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User manual Interroll Z

1. Motor M1 Motor 1 M2 Motor 2 M3 Motor 3 M4 Motor 4 Sensor S1 Sensor 1 S2 Sensor 2 S3 Sensor 3 S4 Sensor 4 S5 This program does not use the connections UP and DOWN or the inputs SIDE1 and SIDE2 28 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Relay module transfer Version 1 2 09 2013 en Translation of the original instructions Product information E1 a F gt DOWN dE SIDE2 M1 D 1 This program is used to control a 90 transfer via a master controller The inputs and outputs required for this have the following assignments Input High Low PLC1 Motor 1 should run Motor 1 should be idle PLC2 Stroke motor 3 4 should run until it reaches the next stop position top or bottom 1 PLC3 see table below PLC4 see table below Output PLC1 Sensor 1 detects object Sensor 1 detects no object PLC2 Sensor 2 detects object Sensor 2 detects no object PLC3 Sensor 3 detects object Sensor 3 detects no object PLC4 Sensor 4 detects object Sensor 4 detects no object SIDE1 Signal from sensor 5 SIDE2 Signal from sensor 6 1 Stop position detected by sensor 5 On reaching the stop position motor 3 stops immediately motor 4 stops just 100 ms later This ensures that the lift will definitely be in the current position Input Meaning PLC3 PLC4 Low Low Motor 2 s
2. Version 1 2 09 2013 en 33 Translation of the original instructions Z Card 3 0 INTERROLL Train release conveyor with 34 start stop Product information M1 Si M2 82 M3 S3 M4 S4 Depending on the program selected only the affected sensors and motors are activated see table below Input and output settings are not affected Number of zones Affected sensors and motors 1 1 for M1 M2 M3 M4 2 S1 for M1 M3 S2 for M2 M4 3 S1 for M1 S2 for M2 S3 for M3 4 S1 for M1 S2 for M2 S3 for M3 S4 for M4 In these programs the Z Card module operates as a conveyor with train release with one two three or four zones respectively This mode corresponds to that of a standard conveyor see page 32 except that a clear signal is sent to the upstream module as soon as the module starts transporting the package to the downstream module In this way a longer row of accumulated packages is transported almost simultaneously WARNING Accidental motor starts If sensor 5 is not connected the starting signal remains on permanently Risk of pinched fingers Invert the signal from sensor 5 with the sensor 5 inversion switch Input High Low PLC1 Package is stopped in zone 1 Package is transported normally in zone 1 PLC2 Package is stopped in zone 2 Package is transported normally in zone 2
3. PLC3 Package is stopped in zone 3 Package is transported normally in zone 3 PLC4 Package is stopped in zone 4 Package is transported normally in zone 4 Output PLC1 Sensor 1 detects object Sensor 1 detects no object PLC2 Sensor 2 detects object Sensor 2 detects no object PLC3 Sensor 3 detects object Sensor 3 detects no object PLC4 Sensor 4 detects object Sensor 4 detects no object Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Product information The connections for motors and sensors have the following assignments Connection Description Motor M1 Motor for zone 1 M2 Motor for zone 2 M3 Motor for zone 3 MA Motor for zone 4 Sensor S1 Sensor for zone 1 S2 Sensorfor zone 2 S3 Sensorfor zone 3 S4 Sensorfor zone 4 S5 Start signal for zone 1 optional This can be used for example for manual placement of a package if there is no upstream system For operation the signal from this sensor must be inverted see warning above Version 1 2 09 2013 en 35 Translation of the original instructions Z Card 3 0 INTERROLL LPA conveyor Product information M1 Si M2 82 M3 S3 M4 S4 Depending on the program selected only the affected sensors and motors are activated see table below Input and output settings are not affected Number of zones Affected sensors and moto
4. Product information The connections for motors and sensors have the following assignments Connection Description Motor M1 Motor for zone 1 M2 Motor for zone 2 M3 Motor for zone 3 MA Motor for zone 4 Sensor S1 Sensor for zone 1 S2 Sensorfor zone 2 S3 Sensorfor zone 3 S4 Sensorfor zone 4 S5 Start signal for zone 1 optional This can be used for example for manual placement of a package if there is no upstream system For operation the signal from this sensor must be inverted see warning above Version 1 2 09 2013 en 37 Translation of the original instructions Z Card 3 0 INTERROLL Merge Product information A merge always has two upstream zones and a downstream zone The path that should be taken can be determined by a master controller e g PLC via inputs PLC2 and PLC3 If a package exits the module the Z Card switches the output PLC1 to High signaling to the master controller that it is ready for a new signal Once a new package is accepted the Z Card switches the output PLC1 back to Low The signal currently pending at inputs PLC2 and PLC3 will be applied to the next package PLC2 PLC3 Meaning Low Low No package is accepted Any incoming packages will remain in front of the module High Low _ The package is transported in the main transport direction no merging Low High The package is merged High High Alternating conveying and jam pre
5. 56 correctly Check the Z Card for visible damage Check the position of all dip switches and all rotary selectors Check all protection devices Clearly specify and monitor the way goods are placed on the conveyor Remove the screws of the Z Card box cover and open the box To turn the rotary selectors use a small screwdriver Set the dip switches carefully with a finger Close the cover of the Z Card box and fix it with the related screws Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Checking the Z Card Replacing the Z Card Version 1 2 09 2013 en Translation of the original instructions Maintenance and cleaning Warning notices concerning maintenance and cleaning N CAUTION Risk of injuries due to incorrect handling Maintenance work and cleaning must only be performed by qualified and authorized persons Perform maintenance work only after switching off the power Ensure that the system cannot be switched on accidentally Set up signs indicating that maintenance work is in progress Maintenance The Z Card must be checked at regular intervals to avoid malfunctions Monthly check the Z Card and its leads for visible damage Annually ensure that the screws of the Z Card are still tight and that the cables are still laid properly and connected to the terminals If a Z Card is damaged it has to be replaced Install a new Z Card see Aba
6. Offset Byte information 00h Control code 02h Reserved 03h Data depending on the message code 04h Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Error telegram Byte information Motor state 1 motor on bit 4 7 or error pending bits 0 3 0 motor off bit 4 7 or no error bits 0 3 Product information Control code The control code is represented as a 16 bit value in the Big Endian format and contains the following information Bit Description 0 9 Contains the ID of the Z Card to which the telegram is to be sent or from which the telegram originates 10 12 Identifies the length of the telegram without the control word 13 14 Identifies the message type Error telegram bit 13 0 bit 14 O e Up Down information bit 13 1 bit 14 0 Reserved bit 13 0 bit 14 1 Other telegrams bit 13 1 bit 14 1 15 Defines whether the message was initiated by the Z Card or the host lt Message from the Z Card bit 15 1 Message of host system bit 15 0 Example Error message from ID 25 1 00 010 0000011001 8819h Data The data bytes contain the actual data of the message The structure of the data depends on the type of message In case of error motor error or error through state table an error telegram is generated by the Z Card The four motor states and the actual state number are output as reference data Offs
7. PNP NPN sensors selectable Sensor 5 inverting switch start sensor 4PLC interfaces digital I O Power LED separate digital error output LEDs for sensor motor and PLC states Software features Zero pressure accumulation ZPA single and train release Low pressure accumulation LPA function Merger and diverter control Used as bus interface without internal logic Used as digital interface without internal logic Version 1 2 09 2013 en 11 Translation of the original instructions Z Card 3 0 INTERROLL UP DOWN SIDE1 SIDE2 PLC1 PLCA 12 Product information Inputs and outputs A general description of the terminals is given below The cables and the meaning of the connections depend on the selected program A galvanically isolated input and output is provided for each connector The function depends on the module type and configuration see Program descriptions page 26 Pin Function Wire color in connecting cable 1 VPLC on Input start stop signal from the PLC or amber switched 24 V from pin 2 2 Vp c 24 V for potential free contact of the PLC or brown Switch to pin 1 3 Optocoupler output digital output status notification green e g position occupied or available 4 Optocoupler external 24 V feeder point white NOTICE Risk of damage to the Z Card due to short circuit Do not connect pin 2 to ground Example of wiring for PLC connection O
8. at connected DriveControl 2 Corresponding pin at connected RollerDrive motor connector For details see DriveControl RollerDrive manual 17 Z Card 3 0 18 INTERROLL Product information CAN bus 1 2 Connection for the CAN bus CAN1A Signal to from upstream module CAN1B Signal to from downstream module CAN2 Signal to from branch 1 Pin Function Wire color in connecting cable 1 CAN low dominant low white 2 CAN high dominant high brown The CAN bus is a serial 2 strand differential bus with a baud rate of 250 kbps and ISO 11898 compliant termination CAN highs peed in compliance with ISO 11898 2 is used The cable length of a physical bus must not exceed 130 m For details see CAN bus communication page 46 and see CAN bus connection page 55 1 The CAN2 connection is provided for easy branching the CAN bus on the merger diverter modules A completely new CAN bus that is physically separated from CAN1 begins here Here the Z Card serves as a repeater that sends and receives all notifications received by the CAN1 bus to the CAN2 bus As a result this creates a logical CAN bus consisting of multiple physical CAN buses lt Each time a notification is sent from CAN1 to CAN2 or vice versa there is an average delay of about 1 ms The maximum bus utilization in a logical CAN bus should not exceed 1000 notifications per second Version 1 2 09 2013 en Translation of the original instructions Z Ca
