Version 1.7. Module Firmware Version 4

Transcription

1 Version 1.7 Module Firmware Version 4 January 2018 Publication EZQ-1000 Module firmware and functionality is protected by U.S. and international patents. For complete patent information visit

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3 Glossary of Terms 3 GLOSSARY OF TERMS Brushless DC Motor Hall Effect Sensor JST LED A D.C. motor with a permanent magnet rotor and coils in the stator. The stator coil currents are sequenced by an external brushless D.C. motor controller. In such motors, current and torque, voltage and rpm are linearly related. The main advantage to this type of motor is the elimination of EMI caused by the arcing brushes and improved motor life. Special sensor embedded within the brushless DC motor of an MDR used to provide motor rotor position feedback to the motor controller This is the name of a particular connector manufacturer that produces a specific plug/socket arrangement for MDR connection to control cards. This name is accepted within the conveyor and MDR industry as a simple description of the particular socket style used on standard EZ-Qube hardware. Light Emitting Diode In the context of this document, LED s are used on EZ-Qube controllers to provide visual indication of module status MDR NPN / PNP PLC PWM Senergy ECO Motorized Drive Roller or Motor Driven Roller - Brushless DC motor and gearbox assembly integrated into a single conveyor roller. Electronics term that indicates the type of transistor circuit used for a logical input or output for controllers. NPN devices will provide a common or ground connection when activated and a PNP device will provide a logic voltage connection when activated. Programmable Logic Controller A wide variety of industrial computing devices that control automatic equipment Pulse Width Modulation a control scheme that utilizes high speed switching transistors to efficiently deliver power in a controlled fashion from EZ-Qube controllers to MDR. EZ-Qube controllers control Senergy brand MDRs and only provide ECO or BOOST mode performance. SYMBOL CONVENTIONS This symbol indicates that special attention should be paid in order to ensure correct use as well as to avoid danger, incorrect application of product, or potential for unexpected results This symbol indicates important directions, notes, or other useful information for the proper use of the products and software described herein. Publication EZQ-1000 Rev 1.7 January 2018

4 IMPORTANT USER INFORMATION The device must be used exactly as recommended by the manufacturer. Failure to do so may interfere with the safety mechanisms incorporated in the device. To ensure proper device operation, the other system components must be designed to operate in the same environmental conditions as EZ-Qube. In addition, all other components must meet EMC requirements. The manufacturer will not be responsible and the warranty is voided if the device is used outside the stated operating conditions, or if inappropriate devices are used with this device. Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes, and standards The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Insight Automation Inc. does not assume responsibility or liability (to include intellectual property liability) for actual use based on the examples shown in this publication Reproduction of the contents of this manual, in whole or in part, without written permission of Insight Automation Inc. is prohibited. Publication EZQ-1000 Rev 1.7 January 2018

5 Summary of Changes 5 SUMMARY OF CHANGES The following table summarizes the changes and updates made to this document since the last revision Revision Date Change / Update 1.0 May 2017 Initial Release 1.1 June 2017 Updated for digital speed output 1.2 August 2017 Updated Motor Pin description and features list 1.3 September 2017 Updated wiring diagrams for +24 to Common for NPN Run inputs 1.4 October 2017 Updated jumper settings in Appendix A, updated wiring diagrams 1.6 November 2017 Revised Accel/Decel information 1.7 January 2018 Added removable terminal block part numbers to Technical Specifications GLOBAL CONTACT INFORMATION Publication EZQ-1000 Rev 1.7 January 2018

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7 Table of Contents 7 TABLE OF CONTENTS Glossary of Terms... 3 Symbol Conventions... 3 Important User Information... 4 Summary of Changes... 5 Global Contact Information... 5 Table of Contents... 7 EZ-Qube Module Features... 9 EZ-Qube Part Numbers... 9 EZ-Qube (Senergy with JST Connector) Terminal Connections Removable Power Terminal Removable I/O Terminal Block MDR Plug-In Connection Proper Motor Roller & Module Grounding Inspection and Cleaning Power Supply Requirements DIP Switch Settings DIP Switch CONFIG positions 6 & 7 Electrical Brake Selection CONFIG SW 1 and SPEED Sw 1 thru 4 MDR Speeds External Voltage at Input 0-10V MDR Speeds ACC/DEC DIP Switches Motor Acceleration/Deceleration Pulsed Speed Output Typical Wiring Diagrams PNP Versions of EZ-Qube NPN Versions of EZ-Qube Analog Speed Control Status and Error Conditions with Timing Diagrams Diagram #1 - Power Supply ON with Motor Roller Connected Diagram #2 - MDR NOT Connected Diagram #3 - Power Supply voltage exceeds 32V Diagram # 4 Voltage Drop below 18V and Voltage Drop below 13V Diagram #5 - Voltage over 32V due to over speeding Diagram #6 - Normal Operation with MDR rotating then Reverse Signal Diagram #7 - MDR Current Exceeding Peak Limit Diagram #8 - Over Current with PWM Limiting Diagram #9 - MDR Stalled Condition with Self Stop Diagram #10 Motor Roller Overload with Self Stop Diagram #10A EZ-Qube Overheated with Self Stop Diagram #11 Motor Not Rotating when RUN is ON Diagram #12 - MDR Phases Error Detected Specifications Technical Specifications Mounting Dimensions and Instructions Appendix A Internal Jumper Settings Notes: Publication EZQ-1000 Rev 1.7 January 2018

