1. Manuals
  2. Brands
  3. TGW Manuals
  4. Control Unit
  5. CRUZCONTROL GENERATION 2 FOR NBC
  6. Installation, operation & maintenance manual

TGW CRUZCONTROL GENERATION 2 FOR NBC Installation, Operation & Maintenance Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

I
, O
, M
NSTALLATION
PERATION
AINTENANCE
M
ANUAL
CRUZ
®
CONTROL
G
2
NBC™
ENERATION
FOR
P/N: 1118211
Revision Date: May 31, 2019

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the CRUZCONTROL GENERATION 2 FOR NBC and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for TGW CRUZCONTROL GENERATION 2 FOR NBC

  • Page 1 NSTALLATION PERATION AINTENANCE ANUAL CRUZ ® CONTROL NBC™ ENERATION P/N: 1118211 Revision Date: May 31, 2019...

  • Page 2: Table Of Contents

    IOM CRUZcontrol® Generation2 for NBC ABLE OF ONTENTS TABLE OF CONTENTS .............................2 TABLE OF FIGURES ..............................3 TABLE OF TABLES ..............................4 CHAPTER 1: IOM INTRODUCTION ..........................5 CHAPTER 2: TGW SYSTEMS POLICIES.........................6 CHAPTER 3: SAFETY RECOMMENDATIONS ......................7 3.1: CRUZ ........................8 CONTROL OGIC AUTIONS 3.2: TGW S...

  • Page 3: Table Of Figures

    IOM CRUZcontrol® Generation2 for NBC ABLE OF IGURES Figure 1: Basic Concept Layout ......................15 Figure 2: Logic Assembly Mode & Alignment ..................18 Figure 3: Function Modules......................... 27 Figure 4: Full Function Module Board Layout ..................28 Figure 5: Full Function Module Circuit ....................28 Figure 6: Release Function Board Layout ...................

  • Page 4: Table Of Tables

    IOM CRUZcontrol® Generation2 for NBC ABLE OF ABLES Table 1: Logic Assemblies Functions ....................19 Table 2: Logic Assemblies Part Numbers ................... 19 Table 3: Function Module Functions ....................20 Table 4: Function Module Part Numbers ..................... 27 Table 5: Maximum Number of Logic Modules per String ..............31 Table 6: Power Supply Part Numbers ....................

  • Page 5: Chapter 1: Iom Introduction

    Chapter 1: IOM I NTRODUCTION IOM Purpose Manual Structure It is the intent of TGW Systems, through this You s h o u l d receive a separate manual, to provide information that acts as a documentation for each product line of TGW guide in the installation, operation, and Systems implemented in your installation.

  • Page 6: Chapter 2: Tgw Systems Policies

    Failure to comply with these guidelines will void 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 7: Chapter 3: Safety Recommendations

    A safety risk evaluation is required for all of our standard equipment. The safety risk evaluation TGW agrees to the following safety instruction or considers every potential hazard on the conveyor, guidelines listed within this manual. This is not to weighs the probability and the severity of the potential conflict with your state or legal requirements.

  • Page 8: Cruz Control Ogic Autions

    IOM CRUZcontrol® Generation2 for NBC 3.1: CRUZ CONTROL OGIC AUTIONS CAUTION 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 9: Tgw Systems Recommended Standards For Conveyors

    TGW recognizes American National Standard Institute (ANSI) booklet entitled Safety Standards for Conveyors and Related TGW recommends these videos for training and education Equipment B20.1. For more information go to: purposes as part of a safe working environment around conveyor http://webstore.ansi.org/default.aspx...

  • Page 10: Tgw Recommends Proper Labels For Conveyor Types

    IOM CRUZcontrol® Generation2 for NBC 3.3: TGW R ECOMMENDS ROPER ABELS FOR ONVEYOR YPES Shown below are some samples of labels applicable to conveyor standards. P/N: 1118211 Revision Date: 05/31/2019 Page 10 of 66...

  • Page 11: Warnings And Safety Instructions

    WARNING Your TGW Systems conveyor is powered by a motor and can be stopped only by turning off electrical power to the motor. As with all Indicates a potentially hazardous •...

  • Page 12: 3.4.1: Warnings And Safety Instructions

    Never remove, deface, or paint over WARNING or CAUTION labels. Any damaged label • will be replaced by TGW Systems at no cost by contacting Lifetime Services. It is very important to instruct personnel in proper conveyor use including the location •...
  • Page 13 IOM CRUZcontrol® Generation2 for NBC WARNING Before servicing or performing any work in the motor control panel, disconnect • and lock out air and the main incoming service. If only the panel disconnect is off, the incoming side will still be hot. P/N: 1118211 Revision Date: 05/31/2019 Page 13 of 66...

