TGW CRUZcontrol Installation, Operation & Maintenance Manual

For nba and xp43

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NSTALLATION

PERATION

AINTENANCE

ANUAL

CRUZcontrol

For NBA

and XP43

IOM P\N: 90480009

Revision Date: March 18, 2019

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Page 1 NSTALLATION PERATION AINTENANCE ANUAL CRUZcontrol ® For NBA and XP43 ® IOM P\N: 90480009 Revision Date: March 18, 2019...
Page 2: Table Of Contents
Reflectors ............................44 Sensor Valve Assemblies ........................44 Extension Cables ..........................44 TGW Systems Controls Guidelines See following pages..............45 TGW-ERMANCO Controls Guidelines ....................45 Cutler-Hammer Cut Sheet – IM08302001E Rev 02 ................56 Cutler-Hammer Cut Sheet – P50244 Rev 02 ..................56 TGW General Information ........................
Page 3: Purpose
IOM CRUZcontrol® Purpose It is the intent of TGW Systems, through this and safe working practices on conveyor manual, to provide information that acts as a systems. guide installation, operation maintenance of TGW Systems conveyors Not all applications and conditions can be featuring CRUZcontrol Logic.
Page 4 Consequential damages of any sort are wholly excluded. the TGW warranty on any failed components that The liability of TGW Systems will be limited to the result from these environment issues. replacement cost of any defective part. All freight and...
Page 5: Cruzcontrol Logic Assembly
E0001905A Progressive Logic, NBA 23 The NBA CRUZcontrol Logic Assembly provides an “air to drive” logic output utilizing a normally closed pneumatic valve. The XenoROL CRUZcontrol Logic Assembly provides an “air to brake” logic output, utilizing a normally open pneumatic valve. With both types of logic, the pneumatic valve is energized for a zone to be running.
Page 6: Basic Logic
IOM CRUZcontrol® Basic Logic Flow Conveyor Zone 6 Zone 5 Zone 4 Zone 3 Zone 2 Zone 1 Stopped Stopped Running Running Running Stopped Stopped Basic Logic functions such that when any two successive photoelectric sensors are blocked, the second zone upstream is set to accumulate.
Page 7: Progressive Logic
IOM CRUZcontrol® Progressive Logic Flow Conveyor Zone 6 Zone 5 Zone 4 Zone 3 Zone 2 Zone 1 Stopped Running Running Running Running Running Stopped Progressive Logic functions such that no zones are set to accumulate unless all downstream zones hold accumulated product and the photoelectric sensors are blocked.
Page 8 Progressive Logic Assemblies should be retained, but only in those locations. CRUZcontrol provides the ability to for slug release. If the line is set to Slug Release, all affected zones will run immediately, regardless of downstream conditions, resulting in the immediate release of product with little or no gaps.
Page 9: Logic Assembly Specifications
The pneumatic valve has a small red lever controlling valve shutoff. This must be set to “0” (not “1”) for proper valve operation. For zone lengths greater than 36 inches, the following extension cable is used to connect to each Logic Assemblies. These are provided pre-installed on the conveyor with the other CRUZcontrol components: TGW Systems Part No. Description RK4.4T1RS4.4T...
Page 10: Logic Module Wiring
Logic Module Wiring Installation CRUZcontrol will come pre-installed on the conveyor: The CRUZcontrol Logic Assemblies are installed into the side channel of the conveyor • bed. The air supply for the conveyor is plumbed the length of the conveyor bed, passing through •...
Page 11: Cruzcontrol On Site Installation
(Some conveyor configurations will result in the conveyor flow direction being reverse from what is shown in the illustration. In those situations, the Interconnection Cables are routed in reverse from that shown.) CRUZcontrol On Site Installation Installation will consist of the following: •...
Page 12: Nba®23 To Rlc®25 Cruzcontrol Installation