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9 EZ-Qube Module Features 9 EZ-QUBE MODULE FEATURES Over-voltage protection with transient voltage suppressor Internal SMD fast 8 Amp fuse Protection from over-voltage produced by over-speeding of MDR Thermal and Over-Current Protection for module and MDR Reverse polarity protection against incorrect wiring of the power terminals Sensing and indication of over voltage from power supply and/or MDR (32 Volts) Sensing and indication of under voltage from power supply (18 Volts) PID speed regulation mode with 31 fixed speed settings Adjustable acceleration and deceleration with 16 fixed settings External 0-10V analogue voltage variable speed control Selectable Dynamic, Free Spin, and Servo brake control modes Automatic error recovery Six status LEDs Removable power and control signal terminal blocks Motor reversing capability while motor is running. Error Output signal and LED indication for module and MDR diagnosis Speed Output signal and LED indication for speed of MDR Build-in communication (UART) with PC for diagnostic and easy configuration Over-Current Protection for Error and Speed Outputs Selectable default rotation direction Hinged clear protective cover for DIP Switch and LEDs Options for PNP or NPN control signal wiring accommodation Run signal inputs are galvanically isolated Options for Senergy ECO and Senergy BOOST motor rollers EZ-QUBE PART NUMBERS Part Number EZQUBE-P EZQUBE-N Description PNP version with standard JST connector, sinking input (+24V signal to energize) and sourcing ERROR output (+24V signal output), pulsed speed output at rotation frequency NPN version with standard JST connector, sourcing inputs (0V signal to energize inputs) and sinking ERROR output (0V signal output), pulsed speed output at rotation frequency Publication EZQ-1000 Rev 1.7 January 2018

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11 EZ-Qube (Senergy with JST Connector) 11 EZ-QUBE (SENERGY WITH JST CONNECTOR) Figure 1 shows an example EZ-Qube module of which accommodates the standard Senergy motor roller with 9-pin JST style connector. Figure 2 shows a Senergy motor roller with JST connector. FIGURE 1 EZ-QUBE MODULE LAYOUT FIGURE 2 - SENERGY MOTOR ROLLER WITH JST CONNECTOR Publication EZQ-1000 Rev 1.7 January 2018

12 12 EZQUBE Reference Manual TERMINAL CONNECTIONS EZ-Qube has three removable terminal connectors designated as PWR, MOTOR and I/O TERMINAL FIGURE 3 - EZ-QUBE CONECTORS Wire terminals on all removable connectors are cageclamp style requiring a small blade screwdriver to open the clamp to insert the wire. See Technical Specifications for replacement part numbers for Removable Terminal Blocks REMOVABLE POWER TERMINAL This is a removable 2 pin plug-in terminal connections. Wire size range is AWG (0.2 mm 2 to 1.5 mm 2 ). Refer to Figure 1 for +24V and 0V terminal designation. Pin No. Signal Name Description 1 +24V 24 Volt DC Power of EZ-Qube 2 GND 0V REMOVABLE I/O TERMINAL BLOCK This is a removable 7 pin plug-in terminal connections. Wire size range is AWG (0.2 mm 2 to 0.5 mm 2 ). The following chart lists each signal and its usage. Refer to Figure 1 for Removable I/O Terminal Block designations. Publication EZQ-1000 Rev 1.7- January 2018

