ensors
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Description
The 22ZC Zone Control System offers
the user an economical means of
conveying product on accumulation
conveyor systems. The heart of this
system is the zone control module. As
shown in Figure 1, one module is
mounted in every zone of the conveyor
system and connected via a flat cable.
Each module accepts a sensor input
and provides an output to an actuator
based on the desired zone control logic
for the application.
The system can be configured to
transport, accumulate, and release
product in a number of different ways to
best fit the application requirements.
This configuration is accomplished by
manipulating DIP switches on each
zone controller, thereby eliminating the
need for any external programming
tools.
In addition, system-wide ON/OFF-delay
timers can be set and broadcast to all
upstream zones from a master zone
controller located at the discharge end
of the conveyor using the patented
ZoneSet feature. This master module
also contains screw terminals for
connection to external devices such as
pendent stations, PLCs, or operator
interface terminals used to control the
discharge of product from the conveyor.
An in-feed module located at the
beginning of the conveyor contains
similar connections for controlling the
flow of product onto the conveyor.
Multiple basic modules are located
between the master and in-feed
modules. Power for both the modules
and the sensors is provided through a
1485T KwikLink power tap.
General Specifications
Features Accepts 2- or 3-wire, NPN, 24V DC
sensor inputs Supports pneumatic and power roller
actuator types Supports single- and dual-zone
transport logic Supports singulation and slug
release modes Selectable sleep and jam detect
functions Selectable ON and OFF time delays Support for normally open or
normally closed actuators
Operation
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Standard Zone Control Logic
2
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Advanced Zone Control Logic
2
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Timer Functions
3
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Dimensions
3
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User Interface
3
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Specifying a System
4
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Zone Controller Modules
4
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Photoelectric Sensor
4
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Power Tap
5
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Flat Cable
5
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Actuator Output Cable
6
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Accessories
6
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22ZC Zone Controller
Operating Voltage
Current Consumption
Input Type
Output Type
Output Rating
Response Time
Housing Material
LED Indicators
Connection Types
Accessories
Operating Environment
Vibration
Shock
Operating Temperature
Relative Humidity
Approvals
24V DC
16mA maximum
24V DC, 2 or 3 wire, sinking (NPN)
24V DC, 2 wire, sinking (NPN)
100mA @ 24V DC
1ms maximum
Valox
Orange: Output and Zone Status
Input: 3 pin MOLEX; Output: 4 pin MOLEX; Power/Signal: IDC Flat
Cable
See Selection Guide
NEMA 1, IP 20 (IEC 529)
10-55Hz, 1mm amplitude, Meets or exceeds IEC 60947-5-2
30G with 1ms pulse duration, Meets or exceeds IEC 60947-5-2
0_C to 50_C (+32_F to 122_F)
5% to 85%, noncondensing
c UL listed, CE marked for all applicable directives PHOTOSWITCH
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Photoelectric Sensors
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Standard Zone Control Logic
Infeed
The infeed zone (Zone 4) will remain
OFF until either product is manually
loaded into its zone (blocking the
sensor) or until an external input is
received by the zone controller. This
controller also provides a discrete
output (zone full) to indicate the
presence of product in its zone (Z4).
Once product is loaded, it will be
conveyed in one of two user defined
transport modes.
Single Zone Transport Mode
In this mode of operation, all zones are
OFF until product is ready to be
transported downstream. This results in
savings in power, and reduces roller
wear and noise. As the product is
introduced onto the conveyor and
transported downstream, it will separate
into zone length gaps. This provides for
smooth, noncontact transport of product
along the conveyor. When the first
product reaches the last zone (zone 1)
it will stop and wait to be released from
the conveyor.
Dual Zone Transport Mode
In this mode of operation, all zones are
ON as soon as power is applied to the
system. As the product is introduced
onto the conveyor and transported
downstream, it will not separate into
zone length gaps. When the first
product reaches the last zone (zone 1)
it will stop and wait to be released from
the conveyor.
� This function is only used for the dual zone
transport mode.