IOM CRUZcontrol® 23 to RLC 25 CRUZcontrol Installation ® ® The accumulating option on your RLC 25 curve simply solves all previous problems associated with V- belt driven curves. IT IS NOT NECESSARY TO CLEAR THE CURVE OF PRODUCT when accumulation reaches it.
Page 13 IOM CRUZcontrol® 1ST CURVE INTERMEDIATE BED 2ND CURVE EXAMPLE "A" 1ST CURVE 2ND CURVE EXAMPLE "B" 1ST CURVE INTERMEDIATE BED EXAMPLE "C" EXAMPLE OF UPSTREAM NBA P/N: 90480009 Revision Date: 03/18/2019 Page 13 of 58...
Page 14: Power Supply Requirements
Class 2 power supply should be used. This limits the output power to a total of 100 VA. The current required for each CRUZcontrol Logic Assembly is 67mA, which allows for up to 53 zones per power supply. There is also a limit on the maximum number of Logic Assemblies that...
Page 15 (provide power to) either the Logic Signal or Slug Signal lines of CRUZcontrol. The Release Out switch should be set to Sourcing. (The Release Out feature is not required to operate CRUZcontrol. These same functions are also provided for with the Function Module, which comes with plug in connections.)
Page 16: Power Supply Wiring
IOM CRUZcontrol® Power Supply Wiring Connection made between two Logic Assemblies using a T Cable: This drawing illustrates a power connection made between two intermediate accumulation zones making use of a T Cable. Note that all power and control signals, including the Slug and Logic Signals, pass through the T Cable uninterrupted.
Page 17 Logic Assemblies doesn’t exceed 53. The number of CRUZcontrol zones that can be connected per string must also be reduced according to the total length of wire and cable used to reach the first CRUZcontrol Logic Assembly of the string (refer to chart under Power Supply Requirements section).
Page 18 Using two Power Supplies to power one extended CRUZcontrol string: A CRUZcontrol string with more than 53 Logic Assemblies would require the use of more than one power supply. This can be done, but it requires that the power supplies be isolated from each other at the +24 volt line.
Page 19: Generation 2 Function Modules
Generation 2 Function Modules Function Modules (Generation 2) Function Modules are an important accessory to CRUZcontrol. They provide electrical isolation for external processes and controls and facilitate CRUZcontrol system applications. There are three different Function Modules, each providing different groups of functions:...
Page 20 IOM CRUZcontrol® Function Module Power Requirements The Function Modules get power by being connected into a string of Logic Assemblies. As a result, it will reduce the maximum number of Logic Assemblies that can be connected into one string. This is shown in the following chart, which is based on a 3 foot cable from the power supply to the first Logic Assembly, and 3 foot maximum zone spacing.
Page 21: Use Of 115 Vac Controls With All Function Modules
IOM CRUZcontrol® Use of 115 VAC controls with all Function Modules Important information regarding the use of 115 VAC controls: These Function Modules will accept 115 VAC level control inputs. There are some cautions that must be observed to avoid Function Module hardware failure.
Page 22: Full Function Module 1138074
The Slug Release line is turned ON. This can occur by applying power (turning ON) the slug line at any point in the CRUZcontrol™ system. The Function Module can be used to supply power to the Slug Release Line and to manipulate the slug signal.
Page 23 IOM CRUZcontrol® Downstream Slug Interrupt Definition: The Slug Release line is disconnected going to the downstream Logic Assembly. Action: Logic Assemblies downstream of the Function Module will not slug release when the Slug Release Line is turned ON either at the Function Module itself or upstream of the Function Module.
Page 24 IOM CRUZcontrol® Full Function Module Technical Data Interface to CRUZcontrol Upstream connection Female, M12, 4-PIN, 300 mm cable Downstream connection Male, M12, 4-PIN, 300 mm cable Power Supply voltage from daisy chain 18…30 VDC Power consumption of ZIM 10 mA, no load ZoneControl system power TB4 input 24…28 VDC typical.
Page 25 IOM CRUZcontrol® Full Function Module Board Layout P/N: 90480009 Revision Date: 03/18/2019 Page 25 of 58...
Page 26 IOM CRUZcontrol® Full Function Module Circuit P/N: 90480009 Revision Date: 03/18/2019 Page 26 of 58...
Page 27 IOM CRUZcontrol® Full Function Module INPUTS OUTPUT Downstream Upstream LOGIC LOGIC Note 0 to 1 transition is delayed by Logic Delay Potentiometer Single Release at TB1 Logic Interrupt at TB1 Logic output signal oscillates at rate determined by ZS ON and ZS OFF potentiometers.
Page 28 IOM CRUZcontrol® Full Function Module INPUTS OUTPUT Downstream Downstream ZONE LOGIC SENSOR STATUS Note 1-2 or 2-3 1-2 or NC 1 to 0 transistion is delayed by Zone Status OFF delay potentiometer 1-2 or 2-3 1-2 or NC 0 to 1 transistion is delayed by Zone Status ON delay potentiometer...
Page 29 IOM CRUZcontrol® Full Function Module (Note: “ZIM” as found in this table refers to Function Module) INPUTS OUTPUTS Downstream Downstream Upstream TB5 (pin LOGIC SLUG SLUG Note No Slug signal Downstream Slug pass-through, Upstream Slug pass-through Downstream Slug pass-through, Upstream Slug interrupt...
Page 30: Release Function Module E0006305
The Slug Release line is turned ON. This can occur by applying power (turning ON) the slug line at any point in the CRUZcontrol system. The Function Module can be used to supply power to the Slug Release Line and to manipulate the slug signal.
Page 31  Auxiliary sensor or external signal (from a PLC for example) as the input: JP4 is NC and signal is input to TB4 Release Function Module Technical Data Interface to CRUZcontrol ZLM1, WLR2100-D Upstream connection Female, M12, 4-PIN, 300 mm cable...
Page 32 IOM CRUZcontrol® Release Function Module Board Layout Release Function Module Circuit P/N: 90480009 Revision Date: 03/18/2019 Page 32 of 58...
Page 33 IOM CRUZcontrol® Release Function Module Logic Truth Tables INPUTS OUTPUT Downstream Upstream LOGIC LOGIC Note Single Release at TB1 Logic Interrupt at TB1 Single Release at TB4 (pin 3) Logic Interrupt at TB4 (pin 3) No effect on Logic Output when TB4 is configured as Zone Status Input...
Page 34 IOM CRUZcontrol® Release Function Module INPUTS OUTPUT Downstream Downstream ZONE LOGIC SENSOR STATUS Note 1-2 or 2-3 1-2 or 2-3 1-2 or 2-3 1-2 or 2-3 Truth Table for Zone Status Circuit STATE Electrical Definition Typical System Definition Downstream <4.0VDC Downstream sensor blocked (Single Acc.) or accumulated (Slug Acc.)
Page 35 IOM CRUZcontrol® Release Function Module (Note: “ZIM” as found in this table refers to Function Module) INPUTS OUTPUTS Downstream Downstream Upstream LOGIC SLUG SLUG Note No Slug signal Downstream Slug pass-through, Upstream Slug pass-through Downstream Slug pass-through, Upstream Slug interrupt...
Page 36: Zone Status Function Module E0006306
Definition: The Slug Release line is turned ON. This can occur by applying power (turning ON) the slug line at any point in the CRUZcontrol system. The Function Module can be used to supply power to the Slug Release Line.
Page 37 IOM CRUZcontrol® Zone Status Function Module Technical Data Interface to CRUZcontrol system Upstream connection Female, M12, 4-PIN, 300 mm cable Downstream connection Male, M12, 4-PIN, 300 mm cable Power Supply voltage from daisy chain 18…30 VDC Power consumption of ZIM...
Page 38 IOM CRUZcontrol® Zone Status Function Module Board Layout Zone Status Module Circuit P/N: 90480009 Revision Date: 03/18/2019 Page 38 of 58...
Page 39: Logic Truth Tables
IOM CRUZcontrol® Logic Truth Tables INPUTS OUTPUT Downstream Upstream LOGIC LOGIC Note Single Release at TB4 Logic Interrupt at TB4 No effect on Logic Output when TB4 is configured as Zone Status Input Truth Table for Logic Circuit Electrical STATE...
Page 40 IOM CRUZcontrol® Zone Status Function Module INPUTS OUTPUTS Downstream Downstream Upstream LOGIC SLUG SLUG Note No Slug signal Downstream Slug pass-through, Upstream Slug pass-through Truth Table for Slug Circuitry (Downstream Inputs) INPUTS OUTPUTS Upstream Downstream SLUG SLUG Note No Slug signal...
Page 41: Generation 2 Function Modules - Definitions
Before applying power to the module, make sure that the cover of the Function Module is closed.  Any motor cables should cross CRUZcontrol cables at an angle of 90 degrees.  If conduit is being used for wiring, use separate conduits for the input power wiring, the output power ...
Page 42: Discharge Logic Assembly
A Discharge Logic Assembly is a Basic Logic Assembly without a solenoid valve attached. It can be used to control the release from the last, discharge zone of a length of CRUZcontrol. Since there is no solenoid valve, the same Discharge Logic Assembly will work for either NBA™23 or XenoROL ®...
Page 43: Nba ® 23 Brake Control
Auxiliary Photoelectric Sensors There is often a need to sense product presence on a CRUZcontrol equipped conveyor, with the sensors connected to a control system other than CRUZcontrol. To allow for this, adequate space has been provided along side of the CRUZcontrol photoelectric sensors to allow for the mounting of a second independent photoelectric sensor, sharing the same holes through the conveyor side channels and the same reflector.
Page 44: Reflectors
Photo sensor with bracket, 20-264 VAC or 15-30 VDC (NPN) operation The 10-30 VDC photo sensors are similar to the CRUZcontrol sensors. They are dark switching, with a 50 mA maximum output current, and come with a 6-foot cable (no connector).
Page 45: Tgw Systems Controls Guidelines See Following Pages
XenoROL. The CRUZcontrol manual states the following: “CRUZcontrol Logic Assemblies are designed to be fail-safe. A loss of module power, a disconnected or severed cable, or a dirty or failed photoelectric sensor will all result in the stopping of a zone, initiating accumulation beginning from the affected zone.
Page 46 ECG 2.1 describes how to determine the location for the sensor. The hardware required in this example, in addition to that already provided with CRUZcontrol, includes the following: Description...
Page 47 IOM CRUZcontrol® The Full Function Module is connected as shown just downstream of the last accumulation zone prior to the curve. Release from that zone is stopped if the Auxiliary Photo Sensor senses full accumulation (blocked for a time delay period), or if the Logic Assembly just downstream of the curve stops the upstream release due to being accumulated.
Page 48 Example 3: This example is similar to Example 1, but will only work if the throughput rate is low. The CRUZcontrol Logic Assemblies must be Basic Logic. Product does not accumulate on the curved section of the conveyor. The conveyor shown is XP43CZ.
Page 49 IOM CRUZcontrol® Conveyor Flow Zone 1 Zone 2 Zone 3 Extension Assembly Logic Assembly Full Function Module The Full Function Module does not require any external logic signals. It is used, connected as shown, for the internal Zone Release Delay feature.
Page 50 What this example will show is a method for control done locally, meaning that it requires no additional external logic. The hardware required in this example, in addition to that already provided with CRUZcontrol, includes the following. The junction box shown is not included in this listing.
Page 51 SWITCH (alternate connection) Operation: All cartons stop at the Work Zone when the CRUZcontrol photoelectric sensor in that zone is blocked. To release cartons stopped at the zone, the Foot Switch needs to be depressed until the carton clears the photoelectric sensor.
Page 52 3. The CRUZcontrol Logic Assembly at the final discharge zone could be Basic Logic, with all other upstream Logic Assemblies Progressive Logic. This would reduce the NBA 23 release rate while still retaining the infeed and throughput rate benefits of Progressive Logic.