13 Terminal Connections 13 Pin No. Signal Name Direction Description V Input 0-10 Volt analog input for speed control 2 Speed Output Outputs frequency proportional to the speed of the MDR 3 Error Output Provides +24V or 0V output when Error condition is active 4 Reverse Input Accepts +24V or 0V input to run motor in opposite direction that is set on DIP Switch CONFIG -2 5 Run A Input Accepts +24V or 0V input for run at speed control (see section Run A and Run B Inputs) 6 Run B Input Accepts +24V or 0V input for run at speed control (see section Run A and Run B Inputs) 7 Common DC common for optocouplers of Inputs (Run A, Run B, Reverse) RUN A AND RUN B INPUTS The combination of signals on the Run A and Run B terminals allows you to dynamically set the speed with your run signals to the EZ-Qube module. The following chart lists the signal states and their respective speed control: Run A Run B Description ON OFF Start motor roller and run at 100% of speed selected on DIP Switches or 0-10V input ON ON Start motor roller and run at 75% of speed selected on DIP Switches or 0-10V input OFF ON Start motor roller and run at 50% of speed selected on DIP Switches or 0-10V input OFF OFF Stop motor roller MDR PLUG-IN CONNECTION MDR connector is a 9 pin JST brand right angle header with 2.5mm center to center pin spacing Pin No. Signal Name Description 1 Hall Sensor GND Ground 2 Hall Sensor Power 5.5 VDC 3 Coil U Motor Winding coil U 4 Coil V Motor Winding coil V 5 Coil W Motor Winding coil W 6 Hall U Hall Effect Sensor output U 7 Hall V Hall Effect Sensor output V 8 Hall W Hall Effect Sensor output W 9 - Not Used Publication EZQ-1000 Rev 1.7 January 2018

14 14 EZQUBE Reference Manual PROPER MOTOR ROLLER & MODULE GROUNDING MDR drive-end shaft and/or fixing bracket must be bonded or otherwise electrically connected to grounded conveyor frame. Improper grounding of MDR and/or Power Supply Common may result in premature MDR and/or EZ-Qube module failure. Proper grounding techniques MUST be observed for all applications. INSPECTION AND CLEANING When inspecting the device, the operator or maintenance personnel should visually inspect all mechanical parts and connections. The inspection should be performed on a monthly basis unless the device is not functioning as expected. In case of damage or if specific maintenance is required, it should be handled only by the manufacturer or buy a technician authorized by the manufacturer to perform such maintenance. For cleaning, use dry or slightly damp piece of cloth to wipe off the exterior of the module. Do not use solvents or abrasives. Do not allow any liquids to penetrate inside the module cover. Any liquids inside the cover will result in damage. POWER SUPPLY REQUIREMENTS The power supply for any and all EZ-Qube modules must meet the following requirements: Supplying 24 Volts DC and a minimum of 5 Amperes per module (for Senergy in BOOST mode) Certified as NEC Class II device Capable of detecting and properly handling short circuit and overload of its DC power output Publication EZQ-1000 Rev 1.7- January 2018

15 DIP Switch Settings 15 DIP SWITCH SETTINGS EZ-Qube has three DIP Switches designated as SPEED, CONFIG and ACC/DEC FIGURE 4 - EZ-QUBE DIP SWITCHES Figure 5 shows ON / OFF positions for DIP switches. The following table defines each of the 16 separate switches: Switch SPEED Switch ACC/DEC Switch CONFIG Function OFF ON Speed Selection Refer to section DIP Switch Positions 1 thru 5 MDR Speeds on page 16 Function OFF ON Accel / Decel Selection Refer to section DIP Switch ACC/DEC Motor Roller Acceleration/Deceleration on page 19 Function OFF ON 1 Speed Range Selection Low Range High Range 2 Direction of Rotation CCW CW 3 Open/Close Loop Open Loop Close Loop(PID) 4 Auto/Manual Error Reset Manual Reset Automatic Reset 5 MDR Selection ECO Mode BOOST Mode 6 Refer to DIP Switch CONFIG positions 6 & 7 Electrical Brake Selection 7 Brake Selection on page 15 8 Deceleration Time Decel Time = Accel Decel Time = 2 * Accel Please note that all switch actions take effect immediately except Switch CONFIG- 2 Direction of Rotation. It will take effect only when the motor is NOT running. Publication EZQ-1000 Rev 1.7 January 2018

