FAMILY EZ-24 EZ-24-HTB EZ-24-HTBS Version 11.7 May 2017 Publication PR-1100 Module firmware and functionality is protected by U.S. and international patents. For complete patent information visit www.pulseroller.com/patents
FAMILY Glossary of Terms 3 GLOSSARY OF TERMS Brushless DC Motor Hall Effect Sensor JST LED Load MDR Normally Open / Normally Closed NPN / PNP Photo-sensor PLC PWM Retro-reflective / Reflex 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 EZ-24 Family hardware. Light Emitting Diode In the context of this document, LED s are used on the EZ-24 Family controllers to provide visual indication of module status A separate (usually wrapped or boxed) object to be transported by the conveyor. The terms tray, tote, or carton may also be used interchangeably in this document. Motorized Drive Roller or Motor Driven Roller - Brushless DC motor and gearbox assembly integrated into a single conveyor roller. Control logic terminology to define the state of the output of a Boolean on or off device. The term specifically describes the state of the output circuit when the device s sensing circuit is un-energized. In the context of photo-sensors; a normally open wired sensor would have its output circuit energized when it detected its reflected light and its output circuit would be de-energized when it did not detect its reflected light. Conversely a photo-sensor wired normally closed would energize its output circuit when it did not see its reflected light and it would de-energize its output circuit when it did detect its reflected light. 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. A device, mounted near the end of the conveyor zone to sense the presence of a load on the zone 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-24 Family controllers to MDR. Term used to describe the two basic types of photo-sensors. Retro-reflective photosensors utilize a reflective target that must be aligned with the photo-sensor such that the light emitted by the photo-sensor is reflected back to it. Reflex (or sometimes known as proximity) type photo-sensors emit light to be reflected back from an object located sufficiently close to the sensor. For both types of photo-sensors, when they detect their reflected light source, their signaling output circuit changes state.
FAMILY Slave Rollers Zone A set of non-motorized conveyor rollers mechanically linked to an MDR. The MDR and slave rollers make up a physical zone. All of the slave rollers in a zone rotate at the same speed and direction as the MDR because of their mechanical linkage A basic (linear or curved) cell of the conveyor consisting of a set of slave rollers driven by one or more MDR s and a single photo-sensor. 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.
FAMILY Important User Information 5 IMPORTANT USER INFORMATION EZ-24 modules contain ESD (Electrostatic Discharge) sensitive parts and components. Static control precautions are required when installing, testing, servicing or replacing these modules. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference any applicable ESD protection handbook. Basic guidelines are: Touch a grounded object to discharge potential static Wear an approved grounding wrist strap Do not touch connectors or pins on component boards Do not touch circuit components inside the equipment Use a static-safe workstation, if available Store the equipment in appropriate static-safe packaging when not in use 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.
FAMILY Summary of Changes 7 SUMMARY OF CHANGES The following table summarizes the changes and updates made to this document since the last revision Revision Date Change / Update 7.0 December 2009 Added specifications for EZ-24-HT and EZ-24-HTB 8.0 May 2010 Added EZ-24-HTBS specification 9.0 September 2010 Updated MDR switch settings and pulse out description 10.0 May 2012 Update for adding Senergy Roller and over-voltage handling 11.0 September 2012 Added Boost 8 mode for Senergy; updated error timing diagrams; added serial number range for over-voltage LED change 11.1 January 2014 Added global contact information 11.2 April 2014 Updated global contact information 11.3 June 2014 Updated formatting 11.4 April 2016 Added patent information and operating temperature spec 11.5 November 2016 Corrected zero voltage input graphic and updated multiple module wiring diagrams 11.6 February 2017 Added Section for Speed Out functionality 11.7 May 2017 Updated Speed Output Jumper Settings section GLOBAL CONTACT INFORMATION
FAMILY Revisions and Serial Numbers 9 REVISIONS AND SERIAL NUMBERS PLEASE NOTE: As of May 2010, EZ-24HT module is discontinued. References to EZ-24HT have been removed from this manual. Please refer to Revision 9.0 for any legacy EZ-24HT information. Revision 10.0 and higher of this manual is valid for the following Items: Item S.N. or Higher Date or Later EZ-24 123004 11 May 2012 EZ-24-HTB 119139 04 April 2012 EZ-24-HTBS 119417 04 April 2012 For modules not meeting this criteria, please refer to Revision 9.0 OVER-VOLTAGE INDICATION Previous to the serial number boundaries listed below, the Over-Voltage LED (as shown in Figure 1 EZ-24 Module with cover removed on page 17) functioned as Under-Voltage indicator and would illuminate in green color when the applied power to the module was greater than 18V. Starting with the serial numbers listed below, this LED now indicates an over voltage condition. This LED will illuminate amber color when the power applied (or generated by connected MDR) is greater than 31V. Item S.N. or Higher EZ-24 127091 EZ-24-HTB 119139 EZ-24-HTBS 119139
