ZoneLogix PRO Zone Controller User Guide Rev 1.0

ZoneLogix™ PRO Zone Controller User
Guide
1
1. Zone 2. Monitor 3. Fieldbus
Guide 1 in the 3-part ZoneLogix™ PRO documentation series

CONTENTS
1 Introduction 6
1.1 Key Terms and Concepts ................................................................................................. 7
2 Getting Started and Installation 8

2.1 Zone Controller Installation ......................................................................................... 10
2.2 Zone Installation ............................................................................................................. 11
2.3 Configuration DIP Switches ......................................................................................... 13
2.4 +24VDC Power Connection.......................................................................................... 14
2.5 Zone-to-Zone Cable Connection ................................................................................. 14
2.6 PNP Photoeye Sensor Connection............................................................................. 15
2.7 Smart I/O Connections ................................................................................................. 16
2.7.1 Basic Mode Functions ......................................................................................................................... 16
2.7.2 Advanced Mode Functions ................................................................................................................ 17
2.8 LED Feedback Indicators .............................................................................................. 18
2.9 System Schematic and Installation Summary ...................................................... 19
3 Basic Mode System Operation & Configuration 20

3.1 System Start Up – Apply 24 VDC Power .................................................................. 20
3.1.1 Zone Discovery ...................................................................................................................................... 20
3.1.2 Lost Package Detection ..................................................................................................................... 20
3.1.3 Sleep Timer............................................................................................................................................. 20
3.2 EOB Zone Configuration................................................................................................ 21
3.2.1 Controlling Object Entry – Forward (normal) Flow Direction ................................................. 21
3.3 Master Zone Configuration .......................................................................................... 21
3.3.1 Controlling Object Exit ......................................................................................................................... 21
3.3.2 Changing Operational Modes........................................................................................................... 21
3.3.3 Controlling Branch Direction............................................................................................................. 21
3.3.4 Controlling Branch Speed .................................................................................................................. 21
3.4 Basic Mode Parameters ............................................................................................... 21
4 Zone Controller Updates 23

5 Advanced Mode System Configuration 24
6 Motor Performance 25
7 Breakout Module 27
7.1 Handshaking Functionality .......................................................................................... 27
7.2 Breakout Module Example: Connect Two Branches............................................ 29
7.3 Breakout Module Example: Connect Two Branches with Branch Monitor.... 29
7.4 Breakout Module Example: Transfer Application ................................................. 30
Copyright ©2013-2019 Automation Controls Group, Inc. A division of Milwaukee Electronics Companies, 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.
8 Diagnostics & Troubleshooting 31
8.1 Feedback LEDs ................................................................................................................ 31
8.1.1 Fuse LED (Red) ...................................................................................................................................... 31
8.1.2 Fault LED (Red)...................................................................................................................................... 32
8.1.3 Motor LED (Amber) .............................................................................................................................. 32
8.2 Firmware Version Display ............................................................................................. 33
8.3 Additional Assistance .................................................................................................... 33
9 Document Revision History 33

Appendix A: Operating Modes 34
A.1. Singulate (ZPA) .................................................................................................................. 34
A.2. Slug ....................................................................................................................................... 34
A.3. ZIP.......................................................................................................................................... 35
A.4. Zone Hold ............................................................................................................................ 35
Copyright ©2013-2019 Automation Controls Group, Inc. A division of Milwaukee Electronics Companies, 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: The ZoneLogix™ PRO System .....................................................................................6
Figure 2: ZoneLogix™ PRO Zone Controller Diagram ..............................................................8
Figure 3: Zone Controller Mounting Tabs................................................................................ 10
Figure 4: The ZoneLogix™ PRO System .................................................................................. 11
Figure 5: UniDrive Motor Stopping Distance .......................................................................... 12
Figure 6: Default DIP Switch and Smart I/O .......................................................................... 13
Figure 7: Zone-to-Zone Communication Connections .......................................................... 14
Figure 8: LED Definitions ........................................................................................................... 18
Figure 9: Schematic Diagram of ZoneLogix™ PRO System................................................. 19
Figure 10: Standard Zone Controller LEDs in Normal Operation ........................................ 20
Figure 11: Motor Performance Curves .................................................................................... 25
Figure 12: Breakout Module (Product 300332) .................................................................... 27
Figure 13: Handshaking Signals Showing Forward and Reverse Flow Request / Permission
Signals .......................................................................................................................................... 28
Figure 14: Handshaking Signals Showing Both Forward / Reverse Request / Permission
Signals .......................................................................................................................................... 28
Figure 15: Internal Diagram of the Breakout Module .......................................................... 28
Figure 16: Breakout Module Connecting Two Branches ...................................................... 29
Figure 17: Breakout Module Connecting Two Branches and Branch Monitor .................. 29
Figure 18: Breakout Modules in a Transfer Application ....................................................... 30
Figure 19: Feedback LEDs ........................................................................................................ 31
Figure 20: Firmware Version Display Example ...................................................................... 33
Figure 21: Singulate (Singulate Mode) ................................................................................... 34
Figure 22: Slug (Slug Mode)...................................................................................................... 34
Figure 23: ZIP (Operating Mode) .............................................................................................. 35
Figure 24: Zone Hold (Singulate, ZIP, and Slug Modes) ....................................................... 35
ZoneLogix™ PRO Zone Controller User Guide | Revision 1.0 November 2019 | Page 4
LIST OF TABLES
Table 1: DC Power Input Connection ....................................................................................... 14

