating panel ................................................................................... 7
2. Unit types .................................................................................................................... 7
2.1 Description of the unit........................................................................................... 8
3. Block diagram.............................................................................................................. 8
4. AS-i Interface............................................................................................................... 9
4.1 Connections ......................................................................................................... 9
4.2 Connection hand-held operating panel (Sub D9 pol.)......................................... 10
4.3 Input data bits..................................................................................................... 10
4.4 Output data bits.................................................................................................. 10
4.5 Supply of the external 24 V DC voltage.............................................................. 11
4.6 Inputs I3 + I4 ...................................................................................................... 11
4.7 Outputs O3 + O4 ................................................................................................ 12
5. Mechanical data ........................................................................................................ 12
6. Prerequisites and guidelines ..................................................................................... 13
7. Enclosure (to the devices) ......................................................................................... 13
8. Function description .................................................................................................. 15
9. Wiring diagram .......................................................................................................... 16

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1. Views

1.1 Top view

Figure 1.1

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 1.2 Front view

Figure 1.2

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 1.3 Bottom view

Figure 1.3

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 1.4 Secondary view

Figure 1.4

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 1.5 Hand-held operating panel

Figure 1.5

2. Unit types
ZB0028 PowerSwitch 0.28 - 0.4 A (0.09 kW)
ZB0029 PowerSwitch 0.35 - 0.5 A (0.12 kW)
ZB0030 PowerSwitch 0.45 - 0.63 A (0.18 kW)
ZB0031 PowerSwitch 0.55 - 0.8 A (0.18 kW)
ZB0032 PowerSwitch 0.7 – 1 A (0.25 kW)
ZB0033 PowerSwitch 0.9 - 1.25 A (0.37 kW)
ZB0034 PowerSwitch 1.1 - 1.6 A (0.55 kW)
ZB0035 PowerSwitch 1.4 – 2 A (0.75 kW)
ZB0036 PowerSwitch 1.8 - 2.5 A (0.75 kW)
ZB0037 PowerSwitch 2.2 - 3.2 A (1.1 kW)
ZB0038 PowerSwitch 3.8 – 4 A (1.5 kW)
ZB0039 PowerSwitch 3.5 - 5 A (1.5 kW)
ZB0040 PowerSwitch 4.5 - 6.3 A (2.2 kW)

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2.1 Description of the unit
The AS-Interface PowerSwitch is a load branch completely prewired internally and rated
for the switching of any three-phase load up to 2.2 kW at 400 V AC - mainly three-phase
standard motors in direct or reversing operation. It integrates a reversing contactor.The
overload or short-circuit protection is below a transparent cover and thus allows visual
diagnosis and diagnosis by the AS-interface. It is not possible to touch live parts even
when the cover is open. The device states are scanned via two inputs which are used
internally: feedback of the auxiliary contact of circuit breakers and the manual operating
mode. The contactor-type reverser is triggered by two outputs which are used internally.
There are also two external inputs and outputs with M12 plug and socket connection.

3. Block diagram

Figure 3.1

Bedientableau = operating panel

Potentialtrennung = electrical isolation

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4. AS-i Interface
AS-i profile: S7.0 (I/O module)
I/O configuration: 7 Hex
ID code: 0 Hex
Protection class: PELV
Number of slaves: max. 31 per string
The parameters P0, P1, P2, P3 are not used.
Reverse polarity protection: yes
Display AS-i voltage: yes, green LED marked "POWER - AS-i"

Display module status: no

Power-on delay: <1s

Operating voltage (AS-i): 26.5...31.6 V

Total current consumption: ≤ 250 mA

AS-i certificate: 06101

4.1 Connections
Connection for AS-i cable via M12 connection (socket):

1 AS-i+
2 0 V auxiliary supply
3 AS-i-
4 +24 V auxiliary supply
5 n. c.

Connection for 2 external inputs (e.g. light barriers) via M12 connection:

1 supply I+
2 signal input I3/I4
3 supply I-
4 linked with 2
5 n. c.

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Connection for 2 external outputs (e.g. for pneumatic valves) via M12 connection:

1 n. c.
2 n. c.
3 supply E-
4 switching output O3/O4
5 n. c.

4.2 Connection hand-held operating panel (Sub D9 pol.)

Pin No. Signal
1 supply I+ (AS-i potential)
2 0V auxiliary supply
3 deactivation internal output stage
4 signal input I1 (AS-i potential)
5 switching output O4
6 switching output O3
7 clockwise/counterclockwise operation
8 clockwise/counterclockwise operation
9 24V auxiliary supply

Note: The matching operating panel has part number ZB0027.

4.3 Input data bits

Data bit State Description
D0 0 feedback: manual operation off
1 feedback: manual operation on
D1 0 feedback: motor protection triggered
1 feedback: motor protection active
D2 0 sensor input I3: sensor not active
1 sensor input I3: sensor active
D3 0 sensor input I4: sensor not active
1 sensor input I4: sensor active

4.4 Output data bits

Data bit State Description
D0 0 contactor off
1 clockwise operation
D1 0 contactor off
1 counterclockwise operation
D2 0 output O3: not active
1 output O3: active
D3 0 output O4: not active
1 output O4: active

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4.5 Supply of the external 24 V DC voltage
Power supply external
Voltage ranges (E+, E-): 24V ±10%, up to max. 400 mA
Protection class: PELV
Supply protected against short circuits: no
Display external voltage: yes, green LED marked "POWER - 24V DC"

Note: No signal is given to the AS-i master if the 24 V auxiliary power supply is not
applied.

4.6 Inputs I3 + I4

Input circuit: positive switching

Sensor supply: via the AS-i system
voltage range (I+, I-): 18 V...31.6 V (total of sensor currents ≤ 170 mA)

Sensor supply protected against short circuits: yes, by current limitation

An existing short circuit is not signalled to the AS-i master.
Switching level high signal: ≥ 10

Input current:
- current limitation: 5 to 13 mA
- switching level high: I > 3 mA
- switching level low: I < 1.5 mA

Delay of the input: < 5 ms

Display switching status: 2 x external inputs with yellow LED

Note: The inputs are rated for the connection of binary 2-wire or 3-wire sensors to IEC
947-5-2. As an alternative mechanical position switches can be connected.

Note: The units connected must not be connected with the external potential or
electrically connected with ground.

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4.7 Outputs O3 + O4

Output circuit: positive switching

Max. current rating continuous (70°C): 150 mA per output
Total current: 400 mA/module
Short-circuit protection of the outputs: yes (total short-circuit protection of all outputs)
Display switching status: 2 x external outputs with yellow LED
Overvoltage protection: yes, DC13

Note: When the communication between master and slave fails, the integrated
watchdog switches off the outputs.

Time constant of the watchdog: ≥ 40 ms

5. Mechanical data
Housing: polycarbonate reinforced glass fibre,
flame-retardant - UV resistant

Dimensions: 182 mm x 180 mm x 90 mm (WxHxD)

Protection: IP54

Cover: transparent housing cover connected

with the basic housing via hinges
(plastic)

Type of locking: Standard = 2 x normal screw, 2 x knurled

screw to be clicked onto the normal
screw as manual turn-lock fastener
included

Connector (400 V AC): HAN Q 5 / housing for motor output in

black, housing for output and input
current 400 V in grey

Coding: motor output socket 4 closed,

400V AC output socket 5 closed

Reversing starter: with mechanical and electrical locking

Motor protection: type SIRIUS

Protection classes: PELV (for AS-i)

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PELV (for auxiliary supply 24 V )
protection class I for 400 V circuit
Operating temperature range: 0 ... +60°C

A safe separation between the circuits is guaranteed in the device.

6. Prerequisites and guidelines

The units conform to
- EMC directives
- low voltage directives and
- have a CE mark

7. Enclosure (to the devices)

Operating instructions Power Switch
(only for units with part number: ZB0028 – ZB0040)
Date: 02/04/2002

AS-i profile S7.0.F

I/O configuration (hex) 7
ID code (hex) 0

Input bits:
D0 = hand-held operating panel
D1 = connected motor protection activated
D2 = ext. input I3
D3 = ext. input I4

Output bits:
D0 = motor contactor 1
D1 = motor contactor 2
D2 = ext. output O3
D3 = ext. output O4

Power connector pin connection:

L1 - contact number 1
L2 - contact number 2
L3 - contact number 3
PE - prepared for PE

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Power socket pin connection:
L1 - contact number 1
L2 - contact number 2
L3 - contact number 3
PE - prepared for PE

Motor socket pin connection:

L1 - contact number 1
L2 - contact number 2
L3 - contact number 3
PE - prepared for PE

Power supply connector:

Pin 1 - AS-i+
Pin 2 - 24 V DC-
Pin 3 - AS-i-
Pin 4 - 24V DC

2 x M12 input socket:

Pin 1 - I+
Pin 2/4 - input (linked)
Pin 3 - I-

2 x M12 output socket:

Pin 1 - n.c.
Pin 2 - n.c.
Pin 3 - 24 V DC
Pin 4 - switching output 24 V DC+

Hand-held operating panel

no hand-held operating panel connected = automatic mode

hand-held operating panel connected = manual mode

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8. Function description
The AS-Interface PowerSwitch is a load branch completely prewired internally and rated
for the switching of any three-phase load up to 2.2 kW at 400 V AC - mainly three-phase
standard motors in direct or reversing operation. It integrates a reversing contactor. The
overload or short-circuit protection is below a transparent cover and thus allows visual
diagnosis and diagnosis by the AS-interface. It is not possible to touch live parts even
when the cover is open. The device states are scanned via two inputs which are used
internally, e.g. feedback of the auxiliary contact of circuit breakers and the manual
operating mode. The contactor-type reverser is triggered by two outputs which are used
internally. There are also two external inputs and outputs with M12 plug and socket
connection.

NOTE!
The guarantee is extinguished as soon as the sealing is damaged as well as in case
of improper connection of the device not in accordance with the operating
instructions!

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9. Wiring diagram

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