FAMILY Table of Contents 11 TABLE OF CONTENTS Glossary of Terms... 3 Symbol Conventions... 4 Important User Information... 5 Summary of Changes... 7 Global Contact Information... 7 Revisions and Serial Numbers... 9 Over-Voltage Indication... 9 Table of Contents... 11 Preface... 13 Who Should Use This Manual?... 13 Purpose of This Manual... 13 Not Included in This Manual... 13 EZ-24 Family Feature Matrix... 15 EZ-24 Module Physical Layout... 17 Electrostatic Discharge (ESD) Warning... 18 Proper MDR & Module Grounding... 18 Hardware Connections... 19 CN-1 MDR Plug-In Connection... 19 CN-2 24VDC Power Connection... 19 CN-3 Field Input and Output Connections... 20 EZ-24... 20 EZ-24HTB... 20 EZ-24HTBS... 20 CN-4 Sensor Connection... 21 EZ-24 Switch Settings... 23 DIP Switch Settings... 23 DIP SW Positions 6, 7, & 8 MDR Selection... 24 EZ-24 Module... 24 EZ-24HTB and EZ-24HTBS... 24 DIP SW positions 9 & 10 Electrical Brake Selection... 25 Rotary Speed Switch Settings... 26 SW #1 Speed Settings for Closed Loop PI (DIP SW #3 ON)... 26 SW #1 Speed Settings for Open Loop (DIP SW #3 OFF)... 27 Rotary SW #2 and SW #3 Accel/Decel Rate Settings... 28 EZ-24 Family Wiring Considerations... 29 RUN Input Signal Wiring... 29 Solid-State PLC Output Modules... 29 Single Module RUN Signal Wiring Examples... 30 Single EZ-24HTBS RUN Signal Wiring... 33 Multiple EZ-24 s controlled from Single PLC Output... 34 Multiple EZ-24HTBS RUN Signal Wiring... 36 Error Output Signal Wiring... 37 Multiple Error Signals for EZ-24... 37 Multiple Error Signals for EZ-24HTB and EZ-24HTBS... 39
12 EZ-24 Reference Manual FAMILY Analog Speed Control Input Wiring... 40 Configuring Zero Voltage Input to Non-Zero Speed... 40 EZ-24 Error Conditions & Timing Diagrams... 42 Diagram #1 - Power Supply ON with MDR Connected... 42 Diagram #2 - Power ON with MDR NOT Connected... 43 Diagram #3 - Power Supply voltage exceeds 31V... 44 Diagram #4 - Voltage over 31V due to over speeding... 45 Diagram #5 - Normal Operation with MDR rotating... 46 Diagram #6 - MDR Current Exceeding Peak Limit... 47 Diagram #7 - Over Current with PWM Limiting... 48 Diagram #8 - MDR Stalled Condition with Self Stop... 49 Diagram #9 - MDR Overload with Self Stop... 50 Diagram #10 - MDR Not Rotating when RUN is ON... 51 Diagram #11 - MDR Phase Error Detected... 52 Diagram #12 RUN and DIR LED States... 53 Speed Out Operation... 55 For EZ-24 Modules... 55 For EZ-24HTB and EZ-24HTBs... 55 EZ-24HTB & EZ-24HTBS Jumper Settings... 57 Motor Running Signal for Speed Output Jumper Setting... 57 Error Output Jumper Settings... 60 Specifications... 63 Electrical Specifications... 63 EZ-24... 63 EZ-24HTB / EZ-24HTBS... 63 Mounting Dimensions... 64 Analog Input Circuit Schematic... 64 Notes:... 65
FAMILY Preface 13 PREFACE WHO SHOULD USE THIS MANUAL? This manual is intended for users who need basic product information and simple application procedures to implement EZ-24 modules to control a Motorized Drive Roller (MDR) that utilizes Brushless DC motor technology. PURPOSE OF THIS MANUAL The purpose of this manual is to: Identify the components and connection points available on a module Provide guidelines for proper installation and wiring Provide data for expected operation and performance for each of the module s settings and modes NOT INCLUDED IN THIS MANUAL Because MDR applications vary; this manual assumes users and application engineers have properly sized their MDR drive train power and power supply capacity per expected motor loading and expected operational duty cycle. Please refer to MDR manufacturer s documentation for application recommendations.
FAMILY EZ-24 Family Feature Matrix 15 EZ-24 FAMILY FEATURE MATRIX Feature EZ-24 EZ-24HTB EZ-24HTBS Over-voltage Protection with transient voltage suppressor and two fuses Protection from over-voltage produced by over-speeding of MDR Thermal and Over-Current Protection for module and MDR Protection against incorrect wiring of the power Sensing and indication of over voltage from power supply and/or MDR 31 fixed speed settings Proportional / Integral (PI) speed regulation mode Programmable control output capability External 0-10V analogue voltage variable speed control Adjustable acceleration and deceleration times by onboard rotary switch Selectable Dynamic, Free Spin, and Servo brake control modes Manual or automatic error recovery modes Convenient sensor connection terminals with sensor output available on main terminal block Five LEDs to identify the power voltage, discreet inputs and status of the MDR Motor reversing capability while motor is running. Error Output signal and LED indication for self and MDR diagnosis Build-in communication (UART) with PC for diagnostic and easy configuration Mechanical Brake Control - Maximum Starting Current Available 5A 8A 8A Maximum Operating Current Available 4A 5A 5A Maximum Peak Current Available 15A 20A 20A
FAMILY EZ-24 Module Physical Layout 17 EZ-24 MODULE PHYSICAL LAYOUT The following image shows the EZ-24 module with the plastic cover removed for clarity. FIGURE 1 EZ-24 MODULE WITH COVER REMOVED The following sections describe the details for these items and will refer back to this figure.
