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

Page: 2 / 66

IOM CRUZcontrol® Generation2 for NBC

P/N: 1118211

Revision Date: 05/31/2019

Page

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

......................................................................................................................8

...........................................................................9

.......................................................................... 10

........................................................................................................... 11

3.4.1: Warnings and Safety Instructions .......................................................................................................... 12

3.5:

EFINITION

ERMS

.................................................................................................................................... 14

CHAPTER 4: CRUZCONTROL CONCEPT ........................................................................................................... 15

......................................................................................................................... 16

4.2:

ASIC

OGIC

................................................................................................................................................... 16

4.3:

ROGRESSIVE

OGIC

...................................................................................................................................... 17

........................................................................................................................ 18

4.5:

UNCTION

ODULES

....................................................................................................................................... 20

............................................................................................................ 24

4.6.1: Use of 115vac Controls ......................................................................................................................... 26

CHAPTER 5: POWER SUPPLIES .......................................................................................................................... 31

.................................................................................................................................. 32

5.2:

OWER

UPPLY USED TO POWER TWO SEPARATE

CRUZ

CONTROL SECTIONS

............................................ 33

5.3:

SING TWO

OWER

UPPLIES TO POWER ONE EXTENDED

CRUZ

CONTROL SECTION

.......................................... 34

................................................................................................................... 35

5.5:

CCESSORIES

................................................................................................................................................. 36

CHAPTER 6: CRUZCONTROL ON SITE INSTALLATION ................................................................................... 39

6.1:

INSTALLED ON THE CONVEYOR

.................................................................................................................. 39

6.2:

IELD

NSTALLATION

........................................................................................................................................ 39

6.3:

ONVEYOR

LOW

........................................................................................................................................... 41

6.3.1: Examples ............................................................................................................................................... 42

6.4:

PERATION

..................................................................................................................................................... 55

CHAPTER 7: LOGIC ASSEMBLY SPECIFICATIONS .......................................................................................... 56

.............................................................................................................. 63

WORKS CITED ....................................................................................................................................................... 65

TGW

ENERAL

NFORMATION

................................................................................................................................ 65

TGW SYSTEMS INFORMATION ............................................................................................................................ 66

Summary of Contents for CRUZCONTROL GENERATION 2 FOR NBC

Page 1: ...INSTALLATION OPERATION MAINTENANCE MANUAL CRUZCONTROL GENERATION 2 FOR NBC P N 1118211 Revision Date May 31 2019...

Page 2: ...L LOGIC TYPES 16 4 2 BASIC LOGIC 16 4 3 PROGRESSIVE LOGIC 17 4 4 CRUZCONTROL COMPONENTS 18 4 5 FUNCTION MODULES 20 4 6 TERMINAL AND JUMPER DESCRIPTIONS 24 4 6 1 Use of 115vac Controls 26 CHAPTER 5 POW...

Page 3: ...8 Two Logic Assemblies using a T Cable 32 Figure 9 Two Separate CRUZcontrol Sections 33 Figure 10 One CRUZcontrol Section with Two Power Supplies 34 Figure 11 Discharge Logic Control 37 Figure 12 Log...

Page 4: ...gic 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 34 T...

Page 5: ...herefore this manual is to be used ONLY as a guide If additional copies of this manual are needed or if you have any question concerning the conveyor please contact your TGW Distributor or TGW Lifetim...

Page 6: ...uipment being installed handled operated and maintained in accordance with the written instructions provided or approved in writing by TGW Systems The warranties specified above do not cover and TGW S...

Page 7: ...stored energy and OSHA Safety and Health Regulations for Construction 1926 555 Conveyors https www osha gov Conveyor Design and Safety Guidelines A safety risk evaluation is required for all of our st...

Page 8: ...is a jam since in the release mode progressive ignores the photo sensors and dumps all the zones at once in the same way slug discharge operates In the progressive release mode for contact accumulati...

Page 9: ...load the Conveyor beyond specified design limits DO NOT attempt to make repairs to the Conveyor while it is running DO NOT modify equipment without checking with the manufacturer DO NOT operate or per...

Page 10: ...RUZcontrol Generation2 for NBC P N 1118211 Revision Date 05 31 2019 Page 10 of 66 3 3 TGW RECOMMENDS PROPER LABELS FOR CONVEYOR TYPES Shown below are some samples of labels applicable to conveyor stan...

Page 11: ...electrical power to the motor As with all powered machinery the drive related components including sprockets chains shafts universal joints and pneumatic devices can be dangerous We have installed or...

Page 12: ...ch side of all conveyor units for safe adjustment and maintenance of all components Provide crossovers or gates at sufficient intervals where needed to eliminate the temptation for personnel to climb...

Page 13: ...1 Revision Date 05 31 2019 Page 13 of 66 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 of...

Page 14: ...o power on the logic line ON On indicates a logical high signal and or powered For example if a slug line is ON then there is power on the slug line Zone status The zone is considered full if the loca...

Page 15: ...cables to ease installation and interfacing CRUZcontrol is a 24VDC system that will automatically start accumulation when product reaches the end of an accumulation line When a release signal is appl...

Page 16: ...he transportation throughput capacity of the conveyor The rate at which product is introduced onto an accumulation conveyor of this type must not exceed the transportation capacity of the conveyor Sin...

Page 17: ...transported on the conveyor can remain tightly packed without any gaps being created Discharge from Progressive Logic Progressive mode only allows slug release All zones connected together will be ac...

Page 18: ...es The sensor is polarized and is not affected by shiny surfaces On NBC applications the reflector is mounted with a 6 inch offset from the photoelectric sensor so that the sensor scans across the con...

Page 19: ...ogic Assembly comes with a momentary button on the front of the housing allowing for selection of either Basic Logic or Progressive Logic mode A Mode LED indicates either Basic green or Progressive am...

Page 20: ...Slug Interrupt Zone Status Full Function Module x x x x x x x x Release Function Module x x x x x Function Module Functions Single Release Definition Only the discharge zone releases when the discharg...

Page 21: ...ase 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 User...

Page 22: ...sing TB4 to release set jumper terminal JP4 2 3 User Action Apply a high signal to TB1 24Vdc 120Vac or TB4 24Vdc No action required Zone Delay Definition After the downstream zone clears the upstream...

Page 23: ...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 The output transition of the Zone Status from OFF...

Page 24: ...n the supply powering CRUZcontrol logic assemblies It can be used when signal voltage is from same power supply that is powering CRUZcontrol logic assemblies TB3 Zone Status TB3 only available on full...

Page 25: ...rrupt JP2 Upstream slug control Pins 1 2 slug pass through Pins 2 3 slug interrupt Pins NC slug interrupt JP3 Release control at TB1 Pins 1 2 single release Pins 2 3 logic interrupt Pins NC pulsed rel...

Page 26: ...f suitable MOV s would include Panasonic ERZV07D241 or Littlefuse V250LA2 Long conduit runs with motor wiring for multiple motors and the use of variable frequency drives all contribute to electrical...

Page 27: ...NBC P N 1118211 Revision Date 05 31 2019 Page 27 of 66 Function Module Part Numbers Table 4 Function Module Part Numbers Part Number Description 1116731 Full Function Module 1116732 Release Function M...

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

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

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

Page 31: ...maximum number of Logic Assemblies that can be in one continuous string based on the cable length and power requirement of Logic Assemblies More than one string of Logic Assemblies can be connected to...

Page 32: ...e 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 sign...

Page 33: ...e of the full capacity of a power supply It could be necessary to extend the T Cable leads to reach the power supply location This should be done with a wire gauge large enough to prevent noticeable v...

Page 34: ...e of a Power Interrupt Cable The VDC line is not passed through while the Slug Release and Singulation Release Signals as well as 0VDC are connected to pass the signals through uninterrupted Figure 10...

Page 35: ...IOM CRUZcontrol Generation2 for NBC P N 1118211 Revision Date 05 31 2019 Page 35 of 66 5 4 CRUZCONTROL TECHNICAL DATA CRUZcontrol Power Supply Specification...

Page 36: ...le which include the photoelectric sensor and appropriate bracket Even though not normally needed an extra reflector and adhesive mounting tape is also included with each kit The 10 30 VDC photo senso...

Page 37: ...connections made to the valve section of the Logic Assembly When used this way the added Logic Assembly is known as the Discharge Logic Assembly DLA The Discharge Logic Assembly is mounted on the char...

Page 38: ...ing brackets provide for the mounting of the Discharge Logic Assembly and reflector either inch or 3 inches above a standard CRUZ side channel Since every application is different there will usually b...

Page 39: ...lectric sensors are tested to insure proper alignment with the reflectors as well as proper functioning of the Logic Assemblies 6 2 FIELD INSTALLATION Bed to bed connections Connection of air supply t...

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

Page 41: ...N 1118211 Revision Date 05 31 2019 Page 41 of 66 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 Lef...

Page 42: ...e Progressive Logic mode CRUZcontrol can t function properly due to product not blocking one or more of the photoelectric sensors This would probably be the most common cause of excessive line pressur...

Page 43: ...o require the speed to be above 100 feet per minute 2 The release of product from the accumulation conveyor could be logically controlled so as to limit the release rate If the NBC C running at 180 fe...

Page 44: ...omatically accumulate A signal must be given to the function module to get it to release Configuration Plug Function module into discharge zone All jumpers are set to pins 1 2 Give function module a r...

Page 45: ...IOM CRUZcontrol Generation2 for NBC P N 1118211 Revision Date 05 31 2019 Page 45 of 66 Figure 16 Non Isolated Input Single Release...

Page 46: ...100 potentiometer to delay the release signal from zone 2 to 3 until product has reached zone 1 Operation Carton flow from zone 3 to zone 2 to zone 1 occurs as normal When a carton first clears the zo...

Page 47: ...IOM CRUZcontrol Generation2 for NBC P N 1118211 Revision Date 05 31 2019 Page 47 of 66 Figure 17 CRUZcontrol around a curve low rate...

Page 48: ...S off R102 potentiometers Range is from 0 20seconds A normal operating range would be about 3 seconds each depending on the speed of the conveyor Wire photoelectric sensor to TB4 Blue wire TB4 1 0VDC...

Page 49: ...le 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...

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

Page 51: ...the downstream logic to start accumulation Configuration When using TB1 to interrupt the logic set jumper terminal JP3 2 3 When using TB4 to interrupt the logic set jumper terminal JP4 2 3 User Actio...

Page 52: ...interface the CRUZcontrol operation with the induction conveyor operation since the functioning of it is based solely on product movement NBC C conveyor when accumulating and subsequently releasing ac...

Page 53: ...IOM CRUZcontrol Generation2 for NBC P N 1118211 Revision Date 05 31 2019 Page 53 of 66 Discharge Logic Assembly...

Page 54: ...cumulation control which accumulates and discharges from accumulation with only very minimal gaps between products The following illustrates an NBC C accumulation lane used to release product to a mer...

Page 55: ...solenoid is also connected to Function Module 1 When the Product Stop is raised solenoid and Function Module not energized product blocking the Photosensor of the CRUZcontrol Logic Assembly will resu...

Page 56: ...63 5 mm Maximum Depth 1 25 in 32 mm Daisy Chain Cable Length Downstream 28 in 711 mm Upstream 28 in 711 mm 1 in Daisy Chain Wire Gauge 22 AWG Daisy Chain Connection Type Overmolded 2x2 Downstream Fem...

Page 57: ...1118211 Revision Date 05 31 2019 Page 57 of 66 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 Ambie...

Page 58: ...VDC 20 15 Voltage Drop per Module TBD Current Consumption TBD 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...

Page 59: ...on 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...

Page 60: ...VDC Duty Cycle 100 Life Expectancy 100 million cycles Input Air Connection 3 8 in 9 5mm barbed fitting Output Air Connection 1 4 in 6mm barbed fitting Operating Mode2 N O Air to Brake Air supply Non...

Page 61: ...or NBC P N 1118211 Revision Date 05 31 2019 Page 61 of 66 Figure Logic Module Wiring 2x2 Female Connector Pin 2 Slug Pin 3 Logic Pin 1 24Vdc VDC Pin 4 0V Black White Brown Blue Product Flow Logic Modu...

Page 62: ...IOM CRUZcontrol Generation2 for NBC P N 1118211 Revision Date 05 31 2019 Page 62 of 66 Function Module Specifications...

Page 63: ...1 Guaranteed OFF Voltage 4 UC Guaranteed ON Voltage 15 0 VDC Typical ON state current draw 2 5 mA TB2 Slug Release input1 18 250 UC1 Guaranteed OFF Voltage 4 UC Guaranteed ON Voltage 15 0 VDC Typical...

Page 64: ...t1 18 250 UC1 Guaranteed OFF Voltage 4 UC Guaranteed ON Voltage 15 0 UC Typical ON state current draw 2 5 mA TB2 Slug Release input1 18 250 UC1 Guaranteed OFF Voltage 4 UC Guaranteed ON Voltage 15 0 U...

Page 65: ...oduct 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 tg...

Page 66: ...nveyor systems and equipment since 1964 TGW Systems provides sorters conveyors and accessories to satisfy a broad spectrum of accumulation transportation and sortation applications TGW Systems Inc 130...

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