Automation Controls Group UniDrive ZoneLogix PRO Manuel utilisateur

ZoneLogix™ PRO Zone Controller User

Guide

1. Zone 2. Monitor 3. Fieldbus

Guide 1 in the 3-part ZoneLogix™ PRO documentation series

Copyright ©2013-2019 Automation Controls Group, Inc. A division of Milwaukee Electronics Companies, Inc. All Rights Reserved. 
 
This document is the property of Automation Controls Group, Inc., and may not be reproduced in whole or in part without prior written approval. 
Other trademarks and service marks used or referenced in this document are the property of their respective owners. 
 
C O N T E N T S 
1Introduction 6 
1.1
 
Key Terms and Concepts .................................................................................................7
 
2Getting Started and Installation 8 
2.1
 
Zone Controller Installation ......................................................................................... 10
 
2.2
 
Zone Installation ............................................................................................................. 11
 
2.3
 
Configuration DIP Switches ......................................................................................... 13
 
2.4
 
+24VDC Power Connection.......................................................................................... 14
 
2.5
 
Zone-to-Zone Cable Connection ................................................................................. 14
 
2.6
 
PNP Photoeye Sensor Connection............................................................................. 15
 
2.7
 
Smart I/O Connections ................................................................................................. 16
 
2.7.1
 
Basic Mode Functions......................................................................................................................... 16
 
2.7.2
 
Advanced Mode Functions................................................................................................................ 17
 
2.8
 
LED Feedback Indicators.............................................................................................. 18
 
2.9
 
System Schematic and Installation Summary ...................................................... 19
 
3Basic Mode System Operation & Configuration 20 
3.1
 
System Start Up –Apply 24 VDC Power .................................................................. 20
 
3.1.1
 
Zone Discovery ...................................................................................................................................... 20
 
3.1.2
 
Lost Package Detection ..................................................................................................................... 20
 
3.1.3
 
Sleep Timer............................................................................................................................................. 20
 
3.2
 
EOB Zone Configuration................................................................................................ 21
 
3.2.1
 
Controlling Object Entry –Forward (normal) Flow Direction................................................. 21
 
3.3
 
Master Zone Configuration .......................................................................................... 21
 
3.3.1
 
Controlling Object Exit......................................................................................................................... 21
 
3.3.2
 
Changing Operational Modes........................................................................................................... 21
 
3.3.3
 
Controlling Branch Direction............................................................................................................. 21
 
3.3.4
 
Controlling Branch Speed.................................................................................................................. 21
 
3.4
 
Basic Mode Parameters ............................................................................................... 21
 
4Zone Controller Updates 23 
5Advanced Mode System Configuration 24 
6Motor Performance 25 
7Breakout Module 27 
7.1
 
Handshaking Functionality .......................................................................................... 27
 
7.2
 
Breakout Module Example: Connect Two Branches............................................ 29
 
7.3
 
Breakout Module Example: Connect Two Branches with Branch Monitor.... 29
 
7.4
 
Breakout Module Example: Transfer Application................................................. 30

Copyright ©2013-2019 Automation Controls Group, Inc. A division of Milwaukee Electronics Companies, Inc. All Rights Reserved. 
 
This document is the property of Automation Controls Group, Inc., and may not be reproduced in whole or in part without prior written approval. 
Other trademarks and service marks used or referenced in this document are the property of their respective owners. 
8Diagnostics & Troubleshooting 31 
8.1
 
Feedback LEDs................................................................................................................ 31
 
8.1.1
 
Fuse LED (Red) ...................................................................................................................................... 31
 
8.1.2
 
Fault LED (Red)...................................................................................................................................... 32
 
8.1.3
 
Motor LED (Amber) .............................................................................................................................. 32
 
8.2
 
Firmware Version Display............................................................................................. 33
 
8.3
 
Additional Assistance.................................................................................................... 33
 
9Document Revision History 33 
Appendix A: Operating Modes 34 
A.1. Singulate (ZPA) .................................................................................................................. 34
 
A.2. Slug ....................................................................................................................................... 34
 
A.3. ZIP.......................................................................................................................................... 35
 
A.4. Zone Hold ............................................................................................................................ 35

