E24 - Hytrol

E24 - Hytrol
E24™
SOLUTIONS Manual
© COPYRIGHT 2015 • HYTROL CONVEYOR COMPANY, INC. BULLETIN NO. 691
C onten t s
Motors
PowerCubes
Control Cards
E24i™ Installation Guide
Diagnostics and Troubleshooting
Application Information
E24™ Standard Control Card
Installation Guide
Diagnostics and Troubleshooting
Card Requirements
Application Information
4
5
5
6
7
8
8
9
E24™ Transfer Control Card
10
E24™ HP Card
14
Installation Guide
Diagnostics and Troubleshooting
Card Requirements
Trouble Shooting
3
3
4
4
Installation Guide
Diagnostics and Troubleshooting
Card Requirements
What is Standard?
Advanced EZLogic Controls
Global Speed Controller
E24EZ Transfer Merge EZLogic® Control Function
11
12
12
13
15
16
16
17
17
18
19
This function controls the traffic in the area of a transfer
merge in Hytrol model E24EZ conveyors. The transfer
merge function provides a “traffic cop” control for an
incoming conveyor line merging onto a trunk conveyor
line at 90° onto a pop-up transfer when both conveyors are
zero-pressure conveyors equipped with EZLogic® zone
controllers. All of the control is provided by the EZLogic®
controllers, and minimal to no wiring is required at installation.
Spur Merge EZLogic® Control Function
21
Square Merge EZLogic® Control Function
23
E24™ Transfer Drawing and Parts List
E24™ Single Diverter
E24™ Double Diverter
E24™ Powered Transition Roller
E24™ Gate
E24EZ Gate
Wiring Diagrams
25
27
28
29
30
31
This function controls the traffic in the area of a spur merge. It
requires a connection kit to connect the merge controller with
the spur discharge zone. The spur-merge function provides a
“traffic cop” control for a spur conveyor line merging onto a
trunk conveyor line when both conveyors are zero-pressure
conveyors equipped with EZLogic® zone controllers. All of the
control is provided by the EZLogic® controllers, and no wiring
of any kind is required at installation.
This function controls the traffic in the area of a square merge.
The square merge function provides a “traffic cop” control for
an incoming conveyor line merging onto a trunk conveyor line
at 90° when both conveyors are zero-pressure conveyors
equipped with EZLogic® zone controllers. All of the control is
provided by the EZLogic® controllers, and minimal wiring is
required at installation.
1 E24™ Motor
2 E24™ Motors
32
33
2
3 E24™ Motors
2 EZLogic® Zones & 1 E24™ Motor per Zone 1 EZLogic® Zone & 1 E24™ Motor per Zone 1 EZLogic® Zone & 2 E24™ Motors per Zone 1 EZLogic® Zones & 3 E24™ Motors per Zone 34
35
35
36
36
1) Motors
Below is a chart of the different standard 24V motors:
Motor Size
36W (E24i™)
100W
125W
160W
200W
Hytrol P/N
033.09022
033.09001
033.090014
033.090023
033.090018
Voltage
24VDC
24VDC
24VDC
24VDC
24VDC
Amperage (Rated)
1.5A
4.0A
5.0A
6.5A
8.0A
Amperage (No Load)
0.13A
0.17A
0.21A
0.27A
0.32A
Watts (Rated)
36W
96W
120W
156W
192W
Speed (Rated)
350 RPM
280 RPM
350 RPM
450 RPM
560 RPM
Speed (Minimum)
70 RPM
56 RPM
70 RPM
90 RPM
112 RPM
Torque (Continuous)
4 in-lbf
15 in-lbf
15 in-lbf
15 in-lbf
15 in-lbf
Torque (Starting)
8 to 11 in-lbf
42 in-lbf
42 in-lbf
42 in-lbf
42 in-lbf
The E24i™ (36W) motor has a built in motor control
card mounted on it. The other motors all require a
separate motor control card. See Section 3 for motor
control cards information.
2) PowerCubes
Below is a chart of the different standard 24V PowerCube motors:
Motor Size
125W (E24i™)
Reducer Ratio
5:1
7.5:1
125W
5:1
160W
7.5:1
160W
5:1
200W
7.5:1
200W
Hytrol P/N
907.0310
907.0311
907.031145
907.031147
907.03115
907.031175
Voltage
24VDC
24VDC
24VDC
24VDC
24VDC
24VDC
Amperage (Rated)
5.0A
5.0A
6.5A
6.5A
8.0A
8.0A
Speed (Maximum)
70 RPM
46.7 RPM
90 RPM
60 RPM
112 RPM
74.7 RPM
Speed (Minimum)
14 RPM
9.3 RPM
18 RPM
12 RPM
22.4 RPM
14.9 RPM
Torque
(Min. Continuous)
40 in-lbf
at 70 RPM
60 in-lbf at
46.7 RPM
30 in-lbf
at 90 RPM
40 in-lbf
at 60 RPM
40 in-lbf at
112 RPM
60 in-lbf
at 74.7 RPM
Torque
(Max. Continuous)
80 in-lbf at 38
RPM or lower
120 in-lbf
at 9.3 RPM
80 in-lbf at
18 RPM
120 in-lbf
at 12 RPM
110 in-lbf at
22.4 RPM
160 in-lbf at
14.9 RPM
Notes:
1) There is not a 100W motor available
for the PowerCube.
2) Other ratios are available: 5:1, 7.5:1,
10:1, 15:1, 20:1, 25:1, and 30:1.
3) The characteristics of the motor
are such that torque increases as the
speed decreases.
4) The motors used on the Powercube
are not the same as the motors used
on the E24™ conveyor. The motors
used in PowerCubes have a shorter
round shaft in lieu of the “D” shaft
used on the E24™ conveyor.
Figure 3A
7.25
4.67
2.90
2.80
2.76
2.36
.188 sq. key
1.50 long
Ø0.24
M6 0.34 Deep, 4 pl.
6.62
4.78
Ø2.95
3.54
Ø0.75
2.36 dia.
0.09
2.09
Lead Assembly = 72”
All mounting holes
sized for M6 fasteners
3
Figure 4A
3) Control Cards
Hytrol has four different motor control cards.
1) E24i™ control card that is integrated with the motor.
Hytrol Part Number 033.09023.
2) Standard control card that is used with the standard 100W motor.
Hytrol Part Number 033.09002.
3) Transfer control card that is used with the E24™ Transfers.
Hytrol Part Number 033.090025.
4) 7A card that is selectable to power the 100W, 125W, 160W or 200W
motors. This is standard when used with the PowerCube motors.
Hytrol Part Number 033.090023.
3.1) E24i (Hytrol Part Number 033.09023)
1
1) Cover - The cover can help reduce the severity of damage to the controller
caused by foreign objects. Caution: The cover does not make the controller
waterproof nor dust proof. Removal of the cover will void the warranty.
2) LED Feedback Indicators - The control board contains four (4) LED
feedback indicators:
One (1) Amber Motor Current Limiting LED
One (1) Red Fault LED
One (1) Green Power LED
One (1) Red Blown Fuse LED
3) Configuration Switches - The control reads the configuration switches
only when the unit is powering up. To change a setting, disconnect power,
set the switch, and then reconnect the power. As shown in Figure 4A:
E24i™ Control Components, the OFF position is to the Left and the ON
position is to the Right.
Configuration Switch Settings:
Switch
Description:
OFF Setting:
ON Setting:
1
Rotation Direction
Counter-Clockwise
Clockwise
2
Braking Action
Zero-Motion Hold
Coast
2 3
L1
L2
5
5
6
L4
1
2
3
4
5
6
3
4
L3
4
P1
P2
P3
P4
1
2
ON
Speed Selection
See Table for Operating Speeds
6
Installation Guide
4) M8 Connector for EZLogic® - The M8 connector is already configured
for use with the Hytrol EZLogic® control.
5) Optional Input-Output (I/O) Connection
Header - A 4-pin Phoenix PT1.5/4-PVH-3.5
plug is supplied. If these I/O connections are
not being used, leave the connector in place
to avoid accidentally shorting the pins.
Note: All inputs and outputs except analog
are PNP only and are active at +18 VDC or
higher.
Optional Inputs and
Outputs Pinout:
Select a Speed - Four (4) switches determine the operating speed, making
it simple to match speed in multiple zones. There is also an option to use
a 0-10V DC input for dynamic remote speed adjustments while the system
is running.
Operating Speeds:
RPM
Out
Pin
Descrption
1
Run (Input)
2
Reverse (Input)
3
Analog Input +
4
Running (Output)
6) DC Power Input Header - The E24i™ DC Power Inputs Pinout:
operates off a +22 to +28 Volt DC power
PT # 033.09022
Signal
supply. The control reads the configuration Pin
US Patent 7,537,107 and
switches only when the unit is powering up.
1
+22European
to +28 Volts
DC 2081859
Patent
Make the power connection only after all other
2
DC
Ground
connections have been made.
On
Caution: Power must be applied with the proper polarity to avoid potentially
SW1 CCW/CW
damaging the controller.
SW2
Note: When adjacent zones are operating from separate power supplies, BRAKE/COAST
SW3
you should connect their DC grounds. However, do not connect the positive
SW4
voltage wires from separate power supplies together.
SPEED
SW5
SW64
350
330
310
290
270
250
230
210
190
170
150
130
110
90
70
50
SPEED, FPM
STD SPEED UP
SPOOL SPOOL
174
254
164
240
154
225
144
211
134
196
124
182
114
167
104
153
95
138
85
123
75
109
65
94
55
80
45
65
35
51
25
36
EZLogic®
In
1
I/O
2
3
DIP SWITCH SETTINGS
SW3 SW4 SW5 SW6
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
4
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
Pwr
+ -
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
Select the Braking Action - Identify the type of braking required and then
set Switch 2.
Switch 2 Settings for Braking Action:
Coasting Stop:
OFF
ON
•
•
Select the Direction of Rotation - Identify the proper direction of rotation
for the motor shaft in order to move the objects from the upstream (entry)
end of the conveyor towards the downstream (exit) end of the conveyor.
The direction of rotation is defined when viewed from the back side of the
motor with the shaft extending away from the viewer.
- For clockwise rotation, set Switch 1 to the ON position.
- For counter-clockwise rotation, set Switch 1 to the OFF position.
•
•
•
•
•
Connect User I/O (Optional) - The connections listed in this section are not
required but may be used when needed.
Power LED (Green)
•
Constantly ON: Power is applied with the proper polarity and
the fuse is not blown.
PNP Run Input - This connection is OR’ed with the EZLogic® Input. When
either is active, or when both are active, the motor will run.
Blown Fuse LED (Red)
Caution: This robust next-generation fuse will not blow under normal
circumstances. Inspect all wiring connections to assure that there are
no short circuits.
PNP Reverse Input - When this input is active and either the PNP Run
input or the EZLogic® input is also active, the motor will run in the opposite
direction from the setting on Switch 1.
Analog +(0-10V DC Input) - This input may be used to override the speed
set by switches 3, 4, 5, and 6.
- If the input is below 0.5V DC, the speed defaults to that set by the
switches. NOTE: The voltage drop across the return cable will cause the
set voltage to vary.
- If the input is 9.0V DC or higher, the speed will be the maximum speed.
- If in the range of 1.0 to 9.0 VDC range, the speed will be proportional to
the input.
- If the input is in the 0.5 to 1.0 VDC range, the speed will be the minimum
speed.
- Unlike the switches, this input is dynamic and may be changed while the
motors are operating.
NOTE: This input is referenced to the DC ground connected to pin 2 on the
Power Input Connector.
PNP Running Output - This output is active when either the PNP Run
input or the EZLogic® input is active, regardless of the condition of the PNP
Reverse input. The maximum output current is 0.5 A.
Application Information
Motor Rated Torque - The motor rated torque is 4 in-lbf as shown in the
curve in the graph on page 6.
Maximum Motor Speed - The maximum speed of the motor is 350 rpm.
Caution: Do not overspeed the motor. Damage may occur without external
over-voltage protection.
Motor Speed and Input Current vs. Torque - The curve below shows
typical E24i™ 36W24 motor speed, input current, and torque at 24V DC.
E24i™ Motor Speed and Input Current vs. Torque:
2.5
350
2.25
325
300
2
275
200
175
150
125
100
75
50
25
0
2
5
4
1.5
1.25
1
0.75
0.5
Stall
225
0
1.75
Motor Rated Torque at 350 rpm
250
Speed (RPM)
Feedback LED’s - This motor provides four (4) LED indicators
shown as item 2 in Figure 4A. The LED’s are useful in diagnosing
various wiring and connection problems. If power is connected, at
least one LED is always illuminated or flashing. When no LED is
illuminated, there is no power.
Motor LED (Amber)
•
Four Flashes in 4 seconds: Components have
overheated and the circuit is limiting the power to the
motor to about half (50%) of normal. This problem
corrects itself when the motor has adequately cooled.
Check for mechanical obstructions.
•
Constantly ON: Motor current is at the maximum
allowed and is being electronically limited. Check for
mechanical obstructions.
•
Flickering: If the motor starts under significant load,
the current may be limited briefly causing the LED to
flicker. If the LED flickers constantly, this is an indication
that the motor is operating at its upper limit and may
never reach the full speed. This is not the cause for
concern and no corrective action is required.
This LED is off under normal circumstances. It illuminates constantly
if the 5.0 amp internal fuse is blown and the power is applied with the
proper polarity. If the blown fuse LED is illuminated, return the motor
to your Integration Partner or supplier for analysis or repair. The 5.0
amp fuse is not user-accessible.
