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VAZ-2E2A-G20-ZPA1
User Manual
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Pepperl+fuchs VAZ-2E2A-G20-ZPA1 User Manual

FACTORY AUTOMATION
MANUAL
VAZ-2E2A-G20-ZPA1
ZPA Motor Control Module
from Firmware Version V.28
VAZ-2E2A-G20-ZPA1
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 Electrical Indus-
try, published by the Central Association of the Electrical Industry (Zentralverband
supplementary clause: "Expanded reservation of proprietorship"
VAZ-2E2A-G20-ZPA1
1 Introduction................................................................................. 5
1.1 Content of this Document ................................................................... 5
1.2 Target Group, Personnel...................................................................... 5
1.3 Symbols Used ...................................................................................... 5
1.4 Intended Use ........................................................................................ 6
1.5 General Safety Instructions ................................................................. 6
1.6 Declaration of Conformity ................................................................... 7
2 Product Description ................................................................... 8
2.1 Use and Application............................................................................. 8
2.2 Operating Modes of the ZPA Motor Control Module....................... 11
2.2.1 Overview.......................................................................................... 11
2.2.2 Standard ZPA................................................................................... 11
2.2.3 Enhanced 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 Indicators and Operating Elements ................................................. 17
2.3.1 LED Indicators ................................................................................. 17
2.3.2 Rotary Switches for Configuration.................................................... 20
2.4 Interfaces and Connections.............................................................. 22
3 Installation................................................................................. 24
3.1 Safety Information.............................................................................. 24
3.2 Preparation ......................................................................................... 24
3.3 Mounting ............................................................................................. 24
3.4 Power Supply Connection................................................................. 25
3.5 Special Requirements when Connecting to a PLC......................... 28
3.6 Connecting Motors, Sensors, and Zone Coupling.......................... 29
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VAZ-2E2A-G20-ZPA1
4 Operating Behavior .................................................................. 34
4.1 Switch-On Behavior............................................................................34
4.2 Switch-On Delay .................................................................................34
4.3 Search Time ........................................................................................34
4.4 Leaving Time.......................................................................................34
4.5 Entry Time...........................................................................................34
4.6 Transportation Time ...........................................................................35
4.7 Motor Run-On Time ............................................................................35
4.8 Release Delay .....................................................................................35
4.9 Idle Mode Delay ..................................................................................35
5 Manual Intervention in the Conveying Process..................... 36
5.1 Manual Feeding of Conveyed Product .............................................36
5.2 Manual Removal of Conveyed Product ............................................36
5.3 Manual Stop/Release..........................................................................36
5.4 Manually Correcting Accumulations ................................................37
6 Troubleshooting........................................................................ 38
6.1 What to Do in the Event of a Fault.....................................................38
4
VAZ-2E2A-G20-ZPA1
Introduction

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
Note!
For full information on the product, refer to the further documentation on the Internet at www.pepperl-fuchs.com.
The documentation comprises the following parts:
■
This document
■
Datasheet
In addition, the documentation may comprise the following parts, if applicable:
■
EU-type examination certificate
■
EU 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.
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VAZ-2E2A-G20-ZPA1
Introduction

1.3 Symbols Used

This document contains symbols for the identification of warning messages and of informative messages.
Warning 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:
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 a ny connected systems and plants, or result in their complete failure.
Informative Symbols
Note!
This symbol brings important information to your attention.
Action
This symbol indicates a paragraph w ith instructions. You are prompted to perform an action or a sequence of actions.

1.4 Intended Use

The VAZ-2E2A-G20 ZPA1 motor control module is a field device for controlling one or two consecutive zones of an accumulation conveyor line. The m otor 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.
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VAZ-2E2A-G20-ZPA1
ISO9001
Introduction

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.
Note!
Disposal
Electronic waste is hazardous waste. When disposing of the equipment, obser ve the current statutory requirements in the respective country of use, as well as local regulations.

1.6 Declaration of Conformity

This product was developed and manufactured under observance of the applicable European standards and guidelines.
Note!
A Declaration of Conformity can be requested from the manufacturer.
The product manufacturer, Pepperl+Fuchs GmbH, D-68307 Mannheim, has a certified quality assurance system that conforms to ISO 9001.
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VAZ-2E2A-G20-ZPA1
ZoneUpstream
zone
Downstream
zone
Roller motor Zone sensor
Conveying direction
Product Description

2 Product Description

2.1 Use and Application

Zero Pressure Accumulation (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.
Each 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
Benefits 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 m odule 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 LEDs.
■
Optimized for operation with DC roller motors type Interroll EC310.
■
Support for conveyed product that is longer than one zone.
■
Detection of accumulations leads to shutdown of the DC roller motors.
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VAZ-2E2A-G20-ZPA1
X1 X2
IN1
MOT1
IN2
MOT2
PWR
X1 IN
X1 OUT
X2 IN
X2 OUT
MOT1
MOT2
ERR1
ERR2
IN1
IN2
IN
OUT
OUT
X2 X2X1X1
IN
OUT
IN
OUT
OUT
IN
OUT
IN
IN
OUT
IN
OUT
MOT1 MOT2 IN2 MOT2 IN2MOT1 IN1
IN
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
Product Description
Figure 2.2
Function of the ZPA Motor Control Module
The ZPA motor control module is an intelligent field module that already contains the logic for zero pressure accumu lation. It assumes the control of one or two consecutive zones powered by DC roller motors. The m otors (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 w ithin 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.
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Figure 2.3
1-zone Operation/2-zone Operation
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.
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VAZ-2E2A-G20-ZPA1
IN
OUT
OUT
X2 X2X1X1
IN
OUT
IN
OUT
OUT
IN
OUT
IN
IN
OUT
IN
OUT
MOT1 MOT2 IN2 MOT2 IN2MOT1 IN1
IN
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
Product Description
Zone coupling
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 accumu lation 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:
Signal in the conveyor direction (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).
Signal against the conveyor direction (release signal): 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 m otor 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.
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VAZ-2E2A-G20-ZPA1
IN (Photo eye)
X OUT
X IN (Release)
MOT
Motor after run
Conveyor good
has left zone
Release from
downstream zone
Conveyor good
is stopped
to downstream zone
from downstream zone
Motor after run
Conveyor good
has left zone
Release from
downstream zone
Conveyor good reaches zone sensor
IN (Photo eye)
X OUT
X IN (Release)
MOT
to downstream zone
from downstream zone
Product Description
Figure 2.5
2. Release signal is set before the conveyed product reaches the zone sensor.
Figure 2.6
Since the ZPA motor control module can control two consecutive zones simultaneously, the zone coupling of these two zones is performed internally. The zone coupling to the upstream and downstream zones is routed via connections X1 and X2.

2.2 Operating Modes of the ZPA Motor Control Module

2.2.1 Overview

The ZPA motor control module has multiple operating modes that realize different accumulation conveyor logics. All operate zone coupling as per the preceding description and are therefore fully compatible with each other. The only exception to this rule are the two operating modes "direct control" and "direction control." These operating modes do not execute logic and a re used for direct control of the connected DC roller motors via the zone coupling interfaces.
For the operation of only one zone, the mode for 1-zone operation must be selected in the case of some operating modes. Different time conditions detect accumulations on the conveyor line and shut down the DC roller motors if one or more conveyed products are stuck. All operating modes support the handling of conveyed product that is longer than the actual zone.
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VAZ-2E2A-G20-ZPA1
5 64
B
2 31
A
8 97
C
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor
Product Description

2.2.2 Standard ZPA

Conveyed product must have completely left the zone before the next conveyed product may enter. As soon as the outgoing conveyed product is no longer detected by the zone sensor, the release signal is set. This operating mode thereby realizes zero pressure accumulation with single accumulation and single release. It ensures a strict separation of the conveyed product while maintaining the maximum safety distance.
The following example describes the sequence in the operating mode "Standard ZPA":
Figure 2.7
■
Step A: Zone (2) has accumulated its conveyed product because downstream zone (3) has not set its release signal (red light). Because zone (2) is occupied, it also does not issue a release to upstream zone (1).
■
Step B: Downstream zone (6) has set the release signal (green light) and the conveyed product is conveyed to the next zone (6). Because the conveyed product has not yet left the zone sensor (5), zone (5) does not issue a release to upstream zone (4).
■
Step C: The conveyed product has left the zone sensor. Therefore, zone (8) sets the release signal for upstream zone (7) to allow the next conveyed product to be transported. Downstream zone (9) has now completely accepted the conveyed product and prohibits further produ ct from entering by withdrawing the release.
The following time conditions are used in the operating mode "Standard ZPA" (see Chapter "Operating Behavior"):
■
Leaving time
■
Entry time
■
Transportation time
■
Motor run-on time
■
Switch-on delay
■
Search time
Please note that this operating mode distinguishes between 1-zone operation and 2-zone operation and separate settings exist for both operating modes.
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VAZ-2E2A-G20-ZPA1
5 64
B
2 31
A
8 97
C
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor
Product Description

2.2.3 Enhanced ZPA

This operating mode implements zero pressure accumulation with block accumulation or block release. A zone will let the following conveyed product enter once the conveyed product located in that zone receives the release signal to leave the zone. This reduces the safety distance between the conveyed product and increases the throughput. If the foremost zone of such an accum ulation conveyor line receives a release signal, the signal will be forwarded directly to the zones behind it. All accumulated conveyed product will be simultaneously transported to the next zone. However, in case of block release, it is always ensured that only one further conveyed product is conveyed into the zone. This conveyed product must then advance all the way to the zone sensor before the next conveyed product may be conveyed.
The following example describes the sequence in the operating mode "Enhanced ZPA."
Figure 2.8
■
Step A: Zone (2) has accumulated its conveyed product because downstream zone (3) has not set its release signal (red light). Because zone (2) is occupied, it also does not issue a release to upstream zone (1).
■
Step B: Downstream zone (6) has set the release signal (green light) and the conveyed product is conveyed to the next zone (6). At the same time, the release signal is forwarded to upstream zone (4) and the following conveyed product is conveyed to zone (5). The conveyed product starts up at the same time.
■
Step C: The previous conveyed product has departed zone (8), so downstream zone (9) withdraws its release. The following conveyed product has also already left upstream zone (7). Zone (8) moves the conveyed product to its zone sensor while it prevents other conveyed product from entering by resetting the release.
The following time conditions are used in the operating mode "Enhanced ZPA" (see Chapter "Operating Behavior"):
■
Leaving time
■
Entry time
■
Transportation time
■
Motor run-on time
■
Switch-on delay
■
Search time
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■
Release delay
Please note that this operating mode distinguishes between 1-zone operation and 2-zone operation and separate settings exist for both operating modes.
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