18 EZ-24 Reference Manual FAMILY ELECTROSTATIC DISCHARGE (ESD) WARNING FIGURE 2 - ESD SENSITIVE AREAS CIRCLED IN RED Setting of switches, changing fuse, and/or otherwise handling EZ-24 module at points indicated in Figure 2 must only be performed by personnel who have been adequately electro-statically discharged. Handling or use of EZ-24 module at points indicated without proper ESD precautions may result in module damage. PROPER MDR & MODULE GROUNDING MDR drive-end shaft and/or fixing bracket must be bonded or otherwise electrically connected to grounded conveyor frame. The 24VDC power supply s DC common terminal must also be connected to ground. Improper grounding of MDR and/or Power Supply Common will result in pre-mature MDR and/or EZ-24 module failure. Proper grounding techniques MUST be observed for all applications.
FAMILY Hardware Connections 19 HARDWARE CONNECTIONS Hardware connections are the same for EZ-24, EZ-24HTB, and EZ-24HTBS except where noted. CN-1 MDR PLUG-IN CONNECTION CN-1 is a 9 pin JST brand right angle header with 2.5mm center to center pin spacing Pin No. Signal Name Description 1 GND Ground 2 Hall Sensor VCC + 6.5 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* Mechanical Brake Mechanical Brake Control *Pin 9 is used for 24VDC mechanical brake signal for EZ-24HTB and EZ-24HTBS modules only. Pin 9 is unused for EZ-24 module CN-2 24VDC POWER CONNECTION CN-2 is a removable 2 pin plug with screw terminal connections Pin No. Signal Name Description 1 24V + 24 Volt DC 2 GND 0V
20 EZ-24 Reference Manual FAMILY CN-3 FIELD INPUT AND OUTPUT CONNECTIONS CN-3 is a removable 7 pin plug with screw terminal connections. The following charts show the EZ-24 Family modules and their respective connections. EZ-24 Pin No. Signal Name Description 1 COM DC Common 2 Run PNP or NPN (auto detection) 3 Reverse PNP or NPN (auto detection) 4 Error Output PNP or NPN (select on DIP switch #4.) 5 Speed Output Reserved for Custom Programmable Output 6 Sensor Output Output from PE sensor from CN-4 pin 2 7 0-10 V 0~10 Volt analog input for speed selection EZ-24HTB Pin No. Signal Name Description 1 COM DC Common 2 Run PNP or NPN (auto detection) 3 Reverse PNP or NPN (auto detection) 4 Error Output PNP (+24V sourcing only)* 5 Speed Output Reserved for Custom Programmable Output 6 Sensor Output Output from PE sensor from CN-4 pin 2 7 0-10 V 0~10 Volt analog input for speed selection EZ-24HTBS Pin No. Signal Name Description 1 COM DC Common 2 Run PNP (+24V signal only) 3 Reverse PNP (+24V signal only) 4 Error Output PNP (+24V sourcing only)* 5 Speed Output Reserved for Custom Programmable Output 6 Sensor Output Output from PE sensor from CN-4 pin 2 7 0-10 V 0~10 Volt analog input for speed selection *Pin 4 Error Output is factory configured to be PNP (+24V sourcing) only for EZ-24HTB and EZ-24HTBS. DIP Switch #4 MUST be set to PNP for Error Output function to operate for EZ- 24HTB and EZ-24HTBS. Setting DIP Switch #4 to NPN will result in no Error output signal generated. Please refer to section Error Output Jumper Settings beginning on page 60 for details on modifying factory default Error output signal function.
FAMILY Hardware Connections 21 CN-4 SENSOR CONNECTION CN-4 is a removable 3 pin plug with screw terminal connections Pin No. Signal Name Description 1 24 V 24 Volt DC 2 Out Sensor Output, Pass Thru to CN-3 Pin 6 3 GND 24 volt ground Please note that CN-4 Sensor Connection provides no control or otherwise affects the operation of the EZ-24. It is only provided as a field wiring convenience. A local sensor or device can be powered from the EZ-24 using CN-4 and its signal passed through to CN-3 Pin 6. In this way the field wiring to the EZ-24 from the central control system can utilize one wiring harness or cable to both receive the signal input from a local sensor and send control signal(s) outputs to the EZ-24
FAMILY EZ-24 Switch Settings 23 EZ-24 SWITCH SETTINGS Unless otherwise noted, all switch settings are identical for EZ-24, EZ-24HTB and EZ-24HTBS DIP SWITCH SETTINGS The following table defines each of the 10 separate switches for the DIP SW: Switch Function OFF ON 1 Direction of Rotation CW CCW 2 Speed Range Selection Low Range High Range 3 Open/Close Loop Open Loop Close Loop(PI) 4 Error Output Type PNP NPN 5 Auto/Manual Error Reset Automatic Reset Manual Reset 6 7 8 9 10 MDR Selection Electrical Brake Method Selection Refer to DIP SW Positions 6, 7, & 8 MDR Selection on page 23 Refer to DIP SW positions 9 & 10 Electrical Brake Selection on page 25 Figure 3 shows ON / OFF positions for DIP switches and a typical settings example: FIGURE 3 - TYPICAL DIP SW SETTINGS EXAMPLE