375
Diagnostics and Troubleshooting
One (1) flash in 4 seconds: The motor has a hardware problem.
Return it to your supplier.
Two (2) flashes in 4 seconds: The input voltage is too high.
Reduce the voltage.
Three (3) flashes in 4 seconds: The input voltage is too low.
Increase the voltage.
Four (4) flashes in 4 seconds: There is a problem with the
motor or commutation sensors.
Five (5) flashes in 4 seconds: Control over temperature.
Six (6) flashes in 4 seconds: Extreme over current.
Constantly ON: The motor is stalled or the sensor is continuously
blocked. Check for mechanical obstructions.
6
Torque (in-lbf)
8
10
0.25
12
0
Input Current (Amperes)
Dynamic Braking with Zero-Motion Hold:
Fault LED (Red) - This LED is off under normal circumstances. If a
problem is detected, it provides one of the following five signals:
3.2) E24™ Standard Control Card
(Hytrol Part Number 033.09002)
1) Motor Connection Header - Caution: Use of extension cables may cause
permanent damage and will void the product warranty.
Unidrive motors come with a built-in 22.0 inch (558.8 mm) or 72.00 inch (1,828.8
mm) connection cable, depending on the motor selected. (Please refer to the
specific UniDrive Motor or PowerCube drive specification sheet for details.) Do
not disassemble this cable. If the cable becomes damaged and on-site repairs are
required, refer to the following wiring sequence from pin one (1) on the left through
pin eight (8) on the right:
1
2
3
4
5
6
7
8
Green
Gray
Blue
Violet
Yellow
Brown
Red
Black
NOTE: The motor connection cable must be oriented as shown in the Figure 6A.
2) DC Power Input Header - Caution: Power must be applied with the proper polarity
to avoid potentially damaging the controller.
A 2-pin Phoenix PT1.2/2-PVH-3.5 plug is supplied.
The 033.09002 operates off a +22 to +28 V DC power
supply. The control reads the configuration switches
only when the unit is powering up. Make the power
connection only after all other connections have been
made.
Figure 6A
CORRECT INCORRECT
CABLE
CONNECTOR
PLUG
(CABLE
CONECTOR
ENCHUFE)
8-PIN MOTOR CONNECTOR
(8-PIN MOTOR CONNECTOR)
DC Power Inputs Pinout:
Pin
Signal
1
+22 to +28 Volts DC
2
DC Ground
NOTE: When adjacent zones are operating from separate power supplies, you should
connect their DC grounds. However, do not connect the positive voltage wires from
separate power supplies together.
Optional Inputs and
Outputs Pinout:
3) Optional Input-Output (I/O) Connection Header
Descrption
- A 4-pin Phoenix PT1.5/4-PVH-3.5 plug is supplied. Pin
If these I/O connections are not being used, leave
1
Run (Input)
the connector in place to avoid accidentally shorting
2
Reverse (Input)
the pins.
3
Analog Input +
NOTE: All input and outputs except analog are PNP
4
Running (Output)
only and are active at +18 VDC or higher.
AMBER L.E.D. (INIDCATES CURRENT LIMITING)
Figure 6B
[INDICADOR LED NARANJA (INDICA CORRIENTE LIMITADA)]
RED L.E.D. (FAULT)
[INDICADOR LED ROJO (FALLA)]
GREEN L.E.D. (POWER CONNECTED)
REPLACEABLE FUSE
(LITTEL FUSE 0454005 OR EQUIVALENT)
INDICADOR LED VERDE (POTENCIA CONECTADA)
[(FUSIBLE REEMPLAZABLE (FUSIBLE LITTLE 0454005 O EQUIVALENTE)]
ON (PRENDIDO)
MOTOR CONNNECTOR
SW1
(CONECTOR DEL MOTOR)
SW2
SW3
SW4
MOTOR RUN
(ARRANQUE DEL MOTOR)
EZLOGIC® CONTROLLER CONNECTOR
(CONECTOR DEL CONTROLADOR EZLOGIC)
MOTOR CABLE
SPEED CONTROL POTENTIOMETER
(CABLE DEL MOTOR)
(CONTROLADOR DE VELOCIDAD)
RED L.E.D. (BLOWN FUSE INDICATOR)
(INDICADOR LED ROJO (INDICADOR DE FUSIBLE FUNDIDO)
DC (-)
(CORRIENTE DIRECTA DC (-)
+24V DC INPUT
(ENTRADA DE CORRIENTE DIRECTA +24V DC)
MOTOR RUNNING OUTPUT
(SALIDA DE MOTOR EN FUNCIONAMIENTO)
ANALOG SPEED INPUT (SALIDA DE VELOCIDAD ANALÓGICA)
MOTOR DIRECTION
6
(DIRECCION DEL MOTOR)
4) Configuration Switches - The control reads the configuration switches
only when the unit is powering up. To change a setting, disconnect power,
set the switch, and then reconnect the power. As shown in Figure 6B. The
OFF position is to the Left and the ON position is to the Right. The switches
are numbered 1 through 4, with 1 being the top switch when viewing the
control board as shown in the figure. They are read only at power-up,
meaning that any changes to switches will not take effect until the power is
cycled to the E24™ system.
Configuration Switch Settings:
Switch:
Description:
OFF Setting:
ON Setting:
1
Rotation Direction
Counter-Clockwise
Clockwise
2
Input Type
NPN
PNP
3
Braking Action
Zero-Motion Hold
Coast
4
Current Limit
1.5A
3.0A
5) LED Feedback Indicators - The control boards contains four (4) LED
feedback indicators:
One (1) Amber Motor Current Limiting LED
One (1) Red Fault LED
One (1) Green Power LED
One (1) Red Blown Fuse LED
6) M8 Connector for EZLogic® - The M8 connector is already configured
for use with the Hytrol EZLogic® control. This connector accepts a drive/no
drive signal from an EZLogic ® zone controller (when used). The connector
is a male 8mm push-type connector that mates with the female connector
of the EZLogic® zone controller. When the control board receives a “run”
signal from the EZLogic® zone controller, it turns on the E24™ motor.
7) Mounting Plate/Heat Sink - This component is for mounting the control
assembly to the conveyor frame using two 1/4 inch, or 0.25 in (6.35 mm),
bolts while keeping the controller cooler.
Caution: If mounting the control on a curved section of conveyor, use washer
between the mounting plate and the conveyor frame. This is to assure that
the mounting plate is not distorted, causing damage to the enclosed printed
circuit board assembly. For best thermal performance mount the controller
on a flat surface.
8) Cover - The cover can help reduce the severity of damage to the controller
caused by foreign objects. Caution: The cover does not make the controller
waterproof nor dustproof. Removal of the cover will void the warranty.
The E24™ operates off a +22 to +28 Volt
DC power supply. The control reads the
configuration switches only when the unit
is powering up. Make the power connection
only after all other connections have been
made.
DC Power Inputs Pinout:
Pin
Signal
1
+22 to +28 Volts DC
2
DC Ground
NOTE: When adjacent zones are operating from separate power supplies,
you should connect their DC grounds. However, do not connect the positive
voltage wires from separate power supplies together.
Installation Guide
Mount the Control - Mount the control in a location where the motor cable
reaches the connection header without putting strain on the cable connector
or the header.
Select the Current Limit - This switch selects the maximum current that
the control board will allow the E24™ motor to use. When the switch is in
the OFF (left) position, the current limit is set at 1.5 amps. When the switch
is in the ON (right) position, the current limit is set at 3.0 amps. For most
applications, the switch should be set to the OFF position
to prevent drawing too much current from the motor power supply.
Select the Braking Action - This switch is used to enable the dynamic
braking feature. When the switch is in the OFF (left) position, the dynamic
braking feature acts to stop motor rotation quickly when the motor is turned
off. When the switch is in the ON (right) position, the motor will coast to a
stop when it is turned off.
Switch 3 Settings for Braking Action:
Dynamic Braking with Zero-Motion Hold:
Coasting Stop:
OFF
ON
Select Input Type - This switch is used to set the type of input accepted
by the “motor-run” input terminal and the “motor direction” input terminal.
It does NOT affect the EZLogic® controller connector input. When switch
2 is in the OFF (left) position, the inputs are NPN type; that is, an input is
activated by connecting the terminal to the DC(-) terminal using a jumper
wire or through a switch. When switch 2 is in the ON 9(right) position, the
inputs are PNP type; that is, an input is activated by connecting the terminal
to the +24V DC terminal using a jumper wire or through a switch. PNP is
recommended.
Select the Direction of Rotation - Identify the proper direction of rotation
for the motor shaft in order to move the objects from the upstream (entry)
end of the conveyor towards the downstream (exit) end of the conveyor.
The direction of rotation is defined when viewed from the back side of the
motor with the shaft extending away from the viewer.
- For clockwise rotation, set Switch 1 to the ON position.
- For counter-clockwise rotation, set Switch 1 to the OFF position.
Connect User I/O (Optional) - The connections listed in this section are not
required but may be used when needed.
Run Input - This connection is OR’ed with the EZLogic® Input. When either
is active, or when both are active, the motor will run.
Reverse Input - When this input is active is active and either the Run
input or the EZLogic® input is also active, the motor will run in the opposite
direction from the setting on Switch 1.
Analog +(0-10V DC Input) - This input may be used to override the speed
set by the speed pot.
- If the input is below 0.5V DC, the speed defaults to that set by the
switches. NOTE: The voltage drop across the return cable will cause the
set voltage to vary.
- If the input is 9.0V DC or higher, the speed will be the maximum speed.
- If in the range of 1.0 to 9.0 VDC range, the speed will be proportional to
the input.
- If the input is in the 0.5 to 1.0 VDC range, the speed will be the minimum
speed.
- Unlike the switches, this input is dynamic and may be changed while the
motors are operating.
NOTE: This input is referenced to the DC ground connected to pin 2 on the
Power Input Connector.
Running Output - This output is active when either the Run input or the
EZLogic® input is active, regardless of the condition of the Reverse input.
The maximum output current is 0.5A. This output is a PNP type output. If
you are using this output to run another motor (for example a zone with two
motor where EZLogic® controls one motor and the output from that motor
is connected to the input of the second motor), the second motor MUST be
switched to PNP.
Select a Speed - The speed control potentiometer is used to vary the
speed of an individual E24™ motor. Speed-up and slow-down areas may
be created to gap product, provide more accurate positioning, etc.
7
Diagnostics and Troubleshooting
Feedback LED’s - This motor provides four (4) LED indicators shown as
item 2 in Figure 4A. The LED’s are useful in diagnosing various wiring and
connection problems. If power is connected, at least one LED is always
illuminated or flashing. When no LED is illuminated, there is no power.
Motor LED (Amber)
•
Four Flashes in 4 seconds: Components have overheated
and the circuit is limiting the power to the motor to about half
(50%) of normal. This problem corrects itself when the motor
has adequately cooled. Check for mechanical obstructions.
•
Constantly ON: Motor current is at the maximum allowed and is
being electronically limited. Check for mechanical obstructions.
•
Flickering: If the motor starts under significant load, the current
may be limited briefly causing the LED to flicker. If the LED
flickers constantly, this is an indication that the motor is operating
at its upper limit and may never reach the full speed. This is not
the cause for concern and no corrective action is required.
Fault LED (Red) - This LED is off under normal circumstances. If a
problem is detected, it provides one of the following five signals:
•
One (1) flash in 4 seconds: The motor has a hardware problem.
Return it to your supplier.
•
Two (2) flashes in 4 seconds: The input voltage is too high.
Reduce the voltage.
•
Three (3) flashes in 4 seconds: The input voltage is too low.
Increase the voltage.
•
Four (4) flashes in 4 seconds: There is a problem with the
motor or commutation sensors.
•
Five (5) flashes in 4 seconds: Control over temperature.
•
Six (6) flashes in 4 seconds: Extreme over current.
•
Constantly ON: The motor is stalled or the sensor is continuously
blocked. Check for mechanical obstructions.
Power LED (Green)
•
Constantly ON: Power is applied with the proper polarity and
the fuse is not blown.
Blown Fuse LED (Red)
Caution: This robust next-generation fuse will not blow under normal
circumstances. Inspect all wiring connections to assure that there are
no short circuits.
This LED is off under normal circumstances. It illuminates constantly
if the 5.0 amp internal fuse is blown and the power is applied with the
proper polarity. If the blown fuse LED is illuminated, return the motor
and the card to your Integration Partner or supplier for analysis or
repair.
Card Requirements
Power Requirements
•
Power In
•
24.0V DC nominal at 3.0 Amp maximum
•
Limited to 1.5A when DIP switch 4 is OFF
•
Normal operation from 22.0 - 28.0 VDC
•
Will allow operation above 28.0 VDC but control will
get hotter.
•
Will allow operation below 22.0 VDC but full speed
will be unattainable
•
29.0 + 0.2 VDC over-voltage detection (unit will cease
normal operation)
•
19.0 + 0.2 VDC under-voltage detection (unit will cease
normal operation)
•
Polarity protection is provided
•
Note that the control’s ground does not attach to
the metal chassis; doing so assures a solid ground
8
but then if the power supply is reversed it’s positive
output
•
Fuse to only be replaced with a 5A Slo-Blo Littlefuse
0454005 or equivalent
•
NPN/PNP Selectable Inputs - can be either an NPN or PNP
input. PNP is recommended.