ZoneLogix™PRO Zone Controller User Guide | Revision 1.0 November 2019 | Page 4
 
 
L I S T O F F I G U R E S 
Figure 1: The ZoneLogix™ PRO System.....................................................................................6 
Figure 2: ZoneLogix™ PRO Zone Controller Diagram ..............................................................8 
Figure 3: Zone Controller Mounting Tabs................................................................................ 10 
Figure 4: The ZoneLogix™ PRO System.................................................................................. 11 
Figure 5: UniDrive Motor Stopping Distance .......................................................................... 12 
Figure 6: Default DIP Switch and Smart I/O .......................................................................... 13 
Figure 7: Zone-to-Zone Communication Connections .......................................................... 14 
Figure 8: LED Definitions........................................................................................................... 18 
Figure 9: Schematic Diagram of ZoneLogix™ PRO System................................................. 19 
Figure 10: Standard Zone Controller LEDs in Normal Operation........................................ 20 
Figure 11: Motor Performance Curves.................................................................................... 25 
Figure 12: Breakout Module (Product 300332) .................................................................... 27 
Figure 13: Handshaking Signals Showing Forward and Reverse Flow Request / Permission 
Signals.......................................................................................................................................... 28 
Figure 14: Handshaking Signals Showing Both Forward / Reverse Request / Permission 
Signals.......................................................................................................................................... 28 
Figure 15: Internal Diagram of the Breakout Module .......................................................... 28 
Figure 16: Breakout Module Connecting Two Branches ...................................................... 29 
Figure 17: Breakout Module Connecting Two Branches and Branch Monitor.................. 29 
Figure 18: Breakout Modules in a Transfer Application....................................................... 30 
Figure 19: Feedback LEDs ........................................................................................................ 31 
Figure 20: Firmware Version Display Example ...................................................................... 33 
Figure 21: Singulate (Singulate Mode) ................................................................................... 34 
Figure 22: Slug (Slug Mode)...................................................................................................... 34 
Figure 23: ZIP (Operating Mode).............................................................................................. 35 
Figure 24: Zone Hold (Singulate, ZIP, and Slug Modes)....................................................... 35 
 
 
 
 
 
 
 
 
 
 
 
 
 

ZoneLogix™PRO Zone Controller User Guide | Revision 1.0 November 2019 | Page 5
 
L I S T O F T A B L E S 
 
Table 1: DC Power Input Connection....................................................................................... 14 
Table 2: PNP Sensor Connection Header ............................................................................... 15 
Table 3: Smart I/O Pin Definitions for the EOB Zone Controller ......................................... 16 
Table 4: Smart I/O Pin Definitions for the Standard Zone Controller ................................ 16 
Table 5: Smart I/O Pin Definitions for the Master Zone Controller in Basic Mode .......... 17 
Table 6: Operating Modes for Smart I/O Pins 1 & 2 on the Master Zone Controller in Basic 
Mode............................................................................................................................................. 17 
Table 7: Speed Input Analog Control....................................................................................... 17 
Table 8: Parameters in Basic Mode......................................................................................... 22 
Table 9: Fault LED ...................................................................................................................... 32 
Table 10: Motor Current LED .................................................................................................... 32 
 
 
 
 

ZoneLogix™PRO Zone Controller User Guide | Revision 1.0 November 2019 | Page 6

Introduction

The ZoneLogix™ PRO Smart Conveyor System is a product that is used in material handling conveyance

applications. The system is comprised of two main components: Zone Controllers and the Branch

Monitor. A typical application consists of some length of roller conveyor (a Branch), divided into zones.

Each zone has a Zone Controller that controls a Brushless DC (BLDC) motor, or solenoid air actuator.

Zone Controllers communicate via a high-speed network. The Branch Monitor provides three different

functions: (1) It acts as a system monitor to allow for monitoring the operation of the Branch, (2) it acts

as a device to configure the behavior of the individual zones, and (3) it provides an EtherNet/IP fieldbus

interface for use with a Programmable Logic Controller (PLC).

ZoneLogix™ PRO was designed to provide levels of operation ranging from basic speed and direction to

advanced sophisticated implementations.

▪Basic Mode: Everything your smart conveyor system needs to get started is already built-into the

ZoneLogix™ PRO system. You can connect up to 255 package-handling segments, or zones, in series

with one UniDrive®motor per zone.

▪Advanced Mode: By adding the ZoneLogix™ PRO Branch Monitor, you can configure each individual

zone according to the needs of the application. Optionally, you can also connect a PLC to further

leverage the networking power of the ZoneLogix™ PRO to provide automated package tracking and

sophisticated control capabilities. You can connect up to 120 zones in a Branch. Multiple Branches

can be connected to each other.

Figure 1: The ZoneLogix™ PRO System

ZoneLogix™PRO Zone Controller User Guide | Revision 1.0 November 2019 | Page 7

1.1

Key Terms and Concepts

▪Branch: A conveyor section that consists of a series of zone controllers with a defined entry End-of-

Branch (EOB) zone (upstream), and an exit Master zone (downstream) {in the Forward (normal) flow

direction}. In between the EOB and Master are Standard zones.

NOTE: A Branch requires a minimum of (1) EOB and (1) Master

▪Forward (normal) Flow Direction: Transportation from EOB (entry) to Master (exit)

▪Reverse Flow Direction: Transportation from Master (becomes entry) to EOB (becomes exit)

▪End-of-Branch (EOB): The EOB is the entry to the Branch in the Forward (normal) Flow Direction

▪Master: The Master zone controller is the exit zone of the Branch in the Forward (normal) flow

direction. It communicates the modes of operation to all zone controllers in the Branch. You can

configure the Master in Basic Mode or Advanced Mode.