24 EZ-24 Reference Manual FAMILY DIP SW POSITIONS 6, 7, & 8 MDR SELECTION EZ-24 MODULE Motor Drive Roller (MDR) SW 6 SW 7 SW 8 Starting Rated Current Current (A) 1 (A) 2 Pulse Roller - 20 Watt OFF ON OFF 2.6 1.8 Pulse Roller - 28 Watt OFF OFF OFF 4.0 1.9 Pulse Roller 35 Watt OFF ON ON 3.5 2.0 Pulse Roller 50 Watt OFF OFF ON 4.0 3.0 Senergy Roller Eco Mode ON OFF OFF 3.0 2.5 Senergy Roller Boost Mode ON ON OFF 5.0 3.5 EZ-24HTB AND EZ-24HTBS Motor Drive Roller (MDR) SW 6 SW 7 SW 8 Starting Rated Current Current (A) 1 (A) 2 Pulse Roller - 20 Watt OFF ON OFF 2.6 1.8 Pulse Roller - 28 Watt OFF OFF OFF 4.0 1.9 Pulse Roller 35 Watt OFF ON ON 3.5 2.0 Pulse Roller 50 Watt OFF OFF ON 7.0 3.0 Senergy Roller Eco Mode ON OFF OFF 3.0 2.5 Senergy Roller Boost Mode ON ON ON 5.0 3.5 Senergy Roller Boost 8 Mode ON ON OFF 8.0 3.5 1 Important Note on Starting Current: The values shown for Starting Current for each MDR selection is the amount of current the module will allow for up to 3 seconds after the module is signaled to run. If the speed setting of the module is set to 100% PWM, then this will be the value of the current seen at the MDR. For speed settings less than 100% PWM, the actual current seen at the motor will be proportionally higher. At very low speed settings with high torque loads, the starting current seen at the MDR may reach the peak current limit of the module. 2 Important Note on Rated Current: The values shown for Rated Current for each MDR selection is the current seen at the MDR when the speed is set to 100% PWM. Under continuous running conditions at 100% PWM; this is the current at which the module s built in current limiting mechanisms will not engage to limit the current and the MDR will not over-heat. At speeds less than 100% PWM, the actual current seen at the MDR will increase and continuous running at speeds less that 100% PWM will eventually result in the module s built in current limiting mechanisms to engage to limit the current to the motor to prevent overheating.
FAMILY EZ-24 Switch Settings 25 DIP SW POSITIONS 9 & 10 ELECTRICAL BRAKE SELECTION Braking Method SW 9 SW 10 Standard Dynamic Braking OFF OFF Free ON OFF Servo Lock 1 OFF ON Servo Lock 2 ON ON Please note that these settings are for electrically controlled braking of MDR. Some MDR s utilize an optional mechanical brake used to hold the MDR in its stopped position. Mechanical brakes are fail-safe in that they must be energized to release and de-energized to engage braking. Only EZ-24HTB and EZ-24HTBS provides 24VDC output to energize mechanical brake The following table defines the MDR Braking Methods available: Method Standard Dynamic Braking Free Servo Brake 1 Servo Brake 2 Description Standard Dynamic braking - MDR power circuit in EZ-24 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-24 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-24 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 1 utilizes 2 of the EZ-24 s power transistors for current injection. Same as Servo Brake 1 except that Servo Brake 2 utilizes 3 of its power transistors for current injection. Do Not use Servo Brake 1 or Servo Brake 2 settings for MDR s with mechanical brake. Doing so will result in damage to MDR and/or EZ-24HTB / HTBS module.
26 EZ-24 Reference Manual FAMILY ROTARY SPEED SWITCH SETTINGS SW #1 SPEED SETTINGS FOR CLOSED LOOP PI (DIP SW #3 ON) Switch Setting Pulse Roller 28W Pulse Roller 20 W Pulse Roller 50W Pulse Roller 35W DIP Sw #2 DIP Sw #2 DIP Sw #2 DIP Sw #2 DIP Sw #2 DIP Sw #2 ON OFF ON OFF ON OFF 0-10V 0-10V 0-10V 1650 2550 Analog Analog Analog 1750 DIP Sw #2 OFF 0 0-10V Analog 3200 DIP Sw #2 ON 1 1700 3300 300 1740 1200 2640 300 1850 2 1800 3400 390 1830 1290 2730 400 1950 3 1900 3500 480 1920 1380 2820 500 2050 4 2000 3600 570 2010 1470 2910 590 2140 5 2100 3700 660 2100 1560 3000 690 2240 6 2200 3800 750 2190 1650 3090 790 2340 7 2300 3900 840 2280 1740 3180 880 2430 8 2400 4000 930 2370 1830 3270 980 2530 9 2500 4100 1020 2460 1920 3360 1080 2630 A 2600 4200 1110 2550 2010 3450 1170 2720 B 2700 4300 1200 2640 2100 3540 1270 2820 C 2800 4400 1290 2730 2190 3630 1370 2920 D 2900 4500 1380 2820 2280 3720 1460 3010 E 3000 4600 1470 2910 2370 3810 1560 3110 F 3100 4700 1560 3000 2460 3900 1660 3210
FAMILY EZ-24 Switch Settings 27 Senergy Boost or Senergy ECO Switch Boost 8 Setting DIP Sw #2 OFF DIP Sw #2 ON DIP Sw #2 OFF DIP Sw #2 ON 0 0-10V Analog 3190 0-10V Analog 2390 1 580 3360 580 2500 2 740 3540 700 2630 3 920 3700 820 2750 4 1090 3890 940 2870 5 1270 4070 1050 2990 6 1450 4240 1180 3100 7 1620 4420 1300 3230 8 1800 4580 1420 3350 9 1970 4760 1540 3470 A 2150 4930 1650 3590 B 2320 5110 1790 3700 C 2500 5280 1900 3840 D 2660 5460 2030 3960 E 2840 5630 2150 4080 F 3010 5800 2270 4200 Please note that all values are in motor RPM. Please consult MDR data for conversion factors for particular speed code / gearbox utilized. SW #1 SPEED SETTINGS FOR OPEN LOOP (DIP SW #3 OFF) All Rollers All Rollers Switch Switch Dip Sw. #2 Dip Sw. #2 Dip Sw. #2 Dip Sw. #2 Setting Setting OFF ON OFF ON 0 0-10V Analog 62.5% 8 42.5% 82.5% 1 25.0% 65.0% 9 45.0% 85.0% 2 27.5% 67.5% A 47.5% 87.5% 3 30.0% 70.0% B 50.0% 90.0% 4 32.5% 72.5% C 52.5% 92.5% 5 35.0% 75.0% D 55.0% 95.0% 6 37.5% 77.5% E 57.5% 97.5% 7 40.0% 80.0% F 60.0% 100.0% Speed setting values are in % PWM