•
NPN Input Signal Levels (When switch 2 is OFF)
•
Active when pulled down below 2.0 VDC
•
Need to be able to sink 3 mA
•
PNP Input Signal Levels (When switch 2 is ON)
•
Active when pulled up above 18.0 VDC
•
Need to be able to source 3 ma
•
Two input signal
•
Motor Run
•
Motor Reverse
•
Analog Speed Input
•
Allow the speed to be controlled from a single point
•
Voltage range: 0-10 VDC
•
Minimum impedance presented to input: 5K
•
PNP Output
•
Signal Levels
•
Sources current when active
•
Maximum current for this unprotected output is
50mA
•
A 150Ω series resistor helps the PNP output limit
current draw for most situations; voltage out is
thus lower as current draw increase
•
Voltage dependents on input power and current
draw.
•
One output signal
•
Motor Running
Environmental Requirements
•
Temperature
•
The unit shall operate within specified limits over the range
of -20 to 40°C (-4 to 120°F)
•
The unit can be stored in the range of -40 to 85°C (-40 to
185°F)
•
Humidity
•
The unit shall operate within specified limits in relative
humidity in the range of 20 to 90% (non-condensing)
•
The unit can be stored in the range of 5 to 95% (noncondensing)
Safety - Unintended Use Considerations
•
Installer
•
This product is intended for installation by qualified
personnel only; although of relatively low voltage there are
dangerous levels of current controlled on the board that are
not protected from misplaced fingers.
•
Note that the cover makes it difficult to touch any
power other than the fuse.
•
A tool will be required to tweak the pot or move
the DIP switches; a plastic-tip screwdriver is
recommended.
•
User
•
Product shall be located away from the user such that
touching of the control is not possible.
•
Should the on-board fuse require replacement, always use
only that detailed in this specification.
E24EZ Connections
Zone Controller
ZONE LENGTH
Unidrive Motor Control
Cordset
6 1/2
E24™ Connections
6 1/2
Unidrive Motor
Unidrive Motor Control
Wiring Harness W/Drops
Trouble Shooting Model E24
The following charts list possible problems that may occur in the operation of an E24 conveyor.
TROUBLE
CAUSE
SOLUTION
No motors on the conveyor will run.
1)
2)
3)
4)
5)
No AC power to the power supply unit.
Main power disconnect on the power supply unit is “off.”
Main fuses blown.
No lights on motor/control board.
Board not receiving run signal
1)
2)
3)
4)
5)
Check AC power.
Set disconnect to “on.”
Replace fuses.
Check output power of power supply.
Check connections and insure run signal is active
Individual zone will not run.
1) Motor/Control Board power pins not connected to wiring
harness.
2) Motor power connector not connected to Control Board. (E24™
motor only.)
3) Blown fuse indicator “ON”. (E24i™)
4) Defective control board.
5) Defective motor.
1) Connect wiring harness and pin connector to power pins
on Motor/Control Board.
2) Connect motor power connector to Motor Control Board.
3) Replace motor.
4) Replace fuse.
5) Replace control board.
Zone will not restart after accumulation.
1) O-ring band(s) stretched or worn.
1) Replace o-ring(s).
Trouble Shooting Model E24EZ
The following charts list possible problems that may occur in the operation of an E24EZ conveyor.
TROUBLE
CAUSE
SOLUTION
No zones on the conveyor
will run.
1)
2)
3)
4)
5)
No AC power to the power supply unit.
Main power disconnect on the power supply unit is “off.”
Main fuses blown.
No lights on Motor/Control Board.
No power to EZLogic® Zone Controller
Individual zone will not run.
1) Motor/control board power pins not connected to wiring harness.
2) EZLogic® zone controller output cable not connected to motor/control
board.
3) Motor power connector not connected to control board. (E24 motor
only.)
4) Zone controller lens is dirty.
5) Reflector missing or damaged.
6) Defective EZLogic® zone controller.
7) Blown fuse indicator “ON”.
8) Blown fuse indicator “ON”. (E24™)
9) Defective control board.
10) Defective motor.
1) Connect wiring harness and pin connector to power pins
on Control Board.
2) Connect cables.
3) Connect motor power connector to motor control board.
4) Clean lens.
5) Replace reflector.
6) Replace EZLogic® zone controller.
7) Replace motor.
8) Replace fuse.
9) Replace control board.
10)Replace motor.
Zone will not restart after
accumulation.
1) Zone controller lens is dirty.
2) O-ring band(s) stretched or worn.
1) Clean lens.
2) Replace o-ring(s).
Zone will not “sleep.”
1) Sleep feature disabled.
2) Upstream zone is blocked.
1) Enable sleep feature.
2) Unblock upstream zone.
Product will not accumulate
from the discharge zone back.
1) No zone stop signal to discharge zone.
1) Check input cable and signal source.
9
1)
2)
3)
4)
5)
Check AC power.
Set disconnect to “on.”
Replace fuses.
Check output power of power supply.
Check EZLogic® connections and IOP.
3.3) E24™ Transfer Control Card
(Hytrol Part Number 033.090025)
1) Motor Connection Header - Caution: Use of extension cables may cause
permanent damage and will void the product warranty.
Unidrive motors come with a built-in 22.0 inch (558.8 mm) or 72.00 inch (1,828.8
mm) connection cable, depending on the motor selected. (Please refer to the specific
UniDrive Motor or PowerCube drive specification sheet for details.) Do not disassemble
this cable. If the cable becomes damaged and on-site repairs are required, refer to the
following wiring sequence from pin one (1) on the left through pin eight (8) on the
right:
1
2
3
4
5
6
7
8
Green
Gray
Blue
Violet
Yellow
Brown
Red
Black
NOTE: The motor connection cable must be oriented as shown in the Figure 10A.
2) DC Power Input Header - Caution: Power must be applied with the proper polarity
to avoid potentially damaging the controller.
A 2-pin Phoenix PT1.2/2-PVH-3.5 plug is supplied.
The 033.09002 operates off a +22 to +28 V DC power
supply. The control reads the configuration switches
only when the unit is powering up. Make the power
connection only after all other connections have been
made.
Figure 10A
CORRECT INCORRECT
(CABLE
CONECTOR
ENCHUFE)
(8-PIN MOTOR CONNECTOR)
Signal
1
+22 to +28 Volts DC
2
DC Ground
Outputs Pinout:
Pin
Descrption
1
Run (Input)
2
Reverse (Input)
NOTE: All input and outputs except analog are PNP
only and are active at +18 VDC or higher.
8-PIN MOTOR CONNECTOR
Pin
NOTE: When adjacent zones are operating from separate power supplies, you should
connect their DC grounds. However, do not connect the positive voltage wires from
separate power supplies together.
Optional Inputs and
3) Optional Input-Output (I/O) Connection Header
- A 4-pin Phoenix PT1.5/4-PVH-3.5 plug is supplied.
If these I/O connections are not being used, leave the
connector in place to avoid accidentally shorting the
pins.
CABLE
CONNECTOR
PLUG
DC Power Inputs Pinout:
3
Analog Input +
4
Running (Output)
AMBER L.E.D. (INIDCATES CURRENT LIMITING)
Figure 10B
[INDICADOR LED NARANJA (INDICA CORRIENTE LIMITADA)]
RED L.E.D. (FAULT)
[INDICADOR LED ROJO (FALLA)]
GREEN L.E.D. (POWER CONNECTED)
REPLACEABLE FUSE
(LITTEL FUSE 0454005 OR EQUIVALENT)
INDICADOR LED VERDE (POTENCIA CONECTADA)
[(FUSIBLE REEMPLAZABLE (FUSIBLE LITTLE 0454005 O EQUIVALENTE)]
ON (PRENDIDO)
MOTOR CONNNECTOR
SW1
(CONECTOR DEL MOTOR)
SW2
SW3
SW4
MOTOR RUN
(ARRANQUE DEL MOTOR)
EZLOGIC® CONTROLLER CONNECTOR
(CONECTOR DEL CONTROLADOR EZLOGIC)
MOTOR CABLE
SPEED CONTROL POTENTIOMETER
(CABLE DEL MOTOR)
(CONTROLADOR DE VELOCIDAD)
RED L.E.D. (BLOWN FUSE INDICATOR)
(INDICADOR LED ROJO (INDICADOR DE FUSIBLE FUNDIDO)
DC (-)
(CORRIENTE DIRECTA DC (-)
+24V DC INPUT
(ENTRADA DE CORRIENTE DIRECTA +24V DC)
MOTOR RUNNING OUTPUT
(SALIDA DE MOTOR EN FUNCIONAMIENTO)
ANALOG SPEED INPUT (SALIDA DE VELOCIDAD ANALÓGICA)
MOTOR DIRECTION
10
(DIRECCION DEL MOTOR)
4) Configuration Switches - The control reads the configuration switches
only when the unit is powering up. To change a setting, disconnect power,
set the switch, and then reconnect the power. As shown in Figure 6B. The
OFF position is to the Left and the ON position is to the Right. The switches
are numbered 1 through 4, with 1 being the top switch when viewing the
control board as shown in the figure. They are read only at power-up,
meaning that any changes to switches will not take effect until the power is
cycled to the E24™ system.
Configuration Switch Settings:
Switch:
Description:
OFF Setting:
ON Setting:
1
Rotation Direction
Counter-Clockwise
Clockwise
2
Input Type
NPN
PNP
3
Braking Action
Zero-Motion Hold
Coast
4
Current Limit
1.5A
4.0A
5) LED Feedback Indicators - The control boards contains four (4) LED
feedback indicators:
One (1) Amber Motor Current Limiting LED
One (1) Red Fault LED
One (1) Green Power LED
One (1) Red Blown Fuse LED
6) M8 Connector for EZLogic® - The M8 connector is already configured
for use with the Hytrol EZLogic® control. This connector accepts a drive/no
drive signal from an EZLogic ® zone controller (when used). The connector
is a male 8mm push-type connector that mates with the female connector
of the EZLogic® zone controller. When the control board receives a “run”
signal from the EZLogic® zone controller, it turns on the E24™ motor.
7) Mounting Plate/Heat Sink - This component is for mounting the control
assembly to the conveyor frame using two 1/4 inch, or 0.25 in (6.35 mm),
bolts while keeping the controller cooler.
Caution: If mounting the control on a curved section of conveyor, use washer
between the mounting plate and the conveyor frame. This is to assure that
the mounting plate is not distorted, causing damage to the enclosed printed
circuit board assembly. For best thermal performance mount the controller
on a flat surface.
8) Cover - The cover can help reduce the severity of damage to the controller
caused by foreign objects. Caution: The cover does not make the controller
waterproof nor dustproof. Removal of the cover will void the warranty.
The E24™ operates off a +22 to +28 Volt
DC power supply. The control reads the
configuration switches only when the unit
is powering up. Make the power connection
only after all other connections have been
made.
DC Power Inputs Pinout:
Pin
Signal
1
+22 to +28 Volts DC
2
DC Ground
NOTE: When adjacent zones are operating from separate power supplies,
you should connect their DC grounds. However, do not connect the positive
voltage wires from separate power supplies together.
Installation Guide
Mount the Control - Mount the control in a location where the motor cable
reaches the connection header without putting strain on the cable connector
or the header.
Select the Current Limit - This switch selects the maximum current that
the control board will allow the E24™ motor to use. When the switch is in
the OFF (left) position, the current limit is set at 1.5 amps. When the switch
is in the ON (right) position, the current limit is set at 3.0 amps. For most
applications, the switch should be set to the OFF position
to prevent drawing too much current from the motor power supply.
Select the Braking Action - This switch is used to enable the dynamic
braking feature. When the switch is in the OFF (left) position, the dynamic
braking feature acts to stop motor rotation quickly when the motor is turned
off. When the switch is in the ON (right) position, the motor will coast to a
stop when it is turned off.
Switch 3 Settings for Braking Action:
Dynamic Braking with Zero-Motion Hold:
Coasting Stop:
OFF
ON
Select Input Type - This switch is used to set the type of input accepted
by the “motor-run” input terminal and the “motor direction” input terminal.
It does NOT affect the EZLogic® controller connector input. When switch
2 is in the OFF (left) position, the inputs are NPN type; that is, an input is
activated by connecting the terminal to the DC(-) terminal using a jumper
wire or through a switch. When switch 2 is in the ON 9(right) position, the
inputs are PNP type; that is, an input is activated by connecting the terminal
to the +24V DC terminal using a jumper wire or through a switch. PNP is
recommended.
Select the Direction of Rotation - Identify the proper direction of rotation
for the motor shaft in order to move the objects from the upstream (entry)
end of the conveyor towards the downstream (exit) end of the conveyor.
The direction of rotation is defined when viewed from the back side of the
motor with the shaft extending away from the viewer.
- For clockwise rotation, set Switch 1 to the ON position.
- For counter-clockwise rotation, set Switch 1 to the OFF position.
Connect User I/O (Optional) - The connections listed in this section are not
required but may be used when needed.
Run Input - This connection is OR’ed with the EZLogic® Input. When either
is active, or when both are active, the motor will run.
Reverse Input - When this input is active is active and either the Run
input or the EZLogic® input is also active, the motor will run in the opposite
direction from the setting on Switch 1.
Analog +(0-10V DC Input) - This input may be used to override the speed
set by the speed pot.
- If the input is below 0.5V DC, the speed defaults to that set by the
switches. NOTE: The voltage drop across the return cable will cause the
set voltage to vary.
- If the input is 9.0V DC or higher, the speed will be the maximum speed.
- If in the range of 1.0 to 9.0 VDC range, the speed will be proportional to
the input.