  • Page 14: Definition O F Terms

    IOM CRUZcontrol® Generation2 for NBC 3.5: D EFINITION ERMS Logic Assembly The logic assembly is to setup the type of automatic accumulation and discharge of product on the conveyor. Function Module The function module provides electrical isolation for external signals used to control a CRUZcontrol system.

  • Page 15: Chapter 4: Cruzcontrol Concept

    IOM CRUZcontrol® Generation2 for NBC Chapter 4: CRUZ CONTROL ONCEPT The CRUZcontrol product line is a set of components used to setup accumulation and discharge on NBC conveyor. It consists of logic modules that detect product that control accumulation, function modules that release product, and 24VDC power supplies.

  • Page 16: Cruz Control Logic Types

    IOM CRUZcontrol® Generation2 for NBC 4.1: CRUZ CONTROL OGIC YPES The following describes the differences between the two logic alternatives. The descriptions as written more closely describe product movement on NBC-N non-contact accumulation conveyor, where accumulated product is brought to a full stop. NBC-C conveyor, where a stopped zone does not have brakes but becomes gravity flow, will have very different product flow characteristics.

  • Page 17: Progressive Logic

    IOM CRUZcontrol® Generation2 for NBC 4.3: P ROGRESSIVE OGIC Accumulation in Progressive Logic Mode A zone is not set to accumulate product until all downstream zones hold accumulation product. Note that with Progressive Logic products being transported on the conveyor can remain tightly packed, without any gaps being created.

  • Page 18: Cruz Control Omponents

    IOM CRUZcontrol® Generation2 for NBC 4.4: CRUZ CONTROL OMPONENTS CRUZcontrol LOGIC ASSEMBLY The CRUZcontrol Logic Assembly consists of a polarized retro-reflective type photoelectric sensor, pneumatic valve and logic module integrated into one assembly. The photoelectric sensor will function reliably on conveyor widths up to 34 inches between frames. The sensor is polarized, and is not affected by shiny surfaces.

  • Page 19: Table 1: Logic Assemblies Functions

    IOM CRUZcontrol® Generation2 for NBC 4.5: L OGIC SSEMBLY YPES The CRUZcontrol Logic Assembly 1114947 provides an “air to brake” logic output utilizing a normally open pneumatic valve. The pneumatic valve is energized for a zone to be running. The CRUZcontrol Logic Assembly 1114948 provides an “air to drive” logic output utilizing a normally closed pneumatic valve.

  • Page 20: Function Modules

    IOM CRUZcontrol® Generation2 for NBC 4.6: F UNCTION ODULES The Function Module provides electrical isolation for external controls and creates controllable zones to facilitate CRUZcontrol applications. Function Module Types There are two different Function Modules, each providing certain of functions. Table 3: Function Module Functions Single Slug...
  • Page 21 IOM CRUZcontrol® Generation2 for NBC Slug Release Definition All zones that are connected in one continuous string release at the same time regardless of zone status. All zones will continue to release until the release signal is removed. Configuration The logic assemblies can be in basic or progressive mode. When releasing from the discharge end of the conveyor line all jumper terminals should be on pins 1-2.
  • Page 22 IOM CRUZcontrol® Generation2 for NBC Pulse Release Definition Upstream Logic Assembly releases for a length of time set by ZS ON (0-20s) and then accumulates for length of time set by ZS OFF (0-20s). Configuration When releasing from the discharge end of the conveyor line jumper terminal JP3, NC - all other jumper terminals should be on pins 1-2.
  • Page 23 IOM CRUZcontrol® Generation2 for NBC Zone Status Indication Definition Indicates full or empty status of the downstream zone on TB3. Configuration JP4, 1-2 and JP5, 1-2 for logic status or 2-3 for sensor status, all other jumper terminals should be on pins 1-2. User Action Connect to TB3 for zone status.

  • Page 24: Terminal And Jumper Descriptions

    IOM CRUZcontrol® Generation2 for NBC 4.7: T ERMINAL AND UMPER ESCRIPTIONS Terminal Descriptions Single release, Logic interrupt, Pulse release. This terminal is an isolated input; it must be used when signal voltage is from a supply that is different than the supply powering CRUZcontrol logic assemblies. It can be used when signal voltage is from same power supply that is powering CRUZcontrol logic assemblies.
  • Page 25 IOM CRUZcontrol® Generation2 for NBC Jumper Descriptions Downstream slug control Pins 1-2 = slug pass through Pins 2-3 = slug interrupt Pins 3-4 = slug interrupt Pins 4-5 = singulation to slug crossover Pins NC = slug interrupt Upstream slug control Pins 1-2 = slug pass through Pins 2-3 = slug interrupt Pins NC = slug interrupt...