28 EZ-24 Reference Manual FAMILY ROTARY SW #2 AND SW #3 ACCEL/DECEL RATE SETTINGS When Open Loop Operation is selected (PI Regulate DIP SW#3 set to OFF), Accel/Decel is measured in time (seconds). When Closed Loop Operation is selected (PI Regulate DIP SW#3 set to OFF); Accel/Decel is measured in distance (mm) Rotary SW #2 Acceleration Rate Rotary SW #3 Deceleration Rate Switch Setting DIP SW #3 OFF Acceleration Time (seconds) DIP SW #3 ON Acceleration Distance 1 (mm) Switch Setting DIP SW #3 OFF Deceleration Time (seconds) DIP SW #3 ON Deceleration Distance 1 (mm) 0 0 0 0 0 0 1 0.1 200 1 0.1 200 2 0.2 400 2 0.2 400 3 0.3 600 3 0.3 600 4 0.4 800 4 0.4 800 5 0.5 1000 5 0.5 1000 6 0.6 1200 6 0.6 1200 7 0.7 1400 7 0.7 1400 8 0.8 1600 8 0.8 1600 9 0.9 1800 9 0.9 1800 A 1.0 2000 A 1.0 2000 B 1.2 2400 B 1.2 2400 C 1.5 3000 C 1.5 3000 D 1.7 3400 D 1.7 3400 E 2.0 4000 E 2.0 4000 F 2.5 5000 F 2.5 5000 1 Accel/Decel distances are noted in table for gear box ratio = 1:1. Actual distance is determined by dividing the value in the table by the gear box ratio of the MDR being used in order to calculate the actual distance. These values are valid for standard 48.5mm diameter rollers. Please consult your Pulse Roller documentation for gear box ratio information to properly calculate accel / decel distances for your application.
FAMILY EZ-24 Family Wiring Considerations 29 EZ-24 FAMILY WIRING CONSIDERATIONS The EZ-24 family of products can be used in a wide variety of connection configurations; however care in selection of the proper version of module should be taken based upon the intended use. RUN INPUT SIGNAL WIRING The primary item to consider is the effect of the controlling circuit (PLC Output for example) and its response to the EZ-24 s PNP/NPN auto-detection circuitry for RUN and REVERSE input signals. SOLID-STATE PLC OUTPUT MODULES The wiring method can sometimes produce unexpected results when used with solid-state PLC outputs when there is the possibility of the solid-state PLC output module being powered off while the EZ-24 module remains powered. Depending on the PLC s solid-state output circuitry, its powered-off state can provide a sufficient reverse current path that will allow enough current to flow to cause the EZ-24 to detect a positive RUN or REVERSE input. The unexpected result is that the EZ-24 could run its MDR without its RUN signal being energized by the PLC controls. Please note that this condition is only applicable for EZ-24 and EZ-24HTB Please note that this condition only occurs if the solid-state PLC Output module is removed from power while the EZ-24 remains powered. If the EZ-24 and PLC Output modules share the same power disconnecting means, then this condition will not occur. Please note that this condition does not occur with relay or dry contact style PLC output modules. Any one of the following actions will eliminate this unexpected behaviour from solid-state PLC output control of the affected EZ-24 family modules: Utilize relay or dry contact style PLC Outputs in lieu of solid-state Assure that EZ-24 and PLC output module share the same power disconnect means such that PLC Output module and EZ-24 are always disconnected from power at the same time Insert a blocking diode in series between the solid-state PLC output and EZ-24 RUN signal. Utilize EZ-24-HTBS module
30 EZ-24 Reference Manual FAMILY SINGLE MODULE RUN SIGNAL WIRING EXAMPLES The following examples show acceptable and unacceptable wiring of the RUN signal for EZ-24 and EZ-24HTB modules. FIGURE 4 - RUN CONNECTION WITH SOLID STATE OUTPUT NOT ALLOWED UNLESS EZ-24 AND PLC OUTPUT MODULE SHARE SAME POWER DISCONNECT MEANS OR BLOCKING DIODE IS ADDED
FAMILY EZ-24 Family Wiring Considerations 31 FIGURE 5 SINGLE EZ-24 WITH RELAY CONTACT SOURCE OR SINK OUTPUT FIGURE 6 SINGLE EZ-24 WITH SOLID STATE SOURCE OUTPUT AND BLOCKING DIODE
32 EZ-24 Reference Manual FAMILY FIGURE 7 SINGLE EZ-24 WITH SOLID STATE SINK OUTPUT AND BLOCKING DIODE
FAMILY EZ-24 Family Wiring Considerations 33 SINGLE EZ-24HTBS RUN SIGNAL WIRING The EZ-24HTBS accommodates solid state PLC output without the need for adding a blocking diode. However, the EZ-24HTBS is restricted for use with sourcing outputs only. The following are acceptable and unacceptable RUN signal wiring examples for EZ-24HTBS: FIGURE 8 EZ-24HTBS RUN SIGNAL NOT ALLOWED WITH SINKING PLC OUTPUT
34 EZ-24 Reference Manual FAMILY FIGURE 9 - EZ-24HTBS RUN SIGNAL IS ALLOWED WITH SOURCING SOLID STATE OR RELAY PLC OUTPUT MULTIPLE EZ-24 S CONTROLLED FROM SINGLE PLC OUTPUT Some applications require that multiple EZ-24 modules be controlled from a single RUN signal from a single PLC output. This would be useful and convenient in applications where multiple MDR s need to run in unison for a single conveyor section. Similar potential conditions arising from the auto-detect circuitry as described above can produce unexpected results.
FAMILY EZ-24 Family Wiring Considerations 35 FIGURE 10 - NO PARALLEL RUN SIGNALS FOR EZ-24 OR EZ-24HTB ALLOWED FOR SOLID STATE OR RELAY OUTPUTS WITHOUT ADDING BLOCKING DIODES FIGURE 11 - EZ-24 / EZ-24HTB AND SOURCING PLC OUTPUT ALLOWED WITH BLOCKING DIODES AS SHOWN
36 EZ-24 Reference Manual FAMILY FIGURE 12 - EZ-24 / EZ-24HTB AND SINKING PLC OUTPUT ALLOWED WITH BLOCKING DIODES AS SHOWN MULTIPLE EZ-24HTBS RUN SIGNAL WIRING EZ-24HTBS allows for multiple RUN signals parallel wired from a single sourcing PLC output without the need for blocking diodes. As with a single EZ-24HTBS however; PLC output is limited to sourcing only and the EZ-24HTBS will not detect a sinking PLC output signal. FIGURE 13 - EZ-24HTBS WITH SOURCING PLC OUTPUT
FAMILY EZ-24 Family Wiring Considerations 37 ERROR OUTPUT SIGNAL WIRING The Error Output signal can be either a PNP or NPN signal that is user selectable via DIP Switch 4. Any single module from the entire EZ-24 family can have its particular Error signal wire to a single PLC input without any special considerations. However, there are special considerations for applications where multiple Error signals need to be wired in parallel to a single PLC input and these differ depending on which specific EZ-24 family module is being utilized. MULTIPLE ERROR SIGNALS FOR EZ-24 FIGURE 14 - NO PARALLEL ERROR SIGNALS FOR EZ-24 WITHOUT BLOCKING DIODES Please note that parallel wiring multiple EZ-24 Error signals to a single point can result in damage to one or all of the connected modules.
38 EZ-24 Reference Manual FAMILY FIGURE 15 - EZ-24 PARALLEL ERROR SIGNAL TO SINKING PLC INPUT WITH BLOCKING DIODES FIGURE 16 - EZ-24 PARALLEL ERROR SIGNALS TO SOURCING PLC INPUT WITH BLOCKING DIODES
FAMILY EZ-24 Family Wiring Considerations 39 MULTIPLE ERROR SIGNALS FOR EZ-24HTB AND EZ-24HTBS DIP Sw. #4 must be set to PNP FIGURE 17 - EZ-24HTB AND EZ-24HTBS PARALLEL ERROR SIGNAL AND SINKING PLC INPUT Please note that EZ-24HTB and EZ-24HTBS can utilize parallel Error signal connections with Sourcing PLC Input module ONLY by making internal jumper configuration change. Please refer to section Error! Not a valid result for table. beginning on page 55 for detailed instructions. DIP Switch #4 MUST be set to PNP setting for ERROR out to operate for EZ-24HTB and EZ- 24HTBS regardless of single module or multiple parallel wired modules configurations. For EZ-24HTB and EZ-24HTBS; NPN switch setting for DIP switch #4 will not produce an ERROR output signal regardless of single module or multiple parallel modules connections.
40 EZ-24 Reference Manual FAMILY ANALOG SPEED CONTROL INPUT WIRING For analog speed control to be enabled DIP Switch #2 must be set to OFF and the Speed Selector Switch must be set to 0. The EZ-24 must also have its RUN signal energized in order for it to act upon the variable voltage applied to the 0-10V terminal. Also please note that if external control of the direction of the motor is desired, a corresponding +24V must also be applied to the REVERSE terminal. FIGURE 18 - ANALOG SPEED CONTROL WIRING Please note that +24V signals for RUN and REVERSE as shown in Figure 18 are applicable to all EZ-24 Family modules. For all modules except EZ-24HTBS, 0V connections for RUN and REVERSE will also work because of the NPN/PNP auto-sensing input signal feature. The EZ- 24HTBS will only operate with +24V applied to RUN and REVERSE signals. Please note that 0 to 10V analog input corresponds to 0 to 100% speed. CONFIGURING ZERO VOLTAGE INPUT TO NON-ZERO SPEED Some analog input applications require that a minimum running speed be established for a 0 voltage analog input. For PLC applications using an analog output, this can be done programmatically. For hard-wired solutions utilizing a speed potentiometer (pot), setting a fixed non-zero speed for a 0 volt analog input requires adding 2 external resistors in conjunction with the external speed pot. Figure 19 shows such a circuit arrangement with 2 resistors and 1 speed pot. The values of the resistors shown are based upon utilizing a 10K Ω speed pot and the desire to fix the minimum speed at 25% of full speed. For speed pots with different resistance value, the 2 resistors shown need to change their values by the same proportion. For example, the values below are for a 10K Ω speed pot; if a 50K Ω speed pot is used, then the 2 resistor values need to be multiplied by 5.