16 16 EZQUBE Reference Manual The DIP Switch and LED area on the EZ-Qube module utilizes a hinged clear plastic protective cover. Simply lift the cover from the bottom edge of the module to open the cover to gain access to the DIP Switch. Be sure to snap the cover back closed when done making and changes to the DIP Switch settings. FIGURE 5 - DIP SWITCH ON-OFF EXAMPLE DIP SWITCH CONFIG POSITIONS 6 & 7 ELECTRICAL BRAKE SELECTION Braking Method SW 6 SW 7 Standard Dynamic Braking OFF OFF Free ON OFF Servo Brake OFF ON Please note that these settings are for electrically controlled braking of MDR. EZ-Qube does not support control for a mechanical brake. The following table defines the MDR Braking Methods available: Method Standard Dynamic Braking Free Servo Brake Description Standard Dynamic braking - MDR power circuit in EZ-Qube is internally shunted to ground during motor stop sequence in order to bring the rotor to a stop. This is the MDR industry standard braking method. MDR power circuit in EZ-Qube is internally disconnected and made an open circuit to allow the rotor to free spin until its mechanical load brings it to a stop. When run signal is removed; the EZ-Qube utilizes the MDR s Hall Effect sensors to determine the position of the rotor and will inject current into the motor windings to maintain rotor position. Servo Brake utilizes of the EZ-Qube s power transistors for current injection. Publication EZQ-1000 Rev 1.7- January 2018

17 DIP Switch Settings 17 CONFIG SW 1 AND SPEED SW 1 THRU 4 MDR SPEEDS No CONFIG SW 1 SPEED SW 4 SPEED SW 3 SPEED SW 2 SPEED SW 1 ECO Mode MDR RPM BOOST Mode MDR RPM ECO & BOOST PWM, % 1 OFF OFF OFF OFF OFF 0-10V Analog ECO Mode Speed Out Hz BOOST Mode Speed Out Hz 2 OFF OFF OFF OFF ON % OFF OFF OFF ON OFF % OFF OFF OFF ON ON % OFF OFF ON OFF OFF % OFF OFF ON OFF ON % OFF OFF ON ON OFF % OFF OFF ON ON ON % OFF ON OFF OFF OFF % OFF ON OFF OFF ON % OFF ON OFF ON OFF % OFF ON OFF ON ON % OFF ON ON OFF OFF % OFF ON ON OFF ON % OFF ON ON ON OFF % OFF ON ON ON ON % ON OFF OFF OFF OFF % ON OFF OFF OFF ON % ON OFF OFF ON OFF % ON OFF OFF ON ON % ON OFF ON OFF OFF % ON OFF ON OFF ON % ON OFF ON ON OFF % ON OFF ON ON ON % ON ON OFF OFF OFF % ON ON OFF OFF ON % ON ON OFF ON OFF % ON ON OFF ON ON % ON ON ON OFF OFF % ON ON ON OFF ON % ON ON ON ON OFF % ON ON ON ON ON % Publication EZQ-1000 Rev 1.7 January 2018

18 18 EZQUBE Reference Manual EXTERNAL VOLTAGE AT INPUT 0-10V MDR SPEEDS The relationship between the external voltage at input 0-10V and the motor speed is linear in the range of the minimum and maximum speeds of the MDR ( ) RPM for ECO and ( ) RPM for BOOST Mode. The table below shows the 24 sample values at equal intervals. No 0-10V ECO Mode BOOST Mode Open Loop Input MDR RPM MDR RPM PWM, % V % V % V % V % V % V % V % V % V % V % V % V % V % V % V % V % V % V % V % V % V % V % Publication EZQ-1000 Rev 1.7- January 2018

19 DIP Switch Settings 19 To determine the speed of the roller, you must know the diameter of your roller tube and the gear reduction ratio of the motor roller in order to calculate the speed based upon the Motor RPM you have selected with DIP Switch Positions 1 thru 5. The following charts list the Senergy roller speed codes and their corresponding gear ratios Speed Code Gear Reduction Ratio 10M : 1 15M 45 : 1 20M : 1 25M 27 : 1 35M 18.3 : 1 45M 15 : 1 Speed Code Gear Reduction Ratio 60M : 1 75M 9 : 1 95M : 1 125M 5 : 1 175M 3.66 : 1 215M 3 : 1 The formula for calculating the roller tube speed in meters per second is: Motor RPM Diameter (in meters) Speed (in meters/second second) = π Tube Gear Reduction 60 For example, for a 75M speed code roller with a 50 mm tube diameter running at 5000 RPM the calculation is: Speed = π. = 1.45 Meters/sec ACC/DEC DIP SWITCHES MOTOR ACCELERATION/DECELERATION The EZ-Qube acceleration/deceleration control is designed to provide a constant G force or ramp slope regardless of the speed for a given SPEED DIP switch setting. The selections made on the ACC/DEC DIP switches set both the acceleration and deceleration G force to the same value. The actual expected time elapsed for a given ramp selection is dependent on the motor RPM selected. The following chart shows the 16 possible ACC/DEC DIP switch settings for G force ramp and the expected ramp time to reach full speed (when accelerating) or to stop (when decelerating) when the motor speed is set to full speed regardless of ECO or BOOST modes. Publication EZQ-1000 Rev 1.7 January 2018