  • Page 26: 1: Use Of 115Vac Controls

    IOM CRUZcontrol® Generation2 for NBC 4.8: U SE OF ONTROLS 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. Function Module signal inputs are protected against 500 volt spikes.

  • Page 27: Figure 3: Function Modules

    IOM CRUZcontrol® Generation2 for NBC Function Module Part Numbers Table 4: Function Module Part Numbers Part Number Description 1116731 Full Function Module 1116732 Release Function Module Figure 3: Function Modules P/N: 1118211 Revision Date: 05/31/2019 Page 27 of 66...

  • Page 28: Figure 4: Full Function Module Board Layout

    IOM CRUZcontrol® Generation2 for NBC Figure 4: Full Function Module Board Layout Figure 5: Full Function Module Circuit P/N: 1118211 Revision Date: 05/31/2019 Page 28 of 66...

  • Page 29: Figure 6: Release Function Board Layout

    IOM CRUZcontrol® Generation2 for NBC Figure 6: Release Function Board Layout P/N: 1118211 Revision Date: 05/31/2019 Page 29 of 66...

  • Page 30: Figure 7: Release Function Module Circuit

    IOM CRUZcontrol® Generation2 for NBC Figure 7: Release Function Module Circuit P/N: 1118211 Revision Date: 05/31/2019 Page 30 of 66...

  • Page 31: Chapter 5: Power Supplies

    IOM CRUZcontrol® Generation2 for NBC Chapter 5: P OWER UPPLIES A 24VDC power supply is needed to power the logic assemblies and the function modules. One power T cable is prewired to the power supply. The power supply is available in 120VAC or 480VAC versions. Power Supply Requirements CRUZcontrol operates from a Class 2 power supply voltage of 24-28VDC.

  • Page 32: Power Supply Wiring

    IOM CRUZcontrol® Generation2 for NBC 5.1: P OWER UPPLY IRING 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 33: One Power Supply Used To Power Two Separate Cruz Control Sections

    IOM CRUZcontrol® Generation2 for NBC 5.2: O OWER UPPLY USED TO POWER TWO SEPARATE CRUZ CONTROL SECTIONS This drawing illustrates the use of one power supply to power two separate, short CRUZcontrol sections on two different conveyors. This can be done to make better use of the full capacity of a power supply.

  • Page 34: Sing Two

    0VDC are connected to pass the signals through uninterrupted. Figure 10: One CRUZcontrol Section with Two Power Supplies Power Supply Part Numbers Table 6: Power Supply Part Numbers TGW Systems Part Number Description Kit Part Number 1117972...

  • Page 35: Cruz Control Technical Data

    IOM CRUZcontrol® Generation2 for NBC 5.4: CRUZ CONTROL ECHNICAL CRUZcontrol Power Supply Specification P/N: 1118211 Revision Date: 05/31/2019 Page 35 of 66...

  • Page 36: Ccessories

    IOM CRUZcontrol® Generation2 for NBC 5.5: A CCESSORIES Auxiliary Photoelectric Sensor 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 37: Figure 11: Discharge Logic Control

    IOM CRUZcontrol® Generation2 for NBC Extension Cables The following extension cables are available to meet application requirements where longer zone lengths or skipped zones must be accommodated. Each cable has 4 conductors, with male and female 2X2 connector ends. Table 10: Extension Cables Part Number Description 1117372...

  • Page 38: Table 11: Discharge Logic Assembly

    IOM CRUZcontrol® Generation2 for NBC The following hardware listing is for two Discharge Logic Assembly kits consisting of the Discharge Logic Assembly, a reflector, and mounting brackets. The mounting brackets provide for the mounting of the Discharge Logic Assembly and reflector either ½ inch or 3 inches above a standard CRUZ side channel.

  • Page 39: Chapter 6: Cruzcontrol On Site Installation

    IOM CRUZcontrol® Generation2 for NBC Chapter 6: CRUZ CONTROL NSTALLATION 6.1: P INSTALLED ON THE CONVEYOR The CRUZcontrol Logic Assemblies are installed on the side channel of the conveyor bed. • The air supply tubing for the conveyor is plumbed the length of the conveyor bed, passing •...