9. for a new free signal from the downstream machine x lt x Signal from Z Card pin 3 4 Low no packages present Signal from the external controller pin 1 2 Low zone is occupied no new packages can be fed in Signal from Z Card pin 3 4 High packages ready for transfer Signal from the external controller pin 1 2 Low zone is occupied no new packages can be fed in For the junction and diverter the corresponding UP or DOWN logic applies depending on whether it is an upstream or downstream unit 15 Z Card 3 0 16 INTERROLL Product information Benson qn Pin Function Wire color in connecting cable Not connected Vsensor Supply voltage via polarity diode brown PNP setting black Sensor signal default low active when detecting an object Usensor output 0 VDC if object detected Usensor output 24 VDC if no object detected NPN setting Sensor signal default low active when detecting an object Usensor out Connected to ground when sensor is free Usensor out Not connected to ground when sensor is detecting object 4 Ground blue Only the sensors mentioned below may be chosen to ensure a fail safe operation in case of cable rupture or sensor damage power supply for sensor from the board is maximal 300 mA for all sensors lt NPN light barrier reflector required active if light is reflected open when in idle sta
10. if necessary Module receives no packages from the upstream module or does not transport any packages to the downstream module Wrong communication switch Check the communication switch to the upstream downstream module and correct if necessary Interface Z Card ZoneControl set incorrectly Correct setting of dip switch 8 Merger diverter module receives passes no packages from to merger diverter module 58 The Z Card has a wrong ID for the CAN Bus communication Verify the ID at the ID rotary selector It must not be set to 0 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Version 1 2 09 2013 en Translation of the original instructions Abandonment and disposal Abandonment N CAUTION Risk of injury due to improper handling Abandonment may only be executed by qualified and authorized persons Only abandon the Z Card after switching off the power Ensure that the Z Card cannot be turned on accidentally Disconnect all cables from the Z Card Unscrew the screws attaching the Z Card to the conveyor frame Extract the Z Card from the conveyor frame Disposal The operator is responsible for the proper disposal of the Z Card In doing so industry specific and local provisions must be observed for the disposal of the Z Card and its pakkaging 59 Z Card 3 0 INTERROLL Appendix List
11. ms or 100 ms Version 1 2 09 2013 en 45 Translation of the original instructions Z Card 3 0 INTERROLL 46 i General telegram structure 01h Product information CAN bus communication This chapter describes the underlying communication between a Z Card and another system e g a PC via the CAN bus The data exchange between a Z Card and a partner is made via dispatch and receipt of data telegrams which have the structures described as follows Each Z Card must have a unique ID in order to address the telegrams Al telegrams sent by the Z Card have a CAN ID matching the configured Z Card ID All telegrams sent by the master e g PLC must have a CAN ID corresponding to the value of the Z Card ID increased by 1000 Example If the ID 25 is set on a Z Card the Z Card sends all of its messages e g CAN status word telegram with the CAN ID 25 A master must send all of these messages e g CAN control word telegram to this Z Card with the CAN ID 1025 The exception to this however is the telegram host system active which uses CAN ID 1000 when sending messages Information on connecting the CAN bus see page 55 Every telegram is generally transferred as an 8 byte telegram Two bytes are reserved for the control code and one byte for the counter respectively The remaining five bytes can contain data If not all five bytes are used depending on the structure the rest are occupied with the OFFh signs
12. of abbreviations CAN Controller Area Network DC DriveControl DOWN Downstream zone HC HybridControl LPA Low Pressure Accumulation PB Powerbus power supply PLC Programmable Logic Controller SIDE Merge or diverter UP Upstream zone ZPA Zero Pressure Accumulation see page 10 Accessories Driveconiols Part Properties Item no HC EC100 110 HybridControl with ZPA and motor 9006 control on one board but can be used separately for RollerDrive EC110 and EC110 Interface card Pat eu Interface card 39650 Pre assembled cables These cables are specially designed and pre assembled for the Z Card Cable Length Item no 24 VDC power cable PB2 controller 500 mm 19 7 in 31909 power supply EC1xx RollerDrive cable 500 mm 19 7 in 31915 1000 mm 39 4 in 31916 2000 mm 78 7 in 31917 EC310 RollerDrive cable 500 mm 19 7 in 51589 1000 mm 39 4 in 51590 1500 mm 59 1 in 53667 2000 mm 78 7 in 51591 3500 mm 137 8 in 51592 Sensor cable 500 mm 19 7 in 31923 1000 mm 39 4 in 31924 1500 mm 59 1 in 31995 2000 mm 78 7 in 31925 60 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Appendix Cable Length Item no CAN bus cable 3500 mm 137 8 in 31919 4500 mm 177 2 in 31920 Communication cable 1000 mm 39 4 in 60580 2000 mm 78 7 in 60581 3000 mm 118 1 in 60583 4000 mm 157 5 in 60585 5000 mm 19
13. programs the Z Card module operates as a conveyor with one two three or four zones and the possibility of stopping each zone via PLC input A zone that has been stopped in this way does not transport the package further to the sensor even if the downstream zone is free The package is transported further only once the stop signal has been cleared If a package that has been stopped is removed or pushed back manually the motor is activated for a maximum of 1 second to transport the package back to the sensor If the pakkage does not reach the sensor within this time the Z Card Switches to the clear state Therefore if the occupied status of a zone remains the package must not be pushed back any further than it is transported for 1 second distance depends on the conveying speed see page 20 Package transport is monitored by timers After a timeout of approx 4 or 20 seconds depending on the program selected the Z Card switches to error and generates an error signal As long as the error signal is activated a zone occupied signal is transmitted to the upstream zone After approximately 1 second the Z Card switches back from this status and initializes the zone in the same way as after a power failure If a package that is in transit still cannot be transported properly the Z Card switches back to error status again after timing out If a transported package is removed manually the Z Card switches to the clear status af
14. to 63 The program change confirmation telegram is sent from a Z Card to acknowledge that a program change telegram has been received and contains the same data Offset Byte information 03h Type of telegram OCh program change confirmation 04h Number of the new program 0 to 63 The host system active telegram is sent from the host system e g PC PLC to all Z Cards at regular intervals and at the same time The Z Card checks the time between two telegrams If no new telegram has been received within the specified timeframe the Z Card stops all motors Once the next host system active telegram is received the Z Card returns to normal operating mode In order to send a telegram to all Z Cards at the same time the telegram must be sent width the Z Card ID 1000 This causes telegrams to be sent to all Z Cards Offset Byte information 03h Type of telegram ODh host system active 04h HighByte timeout 05h LowByte timeout The time interval between two telegrams is 256 x HighByte LowByte in milliseconds Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Version 1 2 09 2013 en Translation of the original instructions Transport and storage Transport Every Z Card is packaged in its own cardboard box N CAUTION Improper transport poses a hazard of injury Transport related tasks should only be carried out by qualified and authorized persons gt Foll
15. turned on accidentally Do not apply AC current to the Z Card at any time as this will cause irreparable damage Do not apply too much stress to the connector pins Bending the wires at the connector can cause damage to the insulation of the wires which could result in failure of the Z Card or the RollerDrive Ensure that the Z Card and the 24 VDC power source are properly earthed through the frame or supporting structure Failure to do so could cause the buildup of static electricity and can cause the motor or Z Card to malfunction or fail prematurely Do not spin the RollerDrive manually as this generates an induction voltage which could damage the Z Card Electrical installation There are special cables designed for the connection of the Z Card see Accessories page 60 VNN Use these cables to connect the Z Card to the power supply to other Z Cards to the RollerDrive or DriveControl to the PLC and to the sensors For the positions of the connector pins see Components page 6 and see Inputs and outputs page 12 Use cable ties to fix the cables to the conveyor frame Insert a sealing grommet into every unused slot of the Z Card box Close the cover of the Z Card box and fix it with the related screws Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 MR INTERROLL Assembly CAN bus connection The following diagram shows an example of how a PLC and multiple Z Cards are conn