20 20 EZQUBE Reference Manual ACC/DEC SW 4 ACC/DEC SW 3 Accel/Decel Times When Speed Setting is 100% ACC/DEC SW 2 ACC/DEC SW 1 Acceleration Time (sec) Deceleration Time (sec) CONFIG SW 8 OFF Deceleration Time (sec) CONFIG SW 8 ON OFF OFF OFF OFF OFF OFF OFF ON OFF OFF ON OFF OFF OFF ON ON OFF ON OFF OFF OFF ON OFF ON OFF ON ON OFF OFF ON ON ON ON OFF OFF OFF ON OFF OFF ON ON OFF ON OFF ON OFF ON ON ON ON OFF OFF ON ON OFF ON ON ON ON OFF ON ON ON ON EXAMPLE # 1 ACCELERATION AND DECELERATION RAMPS EQUAL (CONFIG SW 8 = OFF) Because the ACC/DEC settings are for G force and not time; for any given G force setting, the actual expected time to complete the up/down ramp depends upon the SPEED selection. The times shown in the ACC/DEC chart are for maximum speed. The expected ramp up or ramp down time when the speed setting is less than maximum value will also be shorter in proportion to speed setting. Let s say we set the ACC/DEC switches so that when our speed is set to maximum (i.e RPM in Eco Mode) we want a second ramp up and second ramp down. The setting from the ACC/DEC chart for this is ON/ON/ON/OFF. The graph in Figure 6 shows the ramp up and ramp down curves for 2 motors one set to 100% speed and the other set for 50% speed. Also in this example the CONFIG Sw 8 is set to OFF indicating ramp up and ramp down slopes are equal. Because the switch settings give us a ramp, the slopes of the acceleration and deceleration speed lines are the same for each speed selection. In our example, at after running for 6 seconds, we turn the motors off to initiate the ramp down. Publication EZQ-1000 Rev 1.7- January 2018

21 DIP Switch Settings 21 FIGURE 6 - ACC/DEC RAMP EXAMPLE #1 EXAMPLE # 2 DECELERATION RAMP = 2 X ACCELERATION RAMP (CONFIG SW 8 = ON) We will use the same set-up as Example #1 with the exception of CONFIG Sw 8 set to ON. With this setting, the deceleration ramp time is 2 times the acceleration ramp time The graph in Figure 7 shows the ramp up and ramp down times for 100% speed and for 50% speed when the ACC/DEC switches are set to provide this second ramp and CONFIG Sw 8 is set to ON indicating ramp down time is twice as long as the ramp up time. Because the switch settings give us a ramp, the slopes of the acceleration and deceleration speed lines are the same for each speed selection. In our example, after running for 6 seconds, we turn the motor off to initiate the ramp down. Publication EZQ-1000 Rev 1.7 January 2018

22 22 EZQUBE Reference Manual FIGURE 7 - ACC/DEC RAMP EXAMPLE #2 ACCELERATION / DECELERATION TIME FORMULA To find the Acceleration/Deceleration times for speed settings other than 100%, the following simple formula can be used to calculate the value: T = Speed Max RPM T Where: T = New Ramp Up/Down time Speed = New Speed in RPM from CONFIG SW 1 / SPEED SW 1 thru 4 Max RPM = 5800 for ECO Mode or 4200 for BOOST mode T Max = Time value from ACC/DEC chart For example, let s say we have selected the CONFIG and SPEED DIP switches for the 4000 RPM setting: CONFIG SW 1 = ON SPEED SW 4 thru 1 = OFF/OFF/ON/OFF And we have selected ACC/DEC DIP switches for the second setting: ACC/DEC SW 4 thru 1 = ON/OFF/ON/OFF Our formula for ECO Mode looks like: T = = sec 5800 Publication EZQ-1000 Rev 1.7- January 2018

23 DIP Switch Settings 23 PULSED SPEED OUTPUT The SPEED output on the Removable I/O Terminal Block provides a pulsed signal whose frequency is proportional to the motor s running speed. This relationship is shown below in Figure 8: FIGURE 8 - SPEED OUTPUT SIGNAL IN RELATION TO MOTOR ROTOR REVOLUTION The frequency of the Speed Output for each given speed DIP SW setting is listed in the chart in section CONFIG SW 1 and SPEED Sw 1 thru 4 MDR Speeds on page 17. Publication EZQ-1000 Rev 1.7 January 2018

