Related Manuals for Pepperl+Fuchs VAZ-2E2A-G20-ZPA1
Summary of Contents for Pepperl+Fuchs VAZ-2E2A-G20-ZPA1
- Page 1 FACTORY AUTOMATION MANUAL VAZ-2E2A-G20-ZPA1 ZPA Motor Control Module from Firmware Version V.28...
- Page 2 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 Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the...
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Page 3: Table Of Contents
VAZ-2E2A-G20-ZPA1 Introduction................. 5 Content of this Document ..............5 Target Group, Personnel..............5 Symbols Used ..................5 Intended Use ..................6 General Safety Instructions ..............6 Declaration of Conformity ..............7 Product Description ..............8 Use and Application................8 Operating Modes of the ZPA Motor Control Module....... 11 2.2.1... - Page 4 VAZ-2E2A-G20-ZPA1 Operating Behavior ..............34 Switch-On Behavior................34 Switch-On Delay .................34 Search Time ..................34 Leaving Time..................34 Entry Time...................34 Transportation Time ................35 Motor Run-On Time ................35 Release Delay ..................35 Idle Mode Delay ..................35 Manual Intervention in the Conveying Process..... 36 Manual Feeding of Conveyed Product ..........36 Manual Removal of Conveyed Product ..........36...
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Page 5: Introduction
VAZ-2E2A-G20-ZPA1 Introduction Introduction 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... -
Page 6: Symbols Used
VAZ-2E2A-G20-ZPA1 Introduction 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. -
Page 7: General Safety Instructions
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. ISO9001... -
Page 8: Product Description
VAZ-2E2A-G20-ZPA1 Product Description Product Description 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. - Page 9 VAZ-2E2A-G20-ZPA1 Product Description MOT1 MOT2 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 accumulation. It assumes the control of one or two consecutive zones powered by DC roller motors.
- Page 10 VAZ-2E2A-G20-ZPA1 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.
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Page 11: Operating Modes Of The Zpa Motor Control Module
VAZ-2E2A-G20-ZPA1 Product Description Release from downstream zone Conveyor good Conveyor good is stopped has left zone IN (Photo eye) X OUT to downstream zone X IN (Release) from downstream zone Motor after run Figure 2.5 2. Release signal is set before the conveyed product reaches the zone sensor. -
Page 12: Standard Zpa
VAZ-2E2A-G20-ZPA1 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. -
Page 13: Enhanced Zpa
VAZ-2E2A-G20-ZPA1 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. -
Page 14: Transportation
VAZ-2E2A-G20-ZPA1 Product Description 2.2.4 Transportation In this operating mode, a zone forwards the release signal directly to the zones behind it. At the same time, the release signal also switches on the zone motor. The release is not set independently. Therefore, only a block release is carried out, which does not cause the conveyed product to be separated. -
Page 15: Long Zone - Single Zone
VAZ-2E2A-G20-ZPA1 Product Description 2.2.5 Long Zone - Single Zone This operating mode is designed specifically for the operation of a zone in a range of Standard zones or Enhanced ZPA zones that is significantly longer than the surrounding zones. A longer zone like this would negatively affect the throughput of the entire conveyor line because the distance between the conveyed product is primarily determined by the zone length. -
Page 16: Direct Control
VAZ-2E2A-G20-ZPA1 Product Description 2.2.6 Direct Control In this operating mode, the DC roller motors connected to the ZPA motor control module can be controlled using external signals. In this way, the ZPA control module can, for example, be connected directly to a PLC that follows its own logic for controlling the DC roller motors. The control signals are transferred via the inputs of the respective zone coupling interfaces. -
Page 17: Slave
VAZ-2E2A-G20-ZPA1 Product Description 2.2.8 Slave In this operating mode, the ZPA motor control module functions as a slave to a downstream master zone. Both slave motors are synchronized to the master zone motors. The master zone is extended by the slave. The signals from the rear zone coupling of the master are transmitted by the slave through to the upstream zone. -
Page 18: Indicators And Operating Elements
VAZ-2E2A-G20-ZPA1 Product Description Indicators and Operating Elements 2.3.1 LED Indicators Overview The LEDs on the ZPA motor control module display the following information: Firmware version (only immediately after switching on), Setting of the rotary switch (only immediately after switching on),... - Page 19 VAZ-2E2A-G20-ZPA1 Product Description Note! Motor Fuses Are Safety Fuses For protection against short circuits, each DC roller motor is secured with its own safety fuse with a 5 A rated current. The fuses are not interchangeable. If a fuse is faulty, the module must be replaced.