Table 2: PNP Sensor Connection Header ............................................................................... 15
Table 3: Smart I/O Pin Definitions for the EOB Zone Controller ......................................... 16
Table 4: Smart I/O Pin Definitions for the Standard Zone Controller ................................ 16
Table 5: Smart I/O Pin Definitions for the Master Zone Controller in Basic Mode .......... 17
Table 6: Operating Modes for Smart I/O Pins 1 & 2 on the Master Zone Controller in Basic
Mode ............................................................................................................................................. 17
Table 7: Speed Input Analog Control ....................................................................................... 17
Table 8: Parameters in Basic Mode......................................................................................... 22
Table 9: Fault LED ...................................................................................................................... 32
Table 10: Motor Current LED .................................................................................................... 32
1 Introduction
The ZoneLogix™ PRO Smart Conveyor System is a product that is used in material handling conveyance
applications. The system is comprised of two main components: Zone Controllers and the Branch
Monitor. A typical application consists of some length of roller conveyor (a Branch), divided into zones.
Each zone has a Zone Controller that controls a Brushless DC (BLDC) motor, or solenoid air actuator.
Zone Controllers communicate via a high-speed network. The Branch Monitor provides three different
functions: (1) It acts as a system monitor to allow for monitoring the operation of the Branch, (2) it acts
as a device to configure the behavior of the individual zones, and (3) it provides an EtherNet/IP fieldbus
interface for use with a Programmable Logic Controller (PLC).
ZoneLogix™ PRO was designed to provide levels of operation ranging from basic speed and direction to
advanced sophisticated implementations.
▪ Basic Mode: Everything your smart conveyor system needs to get started is already built-into the
ZoneLogix™ PRO system. You can connect up to 255 package-handling segments, or zones, in series
with one UniDrive® motor per zone.
▪ Advanced Mode: By adding the ZoneLogix™ PRO Branch Monitor, you can configure each individual
zone according to the needs of the application. Optionally, you can also connect a PLC to further
leverage the networking power of the ZoneLogix™ PRO to provide automated package tracking and
sophisticated control capabilities. You can connect up to 120 zones in a Branch. Multiple Branches
can be connected to each other.
Figure 1: The ZoneLogix™ PRO System
1.1 Key Terms and Concepts
▪ Branch: A conveyor section that consists of a series of zone controllers with a defined entry End-of-
Branch (EOB) zone (upstream), and an exit Master zone (downstream) {in the Forward (normal) flow
direction}. In between the EOB and Master are Standard zones.
NOTE: A Branch requires a minimum of (1) EOB and (1) Master
▪ Forward (normal) Flow Direction: Transportation from EOB (entry) to Master (exit)
▪ Reverse Flow Direction: Transportation from Master (becomes entry) to EOB (becomes exit)
▪ End-of-Branch (EOB): The EOB is the entry to the Branch in the Forward (normal) Flow Direction
▪ Master: The Master zone controller is the exit zone of the Branch in the Forward (normal) flow
direction. It communicates the modes of operation to all zone controllers in the Branch. You can
configure the Master in Basic Mode or Advanced Mode.
▪ Standard: Zone controllers that are located between the EOB and Master
▪ Branch Monitor: The Branch Monitor provides a user interface display, and pushbuttons to configure
a Branch. The Branch Monitor helps you gather information about the Branch and configure it for
your needs.
▪ Primary Sensor: Photoeye input for the downstream edge of a zone, when configured for the
Forward (normal) flow direction.
▪ Secondary Sensor: Photoeye input for the downstream edge of a zone, when configured for the
Reverse flow direction.
▪ Smart I/O: General purpose, 24 VDC I/O, that can be used as an extension of a PLC, or configured to
one of several built-in functions.
▪ Analog Speed Input: Allows a zone to be controlled via a 0-10 VDC signal
▪ Basic Mode: Basic Mode is the out of the box solution for ZPA. It uses discrete signals to control
several parameters for Branch configuration (a Branch Monitor is not required). A Branch may contain
up to 255 zones.
▪ Advanced Mode: Advanced Mode utilizes the full power of the Branch Monitor to individually
configure each zone in a Branch. Optionally, the EtherNet/IP fieldbus connection may be used to
control a Branch via a Programmable Logic Controller (PLC). A Branch may contain up to 120 zones.
▪ Branch Serial Communications: Serial communications that allows the Master to configure all
zones within a Branch (Master-to-Zones)
▪ Handshake Communications: Request, Permission, and Sensor signals that pass between adjacent
zones. Allows for zone-to-zone communication for handling package flow.
▪ Protective Extra Low Voltage (PELV): IEC 61140 defines a PELV system as an electrical source in
which the voltage cannot exceed 30 Vrms or 60 VDC under normal or single-fault conditions, and its
DC common (minus (-) output terminal) is connected to earth ground.
2 Getting Started and Installation
Below is an image of the Zone Controller and the various connections. In Basic Mode there are a few
operational mode settings that can be made via Smart I/O settings which are described later in this
manual. To configure a system in Advanced Mode, see Section 5: Advanced Mode System
Configuration.
Figure 2: ZoneLogix™ PRO Zone Controller Diagram
1) Secondary Sensor: Photoeye input for the downstream edge of a zone, when configured for the
Reverse flow direction.
a. Phoenix Contact, 3-pos plug, 1881338
2) To EOB Communication: This is meant to only connect to the “To Master” connection of
another Zone Controller. Zone Controllers are intended to be daisy chained together in a series.
a. RJ45, 8P8C, CAT5 (or better), Ethernet cable
3) Smart I/O: General purpose, 24 VDC I/O, that can be used as an extension of a PLC, or
configured to one of several built-in functions
4) UniDrive® Motor Connection: Motor connection for any UniDrive® Brushless DC Motor. The
motor contains this plug. It is listed here for reference.
a. Motor Input: Molex, 10-pos plug, 172258-1110
5) Primary Sensor: Photoeye input for the downstream edge of a zone, when configured for the
Forward (normal) flow direction.
6) To Master Communication: This is meant to only connect to the “To EOB” connection of
another Zone Controller. Zone Controllers are intended to be daisy chained together in a series.
a. RJ45, 8P8C, CAT5 (or better), Ethernet cable
7) Smart I/O: General purpose, 24 VDC I/O, that can be used as an extension of a PLC, or
configured to one of several built-in functions
8) Power Input: 24 VDC power input

