TGW CRUZcontrol Installation, Operation & Maintenance Manual Download Page 11

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IOM CRUZcontrol®

P/N: 90480009

Revision Date: 03/18/2019

Page

Conveyor Flow

(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:

•

Connection of Air Supply air tubing between conveyor beds, closing and terminating the

ends of the Air Supply tubing, and providing the air supply to the conveyor.

•

Connection of the Logic Assembly interconnection cables from the last zone of a conveyor

bed to the first zone in the next upstream conveyor bed.

•

Providing a suitable 24 VDC power supply and connecting it into the string of Logic

Assemblies.

•

Providing a Singulation Release signal for the discharge zone (using Function Module).

•

Providing a Slug Release signal for the discharge zone, if required (using Function

Module).

•

Obtaining Zone Status indications as required for system control (using Function Module).

•

Terminating unconnected M12 cable ends with Termination Plugs. This is suggested to

protect the cable ends from damage.

•

Adding auxiliary photoelectric sensors as required for discharge and full line condition

sensing.

TGW Systems Part No.

Description

90139992

Male M12 Termination Plug (use for terminating male cable

ends)

90139994

Female M12 Termination Plug (use for terminating female

cable ends)

Photoelectric

Sensor

Logic

Module

Air Supply

Zone Control

Air

Zone Control

Air

Logic Assembly

Interconnection Cable from

downstream zone

(Shown disconnected from

Logic Module Assembly)

Logic Assembly

Interconnection

Cable to upstream

zone.

Summary of Contents for CRUZcontrol

Page 1: ...INSTALLATION OPERATION MAINTENANCE MANUAL CRUZcontrol For NBA and XP43 IOM P N 90480009 Revision Date March 18 2019 ...

Page 2: ...tion Modules 21 Full Function Module 1138074 22 Release Function Module E0006305 30 Zone Status Function Module E0006306 36 Logic Truth Tables 39 Generation 2 Function Modules Definitions 41 Warnings and Cautions 41 Discharge Logic Assembly 42 NBA 23 Brake Control 43 Auxiliary Photoelectric Sensors 43 Reflectors 44 Sensor Valve Assemblies 44 Extension Cables 44 TGW Systems Controls Guidelines See ...

Page 3: ...arrangements preventive maintenance and assists in replacement parts identification This service manual is intended for use by personnel who are knowledgeable of installation and safe working practices on conveyor systems Not all applications and conditions can be covered therefore this manual is to be used as a guide only If additional copies of this manual are needed or if you have any question ...

Page 4: ...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 Systems makes no warranties which extend to damage to the equipment due to deterioration or wear occasioned by chemicals abrasion corrosion or erosion Purchaser s misapplication abuse alteration operation or mainten...

Page 5: ...nveyor should never be operated at greater than 14 psi There are four different CRUZcontrol Logic Assemblies TGW Systems Part No CRUZcontrol Logic Assemblies Description E0001900A Basic Logic XenoROL E0001901A Basic Logic NBA 23 E0001904A Progressive Logic XenoROL E0001905A Progressive Logic NBA 23 The NBA CRUZcontrol Logic Assembly provides an air to drive logic output utilizing a normally closed...

Page 6: ...veyor Discharge from Basic Logic A Singulation Release signal given to the Zone 1 Logic Assembly releases product from that zone As released product clears a photoelectric sensor the product stopped at the next upstream zone is released This will create a one zone length gap between all released products assuming conveyor speeds accumulation conveyor and downstream conveyor are identical If the li...

Page 7: ...signal given to the Zone 1 Logic Assembly releases product from that zone Each successive upstream zone will also begin releasing product but with a two tenths of a second release delay from each zone to the next upstream zone This will create a small gap between released products depending on product sizes the number of products occupying each accumulation zone and the conveyor speed If the line ...

Page 8: ...me degree but with adequate speed and product weight the flowing product should coast through the basic zones without any appreciable effect on the throughput rate One exception is at the charge and discharge ends of a length of NBA 23 where the effects of using Basic Logic Assemblies on the throughput rate needs to be considered If there is a need to maximize throughput rates the use of all Progr...

Page 9: ... 67mA includes logic module MH sensor valve Response Time 2 5ms Connection M12 4 pin Single Key Pneumatic Valve Operating Pressure Range 0 116 psi 0 8 bar Ventilation capacity Qn 100 Nl min Cv 0 100 USGallon min Input Air Connection 3 8 in straight quick connects Output Air Connection in straight quick connect Operating Mode N O or N C two models The pneumatic valve has a small red lever controlli...