- If the input is in the 0.5 to 1.0 VDC range, the speed will be the minimum
speed.
- Unlike the switches, this input is dynamic and may be changed while the
motors are operating.
NOTE: This input is referenced to the DC ground connected to pin 2 on the
Power Input Connector.
Running Output - This output is active when either the Run input or the
EZLogic® input is active, regardless of the condition of the Reverse input.
The maximum output current is 0.5A. This output is a PNP type output. If
you are using this output to run another motor (for example a zone with two
motor where EZLogic® controls one motor and the output from that motor
is connected to the input of the second motor), the second motor MUST be
switched to PNP.
Select a Speed - The speed control potentiometer is used to vary the
speed of an individual E24™ motor. Speed-up and slow-down areas may
be created to gap product, provide more accurate positioning, etc.
11
Diagnostics and Troubleshooting
•
Feedback LED’s - This motor provides four (4) LED indicators shown as
item 2 in Figure 4A. The LED’s are useful in diagnosing various wiring and
connection problems. If power is connected, at least one LED is always
illuminated or flashing. When no LED is illuminated, there is no power.
Motor LED (Amber)
•
Four Flashes in 4 seconds: Components have overheated
and the circuit is limiting the power to the motor to about half
(50%) of normal. This problem corrects itself when the motor
has adequately cooled. Check for mechanical obstructions.
•
Constantly ON: Motor current is at the maximum allowed and is
being electronically limited. Check for mechanical obstructions.
•
Flickering: If the motor starts under significant load, the current
may be limited briefly causing the LED to flicker. If the LED
flickers constantly, this is an indication that the motor is operating
at its upper limit and may never reach the full speed. This is not
the cause for concern and no corrective action is required.
Fault LED (Red) - This LED is off under normal circumstances. If a
problem is detected, it provides one of the following five signals:
•
One (1) flash in 4 seconds: The motor has a hardware problem.
Return it to your supplier.
•
Two (2) flashes in 4 seconds: The input voltage is too high.
Reduce the voltage.
•
Three (3) flashes in 4 seconds: The input voltage is too low.
Increase the voltage.
•
Four (4) flashes in 4 seconds: There is a problem with the
motor or commutation sensors.
•
Five (5) flashes in 4 seconds: Control over temperature.
•
Six (6) flashes in 4 seconds: Extreme over current.
•
Constantly ON: The motor is stalled or the sensor is continuously
blocked. Check for mechanical obstructions.
Power LED (Green)
•
Constantly ON: Power is applied with the proper polarity and
the fuse is not blown.
Blown Fuse LED (Red)
Caution: This robust next-generation fuse will not blow under normal
circumstances. Inspect all wiring connections to assure that there are
no short circuits.
This LED is off under normal circumstances. It illuminates constantly
if the 5.0 am internal fuse is blown and the power is applied with the
proper polarity. If the blown fuse LED is illuminated, return the motor
to your Integration Partner or supplier for analysis or repair. The 5.0
amp fuse is not user-accessible.
Card Requirements
Power Requirements
•
Power In
•
24.0V DC nominal at 3.0 Amp maximum
•
Limited to 1.5A when DIP switch 4 is OFF
•
Normal operation from 22.0 - 28.0 VDC
•
Will allow operation above 28.0 VDC but control will
get hotter.
•
Will allow operation below 22.0 VDC but full speed
will be unattainable
•
29.0 + 0.2 VDC over-voltage detection (unit will cease
normal operation)
•
19.0 + 0.2 VDC under-voltage detection (unit will cease
normal operation)
12
Polarity protection is provided
•
Note that the control’s ground does not attach to
the metal chassis; doing so assures a solid ground
but then if the power supply is reversed it’s positive
output
•
Fuse to only be replaced with a 5A Slo-Blo Littlefuse
0454005 or equivalent
•
NPN/PNP Selectable Inputs - can be either an NPN or PNP
input. PNP is recommended.
•
NPN Input Signal Levels (When switch 2 is OFF)
•
Active when pulled down below 2.0 VDC
•
Need to be able to sink 3 mA
•
PNP Input Signal Levels (When switch 2 is ON)
•
Active when pulled up above 18.0 VDC
•
Need to be able to source 3 ma
•
Two input signal
•
Motor Run
•
Motor Reverse
•
Analog Speed Input
•
Allow the speed to be controlled from a single point
•
Voltage range: 0-10 VDC
•
Minimum impedance presented to input: 5K
•
PNP Output
•
Signal Levels
•
Sources current when active
•
Maximum current for this unprotected output is
50mA
•
A 150Ω series resistor helps the PNP output limit
current draw for most situations; voltage out is
thus lower as current draw increase
•
Voltage dependents on input power and current
draw.
•
One output signal
•
Motor Running
Environmental Requirements
•
Temperature
•
The unit shall operate within specified limits over the range
of -20 to 40°C (-4 to 120°F)
•
The unit can be stored in the range of -40 to 85°C (-40 to
185°F)
•
Humidity
•
The unit shall operate within specified limits in relative
humidity in the range of 20 to 90% (non-condensing)
•
The unit can be stored in the range of 5 to 95% (noncondensing)
Safety - Unintended Use Considerations
•
Installer
•
This product is intended for installation by qualified
personnel only; although of relatively low voltage there are
dangerous levels of current controlled on the board that are
not protected from misplaced fingers.
•
Note that the cover makes it difficult to touch any
power other than the fuse.
•
A tool will be required to tweak the pot or move
the DIP switches; a plastic-tip screwdriver is
recommended.
•
User
•
Product shall be located away from the user such that
touching of the control is not possible.
•
Should the on-board fuse require replacement, always use
only that detailed in this specification.
Trouble Shooting Model E24
The following charts list possible problems that may occur in the operation of an E24 conveyor.
TROUBLE
CAUSE
SOLUTION
No motors on the conveyor will run.
1)
2)
3)
4)
5)
No AC power to the power supply unit.
Main power disconnect on the power supply unit is “off.”
Main fuses blown.
No lights on motor/control board.
Board not receiving run signal
1)
2)
3)
4)
5)
Check AC power.
Set disconnect to “on.”
Replace fuses.
Check output power of power supply.
Check connections and insure run signal is active
Individual zone will not run.
1) Motor/Control Board power pins not connected to wiring
harness.
2) Motor power connector not connected to Control Board. (E24™
motor only.)
3) Blown fuse indicator “ON”. (E24i™)
4) Defective control board.
5) Defective motor.
1) Connect wiring harness and pin connector to power pins
on Motor/Control Board.
2) Connect motor power connector to Motor Control Board.
3) Replace motor.
4) Replace fuse.
5) Replace control board.
Zone will not restart after accumulation.
1) O-ring band(s) stretched or worn.
1) Replace o-ring(s).
Trouble Shooting Model E24EZ
The following charts list possible problems that may occur in the operation of an E24EZ conveyor.
TROUBLE
CAUSE
SOLUTION
No zones on the conveyor
will run.
1)
2)
3)
4)
5)
No AC power to the power supply unit.
Main power disconnect on the power supply unit is “off.”
Main fuses blown.
No lights on Motor/Control Board.
No power to EZLogic® Zone Controller
Individual zone will not run.
1) Motor/control board power pins not connected to wiring harness.
2) EZLogic® zone controller output cable not connected to motor/control
board.
3) Motor power connector not connected to control board. (E24 motor
only.)
4) Zone controller lens is dirty.
5) Reflector missing or damaged.
6) Defective EZLogic® zone controller.
7) Blown fuse indicator “ON”.
8) Blown fuse indicator “ON”. (E24™)
9) Defective control board.
10) Defective motor.
1) Connect wiring harness and pin connector to power pins
on Control Board.
2) Connect cables.
3) Connect motor power connector to motor control board.
4) Clean lens.
5) Replace reflector.
6) Replace EZLogic® zone controller.
7) Replace motor.
8) Replace fuse.
9) Replace control board.
10)Replace motor.
Zone will not restart after
accumulation.
1) Zone controller lens is dirty.
2) O-ring band(s) stretched or worn.
1) Clean lens.
2) Replace o-ring(s).
Zone will not “sleep.”
1) Sleep feature disabled.
2) Upstream zone is blocked.
1) Enable sleep feature.
2) Unblock upstream zone.
Product will not accumulate
from the discharge zone back.
1) No zone stop signal to discharge zone.
1) Check input cable and signal source.
13
1)
2)
3)
4)
5)
Check AC power.
Set disconnect to “on.”
Replace fuses.
Check output power of power supply.
Check EZLogic® connections and IOP.
3.4) E24™ High Performance Card
(Hytrol Part Number 033.090023)
1) Motor Connection Header - Caution: Use of extension cables may cause
permanent damage and will void the product warranty.
Unidrive motors come with a built-in 22.0 inch (558.8 mm) or 72.00 inch (1,828.8
mm) connection cable, depending on the motor selected. (Please refer to the specific
UniDrive Motor or PowerCube drive specification sheet for details.) Do not disassemble
this cable. If the cable becomes damaged and on-site repairs are required, refer to the
following wiring sequence from pin one (1) on the left through pin eight (8) on the
right:
1
2
3
4
5
6
7
8
Green
Gray
Blue
Violet
Yellow
Brown
Red
Black
NOTE: The motor connection cable must be oriented as shown in the Figure 14A.
2) DC Power Input Header - Caution: Power must be applied with the proper polarity
to avoid potentially damaging the controller.
A 2-pin Phoenix PT1.2/2-PVH-3.5 plug is supplied. The
033.090023 operates off a +22 to +28 V DC power
supply. The control reads the configuration switches
only when the unit is powering up. Make the power
connection only after all other connections have been
made.
Figure 14A
CORRECT INCORRECT
(CABLE
CONECTOR
ENCHUFE)
NOTE: All input and outputs except analog are PNP
only and are active at +18 VDC or higher.
8-PIN MOTOR CONNECTOR
Pin
Signal
1
+22 to +28 Volts DC
2
DC Ground
NOTE: When adjacent zones are operating from separate power supplies, you should
connect their DC grounds. However, do not connect the positive voltage wires from
separate power supplies together.
Optional Inputs and
3) Optional Input-Output (I/O) Connection Header
- A 6-pin Phoenix PT1.5/6-PVH-3.5 plug is supplied.
If these I/O connections are not being used, leave the
connector in place to avoid accidentally shorting the
pins.
CABLE
CONNECTOR
PLUG
DC Power Inputs Pinout:
Outputs Pinout:
Pin
Descrption
1
Run (Input)
2
Reverse (Input)
3
Running (Output)
4
Analog Input +
5
DC Ground
4) Configuration Switches - The switches are
6
Shunt
Input
numbered 1 through 8, with 1 being the top switch
when viewing the control board as shown in the figure.
The OFF position is to the Left and the ON position is to the Right. Switches 1, 2, 7, &
8 are read only when the unit is powering up. To change a setting, disconnect power,
set the switch, and then reconnect the power. Switches 3 – 6 change the speed and
can be changed and read while the unit is powered up.
(8-PIN MOTOR CONNECTOR)
Diagram
FIGURE 14B: Hi Performance
Control Components
Configuration Switch Settings:
SW:
Description:
OFF Setting:
ON Setting:
1
Rotation Direction
Counter-Clockwise
Clockwise
2
Braking Action
Zero-Motion Hold
Coast
3
4
5
Speed Selection
Operating Speeds
Motor Selection
Motor Selection Switch Settings
6
7
8
5) LED Feedback Indicators - The control boards
contains four (4) LED feedback indicators:
One (1) Amber Motor Current Limiting LED
One (1) Red Fault LED
One (1) Green Power LED
One (1) Red Blown Fuse LED
8
1
2
3
4 5 6
7
14
6) M8 Connector for EZLogic® - The M8 connector is already configured
for use with the Hytrol EZLogic® control. This connector accepts a drive/no
drive signal from an EZLogic ® zone controller (when used). The connector
is a male 8mm push-type connector that mates with the female connector
of the EZLogic® zone controller. When the control board receives a “run”
signal from the EZLogic® zone controller, it turns on the E24™ motor.
7) Mounting Plate/Heat Sink - This component is for mounting the control
assembly to the conveyor frame using two 1/4 inch, or 0.25 in (6.35 mm),
bolts while keeping the controller cooler.
Caution: If mounting the control on a curved section of conveyor, use washer
between the mounting plate and the conveyor frame. This is to assure that
the mounting plate is not distorted, causing damage to the enclosed printed
circuit board assembly. For best thermal performance mount the controller
on a flat surface.
8) Cover - The cover can help reduce the severity of damage to the controller
caused by foreign objects. Caution: The cover does not make the controller
waterproof nor dustproof. Removal of the cover will void the warranty.
The E24™ operates off a +22 to +28 Volt DC power supply. The control
reads the configuration switches only when the unit is powering up. Make
the power connection only after all other connections have been made.
NOTE: When adjacent zones are operating from separate power supplies,
you should connect their DC grounds. However, do not connect the positive
voltage wires from separate power supplies together.
Installation Guide
Mount the Control - Mount the control in a location where the motor cable
reaches the connection header without putting strain on the cable connector
or the header.
Select the Motor - Select the motor you will be using. Properly match the
control settings to the motor in use to deliver the best and most predictable
performance.
In addition to the standard 100 watt UniDrive motor, this control provides
maximum performance with our 125 watt, 160 watt, 200 watt motors at
their higher speeds. You can also use this control with an optional shunt
regulator that enables regenerative braking mode without creating excess
voltage on the power supply line.
Motor Selection Switch Settings:
SW 7:
SW 8:
Motor:
OFF
OFF
100W24
ON
OFF
125W24
OFF
ON
160W24
ON
ON
200W24
Select a Speed - Four switches determine the operating speed, making it
simple to match speeds in multiple zones. The actual speed selected also
depends on the motor that you selected in the previous step, so set those
switches first.
There is also an option to use a 0-10 V DC input for remote, dynamic speed
adjustment while the system is running.
Switches:
Speed Selection (RPM):
SW 3:
SW 4:
SW 5:
SW 6:
100W24
125W24
160W24
200W24
OFF
OFF
OFF
OFF
280
350
450
560
ON
OFF
OFF
OFF
265
331
426
530
OFF
ON
OFF
OFF
250
312
402
500
ON
ON
OFF
OFF
235
293
378
470
OFF
OFF
ON
OFF
220
274
354
440
ON
OFF
ON
OFF
205
255
330
410
OFF
ON
ON
OFF
190
236
306
380
ON
ON
ON
OFF
175
217
282
350
OFF
OFF
OFF
ON
160
198
258
320
ON
OFF
OFF
ON
145
179
234
290
OFF
ON
OFF
ON
130
160
210
260
ON
ON
OFF
ON
115
141
186
230
OFF
OFF
ON
ON
100
122
162
200
ON
OFF
ON
ON
85
103
138
170
OFF
ON
ON
ON
70
84
114
140
ON
ON
ON
ON
55
65
90
110
Select the Braking Action - This switch is used to enable the dynamic
braking feature. When the switch is in the OFF (left) position, the dynamic
braking feature acts to stop motor rotation quickly when the motor is turned
off. When the switch is in the ON (right) position, the motor will coast to a
stop when it is turned off. If an optional Shunt Regulator is connect, the
control will default to regenerative braking.
Switch 2 Settings for Braking Action:
Dynamic Braking with Zero-Motion Hold:
Coasting Stop:
OFF
ON
Select the Direction of Rotation - Identify the proper direction of rotation
for the motor shaft in order to move the objects from the upstream (entry)
end of the conveyor towards the downstream (exit) end of the conveyor.
The direction of rotation is defined when viewed from the back side of the
motor with the shaft extending away from the viewer.
- For clockwise rotation, set Switch 1 to the ON position.
- For counter-clockwise rotation, set Switch 1 to the OFF position.
Connect User I/O (Optional) - The connections listed in this section are not
required but may be used when needed.
PNP Run Input - This connection is OR’ed with the EZLogic® Input. When
either is active, or when both are active, the motor will run.
PNP Reverse Input - When this input is active is active and either the PNP
Run input or the EZLogic® input is also active, the motor will run in the
opposite direction from the setting on Switch 1.
Analog +(0-10V DC Input) - This input may be used to override the speed
set by switches 4,5, and 6.
- If the input is below 0.5V DC, the speed defaults to that set by the
switches. NOTE: The voltage drop across the return cable will cause the
set voltage to vary.
15
- If the input is 9.0V DC or higher, the speed will be the maximum speed.
- If in the range of 1.0 to 9.0 VDC range, the speed will be proportional to
the input.
- If the input is in the 0.5 to 1.0 VDC range, the speed will be the minimum
speed.
- Unlike the switches, this input is dynamic and may be changed while the
motors are operating.
NOTE: This input is referenced to the DC ground connected to pin 2 on the
Power Input Connector.
PNP Running Output - This output is active when either the PNP Run
input or the EZLogic® input is active, regardless of the condition of the PNP
Reverse input.
Shunt Enable Input - This input is only to be used if an external Shunt
Regulator is attached. Refer to the Shunt Regulator installation guide.
is operating at its upper limit and may never reach the full speed.
This is not the cause for concern and no corrective action is
required.
Power LED (Green)
•
Constantly ON: Power is applied with the proper polarity as
long as the fuse is not blown.
Firmware Version Display - Three (3) of the feedback LED’s are used
to communicate the firmware revision of the control assembly during the
start-up sequence. Each time that power is applies to the board, the green
(power) and red (fault) LEDs will turn on immediately. After 1.0 second, the
amber LED will flash on for 0.75 seconds followed by an off period. An off
period of 1.5 seconds represents a decimal point separating major revisions
from minor revisions.
Start-Up Sequence:
DC Ground - The point is common to the DC ground on pin 2 of the Power
Input Connector, should it be required for reference.
Green
On
Red
On
Diagnostics and Troubleshooting
Off
Feedback LED’s - This control provides four (4) LED indicators shown as
item 2 in Figure 15B. The LED’s are useful in diagnosing various wiring and
connection problems. If power is connected, at least one LED is always
illuminated or flashing. When no LED is illuminated, there is no power.
Blown Fuse (Red) - Caution: This robust next-generation fuse will not
blow under normal circumstances. Inspect all wiring connections to
assure that there are no short circuits.
This LED is off under normal circumstances. It illuminates constantly if
the 10.0 amp internal fuse is blown and the power is applied with the
proper polarity. The 10.0 amp fuse on the board is not user-accessible.
If the blown fuse LED is illuminated, return the board to your Integration
Partner or supplier for analysis or repair.
On
1.0
Amber
1
1.5
2
.75 .4 .75
3
4
Seconds
Continuous
5
6
Off
7
8
The example sequence above represents firmware revision 1.2. When
the red fault LED turns off, the start-up sequence has ended and normal
operation begins.
Card Requirements
Fault LED (Red) - This LED is off under normal circumstances. If a
problem is detected, it provides one of the following five signals:
•
One (1) flash in 4 seconds: The motor has a hardware problem.
Return it to your supplier.
•
Two (2) flashes in 4 seconds: The input voltage is too high.
Reduce the voltage.
•
Three (3) flashes in 4 seconds: The input voltage is too low.
Increase the voltage.
•
Four (4) flashes in 4 seconds: There is a problem with the
motor or commutation sensors or motor cable or connection.
Check to see that the cable is not damaged and that all of
the wires are secure. If the cable has been cut or the wires
disconnected, refer to the Motor Connection Header.
•
Five (5) flashes in 4 seconds: Control Board over temperature
shut down.
•
Six (6) flashes in 4 seconds: Extreme over current.
•
Constantly ON: The motor is stalled or the sensor is continuously
blocked. Check for mechanical obstructions.
Motor LED (Amber)
•
Four Flashes in 4 seconds: Components have overheated
and the circuit is limiting the power to the motor to about half
(50%) of normal. This problem corrects itself when the motor
has adequately cooled. Check for mechanical obstructions.
•
Constantly ON: Motor current is at the maximum allowed and is
being electronically limited. Check for mechanical obstructions.
•
Flickering: If the motor starts under
From
0.8 1.5 2.0
significant load, the current may be
To
1.5 2.0 2.5
limited briefly causing the LED to
flicker. If the LED flickers constantly, Speed (%) 25 30 35
this is an indication that the motor
16
0
.75
Power Requirements
•
Power In
•
24.0V DC nominal at selected motor max amperage
•
Normal operation from 22.0 - 28.0 VDC
•
Will allow operation above 28.0 VDC but control will
get hotter.
•
Will allow operation below 22.0 VDC but full speed
will be unattainable
•
29.0 + 0.2 VDC over-voltage detection (unit will cease
normal operation)
•
19.0 + 0.2 VDC under-voltage detection (unit will cease
normal operation)
•
Polarity protection is provided
•
Note that the control’s ground does not attach to
the metal chassis; doing so assures a solid ground
but then if the power supply is reversed it’s positive
output
•
Fuse is a non-replaceable 10A fuse.
•
PNP Inputs
•
PNP Input Signal Levels
•
Active when pulled up above 18.0 VDC
•
Need to be able to source 3 mA
•
Two input signal
•
Motor Run
•
Motor Reverse
•
Analog Speed Input
•
Allow the speed to be controlled from a single point
•
Voltage range: 0-10 VDC
•
Minimum impedance presented to input: 5K
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
10.0
40
45
50
55
60
65
70
75
80
85
90
95
100
•
PNP Output
•
Signal Levels
•
Sources current when active
•
Maximum current for this unprotected output is
50mA
•
A 150Ω series resistor helps the PNP output limit
current draw for most situations; voltage out is
thus lower as current draw increase
•
Voltage dependents on input power and current
draw.
•
One output signal
•
Motor Running
Environmental Requirements
•
Temperature
•
The unit shall operate within specified limits over the range
of -20 to 40°C (-4 to 120°F)
•
The unit can be stored in the range of -40 to 85°C (-40 to
185°F)
•
Humidity
•
The unit shall operate within specified limits in relative
humidity in the range of 20 to 90% (non-condensing)
•
The unit can be stored in the range of 5 to 95% (noncondensing)
Safety - Unintended Use Considerations
•
Installer
•
This product is intended for installation by qualified
personnel only; although of relatively low voltage there are
dangerous levels of current controlled on the board that are
not protected from misplaced fingers.
•
Note that the cover makes it difficult to touch any
power other than the fuse.
•
A tool will be required to tweak the pot or move
the DIP switches; a plastic-tip screwdriver is
recommended.
•
Should the on-board fuse require replacement, always use
only that detailed in this specification.
•
User
•
Product shall be located away from the user such that
touching of the control is not possible.
What is Standard?
Motors - The 36W24 (033.09022) motor is standard on our 190E24
horizontal conveyor line. It only has 4 in-lb of torque, but that is similar
to what the 100W24 motor has at 1.5A. It has been determined that the
limiting factor on driving the 190E24 is the o-rings and not the motor, thus
the o-ring will slip before the motor stalls. This motor has the advantage
of having the speed range of the 100W24 and the 125W24 motors and
to also have a built in motor control card. Because it has a built in motor
control card, the height of the motor is higher, thus we are only offering, as
standard, the 36W24 on conveyor with the motors mounted on the inside.
When motors need to be mounted on the outside on a 190E24, then the
100W24 (033.09001) motor is used because it can stay within the flanges of
the conveyor. The 100W24 motor is also used on incline 190E24 conveyor
and units that use stronger/stiffer o-rings. We do this more as a precaution
than anything else. Using the 100W24 motor and the standard motor
control card (033.09002) gives us the option to bump the amps up to 3.0 to
give additional torque, if needed.
The 100W24 motor (033.090217) motor is standard on the E24™ transfers.
This motor is different than the motor mentioned above. This motor has
a 1.8” long round keyed shaft, where the above motor has a 2.5” long “D”
shaft.
The 125W24, 160W24, and the 200W24 motors are all optional for all
E24™ applications. These motors provide faster speeds; they do not offer
more torque. In other words, if you are currently moving a product with a
100W24 motor but now you need to move it faster, then
a higher wattage motor would help. If you introduce a heavier product to
the conveyor and the 100W24 motor won’t move it, or it struggles to move
it, getting a higher wattage motor is not going to help. The ONLY time
this is not true is when you are using a speed up spool. Speed up spools
are larger in diameter, so, in effect, you are losing torque capacity when
compared to the standard spool. So, if a 100W24 motor with a speed up
spool barely moves a product, then a higher wattage motor with a smaller
spool may move it just fine. Keep in mind that typically, our standard o-rings
will be the limiting factor.
PowerCube’s are E24™ motors coupled to a right angle worm gear
reducer. The 125W24, 5:1 ratio PowerCube (907.0310) is standard on
our 199CRE24EZ and 199PVE24EZ conveyors. The 124W24, 7.5:1 ratio
PowerCube (907.0311) is standard on our 25CRE24EZ and 25PVE24EZ
conveyors. Other PowerCube’s are available, if needed. Higher wattage
motors (160W and 200W) are available for higher speeds, and other ratios
(up to 30:1) are available for more torque. Just a note: the 100W motor is
not available in a PowerCube configuration.
Motor Control Cards - The 033.09002 motor control card is standard for
use with the 100W24 motor. It is selectable from a 1.5A max setting to a
3.0A max setting. As standard, it is set on the 1.5A setting. Only in certain
cases, such as inclines or using stronger/stiffer o-rings, would we need to
us the 3.0A setting.
The 033.090025 motor control card is commonly referred to as our Transfer
Card. As you guessed, it is standard for use on our E24™ transfers using
the 100W24 motor. It is selectable from 1.5A max setting to a 4.0A max
setting. It is typically set to the 4.0A setting for transfers. Transfers typically
require more torque to get the product out of the way quickly to help with
through put. As stated earlier, torque is proportional to amperage, thus this
card allows all the amps the 100W24 motor is rated for, to get maximum
torque to accelerate the product as quickly as possible.
The 033.090023 motor control card is known as the 7A card. It is required
on all higher wattage motors and PowerCubes. This card is selectable to
be used with all of our motors.
Just a note on sizing power supplies. When using the 36W24 (033.09022)
motor or any 100W24 motor with a card set on the 1.5A setting on a 190E24
conveyor, we assume a 1 amp draw per motor. Why use 1 amp instead of
1.5 amp? Because we have tested and confirmed that with our standard
o-ring, 1 amp is all the motor requires. The o-ring will start slipping before
it gets up to 1.5 amps. Also, count all transfers as using 4 amps and when
using higher wattage motors, use the value of max amp draw of the card.
See chart below for the 7A card (033.090023).
Amp Draw
17
100W24
125W24
160W24
200W24
4.0A
5.0A
6.0A
7.0A
Power switch - When the switch is in the ‘off’ position, the motor will revert to the on board speed potentiometer.
When the switch is in the ‘on’ position, the motor speed will be determined by the GSC.
Global Speed Controller
Control Knob - Rotate clockwise to increase speed, counter-clockwise to decrease speed with 16 voltage steps
The E24™ Global Speed Controller (GSC) is capable of sending a speed reference
input to multiple E24™ version
2.0 controlMaximum
cards from
one source.
The GSC
in-between.
speed
is 275 RPM,
minimum speed is 55 RPM.
supplies an analog signal ranging from 1 to 10 VDC. This signal is passed through
the brown wire of the E24™ wiring harness. Each GSC can control the speed of
up to 20 control cards. The GSC is connected between the power supply and the
Connections
Male connector
into the power supply or female end of a wiring harness. Female end
first wiring harness. The GSC isCable
equipped
with an on/off- switch
and a speedplugs
control
knob.
plugs into a t-cable or the first wiring harness that is to be controlled by the GSC. The speed control is only sent
Power Switch - When the switch is in the ‘off’ position, the motor will revert to the
of the
end
of the
on board speed potentiometer.out
When
thefemale
switch is
in the
‘on’cable.
position, the motor
speed will be determined by the GSC.
Control Knobs - Rotate clockwise
to increase
speed, -counter-clockwise
to wire located in the wiring harness to input terminal number 3 of
E24™ Card
Connection
Connect the brown
decrease speed with 16 voltage steps in-between. Maximum speed is 275 RPM,
minimum speed is 55 RPM. each control card desired to respond to the GSC.
Cable Connections - Male connector plugs into the power supply or female end
of a wiring harness. Female end plugs into a t-cable or the first wiring harness that
20The
Amp
Power
- Requires
Global Speed Controller Hytrol part number 033.09011, (1) Gender
is to be controlled by the GSC.
speed
controlsupply
is only sent
out of the(1)
female
end of the cable.
Changing Cable Hytrol part number 032.70199 and (1) Power T-Cable Hytrol part number 032.70196.
E24™ Card Connection - Connect the brown wire located in the wiring harness to
input terminal number 3 of each control card desired to respond to the GSC.
20 Amp Power Supply - Requires (1) Global Speed Controller Hytrol part number
033.09011, (1) Gender Changing Cable Hytrol part number 032.70199 and (1)
Power T-Cable Hytrol part number 032.70196.
40 Amp Power Supply - Requires (2) Global Speed Controllers Hytrol part number
033.09011 and (1) Gender Changing Cable Hytrol part number 032.70199.
40 Amp Power supply - Requires (2) Global Speed Controllers Hytrol part number 033.09011 and (1) Gender
Changing Cable Hytrol part number 032.70199.
For additional information or questions, please contact our Customer Care Center wecare@hytrol.com
Sincerely,
18
E24EZ Transfer Merge EZLogic® Control Function
Components Required
The components required (in addition to the standard EZLogic® components
normally supplied) to use the transfer merge function include:
• (1) EZLogic® enhanced zone controller, located in the “transfer”
zone of the trunk line. This zone controller will be configured to control
the transfer merge. This controller may be the 032.505 unitized retroreflective zone controller or the 032.506 unitized diffuse zone controller.
If the retro-reflective type is used, a small rectangular reflector must
also be used, mounted between the conveyor rollers in the area of the
“mouth” of the infeeding line.
• A Hytrol-provided “transfer merge connection kit,” Hytrol part
number TC-001504. This kit is used to provide all of the control and
power connections required by EZLogic® and the transfer motor and
lift system. This kit is provided pre-assembled. The installer is only
required to mount the enclosure to the conveyor frame and make all
required plug-in connections. No additional wiring is required.
Connect to E24
wiring harness
Connect to E24
wiring harness
Connect to
transfer motor
Connect to
controller “A”
Connect to
controller “B”
Connect to transfer
solenoid valve
19
Installation and configuration of the
Zone Controller “B”,
transfer merge control includes the
Zone Controller “A”,
in discharge zone of
following steps:
enhanced, in receiving zone
infeeding line
1. Mount the connection kit near
of trunk line
the transfer so that all required
connections are within reach
of the provided cables and
connectors.
2. Connect the E24 wiring harness
connector on the connection
kit box to the wiring harness of
the conveyor. NOTE: This may
require other wiring harness
components, depending on
your conveyor layout. Contact
the Hytrol factory if you have
questions
about
required
cabling.
3. Connect the connector labeled
“To Transfer Motor” to the power connection pins of the E24 transfer motor control board, located on the transfer base.
4. Plug the connector labeled “To Transfer Solenoid Valve” to the solenoid air valve of the transfer, located on the transfer base.
5. Connect to the zone controller in the discharge zone of the feeding conveyor (location “B” in the illustration) using an EZLogic® USB programming
cable and Genesis™ 2.0 software running on a Windows PC.
6. In Genesis™, click the “edit” button on the main screen, then double-click in the “Auxiliary Input Mode” edit box. This will bring up the “Auxiliary Input
Wizard” screen. Make sure “zone stop” is selected, then click “Next.” On the next screen, select “Zone Stop signal must be active for a carton to run
(“failsafe”)” and click the “Finish” button.
7. Disconnect the programming cable from the controller and plug the
connector labeled “connect to controller B” to the auxiliary port.
8. If it is not already installed, install an EZLogic® enhanced zone
controller in the “transfer” zone of the trunk line (location “A” in the
illustration). Connect to the enhanced zone controller in location “A”
using the EZLogic® USB programming cable and Genesis™ 2.0
software.
9. In Genesis™, click the “Edit” button on the main screen, then doubleclick in the “Special Logic Function” edit box. This will bring up the
“Special Logic Configuration Wizard” screen. NOTE: If the “Special
Logic Configuration does not look like the one shown to the right,
you may be connected to a standard zone controller.
10. Select “Transfer Merge” from the list on the left of the wizard, then
click on the green arrow in the center of the wizard. The “Transfer
Merge” function will now appear in the list on the right. Click “Next”,
then click “Continue”. This will bring up the “Transfer Merge”
wizard.
11. The “Transfer Merge” wizard asks for three parameters. The first
two are determined by the mechanical configuration of the conveyor:
the speed of the conveyor, in feet per minute, and the length of the
zones in the trunk line, in inches. The third parameter allows you to
adjust the amount of time that is allowed for a box released from
the infeeding line to clear the infeeding line before the transfer is
allowed to return to the lowered position. This timer is used to adjust
the “drop point” of the box onto the trunk line. This value is entered
in milliseconds of delay required. Usually the default value of 250
milliseconds is sufficient.
12. Once you have entered the required parameters, click “Done.” On the
main Genesis™ screen, the “Special Logic Function” will be listed as
“Transfer Merge,” highlighted in red to indicate that the function has
not yet been written to the zone controller. In addition, the “Auxiliary
Input Mode” will be changed to “Configurable Logic Input” and the
“Auxiliary Output Mode” will be changed to “Configurable Logic
Output (NO)”, also highlighted in red. These settings are necessary for
proper operation of the transfer merge function and are automatically
changed by the wizard. DO NOT ALTER THESE SETTINGS. Click
“Done” to write the changes to the zone controller.
13. Disconnect the programming cable from zone controller “A”.
Connect the other connector labeled “connect to controller A” to
zone controller “A”.
20
Spur Merge EZLogic® Control Function
Components Required
The components required
(in addition to the standard
EZLogic®
components
normally supplied) to use
the spur merge function
include:
•
(1)
EZLogic®
enhanced
zone
controller,
located
in the “spur” zone of
the trunk line (see
illustration).
This
zone controller will be
configured to control
the transfer merge.
This controller may be
the 032.505 unitized
retro-reflective zone
controller or the
032.506
unitized
diffuse zone controller. If the retroreflective type is used, a small rectangular
reflector must also be used, mounted
between the conveyor rollers in the area
of the “mouth” of the infeeding line.
• (1) Hytrol-provided connection kit
(Hytrol part number TC-001506). This
kit utilizes the auxiliary ports on the
zone controllers. The kit consists of
three EZLogic® Auxiliary I/O modules,
a junction box with terminals to provide
the proper wiring connections, and a
mounting bracket and hardware. The
illustration shows the connection kit. Not
shown are the mounting bracket and
hardware. The cover of the junction box is
also not shown so that the terminals and
connections can be seen. Please note,
however, that all connections are prewired from the Hytrol factory. Removal
of the cover is not required to install or
configure the connection kit.
Zone Controller “C”,
located at “mouth” of spur
Zone Controller “A”
(enhanced), located
near center of
“mouth” area of spur
on trunk line
Installation and configuration of the spur merge control using the
connection kit method includes the following steps:
1. Mount the connection kit junction box to the trunk line conveyor on
the spur side.
2. Plug the auxiliary I/O adapters to the auxiliary ports of zone controllers
“B” and “C” as shown in the illustrations above and below. Do not
connect to zone controller “A” at this time.
3. If it is not already installed, install an EZLogic® enhanced zone
controller in location “A”. Connect to the enhanced zone controller
in location “A” using an EZLogic® USB programming cable and
Genesis™ 2.0 software running on a Windows PC.
4. In Genesis™, click the “Edit” button on the main screen, then doubleclick in the “Special Logic Function” edit box. This will bring up the
“Special Logic Configuration Wizard” screen. NOTE: If the “Special
Logic Configuration does not look like the one shown to the right,
you may be connected to a standard zone controller.
5. Select “Spur Merge” from the list on the left of the wizard, then click
on the green arrow in the center of the wizard. The “Spur Merge”
function will now appear in the list on the right. Click “Next”, then
click “Continue”. This will bring up the “Spur Merge” wizard.
21
Zone Controller
“B”, located in the
zone immediately
downstream of the
spur
6.
The “Spur Merge” wizard asks for three parameters. The first two
are determined by the mechanical configuration of the conveyor:
the speed of the conveyor, in feet per minute, and the length of the
zones in the trunk line, in inches. The third parameter allows you to
adjust the amount of time that is allowed for a box released from
the spur line to clear the spur line before releasing the boxes on the
trunk line. This timer is used to compensate for the length of a spur
if the last zone of the spur is several inches away from the trunk
line. It may also be used to give the spur line “priority” by allowing
more boxes to be released from the spur line before the trunk line
is allowed to release. This value is entered in milliseconds of delay
required.
7. Once you have entered the required parameters, click “Done.” On
the main Genesis™ screen, the “Special Logic Function” will be listed
as “Spur Merge,” highlighted in red to indicate that the function has
not yet been written to the zone controller. In addition, the “Auxiliary
Input Mode” will be changed to “Configurable Logic Input” and the
“Auxiliary Output Mode” will be changed to “Configurable Logic
Output (NO)”, also highlighted in red. These settings are necessary
for proper operation of the spur merge function and are automatically
changed by the wizard. DO NOT ALTER THESE SETTINGS. Click
“Done” to write the changes to the zone controller.
8. Disconnect the programming cable from zone controller “A”. Connect
the proper auxiliary I/O adapter to zone controller “A”.
9. Connect the programming cable to zone controller “B”. Select
“Edit”.
10. Double-click the “Auxiliary Output Mode” edit box. This will bring
up the “Auxiliary Output Mode” wizard. Select “Zone Blocked and
Stopped” from the list. Click “Next”. Then click “Finish”. On the main
screen, click “Done”.
11. Disconnect the programming cable from zone controller “B”. Connect
the proper auxiliary I/O adapter to zone controller “B”.
Connect to Zone
Controller “A”
Connect to Zone
Controller “B”
Connect to Zone
Controller “C”
22
Square Merge EZLogic® Control Function
Components Required
The components required (in addition to the standard EZLogic® components
normally supplied) to use the square merge function include:
• (1) EZLogic® enhanced zone controller, located in the “receiving”
zone of the trunk line. This controller may be the 032.505 unitized retroreflective zone controller or the 032.506 unitized diffuse zone controller.
If the retro-reflective type is used, a small rectangular reflector must also
be used, mounted between the conveyor rollers in the area of the “mouth”
of the infeeding line.
• (2) EZLogic® auxiliary I/O modules (032.532)
Installation and configuration of the spur merge control using the connection
kit method includes the following steps:
1. The two auxiliary I/O modules must be wired together as follows:
2.
3.
4.
5.
6.
7.
8.
9.
a. The orange wire from one auxiliary I/O module must be
wired to the brown wire of the other auxiliary I/O module. This
must be done in both directions; in other words, the orange
wire of one must be wired to the brown wire of the other, and
vice versa.
b. The violet wire from one auxiliary I/O module must be wired
to the blue wire of the other auxiliary I/O module. This must be
done in both directions; in other words, the violet wire of one
must be wired to the blue wire of the other, and vice versa.
c. The white and gray wires of the two auxiliary I/O modules are
not used, and may be cut short or otherwise managed.
The result of the above steps should be similar to what is shown
in the illustration. NOTE: These connections may be performed using crimp-on style wire splices, by wiring them to terminals in a junction box (not
supplied), etc.
Connect to the zone controller in the discharge zone of the feeding conveyor (location “B” in the illustration) using an EZLogic® USB programming
cable and Genesis™ 2.0 software running on a Windows PC.
In Genesis™, click the “edit” button on the main screen, then double-click in the “Auxiliary Input Mode” edit box. This will bring up the “Auxiliary Input
Wizard” screen. Make sure “zone stop” is selected, then click “Next.” On the next screen, select “Zone Stop signal must be active for a carton to run
(“failsafe”)” and click the “Finish” button.
5. Disconnect the programming cable from the controller and plug one end of the previously-wired auxiliary I/O module assembly to the auxiliary
port.
If it is not already installed, install an EZLogic® enhanced zone controller in the “receiving” zone of the trunk line (location “A” in the illustration).
Connect to the enhanced zone controller in location “A” using the EZLogic® USB programming cable and Genesis™ 2.0 software.
In Genesis™, click the “Edit” button on the main screen, then double-click in the “Special Logic Function” edit box. This will bring up the “Special Logic
Configuration Wizard” screen.
NOTE: If the “Special Logic
Configuration does not look
Zone Controller “B”,
like the one shown, you may
in discharge zone of
Zone Controller “A”,
be connected to a standard
infedding line.
enhanced, in receiving
zone controller.
zone of trunk line.
Select “Square Merge” from
the list on the left of the wizard,
then click on the green arrow
in the center of the wizard.
The “Square Merge” function
will now appear in the list on
the right. Click “Next”, then
click “Continue”. This will
bring up the “Square Merge”
wizard.
The “Square Merge” wizard
asks for two parameters.
These
are
23
determined by the mechanical configuration of the conveyor: the
speed of the trunk conveyor, in feet per minute, and the length of
the receiving zone in the trunk line, in inches.
10. Once you have entered the required parameters, click “Done.”
On the main Genesis™ screen, the “Special Logic Function” will
be listed as “Square Merge,” highlighted in red to indicate that
the function has not yet been written to the zone controller. In
addition, the “Auxiliary Input Mode” will be changed to “Configurable
Logic Input” and the “Auxiliary Output Mode” will be changed to
“Configurable Logic Output (NO)”, also highlighted in red. These
settings are necessary for proper operation of the square merge
function and are automatically changed by the wizard. DO NOT
ALTER THESE SETTINGS. Click “Done” to write the changes to
the zone controller.
11. Disconnect the programming cable from zone controller “A”.
Connect the other connector from the previously-wired auxiliary I/O
module assembly to zone controller “A”.
24
E24™ Transfer Drawing and Parts List
19
20
21
13
4
11
15
16
14
1
2
17
1
3
5
11
4
8
7
7
18
2
15
16
1
21
9
6
12
3
12
10
5
ITEM
PART NUMBER
DESCRIPTION
ITEM
PART NUMBER
DESCRIPTION
1
2
3
4
5
032.211
033.090017
033.090025
Contact Factory
923.010225
PROX SWITCH - DC,INDUCTIVE,N.O. 30MM DIA
UNIDRIVE MOTOR-DC,1.8"LG KEYED SHAFT(E24)
UNIDRIVE MOTOR CONTROL-E24 1.5/4A RATING
TIMING BELT - 3/8"WIDE X Specify BR
GUIDE TABLE - 100MM BORE, 40MM STROKE
15
16
17
18
19
Contact Factory
Contact Factory
Contact Factory
SA-044897
Contact Factory
SIDE MTG CHNL - TMB TRANSFER
SIDE MTG CHNL - RH, PROX SIDE
LIFT CHNL -2 TO 6 STR TB XFER,17"&UP BRG
TAKE-UP KIT - 190E24EZB
STRAND PLATE ASSY -RH,DR SD,190E24
6
7
8
9
DG-001215
DG-001264
Contact Factory
PT-074144
PT-101157
PLUMBING DIAGRAM - XFER LIFT, 24VDC
PLUMBING DIAGRAM - XFER LIFT, 120VAC
STRAND CROSS BRACE
BRACE MOUNTING CLIP - 1" X 1-1/2"
CONTROL CARD MTG ANGLE - 190E24EZ
20
21
Contact Factory
SEE DETAIL
STRAND PLATE ASSY -RH,DR SD,190E24
DR SHAFT ASSY - 3/4"DIA
10
11
12
13
14
PT-104219-BR
PT-105341
PT-106848-BR
PT-107264-BR
PT-156373-BR
CROSS BRACE - TB XFER, 190E24
O-RING GUARD - 3"RC, 190E24
BTM GD- TB XFER,7.5"HI CHNL,190E24
END GUARD - TB XFER, 190E24
Z-STRIKER BRACKET
25
BR
OAW
B
3
6"
3,6,9
APPROXMATLY
1 3/16” ABOVE ROLLER
6 1/2
8
1 1/2
SECTION B-B
SCALE 1 / 4
B
1
5
3
7
1
2
4
6
ITEM
PART NUMBER
1
2
3
4
010.001
028.800
090.202
912.0294
BEARING - CAST IRON, 2-BOLT, 3/4"BORE
TIMING BELT SPKT - 18 TOOTH, 3/8"PITCH
SHAFT KEY - 3/16"SQ X 1"LG
TIMING BELT - 3/8"PITCH, 44 TOOTH
5
6
7
913.0250
952.0021
Contact Factory
TIMING BELT SPKT - 48 TOOTH
TIMING BELT SPKT - 18 TOOTH, 3/8"PITCH
DRIVE SHAFT - TB XFER, 190E24
26
DESCRIPTION
APPROXMATLY
3/8" BELOW ROLLER
E24™ Single Diverter
24
24
A
25
17
3
21
35
38
14
10
33
1
4
8
9
6 3/8
13
10 19/32
14
4
12
15
2
4
32
28
16
26
5
4
7
B
B
1
26
26
37
36
34
29
27
30
30
31
NOTES:
A
1. SPEED RANGE 50 TO 200 FPM.
2. LARGE PULLEY TO BE PLACED ON E24 MOTOR SHAFT.
3. SEE DG-001539-BR FOR HARDWARE
SECTION B-B
SCALE 5/8
8 3/4
ITEM
PART NO.
ITEM
PART NO.
1
2
3
4
5
010.0021
019.224
019.234
033.090017
033.09002
DESCRIPTION
BEARING - CAST IRON, 2-BOLT, 1"BORE
FEMALE ROD END - 7/16-20 RH THREADS
MALE ROD END - 7/16-20 RH THREADS
UNIDRIVE MOTOR - DC,1-3/8"LG SHAFT (E24)
UNIDRIVE MOTOR CONTROL
21
22
23
24
25
923.0134
927.0203
PT-107698
PT-107701
PT-107719-BR
SUPPORT BLOCK - PIVOT DIVERTER, E24
350-5M-9H TIMING BELT, BANDO (Not Shown)
SIDE SUPPORT ANGLE - E24 PPD (Not Shown)
ACTUATOR ATTACHMENT ANGLE - E24 PPD
DRIVE SHFT-1"DIA,20-3/8"LG,E24 PPD
6
7
8
9
10
090.2002
090.255841
094.10795
094.10796
094.10825
SHAFT KEY - 1/8"SQ X 3/4"LG (Not Shown)
O-RING - 6.207"ID X 3/16"THICK
4-WAY SINGLE SOL AIR VALVE - 24VDC
PICO CONNECTOR CABLE FOR VALVE #094.1079
SPEED CONTROL MUFFLER - 1/8"NPT, BRASS
26
27
28
29
30
PT-108868-L
PT-108868-R
PT-111065-BR
PT-111130
PT-111132
ROLLER SUPT BRACKET - LH
ROLLER SUPT BRACKET - RH
PIVOT ANGLE - E24 PPD
GUARD - E24 PPD
TIMING BELT GUARD - E24 POWER PIVOT
11
12
13
14
15
094.11481
094.1206
094.1406
094.4101
094.42510
1/4"OD POLYURETHANE TUBING - GREEN (Not Shown)
AIR CYLINDER - 2"STROKE, 32MM BORE
PLASTIC ELBOW - MALE, 360D SWIVEL W/RET
DRIVE SPOOL - 2"DIA W/INTEGRAL KEY
SPOOL SPACER - 5/8"LG, 1"SHAFT, NYLON
31
32
33
34
35
PT-111133
PT-119273
Contact Factory
SA-049652-*8
SA-056593
TIMING BELT GUARD - E24 POWER PIVOT
ACTUATOR PLATE - 19-39"BR, E24 PPD
SPOOL SPACER - 3/4"LG, 190NSP,NSPEZ
1.9"OD GALV DBL GRV RLR- NO SPR,4"BR
PIVOT DIVERTER SHEAVE ASSY
16
17
19
20
098.150
098.184
923.0113
913.0252
SPACER - .406"ID X .75"OD X .375"LG
COLLAR - 1"ID X 1-9/16"OD X 5/8"THICK
STEEL PULLEY -KEYWAY,P22-5M-9 X 1/2"B (Not Shown)
STEEL PULLEY - P34-5M-9 X 1/2" B (Not Shown)
36
37
38
39
40
WA-032956-BR-L
WA-032956-BR-R
WA-037046
DG-001539-BR
DG-001542-BR
27
DESCRIPTION
BASE WELD - LH,E24 PPD
BASE WELD - RH, E24 PPD
DIVERT SHAFT WELD - E24 PPD
HARDWARE KIT - DOUBLE E24 PPD (Not Shown)
HARDWARE KIT - SINGLE E24 PPD (Not Shown)
E24™ Double Diverter
A
23
25
24
17
21
35
38
14
33
10
1
9
4
8
6 3/8
13
10 19/32
14
28
4
12
15
28
2
4
7
B
16
32
27
26
5
5
B
4
1
26
26
37
36
37
30
34
29
27
31
SECTION A-A
SCALE 7/16
A
6 1/32
23
2
35
7
16
38
4
SECTION B-B
SCALE 5/8
37
8 3/4
1/2
NOTES:
31
1. SPEED RANGE 50 TO 200 FPM.
2. LARGE PULLEY TO BE PLACED ON E24 MOTOR SHAFT.
3. SEE DG-001539-BR FOR HARDWARE
30
ITEM
PART NO.
ITEM
PART NO.
1
2
3
4
5
010.0021
019.224
019.234
033.090017
033.09002
BEARING - CAST IRON, 2-BOLT, 1"BORE
FEMALE ROD END - 7/16-20 RH THREADS
MALE ROD END - 7/16-20 RH THREADS
UNIDRIVE MOTOR - DC,1-3/8"LG SHAFT (E24)
UNIDRIVE MOTOR CONTROL
DESCRIPTION
21
22
23
24
25
923.0134
927.0203
PT-107698
PT-107701
PT-107719-BR
SUPPORT BLOCK - PIVOT DIVERTER, E24
350-5M-9H TIMING BELT, BANDO (Not Shown)
SIDE SUPPORT ANGLE - E24 PPD
ACTUATOR ATTACHMENT ANGLE - E24 PPD
DRIVE SHFT-1"DIA,E24 PPD
6
7
8
9
10
090.2002
090.255841
094.10795
094.10796
094.10825
SHAFT KEY - 1/8"SQ X 3/4"LG
O-RING - 6.207"ID X 3/16"THICK
4-WAY SINGLE SOL AIR VALVE - 24VDC
PICO CONNECTOR CABLE FOR VALVE #094.1079
SPEED CONTROL MUFFLER - 1/8"NPT, BRASS
26
27
28
29
30
PT-108868-L
PT-108868-R
PT-111065-BR
PT-111130
PT-111132
ROLLER SUPT BRACKET - LH
ROLLER SUPT BRACKET - RH
PIVOT ANGLE - E24 PPD
GUARD - E24 PPD
TIMING BELT GUARD - E24 POWER PIVOT
11
12
13
14
15
094.11481
094.1206
094.1406
094.4101
Contact Factory
1/4"OD POLYURETHANE TUBING - GREEN (Not Shown)
AIR CYLINDER - 2"STROKE, 32MM BORE
PLASTIC ELBOW - MALE, 360D SWIVEL W/RET
DRIVE SPOOL - 2"DIA W/INTEGRAL KEY
SPOOL SPACER - 5/8"LG, 1"SHAFT, NYLON
31
32
33
34
35
PT-111133
PT-119273
Contact Factory
SA-049652-*8
SA-056593
TIMING BELT GUARD - E24 POWER PIVOT
ACTUATOR PLATE - 19-39"BR, E24 PPD
SPOOL SPACER - 3/4"LG, 190NSP,NSPEZ
1.9"OD GALV DBL GRV RLR- NO SPR
PIVOT DIVERTER SHEAVE ASSY
16
17
19
20
098.150
098.184
923.0113
913.0252
SPACER - .406"ID X .75"OD X .375"LG
COLLAR - 1"ID X 1-9/16"OD X 5/8"THICK
STEEL PULLEY -KEYWAY,P22-5M-9 X 1/2"B (Not Shown)
STEEL PULLEY - P34-5M-9 X 1/2" B (Not Shown)
36
37
38
39
40
WA-032956-BR-L
WA-032956-BR-R
WA-037046
DG-001539-BR
DG-001542-BR
28
DESCRIPTION
BASE WELD - LH,E24 PPD
BASE WELD - RH, E24 PPD
DIVERT SHAFT WELD - E24 PPD
HARDWARE KIT - DOUBLE E24 PPD
HARDWARE KIT - SINGLE E24 PPD
E24™ Powered Transition Roller
5
2
1
4
5
6
10
6
OAW
3
7
BR
6
2
7
6
6
10 1/2
8
4
6
1
ITEM
PART NUMBER
1
2
3
4
5
PT-105477
PT-105478
PT-105341
B-03916-BR
SA-049661
6
7
8
9
10
Contact Factory
033.09001
094.41501
033.09002
927.0185
11
12
13
14
15
040.302
049.5285
040.201
049.528
042.10336
3/8-16 X 3/4"LG HEX HEAD CAP SCREW, ZP
3/8-16 SMALL FLANGE LOCKNUT, ZP
5/16-18 X 3/4"LG HEX HEAD CAP SCREW, ZP
5/16-18 SMALL FLANGE LOCKNUT, ZP
#8-32 X 1/2"LG ROUND HEAD MACH SCR, ZP
16
17
041.801
043.101
#8-32 HEX LOCKNUT - NYLON INSERT, ZP
5/16"ID (3/8"BOLT) FLAT STEEL WASHER, ZP
Note:
DESCRIPTION
6"LG SIDE CHNL - 10-1/2"DEEP, 190E24
BUTT CPLG ANGLE - 1-1/4" X 6-1/4" X 10GA
O-RING GUARD - 3"RC, 190E24
BED SPACER - SPECIFY BR
1.7"OD DBL GRV RLR- PLASTISOL - SPECIFY BR
K-BRACKET - 1-1/2" X 1-5/16" X 6-1/4"
UNIDRIVE MOTOR - DC,2-1/2"LG SHAFT (E24)
DRIVE SPOOL - 2-GROOVE, FOR 25-135 FPM
UNIDRIVE MOTOR CONTROL
O-RING - 2-29/32"ID X 3/16"THICK
• 21 in and less - transition roller section
• 24 in and above - E24 section with no powered rollers
29
9
E24™ GATE
48
1/2
GAP
47 1/2
30
E24EZ GATE
7
1
9
11
48"
1/2
GAP
47 1/2
3
45
6
5 9/16
4
5
10
9
ITEM
PART NUMBER
1
2
3
4
5
032.218
032.286
032.501
033.09002
099.102
6
7
8
9
10
11
B-20507-042
B-20508-042
B-20601
CONTACT FACTORY
PT-062877
PT-066668
31
DESCRIPTION
REFLECTOR - 2.20"DIA, .23"DIA MTG HOLE
TILT SWITCH
UNITIZED ZONE CTRL-POL REFLEX TRANSDUCER
UNIDRIVE MOTOR CONTROL
KNOB - BLACK PLASTIC, 1"DIA, 3/8-16 THDS
ACCUM CHNL - 41-7/8"LG
REFLECTOR CHNL - 41-7/8"LG
MTG ANGLE - REFL CHNL,190ABEZ,SPEZ
GATE HINGE ASSEMBLY
GATE LATCH - 5-3/4"LG, DSG
K-BRACKET - 1-1/2" X 1" X 6-1/4"
1 E24™ MOTOR
Connect this end to power supply.
This end should be located toward the hinge of
the gate to allow connection with power supply.
2
A
3
WITH POWER SUPPLY
1
YELLOW
RED
BLACK
YELLOW
BROWN
RED
4
BLACK
8
YELLOW
Detail A
Scale 1.25:1
7
BLACK
5
1-8
9 - 12
Switch #2
set to off (left)
13 - 14
PINS 1 - 8
Motor Connection
PINS 9
Yellow Wire From
Wiring Harness
Power Connection
From Wiring Harness
WITHOUT POWER SUPPLY
POWER SUPPLY
Ref. No.
Part No.
Description
1
2
3
4
032.70502
033.09002
033.09001
032.287
Wiring Harness, 5 Ft Long, with 2 Drops
Unidrive Motor Control
Unidrive Motor - DC, 2 1/2" Lg Shaft
Tilt Switch - Encapsulated, Non-Mercury
5
6
7
8
EB-000007
037.002402
037.002401
036.037
E24 Power Supply - 5 Amps, 115/230V 1 PH
Female 4 Pin Inline Connector
Male 4 Pin Inline Connector
Standard Conductor Wire - 16 AWG, Red
Detail B
Scale 1:1
1-8
9 - 12
Switch #2 set
to off (left)
13 - 14
Use red wire (036.037) to connect motor run (Pin #9)
To Pin #1 on male connector (037.002401)
DO NOT CONNECT YELLOW WIRE FROM
WIRING HARNESS TO TILT SWITCH
Power connection
from wiring harness
This end should be located toward the hinge of
the gate to allow connection with upstream unit.
2
B
3
1
RED
(036.037)
RED
BLACK
BROWN
9
GATE OPERATION:
With this configuration when gate
is in the up position, the gate will
stop, but the power source until
will continue to operate.
FROM
WIRING
RED
HARNESS
BROWN
BLACK
RED
4
YELLOW
BLACK
8
BLACK
32
BLACK
7
YELLOW
Detail C
Scale 1:1
2 E24™ MOTORS
Connect this end to power supply.
This end should be located toward
the hinge of the gate to allow
connection with power supply.
WITH POWER SUPPLY
A
B
1
YELLOW
RED
3
2
BLACK
RED
5
Switch #2
Set to on (Right)
BROWN
YELLOW
4
Detail B
Scale 1 : 1
BLACK
YELLOW
BLACK
Pin 9
Red Wire (036.037)
From Pin 12 of
Upstream Card
8
7
Detail A
Scale 1 : 1
1-8
9-12 13-14
POWER SUPPLY
Pin 1-8
Motor Connection
Switch #2
Set to off (Left)
Pin 9
Yellow Wire From
Wiring Harness
Pin 12
Power
Red Wire (032.037)
Connection
To Pin 9 of Downstream
From Wiring
Card
Harness
Ref. No.
Part No.
Description
1
2
3
4
032.70404
033.09002
033.09001
032.287
Wiring Harness, 5 Ft Long, with 4 Drops
Unidrive Motor Control
Unidrive Motor - DC, 2 1/2" Lg Shaft
Tilt Switch - Encapsulated, Non-Mercury
5
6
7
8
EB-000007
037.002402
037.002401
036.037
E24 Power Supply - 5 Amps, 115/230V 1 PH
Female 4 Pin Inline Connector
Male 4 Pin Inline Connector
Standard Conductor Wire - 16 AWG, Red
Detail C
Scale 1:1
1-8
9-12 13-14
Switch #2
Set to off (Left)
WITHOUT POWER SUPPLY
Pins 1-8
Motor Connection
Pin 9
Red Wire (036.037)
To Pin 1 on male connector (037.002401)
DO NOT CONNECT YELLOW WIRE FROM
WIRING HARNESS TO TILT SWITCH
Pin 12
Red Wire (036.037)
To Pin 9 of Downstream Card
3
GATE OPERATION:
With this configuration when gate
is in the up position, the gate will
stop, but the power source until
will continue to operate.
2
4
RED
9
E
1
RED
D
YELLOW
BLACK
RED (036.037)
To Pin 9
BROWN
BLACK
8
BLACK
Switch #2
Set to on (Right)
Pin 9
Red Wire (036.037)
From Pin 12 of
Upstream Card
This end should be located toward
the hinge of the gate to allow
connection with upstream unit
C
Detail E
Scale 1:1
Power
Connection
from Wiring
Harness
FROM
RED
BROWN WIRING
BLACK HARNESS
9
From Tilt YELLOW
BLACK
Switch
7
33
Detail D
Scale 1:1.6
3 E24™ MOTORS
Detail B
Scale 1:1.14285
WITH POWER SUPPLY
Connect this end to power supply.
This end should be located toward
the hinge of the gate to allow
connection with power supply.
Switch #2
Set to On (Right)
Fron Pin 12
to Pin 9
From Pin 12 to Pin 9
B
A
Switch #2
Set to On (Right)
1
C
YELLOW
RED
BLACK
2
3
9
BROWN
BLACK
8
7
BLACK
YELLOW
RED
4
YELLOW
5
Detail A
Scale 1:1.14285
1-8 9-12 13-14
Pins 1-8
Motor Connection
POWER SUPPLY
WITHOUT POWER SUPPLY
Detail C
Scale 1:1.14285
Part No.
1
2
3
4
032.70404
033.09002
033.09001
032.287
Wiring Harness, 4 Ft Long, with 4 Drops
Unidrive Motor Control
Unidrive Motor - DC, 2 1/2" Lg Shaft
Tilt Switch - Encapsulated, Non-Mercury
5
6
7
8
EB-000007
037.002402
037.002401
036.037
E24 Power Supply - 5 Amps, 115/230V 1 PH
Female 4 Pin Inline Connector
Male 4 Pin Inline Connector
Standard Conductor Wire - 16 AWG, Red
9
Pin 9
Yellow Wire from
Wiring Harness
Power Connection
from Wiring Harness
Pin 12
Red Wire (036.037)
To Pin 9 of Downstream Card
Ref. No.
Switch #2
Set to Off (Left)
Description
This end should be located toward
the hinge of the gate to allow
connection with upstream unit.
D
RED
BLACK
Detail D
Scale 1:1.14285
1-8
9-12 13-14
E
9
Pin 9
Red Wire (036.037)
To Pin 1 on Male
Connector (037.002401)
Do Not Connect Yellow
Wire from Wiring Harness
to Tilt Switch
YELLOW
RED
BROWN
BLACK
BLACK
Pin 1
Red Wire (036.037)
To Pin 9
Detail E
Not to Scale
GATE OPERATION:
With this configuration when gate
is in the up position, the gate will
stop, but the power source until
will continue to operate.
34
2 EZLOGIC® ZONES & 1 E24™ MOTOR PER ZONE
3
1
2
WIRING DETAIL FOR CARDS
1-8
9-12 13-14
BLUE
BROWN
YELLOW
6
BLACK
7
MOUNTED TO CLOSE
WHEN GATE IS OPEN
Pins 1-8
Motor Connection
To Controller
SEE ACCUM KIT
FOR CONTROLLER
Power Connection From
Wiring Harness
5
4
ACCUM POWER / LOGIC IN
EZLogic® controllers will need to be programmed
for zone kill using the Genesis software.
ACCUM POWER / LOGIC OUT
1 EZLOGIC® ZONE & 1 E24™ MOTOR PER ZONE
Ref. No.
Part No.
1
2
3
4
032.70502
033.09002
033.09001
032.563
Description
Wiring Harness, 5 ft Lg, with 2 Drops
Unidrive Motor Control
Unidrive Motor - DC, 2 1/2” LG Shaft
Auxiliary Input Cable - 3’ Lg
5
6
7
032.287
037.002402
037.002401
Tilt Switch - Encapsulated, Non-Mercury
Female 4 Pin Inline Connector
Male 4 Pin Inline Connector
WIRING DETAIL FOR CARDS
1
3
2
BLUE
BROWN
7
MOUNTED TO CLOSE
WHEN GATE IS OPEN
Pins 1-8
Motor Connection
6
YELLOW
BLACK
To Controller
SEE ACCUM KIT
FOR CONTROLLER
Power Connection
From Wiring Harness
5
4
ACCUM POWER / LOGIC IN
EZLogic® controllers will need to be programmed
for zone kill using the Genesis software.
ACCUM POWER / LOGIC OUT
35
Ref. No.
Part No.
1
2
3
4
032.70401
033.09002
033.09001
032.563
Description
Wiring Harness, 4 ft Lg, with 1 Drop
Unidrive Motor Control
Unidrive Motor - DC, 2 1/2” LG Shaft
Auxiliary Input Cable - 3’ Lg
5
6
7
032.287
037.002402
037.002401
Tilt Switch - Encapsulated, Non-Mercury
Female 4 Pin Inline Connector
Male 4 Pin Inline Connector
1 EZLOGIC® ZONE & 2 E24™ MOTOR PER ZONE
WIRING DETAIL FOR CARDS
1
3
Switch #2
Set to On (Right)
Pins 1-8
Motor Connection
Power Connection
From Wiring Harness
BLUE
8
2
MOUNTED TO CLOSE
WHEN GATE IS OPEN
6
BLACK
YELLOW
5
SEE ACCUM KIT
FOR CONTROLLER
Pins 1-8
Motor Connection
BROWN
7
Switch #2
Set to Off (Left) From EZLogic® Controller
Power Connection
From Wiring Harness
4
ACCUM POWER / LOGIC IN
EZLogic® controllers will need to be programmed
for zone kill using the Genesis software.
ACCUM POWER / LOGIC OUT
Ref. No.
Part No.
1
2
3
4
032.70502
033.09002
033.09001
032.563
Wiring Harness, 5 ft Lg, with 2 Drop
Unidrive Motor Control
Unidrive Motor - DC, 2 1/2” LG Shaft
Auxiliary Input Cable - 3’ Lg
5
6
7
032.287
037.002402
037.002401
Tilt Switch - Encapsulated, Non-Mercury
Female 4 Pin Inline Connector
Male 4 Pin Inline Connector
1 EZLOGIC® ZONE & 3 E24™ MOTOR PER ZONE
3
Description
1
7
2
BLUE
WIRING DETAIL FOR CARDS
MOUNTED TO CLOSE
WHEN GATE IS OPEN
SEE ACCUM KIT
FOR CONTROLLER
BLACK
6
5
4
ACCUM POWER / LOGIC IN
Pins 1-8
Motor Connection
YELLOW
BROWN
To Controller
Power Connection
From Wiring Harness
ACCUM POWER / LOGIC OUT
EZLogic® controllers will need to be programmed
for zone kill using the Genesis software.
36
Ref. No.
Part No.
1
2
3
4
032.71003
033.09002
033.09001
032.563
Description
Wiring Harness, 10 ft Lg, with 3 Drops
Unidrive Motor Control
Unidrive Motor - DC, 2 1/2” LG Shaft
Auxiliary Input Cable - 3’ Lg
5
6
7
032.287
037.002402
037.002401
Tilt Switch - Encapsulated, Non-Mercury
Female 4 Pin Inline Connector
Male 4 Pin Inline Connector
HYTROL CONVEYOR COMPANY, INC.
2020 Hytrol Drive
Jonesboro, Arkansas 72401
870.935.3700
www.hytrol.com
EFFECTIVE September 2015
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