Page 53 Example 7: Power Monitoring. There could be situations where it is desirable to monitor the 24 VDC power source for the CRUZcontrol. A loss of power, for whatever reason, will result in all zones going into accumulation, immediately stopping all product movement.
Page 54 Example 8: Product Gapping The following describes a technique, using CRUZcontrol, which creates a gap in a train of moving product. In the situation described, the gap is used to allow for the raising of a product stop. This would apply primarily to the progressive mode of accumulation control, which accumulates and discharges from accumulation with only very minimal gaps between products.
Page 55 IOM CRUZcontrol® activated. This in turn enables accumulation beginning with the next upstream accumulation zone, once the Photosensor in that zone is blocked. Function Module #2 (also a Release Function Module) is configured and wired for Logic Interrupt operation. When it receives a signal (from the PLC), it passes the signal from the down stream accumulation zone to the upstream accumulation zone.
Page 56: Cutler-Hammer Cut Sheet - Im08302001E Rev 02
IOM CRUZcontrol® Cutler-Hammer Cut Sheet – IM08302001E Rev 02 See following pages. Cutler-Hammer Cut Sheet – P50244 Rev 02 See following pages. Page 56 of 58 P/N: 90480009 Revision Date: 03/18/2019...
Page 57: Tgw General Information
IM08302001E Rev 02 Installation Instructions — Conveyor Sensors Power Supply Connect the sensor system to the “Release Out” terminal on the DC WARNING terminal strip using one of the wiring arrangements described IN ORDER TO AVOID ELECTRIC SHOCK OR OTHER POSSIBLE INJURY: (including pros and cons) in Table 2 below, and the requisite cable •...
Page 58 IM08302001E Rev 02 SPECIFICATIONS PS256B-01B1 PS256B-04B1 (-05B1) Input Power 144W, Maximum inrush 30A from cold start Input Voltage 100 - 250 V AC Input Current (Maximum) 115V AC - 2A, 230 V AC - 1A Output Voltage 27V DC Output Power 100W Output Protection Short circuit, overload and overvoltage protection (cycle input power to reset)
Page 59 Cutler-Hammer P50244 Rev 02 Installation Instructions — Conveyor Sensors Power Supply TROUBLESHOOTING WARNING The supply provides two indicators to allow for easy troubleshooting: (RED) (GREEN) IN ORDER TO AVOID ELECTRIC SHOCK OR OTHER POSSIBLE SUPPLY STATUS TROUBLESHOOTING STEPS INJURY: • DO NOT USE THIS PRODUCT FOR HUMAN SAFETY Normal Operation Verify load properly connected to APPLICATIONS.
Page 60 P50244 Rev 02 Page 2 SPECIFICATIONS Input Voltage 342-528 VAC, 47-63 Hz, 3-phase, Delta or Wye Input Current 170mA @ 480 VAC input, nominal Input Wiring 4-wire system, 3 phases plus ground Output Voltage 26VDC (measured at 20% load) Output Power 100W Output Protection Short circuit, overload and overvoltage protection (auto reset)
Page 61: History
Application and Control Guidelines: https://www.tgw-conveyor.com/support/application-control-guidelines Support & Connections: https://www.tgw-conveyor.com/support/iom-manuals/supports-and-connections TGW IOM Manuals: https://www.tgw-conveyor.com/support/iom-manuals Brochures: https://www.tgw-conveyor.com/support/brochures Patents & Trademarks: https://www.tgw-conveyor.com/technologies/patents-and-trademarks After Hours, Contact Information: https://tgw-conveyor.com/tgw/guaranteed-product-performance History Revised: TGW Logo, contact information and address. Page 57 of 58 P/N: 90480009 Revision Date: 03/18/2019...
Page 62: Tgw Systems Information
TGW Systems Information Mission TGW Systems, located in Spring Lake, Michigan, is a leading deliverer of “smart” material handling systems, technologies, products, and services, creating solutions for material flow applications. As a global supplier of conveyor systems and equipment since 1964, TGW Systems provides sorters, conveyors, and accessories to satisfy a broad spectrum of accumulation, transportation, and sortation applications.