16. 0 2 plug AMP MTA 100 2 plug CAN high brown CAN low brown CAN low white O CAN high white Communication cable 1 4 2 3 3 2 1 4 CST 100 4 contact for CST 100 4 contact for AMP MTA 100 4 plug AMP MTA 100 4 plug Q yellow brown brown G yellow green white white O green Cable cross section 0 25 mm Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 Version 1 2 09 2013 en Translation of the original instructions Appendix INTERROLL PLC cable 1 2 3 4 CST 100 4 contact for AMP MTA 100 4 plug O yellow Q brown G green white Cable cross section 0 25 mm End splices Q yellow Q brown green white ES 63 Z Card 3 0 INTERROLL 64 Appendix Installation declaration In accordance with the EC Machinery Directive 2006 42 EC Appendix II B the manufacturer Interroll Automation GmbH Dietmar Hopp Str 3 D 74889 Sinsheim Germany hereby declares with sole responsibility that the product range Z Card 3 0 is not a ready to use machine as defined by the EC Machinery Directive and therefore does not fully comply with the requirements of this directive The commissioning of these conveyor modules is not permitted unless conformity of the entire machine system in which they are installed has been declared in compliance with the EC Machinery Directive The health and safety re
17. 3 fa INSPIRED BY EFFICIENCY User manual Interroll Z Card 3 0 Version 1 2 09 2013 en Translation of the original instructions IAD BA 1541 Interroll T Nr 61460 Manufacturer Interroll Automation GmbH Dietmar Hopp Strake 3 D 74889 Sinsheim Germany Tel 49 72 61 938 0 Fax 49 72 61 938 124 www interroll com Copyright The copyright of this manual remains with Interroll Corporation The operating instructions contain technical regulations and drawings which may not be reproduced partially or in full transmitted by any means utilized without permission for competitive purposes or disclosed to third parties Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Table of contents Introduction Information about the operating instructions 2 Warnings in this manual 2 Further symbols iu ee Rr e a gga agi aie da hiec Res RR ann Rom us 3 Safety General safety instructions 4 Intended use 4 Unintended use 4 Qualified persons 4 DANQETS MP 5 Interfaces to other devices 5 Product information Components casas den he aan A Ba a aa dame eke Saeed eben 6 Connections and switche
18. 48 0 36 0 24 0 16 0 12 0 09 0 06 3 45 0 34 0 26 0 17 0 11 0 09 0 06 0 04 2 40 0 20 0 15 0 10 0 07 0 05 0 04 0 03 1 30 0 07 0 05 0 03 0 02 0 02 0 01 0 01 Default settings are shown in bold 20 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Program rotary switch Product information The required operating mode of the Z Card can be set with the program rotary Switch The programs are divided into four ranges which can be set using dip Switch 1 and 2 see Program range selector switch dip switch 1 2 page 22 The following table lists the available programs and the appropriate switch positions Rotary Dip switch 1 OFF Dip switch 1 ON Dip switch 1 OFF Dip switch 1 ON switch Dip switch 2 OFF Dip switch 2 OFF Dip switch 2 ON Dip switch 2 ON 0 Relay module Relay module fwd rev Relay module transfer Placeholder 1 1 zone ZPA conveyor 1 zone ZPA conveyor 1 zone block conveyor 1 zone conveyor LPA 4 s with start stop 4 s with start stop 20 s with train release start stop 4 s 2 2 zone ZPA conveyor 2 zone ZPA conveyor 2 zone ZPA conveyor 2 zone conveyor LPA 4 s with start stop 4 s with start stop 20 s with train release start stop 4 s 3 3 zone ZPA conveyor 3 zone ZPA conveyor 3 zone train release 3 zone conveyor LPA 4 s with start stop 4 s with start stop 20 s conveyor with start stop 4 s 4 4 zone ZPA conveyor 4 zone ZPA conveyor 4 zone train
19. 6 8 in 60586 PLC cable 3000 mm 118 1 in 31918 24 VDC power cable for the controller power supply PB2 i D A E SL156 2 contact for Blade Terminal F6 3 AMP MTA 156 2 plug O 24 VDC red O 24 VDC red GND black GND black EC1xx RollerDrive cable CST 100 8 contact for End splices AMP MTA 100 2 plug O O No error gray E No error gray REV green O FWD pink REV green Analog speed yellow O FWD pink 24 VDC brown O Analog speed yellow GND white O 24 VDC brown GND white Version 1 2 09 2013 en 61 Translation of the original instructions Z Card 3 0 INTERROLL 62 Appendix EC310 RollerDrive cable DNOu BR wN E CST 100 8 contact for Lumberg connector FKT5 228 AMP MTA 100 2 plug O No error black O No error black Rotation direction white Rotation direction white O Speed yellow green Q O 24 VDC brown G GND blue O Speed yellow green O 24 VDC brown GND blue Sensor cable 7 2 3 4 CST 100 4 contact for Coupling M8x1 3 pole straight AMP MTA 100 4 plug Wenglor S49 or equivalent O O Sensor signal black E 24 VDC sensor output brown Sensor signal black GND blue GND blue 24 VDC sensor output brown CAN bus cable 1 2 1 CST 100 2 contact for CST 100 2 contact for AMP MTA 10
20. 62 ES AJA PB1 EX n n 2 n Hide ca Dn iz i e PROGRAM 2 Coe gt 87 RE 1 HX upupuumuuus nl E 4 C SAI HEBBEEEHEH Lin E Fn MOTOR1 MOTOR2 2 MOTORS MOTOR4 coor I T Tj O I I L3 S Ld CA tm C1 L Os m MOTORZB D D rara m fra ra CJ ard Rev3 1 o 012012 by Interroll o O e e a e O Connection merge diverter 1 O Downstream module connection SIDE1 DOWN Q PLC1 connection ID rotary switch G Main power supply connection Sensor 4 connector O PLC2 connection Sensor 3 connector Controller power supply connection Motor 4 connection O PLC3 connection Dip switches 1 10 see page 22 O PLC4 connection 3 Motor 3 connection Error output connection Program rotary switch O Sensor 5 connector Marking of direction of travel Speed rotary switch 69 Motor 2 connection O Sensor 6 connector Second motor 2 connection Switch for CAN bus termination 69 Motor 1 connection resistance amp Second motor 1 connection CAN bus connection 6 Fuse CAN bus connection 6 Sensor 2 connector Connecting CAN bus branch amp Sensor 1 connector Connection merge diverter 2 Upstream module connection UP SIDE2 Z Card 3 0 INTERROLL Product information Dimensions Tn 205 mm 8 0 in 35 mm 1 38 in poe 20 mm 079110 35 mm 1 38 in 6 lt lt s e e 4 al Su 2 El T a 8 E
21. H signal is pending at the output Off A Low signal is pending at the output Sensors 1 to 6 each have one LED yellow displaying the status of the respective sensor On Sensor 1 is clear e Off Sensor 1 is occupied Motor interfaces 1 to 4 each have one LED yellow displaying the status of the respective input On The speed output of the motor plug is energized motor is running Off The speed output of the motor plug is not energized motor is idle The red error LED shows the error status of the Z Card On An error has occurred Off No error has occurred The yellow Run LED indicates whether the Z Card is energized On The Z Card is properly provided with power Off No appropriate voltage is connected Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Version 1 2 09 2013 en Translation of the original instructions Product information Technical specifications Unless otherwise stated all electrical parameters refer to an ambient temperature of 25 C 77 F Supply voltage 24 VDC Voltage range 23 to 27 VDC Current consumption unloaded with 4 sensors without motors 50 mA max 220 mA 120 mA Output current per motor actuator max 2 A permanent max 8 A permanent per Z Card Output current per motor actuator during braking 30 A briefly tp lt 20 ms tort pause 1s Output cur
22. Sensor Sensor Sensor Sensor Sensor 1 Sensor is interrupted 5 4 3 2 1 0 Sensor is not interrupted Motor information 05h Motor 4 Motor3 Motor2 Motor 1 Motor4 Motor 3 Motor2 Motor 1 error error error error 1 motor error or not connected 1 motor is running 0 no motor error 0 motor is braking or free running PLC information 06h Out 4 Out 3 Out 2 Out 1 In 4 In 3 In 2 In 1 1 input output high 0 input output low Program specific 07h SIDE2 SIDE1 DOWN up program specific information 1 The value of the bit differs depending on whether it is the interface to an upstream or downstream zone Bit Interface to upstream zone downstream zone 1 Z Card is clear Z Card is occupied 0 Z Card is occupied Z Card is clear 48 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL CAN control word telegram Product information The CAN control word telegram is sent by a host system e g PC PLC to a Z Card to influence its behavior bit 13 and 14 of the control word 1 The CAN control word telegram contains the following information PLC input information The PLC input signals that are currently applied to the module can be bypassed with this byte When the input bit is set to 1 the Z Card works independently of the actual signal as if the PLC signal were HIGH If the bit is set to 0 the signal of the physical PLC input is used Logical motor speed The speed of each motor can be r
23. Signal input from PLC at same potential as Z Card or switched 24 V from pin 2 Q Permanent 24 V output Signal output switched from pin 4 O Vexternal Max 24 V e g from PLC Output current max 20 mA Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Product information The following example shows which signals are sent or expected on the UP connection Z Card if the external controller is upstream from the Z Card External controller Z Card E Signal from the external controller Signal from Z Card pin 3 4 pin 1 2 Low no packages present High zone is open packages can be fed in Signal from the external controller Signal from Z Card pin 3 4 pin 1 2 High packages ready for transfer High zone is open packages can be fed in Signal from the external controller Signal from Z Card pin 3 4 pin 1 2 High packages ready for transfer High zone is open packages can be fed in As soon as the external controller switches from High to Low the Z Card also Switches from High to Low Both signals must be High as long as both systems on the transport are active ji X ed Version 1 2 09 2013 en 13 Translation of the original instructions Z Card 3 0 IN
24. TERROLL Product information Signal from the external controller pin 1 2 Low no packages present Signal from Z Card pin 3 4 Low zone is occupied no new packages can be fed in Signal from the external controller pin 1 2 High packages ready for transfer Signal from Z Card pin 3 4 Low zone is occupied no new packages can be fed in The following example shows which signals are sent or expected on the DOWN connection Z Card if the external controller downstream of the Z Card Z Card External controller E Signal from Z Card pin 3 4 Low no packages present Signal from the external controller pin 1 2 High zone is open packages can be fed in Signal from Z Card pin 3 4 High packages ready for transfer Signal from the external controller pin 1 2 High zone is open packages can be fed in 14 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Version 1 2 09 2013 en Translation of the original instructions Product information Signal from Z Card pin 3 4 High packages ready for transfer Signal from the external controller pin 1 2 High zone is open packages can be fed in As soon as the external controller switches from High to Low the Z Card disables the motor and waits
