Pepperl+Fuchs VAZ-2E2A-G20-ZPA1 User manual

VAZ-2E2A-G20-ZPA1
ZPA Motor Control Module
from Firmware Version V.28
FACTORY AUTOMATION
MANUAL

With regard to the supply of products, the current issue of the following document is ap-
plicable: The General Terms of Delivery for Products and Services of the lectrical Indus-
try, published by the Central Association of the lectrical Industry (Zentralverband
lektrotechnik und lektroindustrie (ZV I) e.V.) in its most recent version as well as the
supplementary clause: " xpanded reservation of proprietorship"
VAZ-2 2A-G20-ZPA1

VAZ-2 2A-G20-ZPA1
3
1 Introduct on................................................................................. 5
1.1 Content of th s Document ................................................................... 5
1.2 Target Group, Personnel...................................................................... 5
1.3 Symbols Used ...................................................................................... 5
1.4 Intended Use ........................................................................................ 6
1.5 General Safety Instruct ons................................................................. 6
1.6 Declarat on of Conform ty ................................................................... 7
2 Product Descr pt on ................................................................... 8
2.1 Use and Appl cat on............................................................................. 8
2.2 Operat ng Modes of the ZPA Motor Control Module....................... 11
2.2.1 Overview.......................................................................................... 11
2.2.2 Standard ZPA................................................................................... 11
2.2.3 nhanced ZPA................................................................................. 12
2.2.4 Transportation.................................................................................. 13
2.2.5 Long Zone - Single Zone.................................................................. 14
2.2.6 Direct Control................................................................................... 15
2.2.7 Direction Control.............................................................................. 15
2.2.8 Slave................................................................................................ 16
2.3 Ind cators and Operat ng Elements ................................................. 17
2.3.1 L D Indicators ................................................................................. 17
2.3.2 Rotary Switches for Configuration.................................................... 20
2.4 Interfaces and Connect ons.............................................................. 22
3 Installat on................................................................................. 24
3.1 Safety Informat on.............................................................................. 24
3.2 Preparat on ......................................................................................... 24
3.3 Mount ng ............................................................................................. 24
3.4 Power Supply Connect on................................................................. 25
3.5 Spec al Requ rements when Connect ng to a PLC ......................... 28
3.6 Connect ng Motors, Sensors, and Zone Coupl ng.......................... 29

4
VAZ-2 2A-G20-ZPA1
4 Operat ng Behav or .................................................................. 34
4.1 Sw tch-On Behav or............................................................................34
4.2 Sw tch-On Delay .................................................................................34
4.3 Search T me ........................................................................................34
4.4 Leav ng T me.......................................................................................34
4.5 Entry T me...........................................................................................34
4.6 Transportat on T me ...........................................................................35
4.7 Motor Run-On T me ............................................................................35
4.8 Release Delay .....................................................................................35
4.9 Idle Mode Delay ..................................................................................35
5 Manual Intervent on n the Convey ng Process..................... 36
5.1 Manual Feed ng of Conveyed Product .............................................36
5.2 Manual Removal of Conveyed Product ............................................36
5.3 Manual Stop/Release..........................................................................36
5.4 Manually Correct ng Accumulat ons ................................................37
6 Troubleshoot ng........................................................................ 38
6.1 What to Do n the Event of a Fault.....................................................38

VAZ-2 2A-G20-ZPA1
Introduction
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1 Introduction
1.1 Content of this Document
This document contains information required to use the product in the relevant phases of the
product life cycle. This may include information on the following:
■ Product identification
■ Delivery, transport, and storage
■ Mounting and installation
■ Commissioning and operation
■ Maintenance and repair
■ Troubleshooting
■ Dismounting
■ Disposal
The documentation comprises the following parts:
■ This document
■ Datasheet
In addition, the documentation may comprise the following parts, if applicable:
■ U-type examination certificate
■ U declaration of conformity
■ Attestation of conformity
■ Certificates
■ Control drawings
■ Instruction manual
■ Other documents
1.2 Target Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and
dismounting lies with the plant operator.
Only appropriately trained and qualified personnel may carry out mounting, installation,
commissioning, operation, maintenance, and dismounting of the product. The personnel must
have read and understood the instruction manual and the further documentation.
Prior to using the product make yourself familiar with it. Read the document carefully.
Note!
For full information on the product, refer to the further documentation on the Internet at
www.pepperl-fuchs.com.

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VAZ-2 2A-G20-ZPA1
Introduction
1.3 Symbols Used
This document contains symbols for the identification of warning messages and of informative
messages.
Warn ng Messages
You will find warning messages, whenever dangers may arise from your actions. It is mandatory
that you observe these warning messages for your personal safety and in order to avoid
property damage.
Depending on the risk level, the warning messages are displayed in descending order as
follows:
Informat ve Symbols
Action
This symbol indicates a paragraph with instructions. You are prompted to perform an action or
a sequence of actions.
1.4 Intended Use
The VAZ-2 2A-G20 ZPA1 motor control module is a field device for controlling one or two
consecutive zones of an accumulation conveyor line. The motor control module has two
electronic outputs for controlling a DC roller motor each as well as two sensor inputs for
detecting conveyed product, e.g., via light barriers.
Read through this manual carefully. Before mounting, connecting, and operating the ZPA motor
control module, be sure to familiarize yourself with the device.
Operate the ZPA motor control module only as described in this manual to ensure that the
device and the systems connected to the device work correctly.
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
Warning!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
Caution!
This symbol indicates a possible fault.
Non-observance could interrupt the device and any connected systems and plants, or result in
their complete failure.
Note!
This symbol brings important information to your attention.

VAZ-2 2A-G20-ZPA1
Introduction
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1.5 General Safety Instructions
Responsibility for planning, assembly, commissioning, operation, maintenance, and
dismounting lies with the plant operator.
Installation and commissioning of all devices may only be performed by trained and qualified
personnel.
User modification and or repair are dangerous and will void the warranty and exclude the
manufacturer from any liability. If serious faults occur, stop using the device. Secure the device
against inadvertent operation. In the event of repairs, return the device to your local
Pepperl+Fuchs representative or sales office.
1.6 Declaration of Conformity
This product was developed and manufactured under observance of the applicable uropean
standards and guidelines.
The product manufacturer, Pepperl+Fuchs GmbH, D-68307 Mannheim, has a certified quality
assurance system that conforms to ISO 9001.
Note!
Disposal
lectronic waste is hazardous waste. When disposing of the equipment, observe the current
statutory requirements in the respective country of use, as well as local regulations.
Note!
A Declaration of Conformity can be requested from the manufacturer.
ISO9001

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VAZ-2 2A-G20-ZPA1
Product Description
2 Product Description
2.1 Use and Application
Zero Pressure Accumulat on (ZPA)
During zero pressure accumulation, conveyed product is moved along a conveyor line in a
controlled manner and collisions between the conveyed product is prevented. For this purpose,
a conveyor line is divided into several sections or zones.
ach zone has its own drive, which can be activated independently of the neighboring zones.
At the end of each zone, a zone sensor is installed that detects the conveyed product.
The accumulation conveyor logic ensures that there is only ever one conveyed product present
in a zone. Conveyed products can therefore only be conveyed to the downstream zone once
there is no more conveyed product in that zone. As long as the downstream zone is occupied,
the conveyed product is stopped when it reaches the zone sensor and thus accumulates
irrespective of subsequent conveyed product.
Figure 2.1 Conveying scenario for the example Standard ZPA operation mode
Benef ts and Features of the ZPA Motor Control Module
The ZPA motor control module is easy to install and can be configured for a wide range of
application situations. The main benefits and features of this module are:
■ Compact housing for direct mounting in support profiles and cable ducts.
■ Connection of the power supply using piercing technology via black AS-Interface flat
cable.
■ All other connections are implemented as connectors.
■ Decentralized control: The field module contains the logic for zero pressure accumulation.
A central control unit for the accumulation conveyor line is not required.
■ Support for master-slave operation
■ Control of two successive zones of an accumulation conveyor line using one module.
■ Simple adjustment of the operating mode, the conveyor direction, the motor speed, and
start/stop ramps via rotary switches.
■ Display of status and diagnostic information via L Ds.
■ Optimized for operation with DC roller motors type Interroll C310.
■ Support for conveyed product that is longer than one zone.
■ Detection of accumulations leads to shutdown of the DC roller motors.
ZoneUpstream
zone
Downstream
zone
Roller motor Zone sensor
Conveying direction

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Product Description
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Figure 2.2
Funct on of the ZPA Motor Control Module
The ZPA motor control module is an intelligent field module that already contains the logic for
zero pressure accumulation. It assumes the control of one or two consecutive zones powered
by DC roller motors. The motors (MOT1, MOT2) and zone sensors (IN1, IN2) are connected
directly with the ZPA motor control module for this purpose.
The ZPA motor control module has two separate zone controls. Both zone controls are logically
coupled within the module. The access-side zone control can be deactivated within the
module, so that the outgoing-side zone control controls both DC roller motors as the master.
Only the sensor input (IN1 and IN2) of the master is evaluated in this case.
A coupling with the neighboring zones is created via two interfaces for the zone coupling (X1,
X2). This makes it possible to connect several ZPA motor control modules in series to create an
accumulation conveyor line of any length.
The ZPA motor control module is powered via the black AS-Interface flat cable, which is
connected using piercing technology without the need for tools. The ZPA motor control module
is configured directly on the device using the three rotary switches (S1, S2, S3). In addition to
various operating modes, the motor speed, the conveyor direction, and start and stop ramps
can be configured.
Figure 2.3
1-zone Operat on/2-zone Operat on
If the ZPA motor control module is to only control a single zone, the second zone logic must be
manually deactivated in some operating modes. For this purpose, the rear zone in the conveyor
direction is bypassed internally. The DC roller motor of this zone then runs synchronous to that
of the zone in front (see previous figure). It can therefore support the other DC roller motor by
driving the same zone and thereby doubling the drive power of that zone.
X1 X2
IN1
MOT1
IN2
MOT2
PWR
X1 IN
X1 OUT
X2 IN
X2 OUT
MOT1 MOT2
ERR1 ERR2
IN1 IN2
IN
OUT
OUT
X2 X2X1X1
IN
OUT
IN
OUT
OUT
IN
OUT IN
IN
OUT
IN
OUT
MOT1 MOT2 IN2 MOT2 IN2MOT1 IN1
IN
ZoneUpstream
zone
Downstream
zone
Roller motor Roller motor Zone sensor Roller motor Zone sensor
Conveying direction
Roller motor Zone sensor
Release
Sensor
Zone coupling
Sensor Sensor
Release Release
ZPA motor control module
Zone coupling Zone coupling
2 zones
ZPA motor control module
1 zone
Release
Sensor
Zone Zone ZoneZone

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VAZ-2 2A-G20-ZPA1
Product Description
Zone coupl ng
The two interfaces for zone coupling (X1, X2) are used for receiving and transmitting
information to and from neighboring zones. Additional ZPA motor control modules or other
suitable communication partners can be connected via the zone coupling. The electrical
signals are compatible with the standard 24 V IOs of a PLC. Conveyed product can therefore
also be fed in and discharged at both ends of the accumulation conveyor line by a separate
controller.
Figure 2.4
The interfaces for the zone coupling each consist of one signal input and one signal output.
The meaning of the zone coupling signals depends on the selected conveyor direction and
follows a simple principle:
S gnal n the conveyor d rect on (zone sensor): A zone is communicating to the
downstream zone whether conveyed product is located at its end. It therefore always
corresponds to the signal of the zone sensor (e.g., light barrier).
S gnal aga nst the conveyor d rect on (release s gnal): A zone is communicating to the
upstream zone whether conveyed product may enter. It thus represents the release signal. The
release signal is determined by the accumulation conveyor logic and also set if no conveyed
product has yet reached the zone sensor of the upstream zone.
The logic in the ZPA motor control modules expects the release signal to last until the conveyed
product has left the zone sensor. If the release signal is withdrawn before the conveyed product
has left the zone, the motor is stopped until the release signal is set again.
This results in the following signal sequences:
The dashed lines show the situation in which the downstream zone withdraws the release
signal for a short period of time. In this case, the DC roller motor is stopped immediately without
any run-on time.
1. Conveyed product reaches the zone sensor before the release signal is set.
IN
OUT
OUT
X2 X2X1X1
IN
OUT
IN
OUT
OUT
IN
OUT IN
IN
OUT
IN
OUT
MOT1 MOT2 IN2 MOT2 IN2MOT1 IN1
IN
ZoneUpstream
zone
Downstream
zone
Roller motor Roller motor Zone sensor Roller motor Zone sensor
Conveying direction
Roller motor Zone sensor
Release
Sensor
Zone coupling
Sensor Sensor
Release Release
ZPA motor control module
Zone coupling Zone coupling
2 zones
ZPA motor control module
1 zone
Release
Sensor
Zone Zone ZoneZone

VAZ-2 2A-G20-ZPA1
Product Description
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Figure 2.5
2. Release signal is set before the conveyed product reaches the zone sensor.
Figure 2.6
Since the ZPA motor control module can control two consecutive zones simultaneously, the
zone coupling of these two zones is performed internally. The zone coupling to the upstream
and downstream zones is routed via connections X1 and X2.
2.2 Operating Modes of the ZPA Motor Control Module
2.2.1 Overview
The ZPA motor control module has multiple operating modes that realize different
accumulation conveyor logics. All operate zone coupling as per the preceding description and
are therefore fully compatible with each other. The only exception to this rule are the two
operating modes "direct control" and "direction control." These operating modes do not
execute logic and are used for direct control of the connected DC roller motors via the zone
coupling interfaces.
For the operation of only one zone, the mode for 1-zone operation must be selected in the case
of some operating modes. Different time conditions detect accumulations on the conveyor line
and shut down the DC roller motors if one or more conveyed products are stuck. All operating
modes support the handling of conveyed product that is longer than the actual zone.
IN (Photo eye)
X OUT
X IN (Release)
MOT
Motor after run
Conveyor good
has left zone
Release from
downstream zone
Conveyor good
is stopped
to downstream zone
from downstream zone
Motor after run
Conveyor good
has left zone
Release from
downstream zone
Conveyor good reaches zone sensor
IN (Photo eye)
X OUT
X IN (Release)
MOT
to downstream zone
from downstream zone

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VAZ-2 2A-G20-ZPA1
Product Description
2.2.2 Standard ZPA
Conveyed product must have completely left the zone before the next conveyed product may
enter. As soon as the outgoing conveyed product is no longer detected by the zone sensor, the
release signal is set. This operating mode thereby realizes zero pressure accumulation with
single accumulation and single release. It ensures a strict separation of the conveyed product
while maintaining the maximum safety distance.
The following example describes the sequence in the operating mode "Standard ZPA":
Figure 2.7
■ Step A: Zone (2) has accumulated its conveyed product because downstream zone (3)
has not set its release signal (red light). Because zone (2) is occupied, it also does not
issue a release to upstream zone (1).
■ Step B: Downstream zone (6) has set the release signal (green light) and the conveyed
product is conveyed to the next zone (6). Because the conveyed product has not yet left
the zone sensor (5), zone (5) does not issue a release to upstream zone (4).
■ Step C: The conveyed product has left the zone sensor. Therefore, zone (8) sets the
release signal for upstream zone (7) to allow the next conveyed product to be transported.
Downstream zone (9) has now completely accepted the conveyed product and prohibits
further product from entering by withdrawing the release.
The following time conditions are used in the operating mode "Standard ZPA" (see Chapter
"Operating Behavior"):
■ Leaving time
■ ntry time
■ Transportation time
■ Motor run-on time
■ Switch-on delay
■ Search time
Please note that this operating mode distinguishes between 1-zone operation and 2-zone
operation and separate settings exist for both operating modes.
5 64
B
2 31
A
8 97
C
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor

VAZ-2 2A-G20-ZPA1
Product Description
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2.2.3 nhanced ZPA
This operating mode implements zero pressure accumulation with block accumulation or block
release. A zone will let the following conveyed product enter once the conveyed product
located in that zone receives the release signal to leave the zone. This reduces the safety
distance between the conveyed product and increases the throughput. If the foremost zone of
such an accumulation conveyor line receives a release signal, the signal will be forwarded
directly to the zones behind it. All accumulated conveyed product will be simultaneously
transported to the next zone. However, in case of block release, it is always ensured that only
one further conveyed product is conveyed into the zone. This conveyed product must then
advance all the way to the zone sensor before the next conveyed product may be conveyed.
The following example describes the sequence in the operating mode " nhanced ZPA."
Figure 2.8
■ Step A: Zone (2) has accumulated its conveyed product because downstream zone (3)
has not set its release signal (red light). Because zone (2) is occupied, it also does not
issue a release to upstream zone (1).
■ Step B: Downstream zone (6) has set the release signal (green light) and the conveyed
product is conveyed to the next zone (6). At the same time, the release signal is forwarded
to upstream zone (4) and the following conveyed product is conveyed to zone (5). The
conveyed product starts up at the same time.
■ Step C: The previous conveyed product has departed zone (8), so downstream zone (9)
withdraws its release. The following conveyed product has also already left upstream
zone (7). Zone (8) moves the conveyed product to its zone sensor while it prevents other
conveyed product from entering by resetting the release.
The following time conditions are used in the operating mode " nhanced ZPA" (see Chapter
"Operating Behavior"):
■ Leaving time
■ ntry time
■ Transportation time
■ Motor run-on time
■ Switch-on delay
■ Search time
■ Release delay
Please note that this operating mode distinguishes between 1-zone operation and 2-zone
operation and separate settings exist for both operating modes.
5 64
B
2 31
A
8 97
C
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor

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VAZ-2 2A-G20-ZPA1
Product Description
2.2.4 Transportation
In this operating mode, a zone forwards the release signal directly to the zones behind it. At the
same time, the release signal also switches on the zone motor. The release is not set
independently. Therefore, only a block release is carried out, which does not cause the
conveyed product to be separated.
Connecting a zone sensor is optional in this operating mode. If a zone sensor is connected, the
logic can detect accumulations and shut down the zone DC roller motor, if necessary. If the
downstream zone is operating in a different mode, the zone sensor must be connected so that
its status can be forwarded via the zone coupling.
The following example describes the sequence in the operating mode "Transportation":
Figure 2.9
■ Step A: Downstream zone (3) has not set its release signal (red light). Zone (2) therefore
also does not set its release signal, meaning that the DC roller motor does not rotate.
■ Step B: Downstream zone (6) has set the release signal (green light). Zone (5)
immediately forwards the release signal to its upstream zone (4) and switches on its DC
roller motor. The conveyed product starts up at the same time.
■ Step C: Downstream zone (9) has reset its release signal. Zone (8) immediately resets its
release signal and shuts down the DC roller motor.
The following time condition is used in the operating mode "Transportation" (see Chapter
"Operating Behavior"):
■ Leaving time (only if a zone sensor is connected)
This operating mode can be used without restriction in 1-zone and 2-zone operation. For this
reason, there is no option for a separate switchover.
5 64
B
2 31
A
8 97
C
Roller motorRoller motor Roller motor

VAZ-2 2A-G20-ZPA1
Product Description
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2.2.5 Long Zone - Single Zone
This operating mode is designed specifically for the operation of a zone in a range of Standard
zones or nhanced ZPA zones that is significantly longer than the surrounding zones. A longer
zone like this would negatively affect the throughput of the entire conveyor line because the
distance between the conveyed product is primarily determined by the zone length. This is why
conveyed product is not separated in this case, which might cause the distance between the
conveyed product to increase.
If there is a release signal, it is forwarded directly to the zones behind that zone and the DC
roller motor of the zone is switched on (block release). If there is no conveyed product in front of
the zone sensor, the zone will independently set the release signal to allow more conveyed
product to enter. If no conveyed product has been detected for a certain period of time, the
zone will shut down its DC roller motor. It will start its DC roller motor again if the status of the
upstream zone sensor changes and conveyed product is conveyed into the zone.
The following example describes the sequence in the operating mode "Long Zone":
Figure 2.10
■ Step A: Downstream zone (3) has set its release signal (green light). Zone (2) immediately
forwards it to its upstream zone (1) and conveys its conveyed product to the next zone (3).
■ Step B: Downstream zone (6) has reset its release signal (red light). Because no product
has arrived in front of the zone sensor in zone (5) yet, it will retain its release and move the
conveyed product to its final position. The subsequent conveyed product (4) can enter
freely.
■ Step C: The conveyed product has reached the zone sensor (8). Because the
downstream zone (9) is still not issuing a release signal, zone (7) stops the conveyed
product and resets its release signal to also stop the subsequent conveyed product.
The following time conditions are used in the operating mode "Long Zone" (see Chapter
"Operating Behavior"):
■ Leaving time
■ Switch-on delay
■ Idle mode delay
This operating mode always works in 1-zone operation, meaning that the DC roller motor of the
rear zone is synchronized with that of the front zone and the rear zone sensor has no function.
5 64
B
2 31
A
8 97
C
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor
Roller motor
Zone sensor Zone sensor

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Product Description
2.2.6 Direct Control
In this operating mode, the DC roller motors connected to the ZPA motor control module can be
controlled using external signals. In this way, the ZPA control module can, for example, be
connected directly to a PLC that follows its own logic for controlling the DC roller motors. The
control signals are transferred via the inputs of the respective zone coupling interfaces. The
outputs of the two zone coupling interfaces indicate the status of the zone sensors.
2.2.7 Direction Control
This operating mode supplements the "Direct Control" operating mode with the option of
reversing the direction of rotation of the connected DC roller motors via an external signal. One
input controls both DC motor rollers while the other input reverses their configured direction of
rotation.
The "Direction Control" operating mode will be supported from firmware version V.26.
Connection Signal Meaning
X1 IN Control signal for DC roller motor at MOT1
■ Low: Motor is at a standstill
■ High: Motor is running
X1 OUT Signal for zone sensor at IN1
■ Low: No conveyed product detected
■ High: Conveyed product detected
X2 IN Control signal for DC roller motor at MOT2
■ Low: Motor is at a standstill
■ High: Motor is running
X2 OUT Signal of zone sensor at IN2
■ Low: No conveyed product detected
■ High: Conveyed product detected
Table 2.1
Connection Signal Meaning
X1 IN Control signal for DC roller motors at MOT1 and MOT2
■ Low: Motor is at a standstill
■ High: Motor is running
X1 OUT Signal for zone sensor at IN1
■ Low: No conveyed product detected
■ High: Conveyed product detected
X2 IN Direction reversal for DC roller motors at MOT1 and
MOT2
■ Low: Motors rotate in the direction configured via S2
■ High: Motors rotate in the opposite direction to that
configured via S2
X2 OUT Signal of zone sensor at IN2
■ Low: No conveyed product detected
■ High: Conveyed product detected
Table 2.2

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Product Description
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2.2.8 Slave
In this operating mode, the ZPA motor control module functions as a slave to a downstream
master zone. Both slave motors are synchronized to the master zone motors. The master zone
is extended by the slave. The signals from the rear zone coupling of the master are transmitted
by the slave through to the upstream zone. The zone sensors of the slaves have no function in
this operating mode and do not need to be connected.
As the master, all of the ZPA motor control module operating modes can be used, except for
"Direct Control" and "Direction Control." No special settings are required at the master. As soon
as the upstream ZPA motor control module has been configured as a slave, the switchover to
master operation occurs automatically.
Any number of slaves can be run on a master zone. ach slave corresponds to a ZPA motor
control module. The zone length, which is controlled by the master, is extended by the
connected slaves. The following time conditions for the master and the connected slaves are
added up. Up to four slaves can be taken into account.
1. Search time
2. Transportation time
3. Idle mode delay
Figure 2.11
Please note that the zone couplings between master and slave work in master-slave operation.
There, there are no PLC-compatible zone coupling signals. If the zone coupling of a slave has
not been connected to a compatible master, the corresponding L D flashes "X1 IN" or "X2 IN"
and the ZPA motor control module has no function.
The "Slave" operating mode is supported from firmware version V.28 (master and slave).
X2 X1X1
OUT
IN
OUT IN
MOT MOT MOT1 IN1
X2
IN
OUT
IN
OUT
MOT2 IN2
MasterSlave 1 ... n
IN
OUT
MOT
2
2
2
2
Roller motor Roller motor Roller motor
Master-slave zone
Conveyor direction
Release
Sensor
Zone coupling Zone coupling
Zone
Roller motor Zone sensor
Zone

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Product Description
2.3 Indicators and Operating lements
2.3.1 L D Indicators
Overv ew
The L Ds on the ZPA motor control module display the following information:
■ Firmware version (only immediately after switching on),
■ Setting of the rotary switch (only immediately after switching on),
■ Status of the power supply,
■ Switching states of the connected zone sensors,
■ Operating/fault state of the connected DC roller motors,
■ States of the zone coupling signals.
While the ZPA motor control module is starting up, the L Ds indicate the firmware version and
the setting of the rotary switches using flash codes (binary code; least significant byte is on the
right).
The meaning of the individual zone coupling signals depends on the conveyor direction and
how the ZPA motor control module is connected. (See Chapter "Use and Application", Section
"Zone Coupling").
Figure 2.12
LED Behav or after Sw tch-On
In case of an invalid configuration or an invalid operating mode, the four left L Ds X1 ...X2 OUT
will flash simultaneously.
While the ZPA motor control module is starting up, the L Ds indicate the firmware version and
the setting of the rotary switches S1 ... S3 in four steps using flash codes. The L Ds provide
the information in binary form. The least significant byte is on the right.
The two left L Ds X1 IN and X1 OUT indicate the respective step from 0 ... 3. The steps
designate the type of information.
The remaining L Ds indicate the corresponding values for the steps, such as the setting of a
rotary switch.
ach step is displayed for 1 s. After 4 s, all the steps have been displayed.
Step Information displayed
0 Firmware version
1 S1 setting: Motor speed
2 S2 setting: Start/stop ramp and direction of rotation
3 S3 setting: Operating mode
X1 X2
IN1
MOT1
IN2
MOT2
PWR
X1 IN
X1 OUT
X2 IN
X2 OUT
MOT1 MOT2
ERR1 ERR2
IN1 IN2

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Product Description
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LEDs for PWR, MOT1, MOT2, ERR1, ERR2, IN1, IN2
Status LEDs for zone coupl ng: Conveyor d rect on from left to r ght
Note!
Motor Fuses Are Safety Fuses
For protection against short circuits, each DC roller motor is secured with its own safety fuse
with a 5 A rated current. The fuses are not interchangeable. If a fuse is faulty, the module must
be replaced.
L D Color Description
PWR Green ■ On = Power supply is OK
■ Off = Power supply is not OK
MOT1 Yellow Operating status of DC roller motor 1:
■ On = Motor is active
■ Off = Motor is at a standstill or running down as per set start/stop
ramp
MOT2 Yellow Operating status of DC roller motor 2:
■ On = Motor is active
■ Off = Motor is at a standstill or running down as per set start/stop
ramp
RR1 Yellow Fault status of DC roller motor 1:
■ On = Motor fault or no motor connected
■ Flashing = Motor fuse 1 of the motor control module is faulty
■ Off = No motor fault
RR2 Yellow Fault status of DC roller motor 2:
■ On = Motor fault or no motor connected
■ Flashing = Motor fuse 2 of the motor control module is faulty
■ Off = No motor fault
IN1 Switch state of zone sensor 1:
■ On = Zone sensor has detected conveyed product (high level)
■ Off = Zone sensor has not detected any conveyed product (low
level)
IN2 Switch state of zone sensor 2:
■ On = Zone sensor has detected conveyed product (high level)
■ Off = Zone sensor has not detected any conveyed product (low
level)
Table 2.3
L D Color Description
X1 IN Yellow Input from interface 1: Status of zone sensor of upstream zone
■ On = Zone sensor has detected conveyed product (high level)
■ Off = Zone sensor has not detected any conveyed product (low
level)
X1 OUT Yellow Output from interface 1: Release signal for upstream zone
■ On = Release signal for upstream zone has been set (high level)
■ Off = Release signal for upstream zone has not been set (low
level)

2018-06
20
VAZ-2 2A-G20-ZPA1
Product Description
Status LEDs for zone coupl ng: Conveyor d rect on from r ght to left
X2 IN Yellow Input from interface 2: Release signal from downstream zone
■ On = Release signal from downstream zone has been set (high
level)
■ Off = Release signal from downstream zone has not been set (low
level)
X2 OUT Yellow Output from interface 2: Status of zone sensor at IN2
■ On = Zone sensor has detected conveyed product (high level)
■ Off = Zone sensor has not detected any conveyed product (low
level)
Table 2.4
L D Color Description
X1 IN Yellow Input from interface 1: Release signal from downstream zone
■ On = Release signal from downstream zone has been set (high
level)
■ Off = Release signal from downstream zone has not been set (low
level)
X1 OUT Yellow Output from interface 1: Status of zone sensor at IN1
■ On = Zone sensor has detected conveyed product (high level)
■ Off = Zone sensor has not detected any conveyed product (low
level)
X2 IN Yellow Input from interface 2: Status of zone sensor of upstream zone
■ On = Zone sensor has detected conveyed product (high level)
■ Off = Zone sensor has not detected any conveyed product (low
level)
X2 OUT Yellow Output from interface 2: Release signal for upstream zone
■ On = Release signal for upstream zone has been set (high level)
■ Off = Release signal for upstream zone has not been set (low
level)
Table 2.5
L D Color Description