▪Standard: Zone controllers that are located between the EOB and Master

▪Branch Monitor:The Branch Monitor provides a user interface display, and pushbuttons to configure

a Branch. The Branch Monitor helps you gather information about the Branch and configure it for

your needs.

▪Primary Sensor: Photoeye input for the downstream edge of a zone, when configured for the

Forward (normal) flow direction.

▪Secondary Sensor: Photoeye input for the downstream edge of a zone, when configured for the

Reverse flow direction.

▪Smart I/O: General purpose, 24 VDC I/O, that can be used as an extension of a PLC, or configured to

one of several built-in functions.

▪Analog Speed Input: Allows a zone to be controlled via a 0-10 VDC signal

▪Basic Mode: Basic Mode is the out of the box solution for ZPA. It uses discrete signals to control

several parameters for Branch configuration (a Branch Monitor is not required). A Branch may contain

up to 255 zones.

▪Advanced Mode: Advanced Mode utilizes the full power of the Branch Monitor to individually

configure each zone in a Branch. Optionally, the EtherNet/IP fieldbus connection may be used to

control a Branch via a Programmable Logic Controller (PLC). A Branch may contain up to 120 zones.

▪Branch Serial Communications: Serial communications that allows the Master to configure all

zones within a Branch (Master-to-Zones)

▪Handshake Communications: Request, Permission, and Sensor signals that pass between adjacent

zones. Allows for zone-to-zone communication for handling package flow.

▪Protective Extra Low Voltage (PELV): IEC 61140 defines a PELV system as an electrical source in

which the voltage cannot exceed 30 Vrms or 60 VDC under normal or single-fault conditions, and its

DC common (minus (-) output terminal) is connected to earth ground.

ZoneLogix™PRO Zone Controller User Guide | Revision 1.0 November 2019 | Page 8

Getting Started and Installation

Below is an image of the Zone Controller and the various connections. In Basic Mode there are a few

operational mode settings that can be made via Smart I/O settings which are described later in this

manual. To configure a system in Advanced Mode, see Section 5: Advanced Mode System

Configuration.

Figure 2: ZoneLogix™ PRO Zone Controller Diagram

1) Secondary Sensor: Photoeye input for the downstream edge of a zone, when configured for the

Reverse flow direction.

a. Phoenix Contact, 3-pos plug, 1881338

2) To EOB Communication: This is meant to only connect to the “To Master” connection of

another Zone Controller. Zone Controllers are intended to be daisy chained together in a series.

a. RJ45, 8P8C, CAT5 (or better), Ethernet cable

ZoneLogix™PRO Zone Controller User Guide | Revision 1.0 November 2019 | Page 9

3) Smart I/O: General purpose, 24 VDC I/O, that can be used as an extension of a PLC, or

configured to one of several built-in functions

a. Phoenix Contact, 4-pos plug, 1881341

4) UniDrive®Motor Connection: Motor connection for any UniDrive®Brushless DC Motor. The

motor contains this plug. It is listed here for reference.

a. Motor Input: Molex, 10-pos plug, 172258-1110

5) Primary Sensor: Photoeye input for the downstream edge of a zone, when configured for the

Forward (normal) flow direction.

a. Phoenix Contact, 3-pos plug, 1881338

6) To Master Communication: This is meant to only connect to the “To EOB” connection of

another Zone Controller. Zone Controllers are intended to be daisy chained together in a series.

a. RJ45, 8P8C, CAT5 (or better), Ethernet cable

7) Smart I/O: General purpose, 24 VDC I/O, that can be used as an extension of a PLC, or

configured to one of several built-in functions

a. Phoenix Contact, 4-pos plug, 1881341

8) Power Input: 24 VDC power input

a. Molex, 2-pos plug, 172256-1002

9) DIP Switches: Configures various modes and functions of the Zone Controller

ZoneLogix™PRO Zone Controller User Guide | Revision 1.0 November 2019 | Page 10

This section describes how to install the ZoneLogix™ PRO and UniDrive®motors in the most common

configuration.

2.1

Zone Controller Installation

Mount the Zone Controller in a location where the motor cable reaches the connection header without putting strain

on the cable connector or the header. The Zone Controller can mount to the conveyor frame using two ¼ inch (0.25

in or 6.35 mm) bolts.

CAUTION: If mounting the control on a curved section of conveyor, use washers between the mounting plate and the conveyor

frame. This is to assure that the mounting plate is not distorted, causing damage to the enclosed printed circuit board assembly.

Figure 3: Zone Controller Mounting Tabs

CAUTION: Removal of the cover will void the warranty. The cover does not make the controller waterproof or dustproof.

1. Zone Controller Installation

2. Motor Installation

3. DIP Switch Settings

4. Cable Connections

5. System Configuration

6. Diagnostics & Troubleshooting

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