a. Molex, 2-pos plug, 172256-1002
9) DIP Switches: Configures various modes and functions of the Zone Controller
This section describes how to install the ZoneLogix™ PRO and UniDrive® motors in the most common
configuration.
1. Zone Controller Installation
2. Motor Installation
3. DIP Switch Settings
4. Cable Connections
5. System Configuration
6. Diagnostics & Troubleshooting
2.1 Zone Controller Installation

Mount the Zone Controller in a location where the motor cable reaches the connection header without putting strain
on the cable connector or the header. The Zone Controller can mount to the conveyor frame using two ¼ inch (0.25
in or 6.35 mm) bolts.
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.
Figure 3: Zone Controller Mounting Tabs
CAUTION: Removal of the cover will void the warranty. The cover does not make the controller waterproof or dustproof.
2.2 Zone Installation
A typical zone is installed as shown below.
Figure 4: The ZoneLogix™ PRO System
• The motor is typically placed in the middle of the zone

• The Primary Sensor is used as the zone photoeye sensor input when package flow is left to right (Forward
Direction EOB to Master)
• The Secondary Sensor is used as the zone photoeye sensor input when package flow is right to left (Reverse
Direction Master to EOB)
• The photoeye sensor should be a 24 VDC PNP, where the output is 24 VDC when a package is detected
• The recommended photoeye sensor placement is typically ~6” at <30 m/min, with respect to the
downstream edge of the zone. The sensor position is determined by factors such as the speed and weight of
the object. Heavier loads at higher speeds require greater distance to stop moving.
• Maximum load current of the photoeye sensor should be <150 mA
• Mount the control where there is adequate heatsink and no strain on the cable connections
Figure 5: UniDrive Motor Stopping Distance
2.3 Configuration DIP Switches
The DIP switches are used to configure the zone type and motor rotation direction in the Forward (normal) flow
direction (EOB to Master).
NOTE: The DIP switches are read during power-up only. Set the switches, and then apply power to the Zone Controller.
Figure 6: Default DIP Switch and Smart I/O
NOTE: The direction of rotation is defined as viewed from the back side of the motor with the shaft extending away from the viewer.
2.4 +24VDC Power Connection
CAUTION! Power must be applied with proper polarity to avoid potentially damaging the Zone Controller. Follow the pinout shown
in Table 1 below.
The ZoneLogix™ PRO operates from +22 to +28 volts DC power. Make the power connection only after all other
connections have been made.
Table 1: DC Power Input Connection
Pin: Signal:
0VDC DC Ground
24VDC +22 to +28 VDC, PELV
IMPORTANT! When adjacent zones are operating from separate power supplies, connect their DC grounds. However, do not
connect their positive voltage pins together. The positive voltage differential should be < 4 VDC.
2.5 Zone-to-Zone Cable Connection

The controls pass Branch Serial Communications and Handshaking signals between adjacent zones over standard
Ethernet cables. The To EOB connector must be connected to the To Master connector of an adjacent upstream unit.
The To Master connector must be connected to an adjacent downstream unit using its To EOB connector. When
connecting two branches together, see Section 7: Breakout Module.
Figure 7: Zone-to-Zone Communication Connections
CAUTION! Do not cross wiring of the