24 24 EZQUBE Reference Manual TYPICAL WIRING DIAGRAMS PNP VERSIONS OF EZ-QUBE FIGURE 9 - SINGLE PNP MODULE RUN/REVERSE WIRING To use the REVERSE input, either RUN A or RUN B must also be energized. Please note that you DO NOT have to de-energize both RUN A and RUN B signals in order to change MDR direction with the REVERSE input. FIGURE 10 - PNP MODULE ERROR OUTPUT WIRING Please note that the ERROR output current for either PNP EZ-Qube models is limited to 100 ma. If the device connected to the ERROR output requires a higher current, then you must utilize an interface relay into the circuit. Publication EZQ-1000 Rev 1.7- January 2018

25 Typical Wiring Diagrams 25 FIGURE 11 - MULTIPLE PNP MODULES GETTING RUN SIGNAL FROM SINGLE PLC OUTPUT Figure 11 shows a single PLC output connected to multiple modules for the RUN A signal only for clarity. PLC outputs can also be connected to RUN B and REVERSE inputs as well. Publication EZQ-1000 Rev 1.7 January 2018

26 26 EZQUBE Reference Manual FIGURE 12 - MULTIPLE PNP MODULES PROVIDING SINGLE ERROR INPUT TO PLC In Figure 12, if any of the connected module s ERROR signals energizes, then the PLC input will energize. Please note that connection between the two grounds only required when PLC DC power supply is separate from EZ-Qube DC power supply. Publication EZQ-1000 Rev 1.7- January 2018

27 Typical Wiring Diagrams 27 FIGURE 13 - WIRING DIAGRAM FOR SPEED OUTPUT TO PNP PLC INPUT MODULE Please note that the Speed Output is a pulsed signal whose frequency is proportional to the motor speed. See chart in section CONFIG SW 1 and SPEED Sw 1 thru 4 MDR Speeds on page 17 for details on the pulsed out frequency for each given DIP Switch speed setting. Publication EZQ-1000 Rev 1.7 January 2018

28 28 EZQUBE Reference Manual NPN VERSIONS OF EZ-QUBE FIGURE 14 - NPN MODULE RUN/REVERSE WIRING To use the REVERSE input, either RUN A or RUN B must also be energized. Please note that you do not have to de-energize both RUN A and RUN B in order to change MDR direction with the REVERSE input. FIGURE 15 - SINGLE NPN MODULE ERROR OUTPUT WIRING Please note that the ERROR output current for either NPN EZ-Qube models is limited to 100 ma. If the device connected to the ERROR output requires a higher current, then you must utilize an interface relay into the circuit. Publication EZQ-1000 Rev 1.7- January 2018

29 Typical Wiring Diagrams 29 FIGURE 16 - MULTIPLE NPN MODULES GETTING RUN SIGNAL FROM SINGLE PLC OUTPUT Figure 16 shows a single PLC output connected to multiple modules for the RUN A signal only for clarity. PLC outputs can also be connected to RUN B and REVERSE inputs as well. Please note that connection between the two grounds only required when PLC DC power supply is separate from EZ-Qube DC power supply. Publication EZQ-1000 Rev 1.7 January 2018

30 30 EZQUBE Reference Manual FIGURE 17 - MULTIPLE NPN MODULES PROVIDING SINGLE ERROR INPUT TO PLC In Figure 17, if any of the connected module s ERROR signals energizes, then the PLC input will energize. Please note that connection between the two grounds only required when PLC DC power supply is separate from EZ-Qube DC power supply. Publication EZQ-1000 Rev 1.7- January 2018

31 Typical Wiring Diagrams 31 FIGURE 18 - WIRING DIAGRAM FOR SPEED OUTPUT TO NPN PLC INPUT MODULE Please note that the Speed Output is a pulsed signal whose frequency is proportional to the motor speed. See chart in section CONFIG SW 1 and SPEED Sw 1 thru 4 MDR Speeds on page 17 for details on the pulsed out frequency for each given DIP Switch speed setting. Publication EZQ-1000 Rev 1.7 January 2018

32 32 EZQUBE Reference Manual ANALOG SPEED CONTROL To enable analog speed control; each of the 4 DIP switches on Switch SPEED must be OFF and DIP switch 1 on Switch CONFIG must be OFF. The EZ-Qube must also have its RUN A and/or Run B signal energized in order for it to act upon the variable voltage applied to the 0-10V terminal. FIGURE V ANALOG INPUT WIRING DIAGRAM Please note that in Figure 19, the example shows an NPN version of EZ-Qube where an NPN signal to the Run A terminal and +24V connected to the Common terminal. For the PNP version, the Run A signal would be connected to +24V and the Common terminal connected to 0V. Also note that the combination of Run A and Run B signals as described in section Run A and Run B Inputs on page 13 still applies when using analog speed control. Publication EZQ-1000 Rev 1.7- January 2018