- Page 20 VAZ-2E2A-G20-ZPA1 Product Description Color Description X2 IN Yellow Input from interface 2: Release signal from downstream zone On = Release signal from downstream zone has been set (high level) Off = Release signal from downstream zone has not been set (low...
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Page 21: Rotary Switches For Configuration
VAZ-2E2A-G20-ZPA1 Product Description 2.3.2 Rotary Switches for Configuration On the back of the device, there are three rotary switches for configuring Motor speed via S1 Start/stop ramp and direction of rotation via S2 Operating mode via S3 Figure 2.13 Note! - Page 22 VAZ-2E2A-G20-ZPA1 Product Description Speed [%] Speed 100% Speed 60% acceleration time setting Time [ms] 800 1000 Figure 2.14 The direction of rotation setting defines not only the direction of rotation of the connected DC roller motors but also which of the two zones is the "downstream zone" and which is the "upstream zone."...
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Page 23: Interfaces And Connections
VAZ-2E2A-G20-ZPA1 Product Description Switch setting Operation Mode 1-/2-zone operation Slave 1-zone operation Reserved Table 2.7 Interfaces and Connections Connections: Inputs/Outputs The sensors and motors are connected to the ZPA motor control module via cables with round M8 connectors: Sensors: socket, 4-pin... - Page 24 VAZ-2E2A-G20-ZPA1 Product Description Connection Connector Connector type/assignment X1: Zone coupling, X1 Zone coupling M12 round plug connector interface 1 in accordance with IEC/EN 61076-1-101 M12, 4-pin, socket, screw-locking, coding A 1: X1 IN input signal 2: X1 IN- input GND...
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Page 25: Installation
2. Check that all items are present and correct based on your order and the shipping documents. If you have any questions, please contact Pepperl+Fuchs. 3. Keep the original packing material in case you need to store or ship the unit at a later time. -
Page 26: Power Supply Connection
VAZ-2E2A-G20-ZPA1 Installation Power Supply Connection The power supply is connected to the ZPA motor control module via a black AS-Interface flat cable. The permissible supply voltage is 18 V ... 30 V. The electric connection between the ZPA motor control module and flat cables is established via two metal pins using piercing technology. - Page 27 VAZ-2E2A-G20-ZPA1 Installation Figure 3.2 Connecting flat cables on the narrow side Connecting Flat Cables on the Wide Side The profile edge is not visible from above. For orientation purposes in the figure below, the edge is shown as a hidden edge drawn with a dotted line.
- Page 28 VAZ-2E2A-G20-ZPA1 Installation Figure 3.3 Connecting flat cables on the wide side (profile edge as dotted line) Flat Cable Inserted Incorrectly The figure below shows an incorrectly inserted flat cable. The profile edge (2) does not point to the motor control module; the flat cable is therefore inserted with reverse polarity. The flat cable is located on the reverse polarity protection (1) with a curvature, which means that the cable guide cannot be closed completely (mechanical reverse polarity protection).
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Page 29: Special Requirements When Connecting To A Plc
VAZ-2E2A-G20-ZPA1 Installation Figure 3.4 Flat cable inserted incorrectly (profile edge as dotted line) Special Requirements when Connecting to a PLC The electrical signals from the zone coupling interfaces are compatible with the standard 24 V IOs of a PLC. The inputs (X1 IN, X2 IN) are galvanically isolated. Therefore, there are no special requirements for the connection of other potentials. - Page 30 VAZ-2E2A-G20-ZPA1 Installation Note! The connection of DC roller motors and zone sensors to the ZPA motor control module depends on the circumstances of the zones to be controlled. There are a variety of connection scenarios depending on whether you want to control one or two zones or when changing the mounting side on the conveyor line.