Release Modes
Once product has accumulated on the
conveyor it can be released in one of
the following manners.
1. Singulation Release
Product is released (zone will drive)
from the discharge zone when the
external zone release input (at the
master zone controller Z1) is closed
and maintained. A momentary input can
also be used in conjunction with the
One-Shot Zone Release timer. As the
product clears the sensor, the adjacent
upstream zones will advance as normal
transport dictates.
2. Slug Release
Product is released (zone will drive) in
each zone which has the zone
controller slug respond DIP switch (S2)
enabled AND the external slug release
input closed and maintained. A
momentary input can also be used in
conjunction with the One-Shot Slug
Release timer.
3. Count Release
Product is released (zone will drive)
from the discharge zone until the
user-defined preset count value is
reached when the external zone
release input is closed. Once the preset
has been reached, the discharge zone
will revert to normal transport logic.
4. Timed Release
Product is released (zone will drive)
from the discharge zone for a period of
time selected by the user when the
external zone release input is
momentarily closed. This time preset is
set using the One-shot release timer.
Once the timer has timed out, the
discharge zone will revert to normal
transport logic.
Advanced Zone Control Logic
Along with establishing the standard
transport logic of the zone controller, the
user can also select from three
advanced logic functions. These
include the sleep, jam respond, and
inverted output functions.
Sleep Function
In order to conserve power and reduce
roller wear and noise, the 22ZC can be
configured to power down the zone if
there is no product ready to be
transported on the conveyor. This
feature is called the Sleep function
and can be activated via DIP switch S4
on each zone controller. The Sleep
Timer is part of the Sleep function
and allows the user to set a timer value
of between 0.5 and 20 seconds. The
default value is 20 seconds.
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Jam Respond Function
During the transport of product on the
conveyor, the 22ZC will monitor for a
jam condition (product never leaving the
sending zone). If a jam occurs, the
controller will respond by either
powering down the affected zone or
continuing to drive in an attempt to clear
the jam condition. The response is
determined by the position of DIP
switch S3 on each zone controller.
22ZC Zone Controller
Operation PHOTOSWITCH
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Photoelectric Sensors
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A Jam Timer is part of the Jam
Respond function and allows the user
to set the time that the zone will drive
before powering down. A time value of
between 0.5 and 20 seconds may be
selected. The default value is 5
seconds.
�
Inverted Output Function
The output logic of the 22ZC may be
reversed to make it compatible with
both normally open and normally closed
pneumatic valves. This function can be
activated via DIP switch S5 on each
zone controller.
Timer Functions
The 22ZC Zone Controller provides
systemwide, local, and release timers to
delay the START (ON) and STOP
(OFF) of the rollers on the conveyor.
These can be used to fine tune the flow
of product during the transport,
accumulation, and release phases. Ten
factory presets ranging from 0 to 20
seconds may be selected as timer
values. System wide timers are used to
set the same time delays for all zones
within the system. These include ON,
OFF, JAM, and SLEEP timers. A
patented ZoneSet function allows these
timer values to be set on a single
master zone controller using a rotary
switch/pushbutton combination, and
then broadcast to all upstream zone
controllers. This eliminates the need to
set timer values at each zone controller
in the system.
Local timer values may be set by using
the 22ZC131 Basic Plus Timer zone
controller. This controller makes it
possible to have unique timer values for
specific zones in a system. Those timer
values broadcast by the master zone
controller will be passed along to other
upstream zone controllers but ignored
by this type. Instead, it will apply only
those timer values set locally by the
user. An example of its use would be to
fine tune the flow of product on curved
sections of conveyor to maintain
product alignment.
Release timers are available only on
the 22ZC411 Master zone controller.
They include a ZONE RELEASE ON
and ONESHOT, as well as a SLUG
RELEASE ON and ONESHOT. These
timers are used in conjunction with
external zone and slug release contact
closures to control the release of
product from the discharge zone only.
The ON delay is used to delay the
release of product during unloading
operations, and the ONE-SHOT is used
to accommodate the use of momentary
pushbuttons