25. Version 1 2 09 2013 en Translation of the original instructions Product information Connections and switches QOD 0000 DODO 0008099066 o SIDE PLC1 TE PLOS PLCA ERROR SENSS SE S6 CBNIR CANLB CAN SIDE2 o O L1 L JIL E Li NER Cy E EX LI ET C1 ET O LU 4144 U4 UU TU i E M Foo ur F a e PB2 me 2 UNI Wee REIS 2m D LEE ee Si n i o SPEED kan Le Ped H gl al T ESSE i
26. a 1 el L J E E E 8 9 mm 0 35 in 10 mm 0 39 in E E Type plate The information on the type plate is used to identify the Z Card Z Card 3 Z Card N Handshakes Lud NANA PLC Internal Fuse 8 A Input 22 to 26 Vdc Output 24 Vdc For internal connection refer to User Manual CE Start Sensor 60275 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Product information Control technology Principle of zones O A B g zone Q Direction of travel Package RollerDrive gt Typical Z Card conveyor configuration for RollerDrive EC310 Sensor UP DOWN communications cabling Z Card 24 VDC GND DriveControl necessary Zone Q Direction of travel Package RollerDrive O Sensor Typical Z Card conveyor configuration for RollerDrive EC1xx additional O UP DOWN communications cabling Z Card DriveControl 24 VDC GND Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL ZPA zero pressure accumulation Applications Product information The Z Card provides true zero pressure accumulation and other control options to a conveyor system Each Z Card controls up to four zones A zone is a short conveyor section which consists of a RollerDrive a DriveControl if applicable se
27. cidentally Do not use the Z Card in areas where there is a hazard of explosion Remove equipment or material which is not required from the workspace Regularly inspect the Z Card for visible damage If you notice smoke switch off the power immediately and ensure that it cannot be switched on again accidentally Contact qualified personnel immediately to find the source of the fault gt Because the product does not require maintenance you only need to inspect the Z Card regularly for visible damage and that all cables and screws are firmly in place Exercise caution when installing or performing maintenance on the Z Card and when troubleshooting as a start signal may accidentally be triggered unintentionally starting one of the connected motors Interfaces to other devices By assembling the Z Card in a conveyor module further hazards may occur These hazards are not part of this manual and have to be analyzed during the design installation and startup of the conveyor module gt After assembling the Z Card in a conveyor module check the whole system for a new potential dangerous spot before switching on the conveyor Un Z Card 3 0 Product information Components TITO Overview Cross drive screws Box holder Box Label Cover Z Card board Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL
28. clear to tripped Lift is at highest point S6 Sensor for position monitoring After initializing the Z Card if a package is located in the diverter the system waits until a signal is received at inputs PLC2 and PLC3 indicating where The following types of diverters are available the package should be transported Program Structure Sensors Types used 45 diverter S1 ZPA S2 Train S3 release S4 M4 UP pe gt DOWN i F 3 M3 M1 S1 90 diverter from SIDE S1 ZPA50 ms UPtoSIDEor Oo Ll S2 S2 ZPA DOWN S4 100 ms UP a E DOWN Tem P S6 release 50 ms Mis5M3 si Train release 100 ms Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 Version 1 2 09 2013 en Translation of the original instructions INTERROLL Product information Program Structure Sensors Types used 90 diverter from SIDE1 S2 ZPA 50 ms UP to SIDE1 or t S3 ZPA SIDE2 pa c t Ce HRS S4 100 ms M4 Lmo S5 Train UP S6 release 50 ms Th T Les Train S4 M1 i M3 release SIDES 100 ms 90 diverter from SIDE1 S1 ZPA 50 ms SIDE1toSIDE2 sj S2 ZPA orDOWN 50 ms S3 100 ms MAH M S5 gt DOWN S6 s3 4 rA M1 T M3 s1 SIDE2 Types e ZPA zero pressure accumulation A clear signal is sent to the upstream module onc
29. d SIDE2 Modified for connection with ZoneControl to UP DOWN and ON SIDE1 not SIDE2 Dip switch 9 10 Currently not in use must be set to OFF CAN terminator switch Sets the CAN terminator resistance at the end of the CAN bus line The terminator resistance has to be set for Z Cards at the end of the CAN bus line CAN bus termination Position of switch Not terminated Left Terminated Right Version 1 2 09 2013 en 23 Translation of the original instructions Z Card 3 0 INTERROLL UP DOWN SIDE PLC 1 4 Sensor 1 6 Motor 1 4 Error Run Product information LEDs Each UP DOWN SIDE1 SIDE2 interface has two LEDs yellow LED indicates the status of the respective partner green LED indicates the status of the Z Card The meanings of the LEDs differ depending on whether it is the interface to an upstream or downstream zone LED Interface to upstream zone downstream zone Yellow on Upstream zone is occupied Downstream zone is clear Off Upstream zone is clear Downstream zone is occupied Green on Z Card is clear Z Card is occupied Off Z Card is occupied Z Card is clear There are two LEDs for each interface PLC1 through PLC4 yellow LED indicates the status of the respective input green LED indicates the status of the respective out LED Meaning Yellow on A HIGH signal is pending at the input Off A LOW signal is pending at the input Green on A HIG
30. d signal If a fire door a lift up gate or similar is used this should be monitored by sensor 5 If sensor is 5 is tripped the program switches to stop mode which stops all motors and sends an occupied signal to the upstream zone Once sensor 5 is clear again and the downstream zone is clear the module is ready for a new package to be conveyed from the upstream zone This program does not use any PLC inputs or outputs The connections for motors and sensors have the following assignments Connection Description Motor M1 Rollers in main transport direction M2 Rollers in main transport direction M3 Rollers in main transport direction M4 Rollers in main transport direction Sensor S1 Sensor for downstream zone DOWN S2 S3 S4 S5 Sensor for the fire door lift up gate or similar This program does not use the connections UP DOWN SIDE1 and SIDE2 31 Z Card 3 0 INTERROLL ZPA conveyor with start stop 32 Product information M1 Si M2 82 M3 S3 M4 S4 Depending on the program selected only the affected sensors and motors are activated see table below Input and output settings are not affected Number of zones Affected sensors and motors 1 1 for M1 M2 M3 M4 2 S1 for M1 M3 S2 for M2 M4 3 S1 for M1 S2 for M2 S3 for M3 4 S1 for M1 S2 for M2 S3 for M3 S4 for M4 In these
31. e package This delay time serves to ensure that the package has been completely transported past the sensor before it merged Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Diverter Version 1 2 09 2013 en Translation of the original instructions Product information A diverter always has one upstream zone and two downstream zones The path that should be taken can be determined by a master controller e g PLC via inputs PLC2 and PLC3 If a package exits the module the Z Card switches the output PLC1 to High signaling to the master controller that it is ready for a new signal Once a new package is accepted the Z Card switches the output PLC1 back to Low The signal currently pending at inputs PLC2 and PLC3 will be applied to the next package PLC2 PLC3 Meaning Low Low No package is accepted Any incoming packages will remain in front of the module High Low The package is transported in the main transport direction no diverting Low High The package is ejected High High Alternating conveying and jam prevention The Z Card attempts to transport packages alternately to both downstream zones However if the intended downstream zone is occupied and the other downstream zone is free the package is transported to the other downstream zone If both downstream zones are occupied the package travels up to the sensor of the originally intended zone The
32. e the package has left the module Train release a clear signal is sent to the upstream module once the module starts transporting the package to the downstream module and a new package can be safely fed in 50ms 100 ms Delay of the rollers after detecting the trailing edge of the package This delay serves to ensure that the package has been completely transported past the sensor before it is ejected 43 Z Card 3 0 INTERROLL Product information 4 way transfer DOWN SIDE2 M1 The 4 way transfer allows products to be merged or ejected in two directions or to be transported onwards in the main direction of travel The path that should be taken can be determined by a master controller e g PLC via inputs PLC1 to PLC3 If a package exits the module the Z Card switches the output PLC1 to High signaling to the master controller that it is ready for a new signal Once a new package is accepted it switches the output PLC1 back to Low The signal currently pending at inputs PLC1 to PLC3 will be applied to the next package Input Meaning PLC1 PLC2 PLC3 Low Low Low The Z Card sends an occupied message to all upstream zone and waits for the merger diverter setting Low Low High Package to be transported from UP to DOWN Low High Low Package to be transported from UP to SIDE1 Low High High Package to be transported from UP to SIDE2 High Lo