- Page 31 VAZ-2E2A-G20-ZPA1 Installation Conveyor Direction from Left to Right (Clockwise Rotation) Interface zone coupling Description Behavior X1 IN Output signal from the zone Low level: No conveyed sensor of the upstream zone product detected X2 OUT Output signal of the zone...
- Page 32 VAZ-2E2A-G20-ZPA1 Installation Connect the connection lines of the motors, zone sensors, and the zone coupling signals according to the connection wiring diagram and the conveyor direction. Caution! Malfunctions due to incorrect assignment of connections When connecting the ZPA motor control module, you should never form connection loops as shown in the following figure.
- Page 33 VAZ-2E2A-G20-ZPA1 Installation Downstream Upstream Zone zone zone Single-zone operation Single-zone operation Dual-zone operation MOT1 MOT2 MOT1 MOT2 MOT1 MOT2 MOT1 MOT2 MOT1 MOT2 MOT1 MOT2 Switch S2 = 5..9 (CCW) Figure 3.11 Conveying direction from right to left (counterclockwise) Connect the connection lines of the motors, zone sensors, and the zone coupling signals according to the connection wiring diagram and the conveyor direction.
- Page 34 VAZ-2E2A-G20-ZPA1 Installation Rotary switch S2 = 5..9 (CCW) MOT2 MOT1 MOT2 Upstream zone Zone 1 Zone 2 Downstream zone Female to female crossover cable MOT2 MOT1 MOT2 MOT2 MOT1 MOT2 Rotary switch S2 = 0..4 (CW) Figure 3.13 Conveyor direction from left to right (clockwise) Connect the connection lines of the motors, zone sensors, and the zone coupling signals according to the connection wiring diagram.
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Page 35: Operating Behavior
VAZ-2E2A-G20-ZPA1 Operating Behavior Operating Behavior Switch-On Behavior In the operating modes "Standard ZPA," "Enhanced ZPA," and "Long Zone," the ZPA motor control module waits for the duration of the switch-on delay after the power supply is switched on before it is ready for operation. The only exception is the output of the status of the zone sensor at the relevant interface for zone coupling (X1 or X2). -
Page 36: Entry Time
VAZ-2E2A-G20-ZPA1 Operating Behavior Entry Time Entry time = 8 s The entry time is the time required by conveyed product to leave the upstream zone and therefore its zone sensor after the release signal is set. If the conveyed product requires longer than the entry time, the zone will shut down its motor and wait for the conveyed product to disappear from the upstream zone or appear in front of its zone sensor. -
Page 37: Manual Intervention In The Conveying Process
VAZ-2E2A-G20-ZPA1 Manual Intervention in the Conveying Process Manual Intervention in the Conveying Process Manual Feeding of Conveyed Product It is always possible to manually feed conveyed product. When doing so, it is assumed that the conveyed product is placed in front of a zone sensor. -
Page 38: Manually Correcting Accumulations
VAZ-2E2A-G20-ZPA1 Manual Intervention in the Conveying Process Manual Release When the switch is closed, the release signal of the downstream zone reaches the upstream zone once again (as long as activated by the downstream zone). The upstream zone can pass on any conveyed product present to the downstream zone. -
Page 39: Troubleshooting
If none of the information specified in the checklist solves the problem, in the event of queries contact Pepperl+Fuchs via your sales office. Have the type designation and firmware version of the product ready. In the following checklist, "x" represents the channel for the LED descriptions and can be either "1"... - Page 40 VAZ-2E2A-G20-ZPA1 Troubleshooting Fault Possible cause Remedy The zone does not switch the The zone coupling signal lines Make sure that the zone relevant DC roller motor on in are not connected correctly. coupling to the upstream zone case of incoming conveyed...
- Page 41 Twinsburg, Ohio 44087 · USA Tel. +1 330 4253555 E-mail: sales@us.pepperl-fuchs.com Asia Pacific Headquarters Pepperl+Fuchs Pte Ltd. Company Registration No. 199003130E Singapore 139942 Tel. +65 67799091 E-mail: sales@sg.pepperl-fuchs.com www.pepperl-fuchs.com Subject to modifications / DOCT-5942B Copyright PEPPERL+FUCHS • Printed in Germany 06/2018...