Page 10: ...plumbed the length of the conveyor bed passing through each Logic Assembly and provided with push in quick connectors at the ends of the conveyor bed The zone control air is plumbed from the Logic Assembly to the zone air pucks or cylinders The photoelectric sensors are mounted for each zone along with the reflector across the conveyor bed The photoelectric sensors are tested to insure proper alig...

Page 11: ...nto the string of Logic Assemblies Providing a Singulation Release signal for the discharge zone using Function Module Providing a Slug Release signal for the discharge zone if required using Function Module Obtaining Zone Status indications as required for system control using Function Module Terminating unconnected M12 cable ends with Termination Plugs This is suggested to protect the cable ends...

Page 12: ... ARE NO CONTROLS YOU NEED TO SUPPLY No full line photoeye is required following the curve No special gaps need to be forced between products entering the curve THERE IS NO INDEXING OR OTHER DEVICES MOTORS CONTROLS OR WIRING that need to be engineered or installed NOTE A roller brake is recommended at the discharge end of any NBA 23 accumulation conveyor preceding the curve to prevent coasting prod...

Page 13: ...M CRUZcontrol P N 90480009 Revision Date 03 18 2019 Page 13 of 58 1ST CURVE INTERMEDIATE BED 2ND CURVE 1ST CURVE 2ND CURVE 1ST CURVE INTERMEDIATE BED EXAMPLE C EXAMPLE B EXAMPLE A EXAMPLE OF UPSTREAM NBA ...

Page 14: ...om the power supply to the first Logic Assembly More than one string of Logic Assemblies can be connected to a power supply up to the maximum of 53 zones Power Supplies The following power supplies are available from TGW Systems Technical specifications for each are included with this manual TGW Systems Part No Description 1101825 100 250 VAC input Power Supply Kit including T cable and Mounting B...

Page 15: ...t 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 The Power Monitor contact output provides a contact closure indication of 24 VDC power output being on This is not required to operate CRUZcontrol 342 528 VAC 3 phase input Power Supply This power supply can be connect...

Page 16: ...emblies 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 T CABLE CONVEYOR FLOW 24 VDC POWER SUPPLY 24v 24 VDC Brown 0 VDC Blue ...

Page 17: ...f 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 TGW Systems Part Number Description 224 201 Connectors PS256ADAPT44B3 T Cable one is already provided with Po...

Page 18: ...he 24 volt line This drawing illustrates how to isolate the two strings making use of a Power Interrupt Cable The VDC line pin 1 is not passed through while the Slug Release and Singulation Release Signals as well as DC common 0 vdc are connected so as to pass the signals through uninterrupted TGW Systems Part Number Description ZPI P1 Power Interrupt Cable 8 inches long Last CRUZcontrol Logic Ass...

Page 19: ...unctions These Function Modules replace the previous Generation 1 1138074 Function Module The Release Function Module 1138075 should serve most application requirements A Function Module is shown connected to the most downstream or discharge Logic Assembly One cable from the Function Module does not need to be connected in this situation A Function Module can also be connected between Logic Assemb...

Page 20: ...g 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 Number of Function Modules 0 2 3 7 8 12 Maximum of Logic Module Assemblies per string 33 32 31 The Function Modules require 10mA of current at 24 VDC This needs to be considered as it will reduce the total number of Logic Modules that can be conn...

Page 21: ...ggestions of 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 noise with a good potential for high voltage spikes If there is any doubt the control signals to the Function Modules should be run in conduits separate from motor wiring The Function Modul...

Page 22: ...one status Configuration Apply a high ON signal input to TB1 when JP3 is on 1 2 OR a high ON signal input to TB4 when JP4 is on 1 2 Pulse Release Definition Upstream logic line oscillates between ON and OFF based on the Zone Status ON and Zone Status OFF potentiometer settings and disables normal operation of logic line signals Action Upstream Logic Assembly releases for a duration of time set by ...

Page 23: ...ty status of the downstream zone at two output locations Action Takes an input from one of several user selectable inputs process it through Zone Status ON Delay and Zone Status OFF Delay and outputs to the ZS Relay on TB3 and Zone Status Output on TB5 Configuration Choose the input that determines the zone s empty or full status Downstream logic signal identical to Downstream Sensor signal of a S...

Page 24: ...aw 2 5 mA Output ratings TB5 Logic output PNP 2 21 kohm impedance typical TB5 Zone Status output PNP 2 21 kohm impedance typical TB3 Zone Status Relay 2 250 UC max 100 mA max Resistive load2 Physical properties Terminal block Terminal block wire 30 to 12 AWG 2 5 0 2mm strip length 6 0 mm Screw terminal torque 5 in lbs 0 56 Nm Potentiometers Mechanical angle 270 nominal Stop strength 7 0 oz in mini...

Page 25: ...IOM CRUZcontrol P N 90480009 Revision Date 03 18 2019 Page 25 of 58 Full Function Module Board Layout ...

Page 26: ...IOM CRUZcontrol P N 90480009 Revision Date 03 18 2019 Page 26 of 58 Full Function Module Circuit ...

Page 27: ...t STATE Typical System Definition 0 Downstream zone is ACCUMULATED reflective sensor blocked 1 Downstream zone is NOT ACCUMULATED reflective sensor not blocked 0 No effect 1 Single Release or Logic Interrupt or Pulse Release function determined by JP3 setting 1 2 TB1 Single Release 2 3 TB1 Logic Interrupt NC TB1 Pulse Release 0 No effect 1 Single Release or Logic Interrupt or Zone Status Input fun...

Page 28: ...tion is delayed by Zone Status ON delay potentiometer STATE 0 1 0 1 0 1 1 2 or 2 3 NC 1 2 or NC 2 3 0 1 No effect Truth Table Definitions Typical System Definition ZONE STATUS is controlled from TB4 input ZONE STATUS is controlled from Downstream LOGIC signal ZONE STATUS is controlled from Downstream SENSOR signal Downstream zone is ACCUMULATED Downstream zone is NOT ACCUMULATED Downstream sensor ...

Page 29: ... 4 Note 0 X 0 X 0 0 1 1 2 1 1 2 1 1 Downstream Slug pass through Upstream Slug pass through 1 2 3 0 2 3 0 1 Downstream Slug interrupt Upstream Slug interrupt 1 4 5 0 1 2 1 1 Downstream Logic crossover Upstream Slug pass through STATE Typical System Definition 0 Downstream zone is FULL 1 Downstream zone is EMPTY 0 SLUG line not active 1 SLUG line active 1 2 Downstream Slug pass through Downstream c...

Page 30: ...o supply power to the Slug Release Line and to manipulate the slug signal Action All zones that are connected to the Slug line release regardless of zone status or accumulation status Configuration Use the Function Module in one of 3 ways to activate a Slug Release 1 Apply power from an external source directly to the Slug Release Line at the Slug connection on TB5 with JP1 on 1 2 and JP2 on 1 2 P...

Page 31: ...Voltage 15 0 VDC Typical ON state current draw 24V 4mA TB1 Single Release Logic Interrupt1 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 UC Typical ON state current draw 2 5 mA Output ratings TB5 Logic output PNP 2 21 kohm impedance typical TB5 Zone ...

Page 32: ...IOM CRUZcontrol P N 90480009 Revision Date 03 18 2019 Page 32 of 58 Release Function Module Board Layout Release Function Module Circuit ...

Page 33: ... 1 Downstream zone is NOT ACCUMULATED reflective sensor not blocked 0 No effect 1 Single Release or Logic Interrupt or Pulse Release function determined by JP3 setting 1 2 TB1 Single Release 2 3 TB1 Logic Interrupt NC TB1 Pulse Release 0 No effect 1 Single Release or Logic Interrupt or Zone Status Input function determined by JP4 setting 1 2 TB4 Single Release 2 3 TB4 Logic Interrupt NC TB4 Zone S...

Page 34: ...t blocked Single Acc or not accumulated Slug Acc No effect Truth Table Definitions Typical System Definition ZONE STATUS is controlled from TB4 input Downstream sensor blocked Single Acc or accumulated Slug Acc 0VDC floating OUTPUT Truth Table for Zone Status Circuit 15VDC Electrical Definition Downstream LOGIC 4 0VDC Downstream sensor is blocked Downstream sensor is not blocked Zone Status input ...

Page 35: ... Note 0 X 0 X 0 0 1 1 2 1 1 2 1 1 Downstream Slug pass through Upstream Slug pass through 1 2 3 0 2 3 0 1 Downstream Slug interrupt Upstream Slug interrupt 1 4 5 0 1 2 1 1 Downstream Logic crossover Upstream Slug pass through STATE Typical System Definition 0 Downstream zone is FULL 1 Downstream zone is EMPTY 0 SLUG line not active 1 SLUG line active 1 2 Downstream Slug pass through Downstream cab...

Page 36: ...t any point in the CRUZcontrol system The Function Module can be used to supply power to the Slug Release Line Action All zones that are connected to the Slug line release regardless of zone status or accumulation status Configuration Apply power from an external source directly to the Slug Release Line at the Slug connection on TB5 Power source must be sized appropriately to directly drive all co...

Page 37: ...ut ratings TB5 Logic output PNP 2 21 kohm impedance typical TB5 Zone Status output PNP 2 21 kohm impedance typical TB3 Zone Status Relay1 250 UC max 100 mA max Resistive load1 Physical properties Terminal block Terminal block wire 30 to 12 AWG 2 5 0 2mm strip length 6 0 mm Screw terminal torque 5 in lbs 0 56 Nm Housing Dimensions 5 125 x 3 75 x 1 125 130mm x 95mm x 29mm Mounting 3 16 holes in moun...

Page 38: ...IOM CRUZcontrol P N 90480009 Revision Date 03 18 2019 Page 38 of 58 Zone Status Function Module Board Layout Zone Status Module Circuit ...

Page 39: ...able Definitions 24VDC PNP 0VDC floating Zone Status Function Module Downstream LOGIC Downstream SENSOR TB4 JP4 JP5 ZONE STATUS Note 0 X X 1 2 or 2 3 1 2 or NC 0 1 X X 1 2 or 2 3 1 2 or NC 1 X 0 X 1 2 or 2 3 2 3 0 X 1 X 1 2 or 2 3 2 3 1 X X 0 NC X 0 X X 1 NC X 1 STATE 0 1 0 1 0 1 1 2 or 2 3 NC 1 2 or NC 2 3 0 1 No effect Truth Table Definitions Typical System Definition ZONE STATUS is controlled f...

Page 40: ...nal 1 1 1 Downstream Slug pass through Upstream Slug pass through STATE Typical System Definition 0 Downstream zone is FULL 1 Downstream zone is EMPTY 0 SLUG line not active 1 SLUG line active 0 SLUG line not active 1 SLUG line active 0 SLUG line not active 1 SLUG line active Truth Table for Slug Circuitry Upstream Inputs OUTPUTS Truth Table for Slug Circuitry Downstream Inputs Truth Table Definit...

Page 41: ... to The terms on refer to the pins that are shorted by the actual jumper TB TB stands for terminal block and the number indicates which terminal group is being referred to Warnings and Cautions NOTE To ensure safe operation of this product a qualified electrician must perform installation and servicing Check with local codes before installation For maximum protection follow UL listing requirements...

Page 42: ... until the photoelectric sensor clears again This operation can usually be left enabled and ready to function regardless of whether the receiving conveyor is running or off There would be no need to interface the CRUZcontrol operation with the receiving conveyor operation since the functioning of it is based solely on product movement The following hardware listing is for two Discharge Logic Assem...

Page 43: ...mbly is also XenoROL since an accumulated condition requires air to activate the brake 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...

Page 44: ...ng with a 300 mA maximum output current and comes with a 6 foot cable no connector Reflectors Replacement photoelectric reflectors can be ordered with the following part number TGW Systems Part Number Description 400004 Reflector Sensor Valve Assemblies A Sensor Valve Assembly is used for applications not requiring accumulation logic but the solenoid valve and photoelectric sensor configuration as...

Page 45: ...ects of such a failure A product jam on the conveyor stopping the free flow of product could also create a situation where Progressive 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 pressure resulting from the use of Progressive CRUZcontrol A solution to this problem is to provi...

Page 46: ...T 78 inches long Other lengths available if required Auxiliary Photoelectric Sensor 94510099 PNP Dark Switching Auxiliary Photo Sensor Extension Cable Full Function Module The Full Accumulation Sensor the Auxiliary Photo Sensor shown here is located to sense full carton accumulation on the NBA 23 conveyor after the curve so as to stop further release of cartons to the curve and prevent cartons fro...

Page 47: ...tric sensor as follows All terminal references are as found in the Full Function Module Photoelectric sensor wiring Brown wire to TB4 VDC Blue wire to TB4 0V Black wire to TB4 ZS Input TB4 VDC also connects to TB3 NC TB4 0 VDC also connects to TB1 TB3 COM connects to TB1 TB5 VDC and 0 VDC can also be used if the connection of too many wires to TB4 is a problem If the Logic Assembly just downstream...

Page 48: ...s not accumulate on the curved section of the conveyor The conveyor shown is XP43CZ The hardware required in this example in addition to that already provided with CRUZcontrol includes the following Description TGW Systems Part Number Comments Extension Cable RK4 4T4RS4 4T 156 inches long Other lengths available if required Full Function Module 1138074 Conveyor Flow Extension Cable Full Function M...

Page 49: ...lease of the next carton upstream from Zone 3 needs to be inhibited until the carton released from Zone 2 reaches Zone 1 This delay in release from Zone 3 is accomplished simply by the proper setting of the Singulation Release Delay It should be pointed out that the release delay is not retained in the event of a system shut down What this means is that if a carton is flowing around the curve and ...

Page 50: ...se from the Work Zone through a Release Function Module 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 Description TGW Systems Part Number Male Cable 78 inche...

Page 51: ... Progressive Logic CRUZcontrol Logic Assemblies provide for high throughput rates and efficient release compared to Basic Logic 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 The product throughput rate for Progressive Logic measured in case feet per minute can equal the conveyor speed This...

Page 52: ...f the accumulation conveyor the speed of the receiving conveyor and also the size and weight characteristics of the conveyed product If the NBA 23 running at 180 feet per minute had a Basic Logic Assembly at only the discharge end the release rate would be closer to the 100 product feet per minute capacity of the downstream induction belt conveyor Example 6 NBA 23 accumulation release to XenoROL N...

Page 53: ...ocations should be determined based on system performance The Discharge Logic Assembly is connected to the Logic Assembly at the discharge end of the NBA 23 There is no need for a Function Module to be attached to it The DLA does not need to be given a release signal Product blocking that photoelectric sensor will stop release from the NBA 23 discharge zone until the photoelectric sensor clears ag...

Page 54: ...esent Photosensor Product Stop Solenoid Valve CRUZ Assembly Operation 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 ...

Page 55: ...ion When it receives a signal from the PLC it passes the signal from the down stream accumulation zone to the upstream accumulation zone Accumulation and release function normally meaning as if there no Function Module installed To create a gap in the flow of product the PLC signal to Function Module 2 is turned off This puts the zone upstream of Function Module 2 into accumulation mode once its P...

Page 56: ...IOM CRUZcontrol P N 90480009 Revision Date 03 18 2019 Page 56 of 58 Cutler Hammer Cut Sheet IM08302001E Rev 02 See following pages Cutler Hammer Cut Sheet P50244 Rev 02 See following pages ...

Page 57: ...SIBLE INJURY DONOTUSETHISPRODUCTFORHUMANSAFETYAPPLICATIONS IT WASNOTDESIGNED TESTEDORRECOMMENDEDFORTHISUSE DONOTUSETHISPRODUCTINHAZARDOUSLOCATIONS E G EXPLOSIVEATMOSPSHERES ITWASNOTDESIGNED TESTEDOR RECOMMENDEDFORTHISUSE WARNING Power Monitor Wiring if installed This contact is provided to allow monitoring of the DC Supply by a remote device This contact opens when the DC power is off or has faile...

Page 58: ...inkingonly 3 7Amaximumcurrentshortcircuit over load overvoltageprotection cyclepowertoreset 1 2 SPECIFICATIONS 1 NOTE Total maximum output of supply is 100W Total supply 100 Watts main output power release output power 2 NOTE The power supply may require several minutes off to reset depending on the severity of the overload APPROXIMATEDIMENSIONS3 WIRINGDIAGRAM 3 NOTE OnmodelPS256B 05B1asingle12mmD...

Page 59: ...44B1 PS256A 44B2 MODELS COVERED IN THIS MANUAL IN ORDER TO AVOID ELECTRIC SHOCK OR OTHER POSSIBLE INJURY DO NOT USE THIS PRODUCT FOR HUMAN SAFETY APPLICATIONS IT WAS NOT DESIGNED OR TESTED AND IS NOT RECOMMENDED FOR THIS USE DO NOT USE THIS PRODUCT IN HAZARDOUS LOCATIONS E G EXPLOSIVE ATMOSPSHERES IT WAS NOT DESIGNED OR TESTED AND IS NOT RECOMMENDED FOR THIS USE WARNING TROUBLESHOOTING The supply ...

Page 60: ...X 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 ground1 Output Voltage 26VDC measured at 20 load Output Power 100W Output Protection Short circuit overload and overvoltage protection auto reset Regulation 3 from 20 to 100 load Power Up Delay Output voltage delayed 3 0 5 seconds from applicat...

Page 61: ...idelines 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 h...

Page 62: ...ystems 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 1300 E Mount Garfield Road Norton Shores MI 49441 6097 USA 231 798 4547 Email usinfo tgw group com Web Site www tgw group com Web Site www tgw conveyor com Regional sales offices and authorized Business Partners...

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