Ethernet cables. The left side of the zone
must connect to the adjacent zone on the
left, and the right side of the zone must
connect to the adjacent zone on the right.
Zones should be connected as shown above.
2.6 PNP Photoeye Sensor Connection
Each zone requires an object sensor to detect the objects that are in the zone when they reach the most downstream
edge of the zone. In the Forward (normal) flow direction, the Primary Sensor is the downstream sensor. In
applications where the conveyor is run in Reverse Flow, the Secondary Sensor then becomes the most downstream
sensor. Wire the leads of the sensor to the appropriate terminals on the 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.
Table 2: PNP Sensor Connection Header
Pin Notes:
Signal In PNP sensor input with maximum loading of <150 mA. This input must be 24VDC (active high) when an object blocks
the sensor.
0VDC DC Ground (See CAUTION above)
24VDC Sensor power. Use of this output for any purpose that requires more than 150 mA will cause the self-resettable
fuse to open and temporarily remove 24VDC power to the sensor.
2.7 Smart I/O Connections
The function of each PNP pin depends on the configuration of the Zone Controller. See 2.3 Configuration DIP
Switches. Additional functions are available in Advanced Mode.
2.7.1 Basic Mode Functions

The following functions only apply when the Master Zone Controller DIP switch settings are configured for Basic
Mode.
IMPORTANT! All Smart I/O inputs and outputs except analog are PNP only and are active at 18 VDC or higher. The maximum
current available per output is 500 mA.
Table 3: Smart I/O Pin Definitions for the EOB Zone Controller
I/O Pin: Description:

1 Zone Hold In
2 Not Defined
3 Motor Running Out
4 Forward Request/Reverse Permission In
5 Forward Permission/Reverse Request Out
6 Zone No-Fault Out
Speed In Zone Speed (0-10 VDC Analog In)
Table 4: Smart I/O Pin Definitions for the Standard Zone Controller

1 Zone Hold In
2 Local Speed Inhibit In
3 Motor Running Out
4 Forward Permission/Reverse Request In
5 Forward Request/Reverse Permission Out
6 Not Defined
Speed In Zone Speed (0-10 VDC Analog In)
Table 5: Smart I/O Pin Definitions for the Master Zone Controller in Basic Mode

1 Branch Op Mode 1 In
2 Branch Op Mode 2 In
3 Branch Reverse In
4 Forward Permission/Reverse Request In
5 Forward Request/Reverse Permission Out
6 Branch No-Fault Out
Speed In Branch Speed (0-10 VDC Analog In)
Table 6: Operating Modes for Smart I/O Pins 1 & 2 on the Master Zone Controller in Basic Mode
Branch Op Mode 1 In Branch Op Mode 2 In Branch Operation

Inactive Inactive Singulate (ZPA)
Active Inactive ZIP
Inactive Active Slug
Active Active Disable
Table 7: Speed Input Analog Control
Voltage Operation
<0.5 VDC Zone operates at configured speed
Zone speed is proportional to the input within the
0.5 to 9.0 VDC
full range of the motor selected
>9.0 to 24 VDC Zone operates at full speed
2.7.2 Advanced Mode Functions

See the companion ZoneLogix™ PRO Branch Monitor User Guide for further information about Advanced Mode
functions.
2.8 LED Feedback Indicators
The ZoneLogix™ PRO Zone Controller provides six (6) LED indicators shown below:
Figure 8: LED Definitions
To learn more, see Figure 19: Feedback LEDs.
2.9 System Schematic and Installation Summary
The following is a system schematic and summary of settings:
Figure 9: Schematic Diagram of ZoneLogix™ PRO System
• A Branch is made up of at least (1) EOB and (1) Master