FAMILY EZ-24 Family Wiring Considerations 41 FIGURE 19 - ANALOG CIRCUIT TO SET NON-ZERO SPEED FOR ZERO VOLT INPUT Please note that RUN and REVERSE connections are not shown in Figure 19 for clarity. Please refer to Figure 18 for RUN and REVERSE connection detail. For a 10% minimum speed with a 10K W speed pot, change R1 to 15.5KΩ and R2 to 1.1KΩ. Please consult Insight Automation for other minimum speed setting resistor values.
42 EZ-24 Reference Manual FAMILY EZ-24 ERROR CONDITIONS & TIMING DIAGRAMS The following pages show diagrams that illustrate each error condition along with the visual LED behaviour used to indicate these conditions. DIAGRAM #1 - POWER SUPPLY ON WITH MDR CONNECTED
FAMILY EZ-24 Error Conditions & Timing Diagrams 43 DIAGRAM #2 - POWER ON WITH MDR NOT CONNECTED Freq = 2.5 Hz
44 EZ-24 Reference Manual FAMILY DIAGRAM #3 - POWER SUPPLY VOLTAGE EXCEEDS 31V If input power supply exceeds 33V the fuse will blow
FAMILY EZ-24 Error Conditions & Timing Diagrams 45 DIAGRAM #4 - VOLTAGE OVER 31V DUE TO OVER SPEEDING
46 EZ-24 Reference Manual FAMILY DIAGRAM #5 - NORMAL OPERATION WITH MDR ROTATING
FAMILY EZ-24 Error Conditions & Timing Diagrams 47 DIAGRAM #6 - MDR CURRENT EXCEEDING PEAK LIMIT If EZ-24 is configured for Auto Error Reset (DIP Sw. #5 OFF) then motor will attempt to restart as shown if the RUN signal is still applied. If EZ-24 is configured for Manual Error Reset (DIP Sw. #5 ON) then the RUN signal must be removed for a minimum of 5 msec before MDR will attempt to run again or alternatively the module power can be cycled off then on again to clear the error.
48 EZ-24 Reference Manual FAMILY DIAGRAM #7 - OVER CURRENT WITH PWM LIMITING
FAMILY EZ-24 Error Conditions & Timing Diagrams 49 DIAGRAM #8 - MDR STALLED CONDITION WITH SELF STOP If EZ-24 is configured for Auto Error Reset (DIP Sw. #5 OFF) then motor will attempt to restart as shown if the RUN signal is still applied. If EZ-24 is configured for Manual Error Reset (DIP Sw. #5 ON) then the RUN signal must be removed for a minimum of 5 msec before MDR will attempt to run again or alternatively the module power can be cycled off then on again to clear the error.
50 EZ-24 Reference Manual FAMILY DIAGRAM #9 - MDR OVERLOAD WITH SELF STOP If EZ-24 is configured for Auto Error Reset (DIP Sw. #5 OFF) then motor will attempt to restart as shown if the RUN signal is still applied. If EZ-24 is configured for Manual Error Reset (DIP Sw. #5 ON) then the RUN signal must be removed for a minimum of 5 msec before MDR will attempt to run again or alternatively the module power can be cycled off then on again to clear the error.
FAMILY EZ-24 Error Conditions & Timing Diagrams 51 DIAGRAM #10 - MDR NOT ROTATING WHEN RUN IS ON
52 EZ-24 Reference Manual FAMILY DIAGRAM #11 - MDR PHASE ERROR DETECTED
FAMILY EZ-24 Error Conditions & Timing Diagrams 53 DIAGRAM #12 RUN AND DIR LED STATES
FAMILY Speed Out Operation 55 SPEED OUT OPERATION Pin 5 on CN-3 provides a speed output signal whose on/off pulse frequency is proportional to the motor s actual Hall Effect sensor s signal frequency, thus proportional to the rotational speed of the motor. However, the frequency of the Speed Output signal is dependent both upon the motor type selected and the particular EZ-24 family module being used. MDR # of Motor Poles Electrical Frequency at Rated Speed (100% setting) 28 Watt 10 430 Hz 35 Watt 4 110 Hz 50 Watt 4 140 Hz Senergy ECO 10 483 Hz Senergy BOOST 10 350 Hz FOR EZ-24 MODULES The Speed Out is determined by the following equation: Speed Out [Hz] = Electrical Frequency [Hz] # of Motor Poles For example, for a Senergy ECO MDR set to run at 50% speed, its Electrical Frequency is 50% of 483 Hz which is 241.5 Hz. From the above formula, the Speed Out in Hz will be: Speed Out [Hz] = 241.5 10 = 24.2 Hz Most typically, you will have the frequency of the Speed Out signal and want to know the percentage of maximum speed the motor is running. Motor Speed [% of Rated] = 100 Speed Out Frequency # of Motor Poles Rated Frequency For a Senergy BOOST MDR whose Speed Out is measured to be 30 Hz: FOR EZ-24HTB AND EZ-24HTBS 30 10 Motor Speed [%] = 100 = 85.7% 350 The Speed Out frequency is equal to the Electrical frequency: Speed Out [Hz} = Electrical Frequency [Hz] Most typically, you will have the frequency of the Speed Out signal and want to know the percentage of maximum speed the motor is running.