33. eading the operation manual feel free to contact our customer service See the last page for your local contact information Warnings in this manual The warnings in this document refer to risks which may arise while using the Z Card For relevant warnings see Safety page 4 and the warnings at the beginning of each chapter There are three categories of danger The following signal words are used in the document as required Danger Warning Caution Signal word Meaning Danger Indicates a hazardous situation which if not avoided will result in death or serious injury Warning Indicates a hazardous situation which if not avoided could result in death or serious injury Caution Indicates a hazardous situation which if not avoided may result in minor or moderate injury Nature and source of the hazard Possible consequence of non observance Information about how to avoid the hazard Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL gt Version 1 2 09 2013 en Translation of the original instructions Introduction Further symbols NOTICE This symbol identifies possible material damage Information about how to avoid damage This symbol displays safety instructions This symbol marks useful and important information This symbol marks the steps that have to be carried out Z Card 3 0 INTERROLL Safety General safe
34. ected via a CAN bus Information on connections see page 18 SET X la E Ed aa CAN1A CAN1B CAN2 CAN1A CAN1B CAN2 CAN1A CAN1B CAN2 AN SE ee m TERM TERM TERM Module Zone Z Card CAN bus termination switch Select a unique ID see ID rotary switch page 20 for each Z Card Avoid ring circuits as stated in the CAN specification Make sure that the cable length of a physical bus is no longer than 130 m Activate the terminator switch for the last piece of machinery connected to each CAN1 bus see CAN terminator switch page 23 to terminate it The CAN2 bus is always terminated on the Z Card VVVV 6509000 99 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Initial startup and operation Initial startup Inspections before initial startup Ensure that all bolts are tightened according to the specifications Ensure that no additional dangerous areas arise due to interfaces with other components Ensure that the wiring is in accordance with specifications and legal guidelines Check all protection devices Ensure that no bystanders are in dangerous areas around the conveyor Operation N CAUTION Rotating parts Risk of crushed fingers Ensure there are no bystanders in dangerous areas around the conveyor Ensure that all protection devices are installed Checks before every startup Changing settings
35. educed without manually turning the speed potentiometer or the rotary selector The value in this byte represents a percentage of the speed set manually The value 0 equals 0 96 of the default speed of the respective program and the value 10 equals 100 of the speed that has been set manually Thus to reduce the speed this byte must hold a substitute for the percentage of this reduction The resulting speed is the speed set manually multiplied by the percentage indicated by this byte and then rounded down to a multiple of 596 The following table shows a few sample resulting speeds Rotary Logical motor speed switch 20 50 80 100 0 20 50 80 100 8 15 40 60 80 7 10 35 55 70 Program specific information see table below Byte information Offset Bit7 Bit 6 Bit 5 Bit4 Bit3 Bit 2 Bit 1 Bit 0 Type of telegram 03h 1 CAN control word PLC input information 04h CAN control Invert 1 In 4 In 3 In 2 In 1 1 Set PLC input to high word or do not 0 Use physical PLC input confirmation invert 0 required 0 sensor or not 1 signals Motor speed 1 2 05h Logical motor speed v2 Logical motor speed v1 Motor speed 3 4 06h Logical motor speed v4 Logical motor speed v3 Program specific 07h SIDE2 SIDE1 DOWN UP program specific information Version 1 2 09 2013 en Translation of the original instructions 1 The value of the bit differs depending on whether it is the interface to an upstream or d
36. et Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 03h Motor Motor Motor Motor Motor Motor Motor Motor 4 3 2 1 4 error 3error 2error 1 error offlon off on X off on offlon no yes no yes no yes no yes State number Version 1 2 09 2013 en Translation of the original instructions 04h 47 Z Card 3 0 INTERROLL CAN status word telegram Product information The telegram CAN status word is sent from a Z Card each time the state of a sensor changes or at least every 250 milliseconds As soon as there is a change in the program specific byte the CAN status word is sent with every change The CAN status word telegram contains the following information Sensor information shows the sensor signals currently used Every sensor is represented by one bit Unconnected sensors are shown as interrupted Motor information indicates whether the motors are active forward reverse and whether or not an error is pending Every motor is represented by one bit PLC information shows the current state of the logical PLC inputs and physical PLC outputs connected to the module With the PLC inputs the physical signal is logically connected by way of a an OR to the value provided by the CAN status word telegram e Program specific information see table below Byte information Offset Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Type of telegram 03h 0 CAN status word Sensor information 04h Sensor6
37. hould be idle High Low Motor 2 should rotate clockwise Low High Motor 2 should rotate counterclockwise High High Motor 2 should be idle Connection Description Motor M1 Rollers in main transport direction M2 Belis in diverter direction M3 Lift motor 1 MA Lift motor 2 29 Z Card 3 0 INTERROLL 30 Product information Connection Sensor S1 Description Sensor for downstream zone DOWN S2 Sensor for merge or diverter direction SIDE1 S3 Sensor for a second merge or diverter direction SIDE2 S4 Sensor for upstream zone UP S5 Sensor for lift Sensor switches from tripped to clear Lift is at lowest point Sensor switches from clear to tripped Lift is at highest point This program does not use the connections UP and DOWN or the inputs SIDE1 and SIDE2 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Placeholder Version 1 2 09 2013 en Translation of the original instructions Product information A M1 S1 This program is a 1 zone position that keeps its zone clear provided that the downstream zone DOWN is occupied This function can be used for fire doors or passages for personnel lift up gate for example The upstream zone UP receives a clear message only if this storage space and the downstream zone are clear In all other cases the upstream zone is given an occupie
38. inal instructions Z Card 3 0 INTERROLL Product information Relay module M1 St M2 2 M3 S3 M4 S4 In this program there are four digital inputs which are used to start or stop the four motors and four digital outputs which are used to transmit the status of the sensor to an external controller These inputs and outputs have the following assignments Input High Low PLC1 Motor 1 should run Motor 1 should be idle PLC2 Motor 2 should run Motor 2 should be idle PLC3 Motor 3 should run Motor 3 should be idle PLC4 Motor 4 should run Motor 4 should be idle Output PLC1 Sensor 1 detects object Sensor 1 detects no object PLC2 Sensor 2 detects object Sensor 2 detects no object PLC3 Sensor 3 detects object Sensor 3 detects no object PLC4 Sensor 4 detects object Sensor 4 detects no object SIDE1 Signal from sensor 5 SIDE2 Signal from sensor 6 Connection Description Motor M1 Motor for zone 1 M2 Motor for zone 2 M3 Motor for zone 3 MA Motor for zone 4 Sensor S1 Sensor for zone 1 S2 Sensorfor zone 2 S3 Sensor for zone 3 S4 Sensor for zone 4 S5 This program does not use the connections UP and DOWN or the inputs SIDE1 and SIDE2 The program specific bits offset 07 h in the CAN control word telegram see page 49 have the following meanings Bit O 0 Motor 1 standard direction of rotation 1 Moto
39. ing of the abbreviations see page 60 to SIDE2 or DOWN train release 100 ms 21 Z Card 3 0 INTERROLL Program range selector switch dip switch 1 2 NPN PNP switch dip switch 3 FWD REV switch dip switch 4 i Sensor 5 inverter switch dip 22 switch 5 Product information The programs are divided into four ranges which can be set using dip switch 1 and 2 Program section Dipswitch1 Dipswitch2 ts 0 F OFF OFF 10 1F ON OFF 20 2F OFF ON 30 3F ON ON The Z Card allows the connection of both PNP and NPN sensors The switch must be set depending on the sensor being used CAUTION Setting the switch incorrectly can cause the direction of rotation and the starting behavior to change Risk of injury due to malfunction and accidental motor starts Ensure correct setting Type of sensor Position of switch PNP OFF NPN ON This switch position does not change the output potential of other interfaces Changes the direction of travel for all connected motors simultaneously Direction of travel Position of switch Standard left to right seen from the cable end cw rotation OFF of rollers Reverse right to left seen from the cable end ccw rotation ON of rollers The switch position does not influence the conveyor logic that means motor and sensor assignment remains unaffected If necessary the direction of travel for the individual drives can be cha
40. input PLC4 helps determine whether or not the package should be transported onward from the diverter module The output PLC4 receives the signal indicating whether there is a package at the sensor located at the end of the module PLC4 High Low Input The package should be The package can exit the stopped on the end of diverter diverter module module Output A package is located at the No package located at the sensor on the end of diverter module sensor The connections for motors and sensors have the following assignments 45 diverter 90 diverter Pop up rollers in main Rollers in main transport transport direction direction Rollers in diverter direction Belts in diverter direction Rollers in main transport direction Lift motor 1 Connection Motor M1 M2 M3 M4 Rotating motor for pop up rollers Lift motor 2 41 Z Card 3 0 INTERROLL 42 Product information Connection 45 diverter Sensor S1 90 diverter Sensor for downstream zone DOWN S2 Sensor for merge or diverter direction SIDE1 S3 Sensor in straight direction of travel DOWN for rotation of the pop up rollers Sensor for second diverter direction SIDE2 S4 Sensor in diverter direction SIDE for rotation of the pop up rollers Sensor for upstream zone UP S5 Sensor for lift Sensor switches from tripped to clear Lift is at lowest point lt Sensor switches from
41. ndonment page 59 and see Assembly page 52 Cleaning Dust and dirt in combination with humidity may bridge the electric circuit Therefore in a dirty environment periodic cleaning will help to avoid short circuits which could damage the Z Card Regularly blow off dust and dirt by using low compressed air 57 Z Card 3 0 INTERROLL Symptom Yellow LED is not lit Troubleshooting Troubleshooting Should the module not be functioning properly Ensure that the wiring is correct Ensure that the module is correctly powered and is 24 VDC Verify whether the program rotary selector is in the correct position Possible cause Fuse is blown Help Check fuse and replace it if necessary If the problem continues replace the module No power supply Check 24 VDC power supply of the Z Card Motors are not running and power supply to sensors is off Fuse is blown Check fuse and replace it if necessary No power supply Check 24 VDC power supply of the Z Card Motors are not operating but power supply to sensors is on Incorrect NPN PNP settings Check the setting of the NPN PNP switch and correct it if necessary Motors are rotating in the wrong direction Wrong FWD REV settings Check the the FWD REV switch setting and correct it if necessary RollerDrive selection switch set incorrectly Check the RollerDrive selector switch setting and correct it
42. nged via wiring or the installation position of the RollerDrive Inverts the signal of sensor 5 In order to use sensor 5 as the start sensor for a zero pressure conveyor the sensor signal has to be inverted At Merger and diverter modules the sensor input must not be inverted Sensor 5 signal Position of switch Normal OFF Inverted ON Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Product information Motor type dip switch 6 Sets the type of RollerDrive that can be connected to the Z Card There is a different speed control and error output depending on the type of RollerDrive Connected RollerDrive Position of switch EC100 or EC310 OFF EC200 300 ON Output motor fault dip Sets whether motor errors RollerDrive error as well as the error messages of switch 7 the Z Card should be issued on the error output Motor error output Position of switch Motor fault are not output OFF Motor fault are not output ON RollerDrives that are not connected would also trigger a motor fault Therefore the CAN ID see ID rotary switch page 20 can be used to select which motors are monitored CAN ID Monitored motors 1 Motor 1 2 Motors 1 and 2 3 Motors 1 to 3 4 Motors 1 to 4 ZoneControl dip switch 8 Sets the type of handshake for external interfaces Handshake Position of switch Modified for connection with Z Card or external interfaces to OFF UP DOWN SIDE1 an
43. on 1 2 09 2013 en Translation of the original instructions Assembly Installing the Z Card in a conveyor system Mounting hardware is not supplied with the Z Card Choose adequate screws and nuts for the 8 5 mm x 36 5 mm 0 33 in x 1 44 in long hole in the holder There are two ways to install the Z Card in the conveyor Using an existing Roller bolt Using a newly drilled mounting hole The second way is described here More detailed assembly instructions are available at Interroll Use the box holder as a template and mark the center of the mounting hole Drill an 8 to 8 5 mm 0 31 0 33 in mounting hole at the marked spot Insert a screw in the hole Install the Z Card to the frame with the arrows on the Z Card showing in the direction of travel and the screw protruding through the mounting hole Slip a nut to the screw and tighten it Ensure that there is a ground path between the Z Card and the conveyor frame it is mounted to VVV WV VN The Z Card and conveyor frame should be at the same potential referenced to grounding 53 Z Card 3 0 INTERROLL 54 Assembly Warnings concerning electrical installation NOTICE Risk of damage to the Z Card gt Observe the following notices The electrical installation may only be executed by qualified and authorized persons Disconnect the power before installing removing or rewiring the Z Card Ensure that the conveyor cannot be
44. oubleshooting 22 58 Abandonment and disposal Abaridoriment 222 usare eg UR sabia xn ah ah al see e ea 59 Disposal Gi abra do heey scalam m Bel cau EUR Ree dca ind e EROR d 59 Appendix List of abbreviations 60 INCCOSSONOS ar ate Ses cri uelim LS ne as 60 Installation declaration 64 Version 1 2 09 2013 en 1 Translation of the original instructions Z Card 3 0 INTERROLL Contents Validity of the manual The manual is part of the product Structure of warnings Introduction Information about the operating instructions This manual contains important advice notes and information about the Z Card in all phases of its lifecycle Transport assembly and start up Safe operation maintenance and troubleshooting disposal Accessories The manual describes the Z Card as it is delivered by Interroll In addition to this manual special contractual agreements and technical documents apply to special versions gt Fortrouble free safe operation and warranty claims read the manual and follow the instructions before handling the Z Card gt Keep the manual near to the Z Card Pass the manual on to any subsequent operator or occupant of the Z Card gt Interroll does not accept any liability for faults or defects due to non observance of this manual gt If you have any questions after r
45. ow the instructions below Do not stack more than four cardboard boxes on top of each other Check the fixation of the Z Cards before transport Avoid serious impacts during transport Check each Z Card visually for damage after transport In the event of damage take photos of the damaged parts To maintain the warranty report any damage caused by transport instantly to the transport company and Interroll Do not transfer the Z Cards between warm and cold environments This may cause condensing water VVVVVV A4 Storage N CAUTION Risk of injury due to improper storage Do not stack more than four carton boxes on top of each other gt Check each Z Card for damage after storage 51 Z Card 3 0 INTERROLL 52 Assembly Warnings concerning proper assembly N CAUTION Risk of injury due to accidental motor starts Assembly may only be executed by qualified and authorized persons Disconnect all power before assembling the Z Card Ensure that the conveyor cannot be turned on accidentally Use caution while assembling the Z Card Risk of damage leading to Z Card failure or shortened life expectancy gt Observe the following notices Do not drop or mishandle the Z Card the box or the holder to avoid internal damage Check each Z Card visually for damage prior to assembly Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Versi
46. ownstream zone Bit Interface to upstream zone downstream zone 1 Upstream zone is occupied Downstream zone is clear 0 Upstream zone is clear Downstream zone is occupied Bit 13 and 14 of control word 1 v1 to v4 represent the M1 to M4 motor speed The Z Card sends a 0Ah confirmation after receiving a CAN control word The 4 bytes after the type of telegram contain the settings of the CAN control word message 49 Z Card 3 0 INTERROLL CAN control word confirmation Program change telegram Program change confirmation Telegram host system active 50 Product information The CAN control word confirmation telegram is sent from a Z Card to acknowledge that the CAN control word telegram has been received The PLC data input motor speed v1 to v4 and the function specific data are taken from the CAN control word verification telegram and sent back again as a confirmation Offset Byte information 03h Type of telegram OAh CAN control word confirmation 04h Same data as with corresponding CAN control word telegram 05h 06h 07h The program change telegram is sent from the host system e g PC PLC to a Z Card in order to select a different program The selected program will run once this telegram from the Z Card is received The Z Card responds to this telegram with a confirmation telegram Offset Byte information 03h Type of telegram OBh program change telegram 04h Number of the new program 0
47. put produces a signal as long as there is no error pending in the Z Card Pin Function Wire color in connecting cable 1 Optocoupler output digital output status notification green 2 Optocoupler external 24 V feeder point white Signal Meaning High No error in the Z Card Low Error pending in the Z Card Version 1 2 09 2013 en 19 Translation of the original instructions Z Card 3 0 INTERROLL ID rotary switch Speed rotary switch Product information Rotary and dip switches The three rotary switches ID1 ID2 and ID3 are used to define a unique ID of the Z Card based on the following formula ID ID1 x 100 ID2 x 10 ID3 This ID is used to address the Z Card directly via the CAN bus The master of the CAN bus should be assigned the ID 1000 If a Z Card is assigned the ID 000 it works without being connected to the CAN bus The speed on the Z Card is set using a rotary switch The resulting speed depends on which RollerDrive is being used Speed setting rotary switch EC1xx EC310 EC310 EC310 EC310 EC310 EC310 EC310 Yo of rated 12 1 16 1 24 1 36 1 48 1 64 1 96 1 speed m s m s m s m s m s m s m s 0 100 1 31 0 98 0 65 0 44 0 33 0 25 0 16 9 95 1 17 0 88 0 59 0 39 0 29 0 22 0 15 8 85 1 03 0 77 0 52 0 34 0 26 0 19 0 13 7 80 0 89 0 67 0 45 0 30 0 22 0 17 0 11 6 70 0 76 0 57 0 38 0 25 0 19 0 14 0 09 5 60 0 62 0 46 0 31 0 21 0 15 0 12 0 08 4 50 0
48. quirements as stated in Appendix have been applied The special technical documents mentioned in Appendix VII B have been prepared and will be sent to the responsible authority if necessary Person responsible for EC documentation Interroll Automation GmbH Dietmar Hopp Str 3 D 74889 Sinsheim Applicable EC directives Machinery Directive 2006 42 EC Low Voltage Directive 2006 95 EC EMC Directive 2004 108 EC Applicable harmonized standards ENISO 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology ENISO 13857 Safety of machinery Safe distances to prevent upper and lower limbs from entering hazard zones EN 349 Safety of machinery Minimum distances to prevent crushing of body parts EN 60204 1 Safety of machinery Electrical equipment of machinery Part 1 General requirements Sinsheim dated Dr Ing Heinrich Droste Managing Director A copy of this declaration can be obtained at www interroll com if needed Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Appendix Version 1 2 09 2013 en 65 Translation of the original instructions INTERROLL Cono Version 1 2 09 2013 en For your local contacts please visit Translation of the original instructions interroll com contacts
49. r 1 reversed Bit 1 0 Motor 2 standard direction of rotation 1 Motor 2 reversed Bit 2 0 Motor 3 standard direction of rotation 1 Motor 3 reversed Bit 3 0 Motor 4 standard direction of rotation 1 Motor 4 reversed Version 1 2 09 2013 en 27 Translation of the original instructions Z Card 3 0 INTERROLL Product information Relay module FWD REV M1 St M2 82 M3 3 M4 S4 This program is the same to the relay module except that a delivery in both directions is possible However two motors are switched simultaneously in each case The inputs and outputs have the following assignments Input Meaning PLCI PLC2 PLC3 PLC4 Low Low Motors 1 and 2 should be idle High Low Motors 1 and 2 should rotate clockwise Low High Motors 1 and 2 should rotate counterclockwise High High Motors 1 and 2 should be idle Low Low Motors 3 and 4 should be idle High Low Motors 3 and 4 should rotate clockwise Low High Motors 3 and 4 should rotate counterclockwise High High Motors 3 and 4 should be idle Output High Low PLC1 Sensor 1 detects object Sensor 1 detects no object PLC2 Sensor 2 detects object Sensor 2 detects no object PLC3 Sensor 3 detects object Sensor 3 detects no object PLC4 Sensor 4 detects object Sensor 4 detects no object SIDE1 Signal from sensor 5 SIDE2 Signal from sensor 6 Connection Description
50. rd 3 0 INTERROLL Product information Power supply 1 2 Connection of a 24 VDC power supply unit The Z Card has two connections for the power supply and can therefore be supplied with power in two different ways Power supply only via main power supply Both the motors and the electronics are supplied with power If this voltage drops out or is actively switched off the entire Z Card including motors sensors and control logic will not have power Power supplied via the main and control voltage supply The motors are supplied with power via the main power supply while the electronics including control logic and sensors are powered via the control power supply This allows the motor voltage to be switched off at any time e g by an the emergency stop without cutting power to the the electronics including control logic and sensors A master controller can therefore access the state of the controller e g CAN bus even if the emergency stop function is active NOTICE Damage to the Z Card due to overvoltage Do not connect more than 24 V i Multiple Z Cards in sequence can be connected to a power supply unit The maximum current of the power supply unit must be sufficient for this NOTICE The power supply pins are not protected against incorrect polarity connection Damage to the Z Card Ensure the correct polarity Pin Function 1 24 VDC 2 Ground or 0 VDC Error output The error out
51. release 4 zone conveyor LPA 4 s with start stop 4 s with start stop 20 s conveyor with start stop 4 s 45 merge ZPA 90 merge from UP or 45 merge train release SIDE to DOWN without lift belt 8 45 diverter ZPA 45 diverter train release 9 Transfer 4 ways 50 ms Transfer 4 ways 100 ms 90 merge from UP or 90 merge from UP or 90 merge from UP or 90 merge from UP or SIDE to DOWN ZPA SIDE to DOWN ZPA SIDE to DOWN train SIDE to DOWN train 50 ms 100 ms release 50 ms release 100 ms B 90 merge from UP or 90 merge from UP or 90 merge from UP or 90 merge from UP or SIDE1 to SIDE2 ZPA SIDE1 to SIDE2 ZPA SIDE1 to SIDE2 train SIDE1 to SIDE2 train 50 ms 100 ms release 50 ms release 100 ms C 90 merge from SIDE1 90 merge from SIDE1 or SIDE2 to DOWN ZPA or SIDE2 to DOWN ZPA 50 ms 100 ms D 90 diverter from UP to 90 diverter from UP to 90 diverter from UP to 90 diverter from UP to SIDE or DOWN ZPA SIDE or DOWN ZPA SIDE or DOWN train SIDE or DOWN train 50 ms 100 ms release 50 ms release 100 ms E 90 diverter from UP to 90 diverter from UP to SIDE1 or SIDE2 ZPA SIDE1 or SIDE2 ZPA 50 ms 100 ms F 90 diverter from SIDE1 90 diverter from SIDE1 90 diverter from SIDE1 90 diverter from SIDE1 to SIDE2 or DOWN ZPA 50 ms Version 1 2 09 2013 en Translation of the original instructions to SIDE2 or DOWN ZPA 100 ms to SIDE2 or DOWN train release 50 ms Description of programs see page 26 ff Mean
52. rent all sensors max 300 mA Output voltage per sensor 23 to 27 VDC Output voltage per motor actuator 23 to 27 VDC Output voltage PLC connector PIN2 23 to 27 VDC Input voltage PLC connector PIN 3 4 max 40 VDC collector emitter Input current PLC connector PIN 3 4 max 20 mA collector emitter Fuse 8 A 250 V slow e g little fuse model 218008 Permissible ambient temperature 5 C to 40 C 23 F to 104 F Ambient temperature changes max 1 K min 3 h two cycles according to IEC 68 2 14 Humidity max 90 not condensing Housing material ABS black Protection classification IP54 box sockets cable bushings Weight of Z Card incl box and holder approx 380 g 13 4 oz Housing dimensions W x H x D 35 mm x 170 mm x 85 mm 1 38 in x 6 69 in x 3 35 in Space requirements installed state including cables and holder W x H x D 45 mm x 200 mm x 100 mm 1 77 in x 7 87 in x 3 94 in Installation altitude above sea level max 1000 m 3300 ft 25 Z Card 3 0 INTERROLL 26 Product information Program descriptions In each of the following program descriptions the corresponding conveyor section is displayed stylized The following symbols are used in this diagrams Symbol Meaning Zone gt Conveyor direction M Motor number S Sensor number Version 1 2 09 2013 en Translation of the orig
53. rs 1 1 for M1 M2 M3 M4 2 S1 for M1 M3 S2 for M2 M4 3 S1 for M1 S2 for M2 S3 for M3 4 S1 for M1 S2 for M2 S3 for M3 S4 for M4 The operation of these programs corresponds to that of the ZPA conveyor see page 32 except that the packages are conveyed with low pressure accumulation In this mode the Z Card module operates as a standard conveyor as long as packages are conveyed without stops When the downstream zone and the own zone are occupied the upstream zone will still receive a clear signal for 2 5 seconds after the own sensor has detected the package During this time the own motor runs at half speed If the downstream zone does not send a clear signal within this time an occupied signal is then sent to the upstream zone to avoid receiving more packages If the downstream zone sends a free signal the packages are conveyed and separated provided that there is a gap of at least 15 ms between the packages After the last LPA zone there should be three or four standard zones to ensure a full separation of the packages This program does not use any PLC inputs or outputs WARNING Accidental motor starts If sensor 5 is not connected the starting signal remains on permanently Risk of pinched fingers Invert the signal from sensor 5 with the sensor 5 inversion switch Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL
54. s 7 Dimensions s Luisa yee RAGS AREE ARCA ERE RR MEN UR Ei mus 8 Typeuplate ocur am ends A Rd x EUREN UR ch 8 Control technology 9 Product description 10 Inputs and outputs 12 Rotary and dip switches 20 LEDS ur asa es cT 24 Technical specifications 25 Program descriptions 26 CAN bus communication 46 Transport and storage Transport a SEED ees Lee eee EE EO 51 Storage cin Shoe eRe comen enisi bide cu b eS ies oe 51 Assembly Warnings concerning proper assembly 52 Installing the Z Card in a conveyor system 53 Warnings concerning electrical installation 54 Electrical installation 54 CAN bus connection 55 Initial startup and operation Initial startup sasa do RR 22 Des ER RES IEEE S S Eus de 56 Operation c se ag ak LER aca E E dh ec mu ERA E EEG ER Dra ca 56 Maintenance and cleaning Warning notices concerning maintenance and cleaning 57 Maintenance soos le RI de PE xem ERROR EUR ete nes 57 Cleaning 22 512840 aa gen See a da rca aa GNU at lu 57 Troubleshooting Tr
55. t status it is also possible to connect a higher level control system e g a PLC via a gateway e g Profibus CAN bus to the internal CAN bus This requires that the customer provide only the interface to the PLC gateway No programming on the CAN bus is required The information necessary to transport packages between two different modules zones can be exchanged via the UP DOWN SIDE interface The Z Cards are designed for easy wiring via the CAN bus to allow simple and fast startup and control of a conveyor system Each Z Card contains a set of pre defined zone functionalities that can be set with the program switch Zero Pressure Accumulation ZPA function for all standard modules straight sections curves and merge diverter sections Low pressure accumulation LPA function for straight sections and curves Start stop function Board to board exchange of data 4 interfaces Board to board exchange of data via PLC 4 interfaces CAN Bus applications Error evaluation Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Product information Hardware features Motor output 4 x EC Variable motor speed via rotary selector Direction of rotation of motor selectable FWD REV Selectable RollerDrive type Program switch CAN Bus e Second CAN bus for branches CAN terminator switch D switch UP DOWN interface lt SIDE1 SIDE2 interface e 6 sensor interfaces
56. te lt NPN retro reflective sensor no reflector active if light is reflected closed when in idle state PNP light barrier reflector required active if light is reflected open when in idle state e PNP retro reflective sensor no reflector active if light is reflected closed when in idle state For certain applications an inverted signal is required for sensor 5 start sensor This can be set with the sensor 5 inversion switch see page 22 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Motor 1 4 Version 1 2 09 2013 en Translation of the original instructions Product information Connection of a 24 VDC motor electronically commutated There are two Motor1 and Motor2 connections The signals of ever other connection are identical to the those of the respective main connection This makes it possible to connect two motors that are always to react the same here Pin RollerDrive EC1xx RollerDrive EC200 EC300 13 1 EC310 Function DC EC100 and Pin Function Pin HC EC1xx EC200 EC300 13 1 EC310 1 No error 4 No error 4 2 Not connected Not connected 3 FWD 6 FWD REV 2 4 REV 5 Not connected 5 Not connected Not connected 6 Rotational speed output 8 Rotational speed output 5 analog 0 5 V analog 0 10 V 7 24 VDC supply voltage for 1 24 VDC supply voltage for 1 motor motor 8 Ground 2 Ground 3 1 Corresponding pin
57. ter 4 or 20 seconds WARNING Accidental motor starts If sensor 5 is not connected the starting signal remains on permanently Risk of pinched fingers Invert the signal from sensor 5 with the sensor 5 inversion switch Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Product information The inputs and outputs have the following assignments Input High Low PLC1 Package is stopped in zone 1 Package is transported normally in zone 1 PLC2 Package is stopped in zone 2 Package is transported normally in zone 2 PLC3 Package is stopped in zone 3 Package is transported normally in zone 3 PLC4 Package is stopped in zone 4 Package is transported normally in zone 4 Output PLC1 Sensor 1 detects object Sensor 1 detects no object PLC2 Sensor 2 detects object Sensor 2 detects no object PLC3 Sensor 3 detects object Sensor 3 detects no object PLC4 Sensor 4 detects object Sensor 4 detects no object Connection Description Motor M1 Motor for zone 1 M2 Motor for zone 2 M3 Motor for zone 3 M4 Motor for zone 4 Sensor S1 Sensor for zone 1 S2 Sensor for zone 2 S3 Sensor for zone 3 S4 Sensor for zone 4 S5 Start signal for zone 1 optional This can be used for example for manual placement of a package if there is no upstream system For operation the signal from this sensor must be inverted see warning above
58. to tripped Lift is at highest point The following types of mergers are available Program Structure Sensors Types used 45 merge SIBE M2 S1 ZPA Train release up gt t gt DOWN j j i M3 M1 S1 90 merge from SIDE S1 ZPA 50 ms UP or SIDE to RESET S2 ZPA DOWN Ma M2 S4 100 ms up E S5 Train release 50 ms S4 MIS5M3 Si Train release 100 ms 90 merge from SIDE S1 UP or SIDE to DOWN without lift belt 90 merge from UP or SIDE1 to SIDE2 ZPA50ms ZPA 100 ms Train release 50 ms S3 Train release SIDE2 100 ms MET CN M1 S5 M3 Version 1 2 09 2013 en 39 Translation of the original instructions Z Card 3 0 40 INTERROLL Product information Program Structure Sensors Types used 90 merge from SIDE1 S1 ZPA 50 ms SIDE1 or SIDE2 s2 S2 ZPA toDOWN ij Md S3 100 ms S5 gt DOWN sa T4 M1S5MS3 S1 SIDE2 Types e ZPA zero pressure accumulation A clear signal is sent to the upstream module once the package has left the module Train release a clear signal is sent to the upstream module once the module starts transporting the package to the downstream module and a new package can be safely fed in 50ms 100 ms Delay of the rollers after detecting the trailing edge of th
59. ty instructions The Z Card is designed according to the technical state of the art and is reliable in operation once distributed However risks may still arise Risks of physical injury to the user or bystanders Adverse effects of the Z Card and other material Disregarding the warnings in this manual may lead to serious injury Always read the entire operating and safety instructions before starting to work with the Z Card and follow the information contained herein in full Only instructed and qualified persons may work with the Z Card Always keep this user manual at hand when working on the Z Card so that you can consult it quickly if required Always comply with relevant national safety regulations gt If you have any questions after reading this user manual feel free to contact our customer service See the last page for contact information Intended use The Z Card must only be used for industrial applications and in an industrial environment for the separate control no more than four 24 VDC motors In specifically defined cases two additional motors can be used in parallel to the existing motors The Z Card must be integrated into a conveyor module or conveyor system Any other use is considered inappropriate Use of the Z Card is only allowed in the areas described under product information It must only be operated within the defined operating limits Any modifications that affect the safety of the prod
60. uct are not permitted Unintended use Applications not according to the intended use of the Z Card require approval from Interroll Qualified persons Qualified persons are persons who read and understand the manual and taking national regulations into account can competently execute incidental work Only instructed and qualified persons may work with the Z Card taking the following into account the relevant manuals and diagrams the warning and safety instructions in this manual the system specific regulations and requirements national or local regulations and requirements for safety and accident prevention Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL A Bodily injury Electricity Working environment Faults during operation Maintenance Accidental motor starts Version 1 2 09 2013 en Translation of the original instructions Safety Dangers The following list provides information about the various types of danger or damage that may occur while working with the Z Card gt gt VV VV V Y v Maintenance or repair work must only be performed by authorized and qualified persons in accordance with the applicable regulations Before using the Z Card ensure that no unauthorized persons are near the conveyor Only perform installation and maintenance work after you have switched off the power Ensure that the power cannot be turned on ac
61. vention The Z Card attempts to transport packages alternately from both upstream zones However if the intended upstream zone is clear and the other upstream zone is occupied the package is transported from the other upstream zone The input PLC4 helps determine whether or not the package should be transported onward from the merger module The output PLC4 receives the signal indicating whether there is a package at the sensor located at the end of the module PLC4 High Low Input The package should be The package can exit the stopped at the end of merger merger module module Output A package is located at the No package located at the sensor at the end of merger sensor module The connections for motors and sensors have the following assignments Connection Description Motor M1 Rollers in main transport direction M2 Belts in merge direction M3 For 45 merge same as motor 1 For 90 merge Lift motor 1 M4 For 45 merge same as motor 2 For 90 merge Lift motor 2 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Product information Connection Description Sensor S1 Sensor for downstream zone DOWN S2 Sensorfor merge direction SIDE1 S3 Sensor for a second merge or diverter direction SIDE2 S4 Sensor for upstream zone UP S5 Sensor for lift Sensor switches from tripped to clear Lift is at lowest point Sensor switches from clear
62. veral idler rollers and associated sensors and switches Zero pressure accumulation occurs as zones hold packages until the next downstream zone is identified by the logic device as clear When accumulation OCCUIS signal is passed upstream until each consecutive zone is occupied Packages never push each other and no line pressure occurs In the figure above the Zone A sensor has detected a package The Z Card of Zone A detects that a package is present in the zone checks whether Zone B is clear and requests permission to transport the package further to Zone B Since there is also a package in Zone B the Z Card of Zone B denies permission until this package has been transferred to Zone C single mode or at least until onward transport has been started wave like train release mode The Z Card of Zone A activates the RollerDrives in this zone only after it receives permission from the Z Card of Zone B Product description A Z Card can control up to four RollerDrives at different speeds and receive feedback signals from up to five sensors Depending on the software one Z Card is responsible for up to four zones The combination of a Z Card and the connected zones RollerDrives DriveControls and sensors is referred to as a module To configure larger conveyor systems several modules can easily be connected via UP DOWN SIDE handshakes on the Z Card To configure the system specific modules or to visualize the system and curren
63. w Low Package to be transported from SIDE1 to DOWN High Low High Package to be transported from SIDE1 to SIDE2 High High Low Package to be transported from SIDE2 to DOWN High High High Package to be transported from SIDE2 to SIDE1 Input PLC4 and outputs PLC2 to PLC4 are not used The connections for motors and sensors have the following assignments Connection Description Motor M1 Rollers in main transport direction M2 Belts in diverter direction M3 Lift motor 1 M4 Lift motor 2 44 Version 1 2 09 2013 en Translation of the original instructions Z Card 3 0 INTERROLL Product information Connection Description Sensor S1 Sensor for downstream zone DOWN S2 Sensor for first merge or diverter direction SIDE1 S3 Sensor for a second merge or diverter direction SIDE2 S4 Sensorfor upstream zone UP S5 Sensor for lift Sensor switches from tripped to clear Lift is at lowest point Sensor switches from clear to tripped Lift is at highest point S6 Sensor for position monitoring After initializing the Z Card if a package is located in the module the system waits until a signal is received at inputs PLC1 PLC2 and PLC3 indicating where the package should be transported A delay after detecting the trailing edge of the package serves to ensure the package has been completely transported past the sensor before it is merged or ejected Depending on the program selected this delay is 50

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