33 Typical Wiring Diagrams 33 It is also possible to make use of a potentiometer for speed regulation. This would allow setting the speed manually by adjusting the potentiometer as shown in Figure 20. FIGURE 20 - ANALOG POTENTIOMETER WIRING EXAMPLE Figure 20 shows an example of a PNP version of EZ-Qube with the Run A signal connected to +24V and the Common connected to 0V. For the NPN versions, Run A and/or Run B signals would connect to 0V and the Common terminal would connect to +24V. When using potentiometer control, you may achieve more precise and stable control if you power the potentiometer portion of the circuit from a power supply separate from the EZ-Qube power supply. Please note that this separate power supply and the EZ-Qube power supply should have their 0 DC terminals connected to provide a common DC reference. Publication EZQ-1000 Rev 1.7 January 2018

34 34 EZQUBE Reference Manual Figure 21 shows the motor speed in RPM versus the analog input voltage for both ECO and BOOST modes of operation. FIGURE 21 - SPEED VS. ANALOG VOLTAGE CHART The internal resistance of analog input is 100 kω. The current consumption of this input is 100 µa when the applied voltage is equal to 10V Publication EZQ-1000 Rev 1.7- January 2018

35 Status and Error Conditions with Timing Diagrams 35 STATUS AND ERROR CONDITIONS WITH TIMING DIAGRAMS Figure 1 on page 11 depicts the location of each EZ-Qube LED indicator. The following chart lists each and their primary functions. LED LED State Description ON at normal brightness Input power is between 18V and 31V Power FLASH at 0.1s interval Input power is below 18V ON at high brightness Input voltage is greater than 31V Run ON if Run A or Run B is ON RUN signal(s) are on Motor Flashing RUN signal(s) are on and flash rate is proportional to motor speed Limit ON Current is being limited to motor Flash & Blink See Timing Diagrams Temp ON Calculated motor temperature is above 105 C 0.2s Flash at 0.4 sec interval Motor roller is disconnected Fault Flash at 1.0 s interval Controller has stopped the motor due to error condition Other flash rates See Timing Diagrams These LED s can also display brief indications of normal events. The following pages show timing diagrams that illustrate normal status and each error condition along with the visual LED behaviour used to indicate these conditions. Publication EZQ-1000 Rev 1.7 January 2018

36 36 EZQUBE Reference Manual DIAGRAM #1 - POWER SUPPLY ON WITH MOTOR ROLLER CONNECTED Publication EZQ-1000 Rev 1.7- January 2018

37 Status and Error Conditions with Timing Diagrams 37 DIAGRAM #2 - MDR NOT CONNECTED Publication EZQ-1000 Rev 1.7 January 2018

38 38 EZQUBE Reference Manual DIAGRAM #3 - POWER SUPPLY VOLTAGE EXCEEDS 32V Publication EZQ-1000 Rev 1.7- January 2018

39 Status and Error Conditions with Timing Diagrams 39 DIAGRAM # 4 VOLTAGE DROP BELOW 18V AND VOLTAGE DROP BELOW 13V Publication EZQ-1000 Rev 1.7 January 2018

40 40 EZQUBE Reference Manual DIAGRAM #5 - VOLTAGE OVER 32V DUE TO OVER SPEEDING Publication EZQ-1000 Rev 1.7- January 2018

41 Status and Error Conditions with Timing Diagrams 41 DIAGRAM #6 - NORMAL OPERATION WITH MDR ROTATING THEN REVERSE SIGNAL Publication EZQ-1000 Rev 1.7 January 2018

42 42 EZQUBE Reference Manual DIAGRAM #7 - MDR CURRENT EXCEEDING PEAK LIMIT Publication EZQ-1000 Rev 1.7- January 2018

43 Status and Error Conditions with Timing Diagrams 43 DIAGRAM #8 - OVER CURRENT WITH PWM LIMITING Publication EZQ-1000 Rev 1.7 January 2018

44 44 EZQUBE Reference Manual DIAGRAM #9 - MDR STALLED CONDITION WITH SELF STOP Publication EZQ-1000 Rev 1.7- January 2018

45 Status and Error Conditions with Timing Diagrams 45 DIAGRAM #10 MOTOR ROLLER OVERLOAD WITH SELF STOP Publication EZQ-1000 Rev 1.7 January 2018

46 46 EZQUBE Reference Manual DIAGRAM #10A EZ-QUBE OVERHEATED WITH SELF STOP Publication EZQ-1000 Rev 1.7- January 2018

47 Status and Error Conditions with Timing Diagrams 47 DIAGRAM #11 MOTOR NOT ROTATING WHEN RUN IS ON Publication EZQ-1000 Rev 1.7 January 2018

48 48 EZQUBE Reference Manual DIAGRAM #12 - MDR PHASES ERROR DETECTED Publication EZQ-1000 Rev 1.7- January 2018

49 Specifications 49 SPECIFICATIONS TECHNICAL SPECIFICATIONS Input Power Supply Requirements Control Input Voltage Range Current Consumption 24VDC +15% / -25% NEC Class II Certified (14 30) VDC ~ 30 ma without Motor Roller Max Peak Current Max Start Current (BOOST Mode) 16A 5A (for 1.5 seconds) Max. Rated Current (BOOST Mode) 3.6A Built in Current Limits Input Power Fuse 8A Max. Current ERROR & Speed Outputs - total 100mA Supported Motor Rollers PWM frequency Time delay initial setting Time to start motor rotation Ambient Operating Temperature Storage Temperature Environmental Rating Weight Removable Power Terminal Part Removable I/O Terminal Part Senergy Standard (JST Version) ECO and BOOST Mode only 33kHz < = 20 msec from power ON. < = 5 msec -10 C to 40 C -40 C to 85 C IP20 For Indoor Use Only Altitude up to 2000m Maximum Relative Humidity: 70% for temperatures up to 30 C and decreasing linearly to 50% at 50 C Environmental Pollution Class 2 Approximately 70g Degson 8EDGK P-11 Degson 8EDGK P-11 Publication EZQ-1000 Rev 1.7 January 2018

50 50 EZQUBE Reference Manual MOUNTING DIMENSIONS AND INSTRUCTIONS DIMENSIONS All dimensions in mm. Mounting dimensions as shown below in Figure 22 are the same for all versions of EZ-Qube. FIGURE 22 - EZ-QUBE DIMENSIONS MOUNTING EZ-Qube module must be mounted with its long side parallel to the conveyor frame and with its heat sink plate in contact with the conveyor frame. Attach module to frame using fasteners through the 2 mounting holes on the module through matching holes drilled into conveyor frame as shown in Figure 23 and Figure 24. Other mounting and installation requirements: Metal Heat Sink surface must face the conveyor frame and Heat Sink must not be accessible by any personnel without removing the module from the frame Module must be mounted on electrically grounded metal surface or provided with a conductor wire connecting the module s metal heat sink plate to electrical ground. Module must be mounted in such a way such that there are no interferences with an operator s ability to remove or unplug the power, motor, and control signal connectors. Module should be mounted in such a way and location such that any personnel can easily retreat away from the module in the event of a device failure Module must be mounted such that it can be accessed by personnel of any height. Publication EZQ-1000 Rev 1.7- January 2018

51 Specifications 51 FIGURE 23 - EZ-QUBE ATTACHMENT TO CONVEYOR FRAME FIGURE 24 - HEAT SINK ATTACHMENT TO FRAME Publication EZQ-1000 Rev 1.7 January 2018

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53 53 APPENDIX A INTERNAL JUMPER SETTINGS In the event you may need to change the electrical input or output type between PNP and NPN, there are internal jumpers located on the circuit board to do this. Modifying internal jumper settings involves removing the module s plastic housing cover. Handling the EZ-Qube module without the cover must only be done by personnel who have been adequately electrostatically discharged. Handling the module with the housing cover removed without proper ESD precautions may result in module damage. On the PCB of the EZ-Qube there are three (3) jumpers (see below in Figure 25): 1. Error Error output can be either PNP or NPN. 2. Speed Speed output can be either PNP or NPN. 3. Err.Type When Error is active, signal can be either ON or OFF. In all places, the jumper MUST be installed in either position in order for the module to function properly. FIGURE 25 - EZ-QUBE JUMPERS Error Output States EZQUBE Jumper state Normal When Error is Error Output Err. Type Jumper Error Jumper Operation Active NPN ON OFF NPN OFF ON PNP OFF ON PNP ON OFF Publication EZQ-1000 Rev 1.7 January 2018

54 Speed Output States Speed Jumper Speed Output NPN PNP Publication EZQ-1000 Rev 1.7- January 2018

55 55 NOTES: Publication EZQ-1000 Rev 1.7 January 2018

56 Publication EZQ-1000 Rev 1.7- January 2018