56 EZ-24 Reference Manual FAMILY Motor Speed [% of Rated] = 100 Speed Out Frequency Rated Frequency For a 50 Watt MDR whose Speed Out is measured to be 95 Hz: Motor Speed [%] = 100 95 140 = 68% Please note that for EZ-24HTB and EZ-24HTBS, you can change the Speed Output terminal to provide a digital motor running signal instead of the frequency-based signal as described above. Please see section Motor Running Signal for Speed Output Jumper on page 57 for details.
FAMILY EZ-24HTB & EZ-24HTBS Jumper Settings 57 EZ-24HTB & EZ-24HTBS JUMPER SETTINGS This section pertains to EZ-24HTB and EZ-24HTBS modules ONLY. There are no user settable jumper modifications available for EZ-24 modules Modifying internal jumper settings involves removing the module s plastic housing cover. Handling of EZ-24 with or without the plastic cover must only be performed by personnel who have been adequately electro-statically discharged. Handling EZ-24 module with cover removed without proper ESD precautions may result in module damage. MOTOR RUNNING SIGNAL FOR SPEED OUTPUT JUMPER SETTING By default, EZ-24HTB and EZ-24HTBs provide mechanical brake release control to Pin 9 of the motor JST connector and a motor running frequency-based varying signal on the Speed Output terminal. The Speed Output terminal can be modified to provide a digital motor running signal instead of the default frequency-based output. However, because this signal and the mechanical brake control output share common circuitry, to enable the motor running digital output on the Speed Output terminal; the mechanical brake control must be disconnected. Figure 20 shows the default jumper settings and Figure 21 shows the jumper settings to configure the Speed Output to provide a digital motor running signal while at the same time disabling the mechanical brake release function to Pin 9 of the motor JST connector. Making this jumper change will disable the mechanical brake control. If you connect a motor roller with a mechanical brake and try to run, you may damage the module
58 EZ-24 Reference Manual FAMILY Figure 20 below shows the factory default jumper configuration for EZ-24HTB / EZ-24HTBS which provides mechanical brake control. FIGURE 20 - DEFAULT JUMPER CONFIGURATION FOR EZ-24HTB AND HTBS
FAMILY EZ-24HTB & EZ-24HTBS Jumper Settings 59 Figure 21 shows the jumper configuration for motor running signal on Speed Output terminal and no mechanical brake function. FIGURE 21 - JUMPER SETTING FOR MOTOR RUNNING OUTPUT / NO MECHANICAL BRAKE
60 EZ-24 Reference Manual FAMILY ERROR OUTPUT JUMPER SETTINGS By default, EZ-24HTB and EZ-24HTBS modules are shipped from the factory with the ERROR output configured to be PNP (sourcing) which is intended for a sinking PLC input card. This default configuration is depicted in the example wiring shown in Figure 17 on page 39. Figure 22 shows the factory default jumper settings for the PNP (Sourcing) ERROR output signal. FIGURE 22 - DEFAULT ERROR OUTPUT JUMPER SETTINGS For the default jumper configuration shown in Figure 22, DIP Switch #4 MUST be set to PNP setting for ERROR output to operate for any single module or parallel wired modules configuration. NPN switch setting will not produce ANY ERROR output signal for single or parallel connection.
FAMILY EZ-24HTB & EZ-24HTBS Jumper Settings 61 For applications or situations where the ERROR output signal needs to connect to a sourcing type PLC input point, then the ERROR output needs to be configured as a sinking circuit. Figure 23 shows the jumper configuration for an NPN (Sinking) ERROR output signal. FIGURE 23 - JUMPER SETTING FOR NPN (SINKING) ERROR OUTPUT SIGNAL For the default jumper configuration shown in Figure 23, DIP Switch #4 MUST be set to NPN setting for ERROR output to operate for any single module or parallel wired modules configuration. PNP switch setting of DIP Switch #4 will not produce ANY ERROR output signal for single or parallel connections.
FAMILY Specifications 63 SPECIFICATIONS ELECTRICAL SPECIFICATIONS EZ-24 Input Power Voltage Range (18-28) V Nominal 24VDC: Control Input Voltage Range (14 30) VDC Current Consumption ~ 50 ma without MDR Max Peak Current 15A Built in Current Limits Max Start Current 5A, (or less, depending on the MDR) Max. Lock Current 4A, (or less, depending on the MDR) 5A fuse to power supply protection External speed Input Analog Voltage: 0 10V PWM frequency 20kHz Time delay initial setting < = 50 msec from power ON. Time to start motor rotation < = 10 msec Operating Temperature 0 to 50 C Storage Temperature -40 to 85 C EZ-24HTB / EZ-24HTBS Input Power Voltage Range (18-28) V Nominal 24VDC: Control Input Voltage Range (14 30) VDC Current Consumption ~ 50 ma without MDR Max Peak Current 20A Built in Current Limits Max Start Current 8A, (or less, depending on the MDR) Max. Lock Current 5A, (or less, depending on the MDR) 8A fuse to power supply protection External speed Input Analog Voltage: 0 10V PWM frequency 20kHz Time delay initial setting < = 50 msec from power ON. Time to start motor rotation < = 10 msec Operating Temperature 0 to 50 C Storage Temperature -40 to 85 C
64 EZ-24 Reference Manual FAMILY MOUNTING DIMENSIONS All dimensions are in mm and are the same for all EZ-24 Family ANALOG INPUT CIRCUIT SCHEMATIC
65 NOTES: