Unidrive ZoneLogix Plus Guide

Installation and
Troubleshooting Guide
ZoneLogix® Plus
Smart Conveyor Control
Part # 301208
With IntelliZone® Handling Technology™

Copyright ©2020 Automation Controls Group, Inc. A division of Milwaukee Electronics, Inc. All Rights Reserved.
This document is the property of Automation Controls Group, Inc., and may not be reproduced in whole or in part without prior written approval.
Other trademarks and service marks used or referenced in this document are the property of their respective owners.
CONTENTS
1 Product Diagram 4
2 General Notes 5
2.1 Motor Cable & Connection Header ......................................................................................................... 5
2.2 +24VDC Power Input Connection Header............................................................................................. 5
2.3 PNP Sensor Connection Header.............................................................................................................. 5
2.4 Smart/User Input-Output (I/O) Connection Header ............................................................................ 5
2.5 Feedback LED Indicators .......................................................................................................................... 5
2.6 Configuration Switches.............................................................................................................................. 6
2.7 Upstream Cable Connection..................................................................................................................... 6
2.8 Downstream Cable Connection............................................................................................................... 6
2.9 Mounting Plate/Heat Sink........................................................................................................................ 6
2.10 Cover.............................................................................................................................................................. 6
3 Installation Guide 6
3.1 Mount the Control....................................................................................................................................... 6
3.2 Select a Motor.............................................................................................................................................. 6
3.3 Select a Speed............................................................................................................................................. 7
3.4 Configure the Location .............................................................................................................................. 7
3.5 Configure the Operating Mode................................................................................................................. 7
3.6 Configure the Rotation .............................................................................................................................. 7
3.7 Configure Communications...................................................................................................................... 7
3.8 Connect User Input/Output ...................................................................................................................... 7
3.8.1 Entry Zone........................................................................................................................................ 7
3.8.2 Intermediate Zone......................................................................................................................... 8
3.8.3. Exit Zone………………………………………………………………………………………………………………..8
3.8.4. Slug & Reverse Slug Input Operation……………………………………………………………………….8
3.8.5. Analog Speed Control Input…………………………………………………………………………………….8
3.8.6. Other Modes of Operation……………………………………………………………………………………….8
4. Special Functions 9
4.1 Configuring the Control as a BMC…………………………………..……………………………………………..…..9
4.2 Shunt Input……………………………………………………………………………………………………………………...9
4.3 Search and Rescue………………………………………………………………………………………………………..…9
4.3.1 During Power Up ............................................................................................................................ 9
4.3.2 After Discharge of a Parcel from the Downstream Edge of a Zone................................... 9
4.3.3 After Removal of a Slug Signal................................................................................................... 9
4.3.4 After Removal of a Rev Slug Signal........................................................................................... 9
5 Diagnostics & Troubleshooting 10
5.1 Feedback LEDs..........................................................................................................................................10
5.1.1 Fuse LED (Red) .............................................................................................................................10
5.1.2 Fault LED (Red).............................................................................................................................10
5.1.3 Motor LED (Amber)......................................................................................................................10
5.1.4 Power LED (Green) ......................................................................................................................10
5.2 Firmware Version Display .......................................................................................................................10
5.3 6-Wire Modular Cable Orientation ........................................................................................................10
5.4 Additional Assistance...............................................................................................................................10
6 IMPORTANT Safety & Caution/Warning Information . 11
7 Document Revision History 11
Application Related (ZPA vs ZIP) 12

Copyright ©2020 Automation Controls Group, Inc. A division of Milwaukee Electronics, Inc. All Rights Reserved.
This document is the property of Automation Controls Group, Inc., and may not be reproduced in whole or in part without prior written approval.
Other trademarks and service marks used or referenced in this document are the property of their respective owners.
LIST OF FIGURES
Figure 1: ZoneLogix®Plus Control Components...................................................4
Figure 2: Firmware Version Display Example .....................................................10
Figure 3: ZIP Mode performance compared to ZPA Mode………………….……….11
LIST OF TABLES
Table 1: DC Power Inputs Pinout..........................................................................5
Table 2: Sensor Connections Pinout.....................................................................5
Table 3: Smart/User Input-Output Pinout..............................................................5
Table 4: Configuration Switch Settings .................................................................6
Table 5: Motor Selection Switch Settings..............................................................6
Table 6: Operating Speed Selection Switch Settings............................................7
Table 7: Zone Type Selection Switch Settings......................................................7
Table 8: Singulation Type Selection Switch Settings ............................................7

ZoneLogix Plus ACG P/N 301208 July 23, 2021 Page 4
1 Product Diagram
1) Motor Connection Header
2) +24V DC Power Input Header (plug included)
3) PNP Sensor Connection Header (plug included)
4) Smart/User Input-Output Connection Header (plug included)
5) LED Indicators
6) Configuration Switches
7) Upstream Peer-to-Peer RJ-25 Connection
8) Downstream Peer-to-Peer RJ-25 Connection
9) Mounting Plate/Heat Sink
10) Cover
NOTE: This guide refers to the components by their item number as listed above.
Figure 1: Zone Logix
®Plus Control Components

ZoneLogix Plus ACG P/N 301208 July 23, 2021 Page 5
2 General Notes
2.1 Motor Cable & Connection Header
CAUTION: If a longer motor cable is required only use 24 inch
motor extension cables obtained from Automation Controls
Group (ACG P/N 301135). A maximum of two (2) motor
extension cables may be used. The motor’s maximum speed will
decrease by approximately 2% for each motor extension cable
used.
UniDrive® motors and controls are designed to operate together as
a complete and compatible drive system. Proper care must be
taken to prevent damage to the control, motor and connection
cable.
UniDrive® motors come with a permanent, built-in power & control
cable having a 20 inch cable length for connection to compatible
ACG controls. See the specific UniDrive® motor or PowerCube™
specification sheet for details. Do not attempt to connect the motor
cable to any control other than a control manufactured by
Automation Controls Group (ACG).
Do not put tension on the motor cable connection. This could result
in intermittent motor connections.
The motor connector is designed to be installed on the control and
then remain connected to the control for the life of the motor. Do
not remove the motor connector from the control except in the rare
instance of motor or control replacement.
Power to the control and motor should be removed by turning off
or removing input power at the source (Lock-out & Tag-out
preferred). The motor connector must not be used as a power
on/off switch.
Do not disassemble the motor cable. If the motor cable becomes
damaged obtain a replacement motor.
2.2 +24V DC Power Input Connection Header
CAUTION: Power must be applied with proper polarity to
avoid potentially damaging the control. Follow the pinout
shown in Table 2: Sensor Connections Pinout.
A 2-pin Phoenix PT1.2/2-PVH-3.5 plug is supplied. The control
operates off a +22 to +28 Volt DC power supply. The control reads the
configuration switches only when the unit is powering up. Make the
power connection only after all other connections have been made.
Pin:
Signal:
+
+22 to +28 Volts DC
-
DC Ground
Table 1: DC Power Inputs Pinout
NOTE: When adjacent zones are operating from separate
24VDC power supplies you must connect their 0VDC grounds
together. However, do not connect their positive voltage
terminals together.
2.3 PNP Sensor Connection Header
CAUTION: If the sensor is mounted on non-conductive
equipment, such as a plastic slide, ground the body of
the sensor to provide a non-destructive discharge path
in the event of a static electric shock.
A 3-pin Phoenix PT1.5/3-PVH-3.5 plug is supplied.
Pin:
Signal:
-
DC Ground
IN
Input From Sensor
+
+VDC*
Table 2: Sensor Connections Pinout
*NOTE: The +VDC signal for the + Pin is fused with a 0.1
Amp self-resetting fuse. Use of this output for any purpose
that requires more than 0.1 Amps will cause the fuse to
open and temporarily disable this output.
2.4 Smart User Input-Output Connection Header
A 7-pin Phoenix PT1.5/7-PVH-3.5 plug is supplied. The function of
Smart 1 Input and Smart 2 Output depends on the current switch 3
settings for the control. If these I/O connections are not being used,
leave the connector in place to avoid accidentally shorting the pins.
Pin:
Description:
1
Smart 1 Input
2
Slug Mode
3
Reverse Slug
4
Smart 2 Output
5
Analog Input +
6
Analog Input –
7
Shunt Input
Table 3: Smart/User Input-Output Pinout.
NOTE: Smart I/O is active above 18 Volts DC (PNP)
2.5 LED Indicators
The control board contains four (4) LED feedback indicators:
§ One (1) Red Fuse LED
§ One (1) Red Fault LED
§ One (1) Amber Motor Current Limiting LED
§ One (1) Green Power LED
To l e ar n mo re , s e e 5.1 LED Indictors and 5.2 Firmware Version Display.

ZoneLogix Plus ACG P/N 301208 July 23, 2021 Page 6
2.6 Configuration Switches
NOTE: The configuration switches are read only
during power-up. Set the switches before
delivering power to the control.
The control reads the configuration switches only when the
unit is powering up. To change a setting, disconnect input
power, set the switch, and then reconnect power. The OFF
position is to the Left and the ON position is to the Right (See
Figure 1). Switch descriptions are given in the following table:
Switch:
Description:
OFF Setting:
ON Setting:
1
Rotation Direction
Q Counter-Clockwise*
P Clockwise*
2
Singulation Type
ZPA Mode
ZIP Mode
3
Zone Type
Exit or Transport
Entry or Transport
4
Speed
Selection
See Table 6: Operating Speed Selection
Switch Settings.
5
6
7
Motor
Selection
See Table 5: Motor Selection Switch
Settings.
8
Table 4: Configuration Switch Settings
*NOTE: The direction of rotation is defined
when viewed from the back side of the motor
with the shaft extending away from the viewer.
2.7 Upstream Cable Connection
This RJ-25 connector is intended for use with a 6-wire
modular phone cable to connect to an adjacent upstream
ZoneLogix Plus control. See Section 5.3 for information on
the 6-Wire Modular Cable Orientation. The Modular RJ-25
Cable is not provided.
2.8 Downstream Cable Connection
This RJ-25 connector is intended for use with a 6-wire
modular phone cable to connect to an adjacent downstream
ZoneLogix Plus control. See Section 5.3 for information on
the 6-Wire Modular Cable Orientation. The Modular RJ-25
Cable is not provided.
2.9 Mounting Plate/Heat Sink
This component is for mounting the control assembly to the
conveyor frame using two ¼ inch (6.35 mm), bolts to keep
the controller cooler.
CAUTION: If mounting the control on a curved section of
conveyor, use washers between the mounting plate and the
conveyor frame. This is to assure that the mounting plate is
not distorted, causing damage to the enclosed printed circuit
board assembly.
2.10 Cover
CAUTION: Removal of the cover will void the warranty. The
cover does not make the control waterproof or dustproof.
The cover can help reduce the severity of damage to the
control from foreign objects.
3 Installation Guide
This section describes how to install and use the Control and
UniDrive® Motor in the most common configurations.
3.1 Mount the Control
Mount the control in a location where the motor cable
reaches the motor connector without putting strain on the
connector.
3.2 Select Motor Rating Being Used
Select the motor you will be using. Properly match the control’s motor
selection to the motor that is actually being operated by the control.
In addition to the standard 48 watt UniDrive® motor, this control
provides maximum performance with our 60 watt, 80 watt, and 100
watt UniDrive motors at their operating higher speeds.
SW8:
SW7:
Motor:
Comments:
OFF
OFF
UD048
Previously 100W24
OFF
ON
UD060
Previously 125W24
ON
OFF
UD080
Previously 160W24
ON
ON
UD100
Previously 200W24
Table 5: Motor Selection Switch Settings
1. Mount the Control
2. Select a Motor
3. Select a Speed
4. Configure the Location
5. Configure the Operating Mode
6. Configure the Rotation
7. Configure Communications
8. Connect User Input/ Output

ZoneLogix Plus ACG P/N 301208 July 23, 2021 Page 7
3.3 Select a Speed
Three switches determine the operating speed, making it
simple to match speeds in multiple zones. The actual speed
selected also depends on the motor that you selected in the
previous step, so set those switches first.
There is also possible to use the 0-10Vdc differential Analog
control input for remote, dynamic speed adjustment while
the system is running.
Switches:
Speed Selection (RPM):
SW6
SW5
SW4
UD048
UD060
UD080
UD100
OFF
OFF
OFF
280
350
450
560
OFF
OFF
ON
248
310
399
496
OFF
ON
OFF
216
270
348
432
OFF
ON
ON
184
230
297
368
ON
OFF
OFF
152
190
246
304
ON
OFF
ON
120
150
195
240
ON
ON
OFF
88
110
144
176
ON
ON
ON
56
70
93
112
Table 6: Operating Speed Selection Switch Settings
3.4 Configure the Location
Identify the location of the control and then set Switch 3.
§ If this control is placed at the entry end of the conveyor section
where objects are loaded, set Switch 3 to the ON position.
§ If this control is placed at the exit end of the conveyor section
where objects are discharged, set Switch 3 to the OFF position.
§ If this control is placed between two other controls, the
position of Switch 3 has no effect and can be in either position.
Entry:
In Between:
Exit:
ON
No Effect
OFF
Table 7: Zone Type Selection Switch Settings
3.5 Configure the Operating Mode
Identify the operating mode that this section of conveyor will
use for transporting objects and then set Switch 2.
§ If the conveyor will be operating in the conventional Zero-
Pressure Accumulation (ZPA) mode, set Switch 2 to the
OFF position.
§ If the conveyor will be operating in the higher throughput,
enhanced accumulation ZIP mode, set Switch 2 to the ON
position.
§ If the conveyor will be operating in Slug Mode or Reverse
Slug, or as a stand-alone unit, the position of Switch 2 has
no effect because the Slug Mode and Reverse Slug inputs
override all of the accumulation logic.
ZPA:
Slug Mode, Reverse Slug,
or Stand-alone:
ZIP:
OFF
No Effect
ON
Table 8: Singulation Type Selection Switch Settings
3.6 Configure the Rotation
Identify the proper direction of rotation for the motor shaft
in order to move objects from the upstream (entry) end of
the conveyor towards the downstream (exit) end of the
conveyor.
The direction of rotation is defined when viewed from the
back side of the motor with the shaft extending away from
the viewer.
§ For P clockwise rotation set Switch 1 to the ON position.
§ For Q counter-clockwise rotation set Switch 1 to OFF.
NOTE: See Switch 1 in Table 4: Configuration Switch Settings.
3.7 Configure Communications
Make the peer-to-peer communication/handshake
connections. These controls pass request and permission signals
between adjacent zones over the 6-wire modular RJ-25 phone
cables. See Section 5.3 for information on the cable orientation.
§ At the exit end of the conveyor, leave the downstream
peer-to-peer RJ-25 connection (item 8) unconnected.
§ Connect one end of a 6-wire phone cable to the Upstream
Peer-to-Peer RJ-25 Connection (item 7) and then connect
the other end of the phone cable to the downstream phone
jack on the adjacent upstream control.
§ At each adjacent intermediate control, connect another 6-
wire phone cable to the Upstream Peer-to-Peer RJ-25
Connection (item 7) and then connect the other end of that
cable to the downstream phone jack on the adjacent
upstream control.
§ At the entry zone control at the most upstream zone, leave
the upstream peer-to-peer RJ-25 connection (item 7)
unconnected.
3.8 Connect User Input/Output
3.8.1 Entry Zone
1. Use Smart 1 Input (a PNP input called request) to notify the
control that there is a parcel ready for input to the zone.
If the zone is not already occupied, when this signal is active,
it will cause the zone to run.
The signal may be provided by any number of alternative
sources such as a PLC, a simple switch, a photo sensor, etc.
as long as the input voltage is above 18 volts when active.
2. Use Smart 2 Output (a PNP output called permission) to
notify an external device that the zone is empty and ready to
receive a parcel.

ZoneLogix Plus ACG P/N 301208 July 23, 2021 Page 8
3.8.2 Intermediate Zone
An intermediate zone is between two adjacent controlled
zones.
NOTE: Do not connect anything to the Smart 1 Input
or the Smart 2 Output in an Intermediate Zone
3.8.3 Exit Zone
1. Use Smart 1 Input (a PNP input called permission) to notify
the control that it has permission to discharge a parcel.
The signal may be provided by any number of alternative
sources such as a PLC, a simple switch, a photo sensor, etc.
as long as the input voltage is above 18 volts when active.
Note that when permission is removed the zone will attempt
to stop any discharge that may be in process.
2. Use Smart 2 Output (a PNP output called request) to notify
an external device that the zone is occupied and ready to
discharge a parcel.
3.8.4 Slug & Reverse Slug Input Operation
1. Use Slug Mode (a PNP input) to override all logic internal to
the control and force this zone and all upstream zones to run
regardless of whether they are occupied or empty. Slug
Mode is sometimes referred to as Jog
NOTE: When this signal is active, parcels will be
pushed off the end of the conveyor if there is
nothing in place to receive them.
2. Use Reverse Slug (a PNP input) in one of two ways:
§ Alone: Assert it by itself to cause the zone and all
upstream zones to coast. The motors will not be
energized and will not provide any active braking power.
§ In Combination: Assert it in combination with the Slug
Mode input to override all logic internal to the control and
force this zone and all upstream zones to run in the
reverse direction regardless of whether they are occupied
or empty.
3.8.5 Analog Speed Control Input
Use the control’s Analog In+ and Analog In- inputs in
combination to provide a 0-10 V differential signal that
overrides the settings of the speed control DIP switch.
If the voltage differential is less than 0.5 VDC, the
control ignores the analog input and the control’s DIP
switch speed settings will prevail.
If the signal is 9.5 VDC or higher, the control operates
the motor at its maximum speed setting.
Automation Controls Group has available a manual
Analog Speed Control Module (ACG P/N 300128) for
use with this control for manually setting the same
motor speed on up to 10 zones.
To provide the required differential Analog Speed
Input voltage using a PLC, the PLC Analog Output
Module you select should be able source and sink a
minimum of 20mA.
3.8.6 Other Modes of Operation
For additional assistance, please contact
our ACG Service line at [phone]
or email us at [e-mail]

ZoneLogix Plus ACG P/N 301208 July 23, 2021 Page 9
4 Special Functions
4.1 Configuring the Control as a BMC
In certain applications it may be necessary to eliminate the motor Run-
On-Time which is a part of the Search & Rescue function (see section
4.3 below). To accomplish this, the control can be configured as a
Basic Motor Control (BMC) or standalone motor control. To
accomplish this implement the following steps;
1) Place control DIP switch 3 in the ON position (slide the switch to
the right)
2) On the GREEN 3-pin sensor connector, wire the sensor input
(center pin) to the sensor + voltage (pin on the right).
3. Apply a 24Vdc signal to the Slug Mode input (I/O pin 2) to start
and stop the motor.
4. When the Slug Mode input goes high then I/O pin 4 will go high
to indicate that the motor is running.
5. I/O pin 4 will float at approximately 13Vdc when it goes “low”.
To force I/O pin 4 to go to 0Vdc, connect a 10K ohm, 1/2W
resistor between I/O pin 4 and 0Vdc.
4.2 Shunt Input
The Shunt Input can be used during regen operation to
increase the control’s overvoltage shutdown limit.
When the Shunt Input is active high (voltage > 18Vdc), the
control’s over-voltage shutdown limit is increased from 29Vdc
to 31Vdc providing additional operating margin before the
control shuts down due to an over-voltage condition.
A separate 6A, 10W Shunt Regulator module is available (ACG P/N
110547) and connects directly to the +24V DC power supply. This
module can be used, to limit any increase in the +24V DC power
supply voltage to less than 28Vdc, in the event that the motor and
control regenerate energy back into the power supply.
4.3 Search and Rescue
This function has been added to the control in order to avoid
situations where parcels could become stranded between photo
sensors, creating a nuisance at the very least. This function is
active after the following events:
§ During Power Up
§ After Discharge of a Parcel from the Downstream Edge of a Zone
§ After Removal of a Slug Mode Signal (if Reverse Slug is Not Active)
§ After Removal of a Rev Slug Signal (if Slug Mode is Not Active)
4.3.1 During Power Up
When power is first applied, each control goes through a self-
check and reports its firmware revision as described in 5.2
Firmware Version Display.
Beginning at the Exit end and then flowing zone by zone after
very brief intervals to avoid creating high inrush current at the
power supply, each zone then runs for a period of time (Run-
on-Time), or until a parcel arrives at the respective zone
sensor, whichever comes first.
In this fashion, any parcels that may have been stranded
between sensors when power was removed are discovered
and will then be processed by the conveyor in either ZPA or
ZIP control mode as determined by the switch settings.
NOTE: 2.5 seconds is the nominal Run-On-Time when the
controls are set for maximum speed. This time is increased
if zones are set to a lower speed than maximum speed.
For example, if a zone is set to half its maximum speed,
the nominal Run-On-Time is doubled to 5.0 seconds.
4.3.2 After Discharge of a Parcel from the
Downstream Edge of a Zone
It is not unusual for operators who are manually loading
parcels onto a conveyor to place two small parcels in a single
zone. If the zone stopped immediately after a parcel passed
its downstream sensor the second parcel could become
stranded.
Therefore, each zone will operate for the additional period of
time (Run-On-Time) after these events.
This is a local function that directly affects only the zone that
just discharged its parcel.
4.3.3 After Removal of a Slug Mode Signal
(If Reverse Slug is Not Active)
During Slug mode of operation, parcels are not tracked by the
system logic. Some parcels will likely be between sensors at
the time the Slug signal is removed.
Beginning with the zone where the Slug signal was asserted
and cascading upstream, each zone will run for an additional
period of time (Run-On-Time) until either the time expires or
a parcel is discovered.
4.3.4 After Removal of a Rev Slug Signal
(If Slug Mode is Not Active)
Since Reverse Slug causes the zones to coast, parcels that
were in motion will come to rest in more or less random
locations.
Beginning with the zone where the Reverse Slug signal was
asserted and cascading upstream, each zone will run for an
additional period of time (Run-On-Time) until either the timer
expires or a parcel is discovered.

ZoneLogix Plus ACG P/N 301208 July 23, 2021 Page 10
5 Diagnostics & Troubleshooting
5.1 LED Indicators
The control provides four (4) LED indicators shown as item 5
in Figure 1. These LEDs are often useful in diagnosing various
wiring and connection problems. If power is connected there
will always be at least one LED illuminated or flashing. When
no LED is illuminated, there is no power.
5.1.1 Fuse LED (Red)
CAUTION: The control’s internal fuse will not blow under
normal operating circumstances. Inspect all wiring
connections to assure that there are no short circuits.
This LED is off under normal circumstances. It illuminates
constantly if the internal 15 amp internal fuse is blown and
power is applied with the proper polarity. The 15 amp fuse
on the board is not user-accessible. If the blown fuse LED is
illuminated, return the board to your distributor or supplier
for analysis or repair.
NOTE: The control’s on-board fuse is NOT replaceable.
5.1.2 Fault LED (Red)
This LED is off under normal circumstances. If a problem is
detected, it provides one of the following five signals:
§ One (1) flash in 4 seconds: The board has a hardware
problem. Return it to your supplier.
§ Two (2) flashes in 4 seconds: The input voltage is too high.
§ Three (3) flashes in 4 seconds: The input voltage is too low.
§ Four (4) flashes in 4 seconds: There is a problem with the
motor cable or connection. Check to see that the cable is
not damaged and that all of the wires are secure.
§ Five (5) flashes in 4 seconds: control over temperature.
§ Six (6) flashes in 4 seconds: Extreme over current.
§ Constantly ON: The motor is stalled or the sensor is
continuously blocked. Check for mechanical obstructions.
5.1.3 Motor LED (Amber)
§ Constantly ON: Motor current is at the maximum allowed and is
being electronically limited. Check for mechanical obstructions.
§ Flickering: If the motor starts under significant load, the current
may be limited briefly causing the LED to flicker. If the LED
flickers constantly, this is an indication that the motor is
operating at its upper limit and may never reach the full speed.
This is not a cause for concern and no corrective action is
required.
5.1.4 Power LED (Green)
Constantly ON: Power is properly applied as long as the fuse
is not blown.
5.2 Firmware Version Display
Three (3) of the feedback LEDs are used to communicate the
firmware revision of the control assembly during the start-up
sequence.
Each time that power is applied to the board, the green
(power) and red (fault) LEDs will turn on immediately. After
1.0 second the amber LED will flash on for 0.75 seconds
followed by an off period.
An off period of 1.5 seconds represents a decimal point
separating major revisions from minor revisions. An example
is shown below.
This example sequence represents firmware revision 1.2.
When the red fault LED turns off, the startup sequence has
ended and normal operation begins.
5.3 RJ25, 6-Wire, Modular Cable Orientation, L<10Ft
5.4 Additional Assistance
To request the latest revision to our User Manual, visit our
website at www.automationcontrolsgroup.com.
For additional assistance, please contact
our ACG Service line at [phone]
or email us at [e-mail]
Figure 2: Firmware Version Display Example

ZoneLogix Plus ACG P/N 301208 July 23, 2021 Page 11
6 Safety & Cautions/Warnings
Safety Related:
1) Read and understand the National and Local Regulations that apply
prior to installing and using the control and its associated UniDrive
motor.
2) Contact the manufacturer of the conveyor or equipment this control
and the UniDrive motor are installed on and obtain, read and
understand their installation and safety related instructions.
3) Read and understand the information in this installation manual and
in the control and UniDrive motor performance specifications prior to
installing and using this control and its associated UniDrive motor.
4) Maintenance or repair should only be performed by authorized and
qualified personnel.
5) Maintenance or repair should only be performed after input power to
the control has been turned off. Use of lock-out and tag-out is the
preferred procedure to prevent input power from being turned on
while working on the control and motor.
6) Use of a PELV 24V power supply is highly recommended. A PELV
(Protective Extra Low Voltage) supply is a power source in which its DC
common (0VDC terminal) is connected to earth ground for Safety and
EMI reduction and the output voltage cannot exceed 30Vrms under
normal or single-fault conditions.
7) If a UL/CSA Recognized UniDrive Motor is being used in a UL/CSA
Listed End Application then UL’s Conditions of Acceptability must be
implemented by the End-User. A copy of UL’s Conditions of
Acceptability can be obtained from the Automation Controls Group
(ACG).
8) The control and UniDrive Motor must not be used in a Hazardous
Location
Cautions & Warnings:
1) Properly match the control’s motor selection, using control DIP
Switches SW7 & SW8, to the UniDrive motor that is being operated by
the control.
2) Provide adequate heatsinking for the UniDrive motor to prevent the
motor case temperature from exceeding 70C (158F).
3) Do not touch the motor case during operation, or immediately after
removing input power, as the motor case may be hot. Protect the
operator from accidentally touching a hot motor case during system
operation according to National and Local Regulations
4) Proper care must be taken to prevent damage to the control, UniDrive
motor and the motor connection cable. The motor cable is to be
routed securely away from moving parts or sources of heat. Do not
put tension on the motor cable connection. Do not disassemble the
motor cable. If the motor cable becomes damaged obtain a
replacement motor.
5) The motor connector must not be used as a power on/off switch.
6) The control and UniDrive motor are to be mounted in a location free
from potential impact or other physical damage.
7) 24VDC Power must be applied to the control with the proper polarity
to avoid potentially damaging the control.
8) When adjacent zones are operating from separate 24VDC power
supplies you must connect their 0VDC grounds together. However, do
not connect their positive voltage terminals together.
7 Document Revision History
The following changes have been made to this document:
Rev:
Date:
Summary:
1.0
Oct 2020
Initial Release
1.1
July 2021
Updated wording on removing 24Vdc power to
the control in the Motor Cable & Connection
Header Description (Section 2.1).
Updated Configuring the Control as a Basic
Motor Control (BMC) to remove the wording
on communication cables (Section 4.1).

ZoneLogix Plus ACG P/N 301208 July 23, 2021 Page 12
Application Related – ZPA vs ZIP
ZPA Mode (Standard Singulation) compared to ZIP Mode showing the
increased parcel throughput possible in ZIP Mode
Figure 3: ZIP Mode Performance
compared to ZPA Mode