By replacing the traditional PLC/software combination with a fully integrated module an Integrated Controller simplifies conveyor installations and cuts costs by up to 75%.

Rockwell Automation introduces the Allen-Bradley 22ZC Zone Controller, a groundbreaking new product designed specifically for Zero Pressure Accumulator Conveyors. By replacing the traditional PLC/software combination with a fully integrated module, the Allen-Bradley 22ZC provides many benefits for both the machinery manufacturer and user. These include quick and easy installation, simplified programming and reduced interconnecting wiring.

Installation costs are significantly reduced.

For example, the cost per zone using a traditionally wired unit is typically GBP 150 to GBP 200 - using the 22ZC this is reduced by up to 75%.

Machine builders can use these savings to gain extra business by offering a price advantage or increase their margin in a highly competitive market.

Using the new 22ZC provides a modern solution for accumulator conveyor systems used in a range of industries including materials handling, baggage systems, process, warehousing and logistics.

A zone controller is used to control the flow of products on a conveyor system.

A sensor detects the presence of a product and sends an actuator output signal to start and stop the rollers in that zone.

A zero pressure conveyor system ensures that a gap between products is always maintained - preventing them from touching each other.

The Allen-Bradley 22ZC controller comprises a discrete integrated unit with built in intelligence.

The 22ZC replaces the PLC, its interconnecting wiring and associated software.

It is used to control a 'zone' of the conveyor, using an input from a sensor and providing an output to an actuator.

A 22ZC based conveyor control system comprises a master zone controller for the discharge zone, an in-feed zone controller and a number of intermediate zone controllers, which are available with or without a timer.

Up to 60 controllers can be connected to a single power supply and by using multiple power supplies even the largest conveyor systems can be controlled using the 22ZC system.

No programming or software is required and seven DIP switches on each unit enable the controllers to be easily configured to suit different operating modes, for example, single or dual zone, slug or jam respond, sleep function, inverted output and zone set.

In addition, the master zone controller has two, 10 position rotary switches to configure both the system and discharge zone release timers.

System wide ON/OFF delay timers can be set and broadcast to all upstream zones from a master zone controller located at the discharge end of the conveyor using the ZoneSet feature.

The low profile modules are specially designed to fit into any industry standard steel conveyor frame.

Installation is quick and simple using a special four conductor flat cable, which provides power and communications to each module.

Insulation Displacement Connectors (IDC) are used to pierce the insulation of the cable, providing the electrical connections.

Each controller has IDC connectors for both the upstream and downstream circuits.

An installation port allows segments of a large conveyor system to be connected together using commissioning cables.

This enables a complete conveyor to be programmed and commissioned during manufacture, considerably reducing the time required on site and enabling further cost savings to be made.

Each controller has a sensor port which enables connection to the Allen-Bradley AccuSight photoelectric sensor.

Easy to install and maintain, the AccuSight is ideal for narrow conveyor system side rails.

Standard connecting cables enable sensors to be connected quickly to the sensor port on the zone controller while the actuator port provides a connection to an Allen-Bradley SMC soft starter or PowerFlex drive controlling the roller motors.

With the introduction of the Allen-Bradley 22ZC Zone Controller, Rockwell Automation has provided conveyor system manufacturers with a unique, new technology solution that reduces installation costs and speeds installation time.

Because there is no software, troubleshooting and maintenance are simplified for the user and the built in intelligence reduces the total operating cost over the life of the unit.