  • Page 40: Figure 12: Logic Assembly

    IOM CRUZcontrol® Generation2 for NBC Figure 12: Logic Assembly P/N: 1118211 Revision Date: 05/31/2019 Page 40 of 66...

  • Page 41: 6.3: Conveyor Flow

    IOM CRUZcontrol® Generation2 for NBC 6.3: CONVEYOR FLOW The standard wiring is for left hand flow conveyors, for right hand flow conveyors the wiring direction will be reversed. Figure 13: Left Hand Flow Figure 14: Right Hand Flow P/N: 1118211 Revision Date: 05/31/2019 Page 41 of 66...

  • Page 42: 6.3.1: Examples

    IOM CRUZcontrol® Generation2 for NBC 6.3.1: Examples This guideline provides various suggestions on how to apply CRUZcontrol to meet some specific control requirements. Example 1: Applying Progressive CRUZcontrol While this example is based specifically on contact accumulation NBC-C, the principals covered also apply to non-contact accumulation conveyor NBC-N.
  • Page 43 IOM CRUZcontrol® Generation2 for NBC Example 2: Progressive Logic Accumulation Release Control CRUZcontrol Logic Assemblies set to Progressive Logic mode provide for high throughput rates and efficient release, compared to Basic Logic mode. In simple terms, Basic Logic tries to create zone length gaps in the flow of product, where as Progressive Logic allows product to flow without creating gaps.

  • Page 44: Figure 15: Isolated Input Single Release

    IOM CRUZcontrol® Generation2 for NBC Example 3: Releasing from CRUZcontrol Releasing from CRUZcontrol Problem Releasing Accumulated Product Solution When using CRUZcontrol the product will automatically accumulate. A signal must be given to the function module to get it to release. Configuration Plug Function module into discharge zone.

  • Page 45: Figure 16: Non-Isolated Input Single Release

    IOM CRUZcontrol® Generation2 for NBC Figure 16: Non-Isolated Input Single Release P/N: 1118211 Revision Date: 05/31/2019 Page 45 of 66...
  • Page 46 IOM CRUZcontrol® Generation2 for NBC Example 4: CRUZcontrol around a curve. (Low rate) CRUZcontrol around a curve – Low Rate Problem Product releasing into a curve then not having a zone to occupy. This situation occurs because it takes longer for product to go from zone 2 to zone 1 than it does for product to go from zone 3 to zone 2.

  • Page 47: Figure 17: Cruzcontrol Around A Curve (Low Rate)

    IOM CRUZcontrol® Generation2 for NBC Figure 17: CRUZcontrol around a curve (low rate) P/N: 1118211 Revision Date: 05/31/2019 Page 47 of 66...
  • Page 48 IOM CRUZcontrol® Generation2 for NBC Example 5: CRUZcontrol around a curve. (High rate) CRUZcontrol around a curve – High Rate Problem Product releasing into a curve then not having a zone to occupy. This situation occurs because it takes longer for product to go from zone 5 to zone 4 than it does for product to go from zone 6 to zone 5.
  • Page 49 IOM CRUZcontrol® Generation2 for NBC Note that stopping the release of product as done in this example could result in a product left partially on the powered curve with the trailing end on the stopped discharge end of the accumulation conveyor. If this is a concern, a photo sensor should be added to the discharge zone, with appropriate logic to insure that no products are stopped partially released.

  • Page 50: Figure 18: Cruzcontrol Around A Curve. (High Rate)

    IOM CRUZcontrol® Generation2 for NBC Figure 18: CRUZcontrol around a curve. (High rate) Figure 19: Function Module Wiring P/N: 1118211 Revision Date: 05/31/2019 Page 50 of 66...

  • Page 51: Figure 20: Work Zone

    IOM CRUZcontrol® Generation2 for NBC Example 6: Creating a work zone Creating a work zone Problem Creating a work zone in the middle of a section of CRUZcontrol Solution Use the release function module and interrupt the downstream logic to start accumulation.
  • Page 52 IOM CRUZcontrol® Generation2 for NBC Example 7: NBC-C accumulation release to NBC-N conveyor NBC-C accumulation release to NBC-N conveyor Problem Creating line pressure when feeding a slower conveyor Solution Use logic assembly as a discharge logic assembly Configuration Place Discharge Logic Assembly (DLA) downstream of conveyor discharge zone. Set mode to basic.
  • Page 53 IOM CRUZcontrol® Generation2 for NBC Discharge Logic Assembly P/N: 1118211 Revision Date: 05/31/2019 Page 53 of 66...
  • Page 54 IOM CRUZcontrol® Generation2 for NBC 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: Operation

    IOM CRUZcontrol® Generation2 for NBC 6.4: O PERATION The Product Present Photosensor is connected to a PLC (programmable logic controller). The Photosensor is used to sense if product is accumulated behind the Product Stop, ready to be released. The Photosensor is also used to sense a gap in the flow of product adequate enough to raise the Product Stop after releasing product from the lane.

  • Page 56: Chapter 7: Logic Assembly Specifications

    IOM CRUZcontrol® Generation2 for NBC Chapter 7: L OGIC SSEMBLY PECIFICATIONS Logic Assembly Figure - Logic Module Table - Logic Module Mechanical Specification Maximum Height 3.35 in. (85.1 mm) Maximum Width 2.5 in. (63.5 mm) Maximum Depth 1.25 in. (32 mm) Daisy Chain Cable Length Downstream - 28 in.
  • Page 57 IOM CRUZcontrol® Generation2 for NBC Color Back cover and manifold - Black; Front cover - PMS 420 Mounting Twin Keyhole (same as current module) Ambient Temperature – Operating +14…122°F (-10…+50C) Ambient Temperature – Storage -40…158°F (-40…+70C) P/N: 1118211 Revision Date: 05/31/2019 Page 57 of 66...
  • Page 58 IOM CRUZcontrol® Generation2 for NBC Table - Logic Module Electrical Specification Supply Voltage 24 VDC (-20%/+15%) Voltage Drop per Module Current Consumption Maximum Logic Output Current 100 mA Response Time <2.5 ms Switching Frequency 200 Hz Maximum # of Logic Modules per String End Tap (95W, 24Vs) - 4 ft.
  • Page 59 IOM CRUZcontrol® Generation2 for NBC Figure - Sensor Table - Sensor Optical Specification Sensor Model ZL2-P2400S04 Sensor Part Number 2048176 Sensor Type Reflex, Polarized Switching Logic Light operate Light Source Red LED Output Indicator Amber Power Indicator Green Life Expectancy 100,000 hours @ 77°F (25C) Light Spot Diameter 4.9 in.
  • Page 60 IOM CRUZcontrol® Generation2 for NBC Table - Sensor Electrical Specification Supply Voltage 10…30 VDC Ripple <5 Vss Current Consumption <20 mA (without load) Output Current Max. 50 mA Response Time <1.25 ms Switching Frequency 400 Hz Cable Length 28 in. (711mm), ±1 in. Connection to Logic Module Hard-wire on the Downstream side Ambient Temperature –...
  • Page 61 IOM CRUZcontrol® Generation2 for NBC Figure – Logic Module Wiring Pin 1(+24Vdc VDC) Brown Female Male Connector Pin 4 (0V) Blue Connector Pin 3 (Logic) White Pin 2 (Slug) Black Logic Module Housing Product Flow P/N: 1118211 Revision Date: 05/31/2019 Page 61 of 66...
  • Page 62 IOM CRUZcontrol® Generation2 for NBC Function Module Specifications P/N: 1118211 Revision Date: 05/31/2019 Page 62 of 66...

  • Page 63: Function Module Technical Data

    IOM CRUZcontrol® Generation2 for NBC 7.1: F UNCTION ODULE ECHNICAL Table – Full Function Module Specification Technical Data Interface to CRUZcontrol Upstream connection Male, 2X2, 4-PIN, 300 mm cable Downstream connection Female, 2X2, 4-PIN, 300 mm cable Power Supply voltage from daisy chain 18…30 VDC Power consumption of ZIM 10 mA, no load...
  • Page 64 IOM CRUZcontrol® Generation2 for NBC Technical Data Interface to CRUZcontrol Upstream connection Male, 2X2, 4-PIN, 300 mm cable Downstream connection Female, 2X2, 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 65: Works Cited

    IOM CRUZcontrol® Generation2 for NBC ORKS ITED SICK. (2019). Sick Sensor Intelligence. Retrieved from https://www.sick.com/us/en/search?text=power- supply TGW G ENERAL NFORMATION TGW Website Link: www.tgw-conveyor.com TGW Maintenance Videos: https://www.tgw-conveyor.com/media-center/maintenance-videos TGW Product Videos: https://www.tgw-conveyor.com/media-center/video-gallery 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...

  • Page 66: Tgw Systems Information

    NFORMATION 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.

Table of Contents