• Forward (normal) package flow is from EOB to Master. See 3.3.3 Controlling Branch Direction for instructions
to reverse the flow direction.
• Standard Zone Controllers are placed between EOB and Master
• Identify the Zone Controller location in the Branch, and set the DIP switches as noted above
• Identify the proper direction of rotation for each motor to move packages from the upstream (entry) end of
the conveyor to the downstream (exit) end (EOB to Master); may depend on motor mounting orientation.
• Connectors/Plugs:
o Photoeye Sensors: Phoenix Contact, 3-pos plug, 1881338
o Smart I/O: Phoenix Contact, 4-pos plug, 1881341
o Power Input: Molex, 2-pos plug, 172256-1002
o Molex Crimping Tool: Molex, 20-22 AWG tool, 0638275400
o Molex Crimp Terminals: Molex, 20-22 AWG terminals, 172253-3123
o Molex Crimping Tool: Molex, 16-18 AWG tool, 0638275300
o Molex Crimp Terminals: Molex, 16-18 AWG terminals, 172253-3023
o Communication Cables: Standard CAT5, or better, RJ45 Ethernet cables
CAUTION! Power must be applied with proper polarity to avoid potentially damaging the Zone Controller.
CAUTION! Do not cross wiring of the Ethernet cables. The left side of the zone must connect to the adjacent zone on the left, and the
right side of the zone must connect to the adjacent zone on the right. Zones should be connected as shown above.
IMPORTANT! When adjacent zones are operating from separate power supplies, connect their DC grounds. However, do not
connect their positive voltage pins together.
NOTE: The direction of motor rotation is defined as viewed from the back side of the motor with the shaft extending away from the
viewer.
NOTE: The DIP switches are read during power-up only. Set the switches, and then apply power to the Zone Controller.
3 Basic Mode System Operation & Configuration
3.1 System Start Up – Apply 24 VDC Power
3.1.1 Zone Discovery
When powered on, the Master Zone Controller initiates a Branch discovery process. The Master communicates
sequentially to upstream Zone Controllers and initializes each zone. Each zone should have the following LEDs
illuminated:
• The Pwr LED should be illuminated solid
• The EOB Zone Controller should have the Down comm LED illuminated solid
• The Master Zone Controller should have the Up comm LED illuminated and the Down comm LED will blink
at a ½ second rate only when the optional Branch Monitor is connected.
• All Standard Zone Controllers should have the Up and Down comm LEDs illuminated solid
NOTE: When illuminated, the Up comm LED indicates a good connection to the zone on the left. The Down comm LED indicates a
good connection to the zone on the right.
• Check all photoeye sensors to ensure the indicator LEDs are illuminated correctly (see manufacturer’s manual)
Figure 10: Standard Zone Controller LEDs in Normal Operation
3.1.2 Lost Package Detection

During power up, 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 up to the value of the Sleep Timer (default is 5
seconds) or until an object arrives at the respective zone sensor, whichever comes first. This process will ‘find’ objects
that may have been stranded between zone sensors if power was removed while an object was being transported.
3.1.3 Sleep Timer

A zone will run for up to the value of Sleep Timer (default is 5 seconds) until either an object arrives at the zone sensor,
or until the timeout expires. The purpose of this functionality is to ensure that an object is not stranded between
sensors.
3.2 EOB Zone Configuration
3.2.1 Controlling Object Entry – Forward (normal) Flow Direction
Use Smart I/O Pin 4 (Forward Request/Reverse Permission In) to notify the control that there is a package ready for
input to the zone. If the zone is empty 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 photoeye sensor, etc.
Use Smart I/O Pin 5 (Forward Permission/Reverse Request Out) to notify an external device that the zone is empty and
ready to receive a package.
3.3 Master Zone Configuration

3.3.1 Controlling Object Exit
Use Smart I/O Pin 4 (Forward Permission/Reverse Request In) to notify the zone that it has permission to discharge a
package. The signal may be provided by any number of alternative sources such as a PLC, a simple switch, a photoeye
sensor, etc.
NOTE: When permission is removed the zone will attempt to stop any discharge that may be in process.
Use Smart I/O Pin 5 (Forward Request/Reverse Permission Out) to notify an external device that the zone is occupied
and ready to discharge a package.
Use Smart I/O Pin 6 (Branch No-Fault Out) to provide an indication of a fault in the Branch when this output goes
inactive.
3.3.2 Changing Operational Modes

The default Operational Mode for the Branch is Singulate. Smart I/O Pins 1 and 2 on the Master Smart I/O
Connection Header provide other Operational Modes as listed in Table 5: Smart I/O Pin Definitions for the Master
Zone Controller in Basic Mode.
3.3.3 Controlling Branch Direction

Use Smart I/O Pin 3 on the Master (Branch Reverse In) to reverse the flow direction of the Branch. Reverse mode
requires an additional photoeye sensor connected to the Secondary Sensor input (see Section 2.2: Zone Installation).
3.3.4 Controlling Branch Speed

Use Speed In (0-10VDC) on the Master to control the speed of the Branch. See Table 7: Speed Input Analog Control.
3.4 Basic Mode Parameters

The following are the parameters available in Basic Mode:
Table 8: Parameters in Basic Mode
Parameter: Description: Settings:

Op Mode The Operational Mode (Op Mode) of a zone defines its Smart I/O Pins 1 & 2
overall function in the branch.
• Disable: Zone motor is disabled. To prevent Branch Op Branch Op Branch Operation
automatic Branch operation following a loss of Mode 1 In Mode 2 In
power, this mode prevents the Branch from 0 VDC 0 VDC Singulate (ZPA)
automatically starting. 24 VDC 0 VDC ZIP
• Slug: Zone mode where the zone is set to run and
does not control spacing between objects. If the 0 VDC 24 VDC Slug
downstream zone is in accumulation, then the 24 VDC 24 VDC Disable
object will be held and upstream zones will
accumulate. Upstream objects move in unison when
downstream photoeye is cleared.
• ZIP: Zone operation mode that increases
throughput (at the cost of assuring objects
never touch) by allowing a second object to
enter a zone once the first object has been
transported to the downstream-edge photo-eye
sensor. Note that the result is a gap between
objects equal to the zone length less the object
length.
• Sing (Singulate): A transportation technique
that assures that objects are separated (i.e.
“singulated”) by some minimum distance. This
zone operation mode ensures objects never touch
and that there is one object per zone. Also
known as Zero Pressure Accumulation (ZPA). The
upstream object moves only after the downstream
object clears the photoeye.
Speed Defaults to 100% of full scale. Basic Mode has one motor Speed In Pin
selection that defines the speed range.
• 100W Motor = 56-280 RPM Voltage Operation
Zone operates at configured
<0.5 VDC
speed
Zone speed is proportional
0.5 to 9.0 VDC to the input within the full
range of the motor selected
>9.0 to 24 VDC Zone operates at full speed
Direction This feature sets the flow direction of the Branch. Smart I/O Pin 7 – Branch Reverse In
Forward (normal) Flow is from EOB to Master, utilizing the Voltage Operation
Primary Sensor.
Forward (normal) flow
0 VDC
direction
Reverse Flow is from Master to EOB, utilizing the Secondary
Sensor. 24 VDC Reverse flow direction
Current This setting is fixed in Basic Mode dependent upon the Fixed: 4.0 A
Limit Motor Selection.
• 100W Motor = 4.0 A
Sleep Time This value defines the timeout period for three different Fixed: 5 sec
timer scenarios:
• When an object enters a zone (passes the
upstream zone sensor) but does not reach the
downstream sensor within the defined timeout
period.
• When an object leaves a zone (passes the
downstream zone sensor), and there are no
upstream objects that result in the motor
needing to run, then the motor continues to run
a short “motor run-on” period, the idea being to
handle any stray objects that might be present.
• When in Slug Mode, when an object leaves a zone
(passes the downstream zone sensor), and there
are no upstream objects that result in the motor
needing to run, then after this timeout the zone
will shut down (since there are no more objects
to transport).
Jam Time When a zone is discharging an object (that is, the motor is Fixed: 6 sec
running) and the object remains at the downstream sensor
for longer than the defined timeout period.
Motor Defines the type of motor for the zone. In Basic Mode this Fixed: 100W
Selection is fixed at the 100W motor.
4 Zone Controller Updates
The ZoneLogix™ PRO system is designed to automatically adjust firmware in the Zone Controllers in order to ensure
all zones are at the same firmware revision. This is beneficial because a lot of testing goes into the development of a
system, and generally the firmware revision of all controls should remain at the level of test and validation. For
example, if you were to replace a Zone Controller on a 5-year-old system with a new controller, the system would
automatically update (in this example downgrade) the firmware in the new controller to match the rest of the system.
Additionally, the complete configuration of the entire branch is stored in every Zone Controller. This provides full
system backup redundancy across all Zone Controllers. Below are examples of how to replace Zone Controllers in
existing applications.
▪ Replace Master Zone Controller

In a Branch, the Master Zone Controller will decide the firmware of all the zones. Therefore, it is critical that if the
Master Zone Controller has failed and needs replacement, you should do the following:
• Remove the failed Master from the Branch
• Remove an existing Standard Zone Controller from the same Branch, insert it into the Master Zone
position, and set the DIP switch of this Zone Controller to Master
• Add a new Standard Zone Controller to fill the empty zone
All Zone Controllers contain the configuration of the Branch, therefore, by swapping the failed Master with another
Zone Controller from the same Branch, the configuration for the Branch is maintained.
▪ Replace EOB or Standard Zone Controller

If a Standard or EOB Zone Controller needs replacement, simply remove the failed controller and replace with a new
one. The Master Zone Controller will automatically recognize that a new controller has been installed and will
perform the following actions:
• The Master will upgrade or downgrade the firmware in the new controller to match the existing Zone
Controllers in the branch
• The Master will push the complete configuration for every zone, into the new controller for redundant
backup storage
5 Advanced Mode System Configuration
Basic Mode provides a limited number of features. In Advanced Mode, the ZoneLogix™ PRO can be configured in
many different arrangements to provide the most versatile material handling control available.
When the ZoneLogix™ PRO is configured in Advanced Mode, each zone is configured by the ZoneLogix™ PRO Branch
Monitor. Alternatively, each zone can be controlled by a PLC connected via EtherNet/IP.
See the companion ZoneLogix™ PRO Branch Monitor User Manual and ZoneLogix™ PRO Fieldbus Manual for further
information about Advanced Mode System Configuration.
6 Motor Performance
Below are the typical motor speed/torque curves for ZoneLogix™ PRO at various current limits.
Figure 11: Motor Performance Curves
7 Breakout Module
The Breakout Module is an optional component to interconnect ZoneLogix™ PRO Branches using standard RJ-45
cabling. The Breakout Module enables additional innovative solutions such as parallel sections and left and/or right
spur connections.
Figure 12: Breakout Module (Product 300332)
A connection is typically made from a ZoneLogix™
PRO Zone Controller to the All Signals connector on
the left side of the Breakout Module. The
Handshaking Only connector (right side) is most often
used to connect two branches together to provide
object flow control by the ZoneLogix™ PRO.
The Serial Only port (bottom left side) can be
connected to the ZoneLogix™ PRO Branch Monitor or
where it is needed to separate sections of the Branch
to handle unique configurations. The discrete wiring
header (bottom right) provides access to the
Handshaking signals of the ZoneLogix™ PRO allowing
external object flow control.
The Breakout Module is essentially a signal splitter, that allows you to split, or ‘breakout’, the Handshaking and Serial
signals into separate connections.
7.1 Handshaking Functionality

The Handshaking is the zone-to-zone communications that is responsible for handling package flow. This is primarily
controlled by a Request/Permission model. Whether the Branch is going Forward or Reverse, these (4) signals control
the flow between Zone Controllers:
• (Forward [Fwd] or Reverse [Rev]) Request Output
o The zone is making a request … “Can you take my box?”
• (Forward [Fwd] or Reverse [Rev]) Request Input
o The zone is receiving the request … “Oh, I got a request to take a box! A zone is requesting
permission to send a box to me.”
• (Forward [Fwd] or Reverse [Rev]) Permission Output
o The zone is giving permission … “OK, I give you permission, now go ahead and send me your box!”
• (Forward [Fwd] or Reverse [Rev]) Permission Input
o The zone is receiving the permission … “I got permission to send my box! Here it is!”
NOTE: ‘Request Out’ points in the direction of flow
From the description above, you can see there are (2) inputs and (2) outputs per zone-to-zone connection. These I/O
are fixed, meaning that they are dedicated inputs and outputs in the hardware design. Therefore, they provide
different functionality depending upon the flow direction as shown below.
Zones numbered #5 and #4 are shown for clarity, since the Branch is enumerated with the Master being Zone #1, and
the EOB being the last zone in the Branch. The depiction below, shows (2) Standard zones in a Branch where the EOB
would be on the left end of the Branch, and the Master would be on the right.
Figure 13: Handshaking Signals Showing Forward and Reverse Flow Request / Permission Signals
Figure 14: Handshaking Signals Showing Both Forward / Reverse Request / Permission Signals
Figure 15: Internal Diagram of the Breakout Module
7.2 Breakout Module Example: Connect Two Branches
This example shows a connection between two Branches. The Master on the left is connected to ‘All Signals’. This
refers to the fact that the RJ45 cable contains two communication systems; Branch Serial Communications (Master-to-
Zones) and Handshaking (Zone-to-Zone). The Breakout Module acts as a signal splitter. It takes the ‘All Signals’ and
splits or ‘breaks out’ the serial and Handshaking. In this example, the Breakout Module effectively connects the
Handshaking from the Master on the left Branch, to the Handshaking on the EOB on the right Branch. Therefore,
package flow can continue across Branches.
Figure 16: Breakout Module Connecting Two Branches
7.3 Breakout Module Example: Connect Two Branches with Branch Monitor
This example shows the same connection of two Branches as above, but also adds the connection to the Branch
Monitor. The Branch Monitor is used to configure the Branch on the left side. A separate Branch Monitor is required
for the Branch on the right.
Figure 17: Breakout Module Connecting Two Branches and Branch Monitor
7.4 Breakout Module Example: Transfer Application
This example shows the setup of a transfer in a Branch. Based on the package flow, this Branch is going in the
Forward direction … EOB to Master. The Breakout Modules are used to break the Handshaking and allow the serial
communications to pass through. At Zone #5, we do not want the Handshaking between Zone #5 and Zone #4. This
wouldn’t make sense for the application. The Breakout Module “breaks” the Handshaking so that Zone #5 cannot
make a Request to Zone #4. This same scenario is true between Zone #3 and Zone #2.
Figure 18: Breakout Modules in a Transfer Application
8 Diagnostics & Troubleshooting
8.1 Feedback LEDs
The ZoneLogix™ PRO Zone Controller provides six (6) LED indicators as shown in Figure 8: LED .
Figure 19: Feedback LEDs
The Down LED is normally off, but blinks

at a ½ sec rate when the optional Branch
Monitor is connected to the Master
8.1.1 Fuse LED (Red)

CAUTION: This fuse will not blow under normal 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 10-amp fuse is blown and power is
applied with the proper polarity.
The 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.
8.1.2 Fault LED (Red)
Table 9: Fault LED
Fault LED Description

OFF No fault is present
Zone Communications, Invalid Branch Configuration,
1 flash (in 5 sec)
or Unsupported Zone Controller in Branch
Power input over voltage … reduce voltage.
2 flashes (in 5 sec)
Proper range is 22-28 VDC.
Power input under voltage – increase voltage.
Proper range is 22-28 VDC.
Motor Connection. Check that cable is secured and
not damaged.
5 flashes (in 5 sec) Zone Controller Over Temperature
6 flashes (in 5 sec) Extreme Motor Over Current
7 flashes (in 5 sec) Product model does not match Master
8 flashes (in 5 sec) Software version does not match Master
Motor Stalled, Sensor Blocked, or Firmware Update in
ON Constant
Process
8.1.3 Motor LED (Amber)
Table 10: Motor Current LED
Motor Current LED Description

