Pepperl+Fuchs VAZ-2E2A-G20-ZPA1 Bedienungsanleitung

VAZ-2E2A-G20-ZPA1

ZPA Motor Control Module

from Firmware Version V.28

FACTORY AUTOMATION

MANUAL

With regard to the supply of products, the current issue of the following document is ap-

plicable: The General Terms of Delivery for Products and Services of the lectrical Indus-

try, published by the Central Association of the lectrical Industry (Zentralverband

lektrotechnik und lektroindustrie (ZV I) e.V.) in its most recent version as well as the

supplementary clause: " xpanded reservation of proprietorship"

VAZ-2 2A-G20-ZPA1

1 Introduct on................................................................................. 5

1.1 Content of th s Document ................................................................... 5

1.2 Target Group, Personnel...................................................................... 5

1.3 Symbols Used ...................................................................................... 5

1.4 Intended Use ........................................................................................ 6

1.5 General Safety Instruct ons................................................................. 6

1.6 Declarat on of Conform ty ................................................................... 7

2 Product Descr pt on ................................................................... 8

2.1 Use and Appl cat on............................................................................. 8

2.2 Operat ng Modes of the ZPA Motor Control Module....................... 11

2.2.1 Overview.......................................................................................... 11

2.2.2 Standard ZPA................................................................................... 11

2.2.3 nhanced ZPA................................................................................. 12

2.2.4 Transportation.................................................................................. 13

2.2.5 Long Zone - Single Zone.................................................................. 14

2.2.6 Direct Control................................................................................... 15

2.2.7 Direction Control.............................................................................. 15

2.2.8 Slave................................................................................................ 16

2.3 Ind cators and Operat ng Elements ................................................. 17

2.3.1 L D Indicators ................................................................................. 17

2.3.2 Rotary Switches for Configuration.................................................... 20

2.4 Interfaces and Connect ons.............................................................. 22

3 Installat on................................................................................. 24

3.1 Safety Informat on.............................................................................. 24

3.2 Preparat on ......................................................................................... 24

3.3 Mount ng ............................................................................................. 24

3.4 Power Supply Connect on................................................................. 25

3.5 Spec al Requ rements when Connect ng to a PLC ......................... 28

3.6 Connect ng Motors, Sensors, and Zone Coupl ng.......................... 29

VAZ-2 2A-G20-ZPA1

4 Operat ng Behav or .................................................................. 34

4.1 Sw tch-On Behav or............................................................................34

4.2 Sw tch-On Delay .................................................................................34

4.3 Search T me ........................................................................................34

4.4 Leav ng T me.......................................................................................34

4.5 Entry T me...........................................................................................34

4.6 Transportat on T me ...........................................................................35

4.7 Motor Run-On T me ............................................................................35

4.8 Release Delay .....................................................................................35

4.9 Idle Mode Delay ..................................................................................35

5 Manual Intervent on n the Convey ng Process..................... 36

5.1 Manual Feed ng of Conveyed Product .............................................36

5.2 Manual Removal of Conveyed Product ............................................36

5.3 Manual Stop/Release..........................................................................36

5.4 Manually Correct ng Accumulat ons ................................................37

6 Troubleshoot ng........................................................................ 38

6.1 What to Do n the Event of a Fault.....................................................38

VAZ-2 2A-G20-ZPA1

Introduction

2018-06

1 Introduction

1.1 Content of this Document

This document contains information required to use the product in the relevant phases of the

product life cycle. This may include information on the following:

■

Product identification

■

Delivery, transport, and storage

■

Mounting and installation

■

Commissioning and operation

■

Maintenance and repair

■

Troubleshooting

■

Dismounting

■

Disposal

The documentation comprises the following parts:

■

This document

■

Datasheet

In addition, the documentation may comprise the following parts, if applicable:

■

U-type examination certificate

■

U declaration of conformity

■

Attestation of conformity

■

Certificates

■

Control drawings

■

Instruction manual

■

Other documents

1.2 Target Group, Personnel

Responsibility for planning, assembly, commissioning, operation, maintenance, and

dismounting lies with the plant operator.

Only appropriately trained and qualified personnel may carry out mounting, installation,

commissioning, operation, maintenance, and dismounting of the product. The personnel must

have read and understood the instruction manual and the further documentation.

Prior to using the product make yourself familiar with it. Read the document carefully.

Note!

For full information on the product, refer to the further documentation on the Internet at

www.pepperl-fuchs.com.

2018-06

VAZ-2 2A-G20-ZPA1

Introduction

1.3 Symbols Used

This document contains symbols for the identification of warning messages and of informative

messages.

Warn ng Messages

You will find warning messages, whenever dangers may arise from your actions. It is mandatory

that you observe these warning messages for your personal safety and in order to avoid

property damage.

Depending on the risk level, the warning messages are displayed in descending order as

follows:

Informat ve Symbols

Action

This symbol indicates a paragraph with instructions. You are prompted to perform an action or

a sequence of actions.

1.4 Intended Use

The VAZ-2 2A-G20 ZPA1 motor control module is a field device for controlling one or two

consecutive zones of an accumulation conveyor line. The motor control module has two

electronic outputs for controlling a DC roller motor each as well as two sensor inputs for

detecting conveyed product, e.g., via light barriers.

Read through this manual carefully. Before mounting, connecting, and operating the ZPA motor

control module, be sure to familiarize yourself with the device.

Operate the ZPA motor control module only as described in this manual to ensure that the

device and the systems connected to the device work correctly.

Danger!

This symbol indicates an imminent danger.

Non-observance will result in personal injury or death.

Warning!

This symbol indicates a possible fault or danger.

Non-observance may cause personal injury or serious property damage.

Caution!

This symbol indicates a possible fault.

Non-observance could interrupt the device and any connected systems and plants, or result in

their complete failure.

Note!

This symbol brings important information to your attention.

VAZ-2 2A-G20-ZPA1

Introduction

2018-06

1.5 General Safety Instructions

Responsibility for planning, assembly, commissioning, operation, maintenance, and

dismounting lies with the plant operator.

Installation and commissioning of all devices may only be performed by trained and qualified

personnel.

User modification and or repair are dangerous and will void the warranty and exclude the

manufacturer from any liability. If serious faults occur, stop using the device. Secure the device

against inadvertent operation. In the event of repairs, return the device to your local

Pepperl+Fuchs representative or sales office.

1.6 Declaration of Conformity

This product was developed and manufactured under observance of the applicable uropean

standards and guidelines.

The product manufacturer, Pepperl+Fuchs GmbH, D-68307 Mannheim, has a certified quality

assurance system that conforms to ISO 9001.

Note!

Disposal

lectronic waste is hazardous waste. When disposing of the equipment, observe the current

statutory requirements in the respective country of use, as well as local regulations.

Note!

A Declaration of Conformity can be requested from the manufacturer.

ISO9001

2018-06

VAZ-2 2A-G20-ZPA1

Product Description

2 Product Description

2.1 Use and Application

Zero Pressure Accumulat on (ZPA)

During zero pressure accumulation, conveyed product is moved along a conveyor line in a

controlled manner and collisions between the conveyed product is prevented. For this purpose,

a conveyor line is divided into several sections or zones.

ach zone has its own drive, which can be activated independently of the neighboring zones.

At the end of each zone, a zone sensor is installed that detects the conveyed product.

The accumulation conveyor logic ensures that there is only ever one conveyed product present

in a zone. Conveyed products can therefore only be conveyed to the downstream zone once

there is no more conveyed product in that zone. As long as the downstream zone is occupied,

the conveyed product is stopped when it reaches the zone sensor and thus accumulates

irrespective of subsequent conveyed product.

Figure 2.1 Conveying scenario for the example Standard ZPA operation mode

Benef ts and Features of the ZPA Motor Control Module

The ZPA motor control module is easy to install and can be configured for a wide range of

application situations. The main benefits and features of this module are:

■

Compact housing for direct mounting in support profiles and cable ducts.

■

Connection of the power supply using piercing technology via black AS-Interface flat

cable.

■

All other connections are implemented as connectors.

■

Decentralized control: The field module contains the logic for zero pressure accumulation.

A central control unit for the accumulation conveyor line is not required.

■

Support for master-slave operation

■

Control of two successive zones of an accumulation conveyor line using one module.

■

Simple adjustment of the operating mode, the conveyor direction, the motor speed, and

start/stop ramps via rotary switches.

■

Display of status and diagnostic information via L Ds.

■

Optimized for operation with DC roller motors type Interroll C310.

■

Support for conveyed product that is longer than one zone.

■

Detection of accumulations leads to shutdown of the DC roller motors.

ZoneUpstream

zone

Downstream

zone

Roller motor Zone sensor

Conveying direction

VAZ-2 2A-G20-ZPA1

Product Description

2018-06

Figure 2.2

Funct on of the ZPA Motor Control Module

The ZPA motor control module is an intelligent field module that already contains the logic for

zero pressure accumulation. It assumes the control of one or two consecutive zones powered

by DC roller motors. The motors (MOT1, MOT2) and zone sensors (IN1, IN2) are connected

directly with the ZPA motor control module for this purpose.

The ZPA motor control module has two separate zone controls. Both zone controls are logically

coupled within the module. The access-side zone control can be deactivated within the

module, so that the outgoing-side zone control controls both DC roller motors as the master.

Only the sensor input (IN1 and IN2) of the master is evaluated in this case.

A coupling with the neighboring zones is created via two interfaces for the zone coupling (X1,

X2). This makes it possible to connect several ZPA motor control modules in series to create an

accumulation conveyor line of any length.

The ZPA motor control module is powered via the black AS-Interface flat cable, which is

connected using piercing technology without the need for tools. The ZPA motor control module

is configured directly on the device using the three rotary switches (S1, S2, S3). In addition to

various operating modes, the motor speed, the conveyor direction, and start and stop ramps

can be configured.

Figure 2.3

1-zone Operat on/2-zone Operat on

If the ZPA motor control module is to only control a single zone, the second zone logic must be

manually deactivated in some operating modes. For this purpose, the rear zone in the conveyor

direction is bypassed internally. The DC roller motor of this zone then runs synchronous to that

of the zone in front (see previous figure). It can therefore support the other DC roller motor by

driving the same zone and thereby doubling the drive power of that zone.

X1 X2

IN1

MOT1

IN2

MOT2

PWR

X1 IN

X1 OUT

X2 IN

X2 OUT

MOT1

MOT2

ERR1

ERR2

IN1

IN2

OUT

X2 X2X1X1

OUT

OUT IN

OUT

MOT1 MOT2 IN2 MOT2 IN2MOT1 IN1

ZoneUpstream

zone

Downstream

zone

Roller motor Roller motor Zone sensor Roller motor Zone sensor

Conveying direction

Roller motor Zone sensor

Release

Sensor

Zone coupling

Sensor Sensor

Release Release

ZPA motor control module

Zone coupling Zone coupling

2 zones

ZPA motor control module

1 zone

Release

Sensor

Zone Zone ZoneZone

2018-06

VAZ-2 2A-G20-ZPA1

Product Description

Zone coupl ng

The two interfaces for zone coupling (X1, X2) are used for receiving and transmitting

information to and from neighboring zones. Additional ZPA motor control modules or other

suitable communication partners can be connected via the zone coupling. The electrical

signals are compatible with the standard 24 V IOs of a PLC. Conveyed product can therefore

also be fed in and discharged at both ends of the accumulation conveyor line by a separate

controller.

Figure 2.4

The interfaces for the zone coupling each consist of one signal input and one signal output.

The meaning of the zone coupling signals depends on the selected conveyor direction and

follows a simple principle:

S gnal n the conveyor d rect on (zone sensor): A zone is communicating to the

downstream zone whether conveyed product is located at its end. It therefore always

corresponds to the signal of the zone sensor (e.g., light barrier).

S gnal aga nst the conveyor d rect on (release s gnal): A zone is communicating to the

upstream zone whether conveyed product may enter. It thus represents the release signal. The

release signal is determined by the accumulation conveyor logic and also set if no conveyed

product has yet reached the zone sensor of the upstream zone.

The logic in the ZPA motor control modules expects the release signal to last until the conveyed

product has left the zone sensor. If the release signal is withdrawn before the conveyed product

has left the zone, the motor is stopped until the release signal is set again.

This results in the following signal sequences:

The dashed lines show the situation in which the downstream zone withdraws the release

signal for a short period of time. In this case, the DC roller motor is stopped immediately without

any run-on time.

1. Conveyed product reaches the zone sensor before the release signal is set.

OUT

X2 X2X1X1

OUT

OUT IN

OUT

MOT1 MOT2 IN2 MOT2 IN2MOT1 IN1

ZoneUpstream

zone

Downstream

zone

Roller motor Roller motor Zone sensor Roller motor Zone sensor

Conveying direction

Roller motor Zone sensor

Release

Sensor

Zone coupling

Sensor Sensor

Release Release

ZPA motor control module

Zone coupling Zone coupling

2 zones

ZPA motor control module

1 zone

Release

Sensor

Zone Zone ZoneZone

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