OFF Motor is not being current limited
Motor in intermittent current limit. Can occur when
starting motor with heavy loads. If flickering
Flickering
constantly, this indicates the motor is operating at
max limit and may not reach full speed.
Motor at max current limit. Check for mechanical
ON Constant
obstruction.
8.2 Firmware Version Display
Three (3) of the feedback LEDs are used to communicate the firmware revision of the Zone Controller during the start-
up sequence. Each time that power is applied to the board, the green (power) and red (fault) LEDs light up
immediately. After 1 second the amber LED flashes 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:
Figure 20: Firmware Version Display Example
The example sequence above represents firmware revision 1.2. When the red (fault) LED turns off, the start-up
sequence has ended, and normal operation begins.
8.3 Additional Assistance

For updated revisions to our user manuals, visit our website: www.automationcontrolsgroup.com
For additional assistance, please contact:
Sales / Customer Service
(619) 677-6530
9 Document Revision History

The following changes have been made to this document:
Rev: Date: Summary:

1.0 November 2019 Original Release.
Appendix A: Operating Modes
A.1. Singulate (ZPA)

Figure 21: Singulate (Singulate Mode)
Package 2 will be held in Zone 3 and not allowed to enter Zone 2 until Package 1 has cleared the Zone 2 sensor.
A.2. Slug
Figure 22: Slug (Slug Mode)
All zones will run in this mode if the Sleep Timer has not expired, however if Zone 2 is in accumulation it will stop Zone 3.
ZoneLogix™ PRO Branch Monitor Guide | Revision 0.1 September 2019 | Page 34
A.3. ZIP
Figure 23: ZIP (Operating Mode)
Zone 3 will have permission to release Package 2 into Zone 2 once Package 1 has hit zone 2 sensor.
A.4. Zone Hold

Figure 24: Zone Hold (Singulate, ZIP, and Slug Modes)
If Zones 2 and 3 were put into Zone Hold, Package 2 will be held in Zone 3 when it is detected by the Zone 3 sensor.
Zone 2 would attempt to hold Package 1, however depending on Package 1 position at the time it may be pulled into
Zone 1.
ZoneLogix™ PRO Branch Monitor Guide | Revision 0.1 September 2019 | Page 35

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ZoneLogix™ PRO Zone Controller User

Guide 1 in the 3-part ZoneLogix™ PRO documentation series

2 Getting Started and Installation 8

3 Basic Mode System Operation & Configuration 20

4 Zone Controller Updates 23

9 Document Revision History 33

Table 1: DC Power Input Connection ....................................................................................... 14

Figure 1: The ZoneLogix™ PRO System

NOTE: A Branch requires a minimum of (1) EOB and (1) Master

8) Power Input: 24 VDC power input

1. Zone Controller Installation

3. DIP Switch Settings

6. Diagnostics & Troubleshooting

2.1 Zone Controller Installation

Figure 3: Zone Controller Mounting Tabs

Figure 4: The ZoneLogix™ PRO System

• The motor is typically placed in the middle of the zone

Figure 6: Default DIP Switch and Smart I/O

2.5 Zone-to-Zone Cable Connection

CAUTION! Do not cross wiring of the

Table 2: PNP Sensor Connection Header

2.7.1 Basic Mode Functions

I/O Pin: Description:

I/O Pin: Description:

I/O Pin: Description:

Branch Op Mode 1 In Branch Op Mode 2 In Branch Operation

Table 7: Speed Input Analog Control

2.7.2 Advanced Mode Functions

Figure 8: LED Definitions

To learn more, see Figure 19: Feedback LEDs.

• A Branch is made up of at least (1) EOB and (1) Master

Figure 10: Standard Zone Controller LEDs in Normal Operation

3.1.2 Lost Package Detection

3.1.3 Sleep Timer

3.3 Master Zone Configuration

3.3.2 Changing Operational Modes

3.3.3 Controlling Branch Direction

3.3.4 Controlling Branch Speed

3.4 Basic Mode Parameters

Parameter: Description: Settings:

▪ Replace Master Zone Controller

▪ Replace EOB or Standard Zone Controller

7.1 Handshaking Functionality

NOTE: ‘Request Out’ points in the direction of flow

Figure 15: Internal Diagram of the Breakout Module

Figure 16: Breakout Module Connecting Two Branches

Figure 18: Breakout Modules in a Transfer Application

Figure 19: Feedback LEDs

The Down LED is normally off, but blinks

8.1.1 Fuse LED (Red)

Table 9: Fault LED

Fault LED Description

8.1.3 Motor LED (Amber)

Table 10: Motor Current LED

Motor Current LED Description

Figure 20: Firmware Version Display Example

8.3 Additional Assistance

9 Document Revision History

Rev: Date: Summary: