Controls Manual
Bastian Automation Engineering
Model: Standard ZiPline 9006 Drive Card
Effective June, 2015
Supercedes July, 2014 Version
2155 Fields Blvd.
Greenfield, IN 46140
Phone: (317) 467-2583
Web: www.bastiansolutions.com
Contents
1 Introduction
1
2 Base Configuration
2
3 Zone Stop
2
4 Slug Release
3
5 Slaved, NO Photoeye
3
6 Master Head End Zone
4
7 Base Configuration and PLC Monitor Input
4
8 Entry Zone with Wake-Up Eye
5
9 Run, Entry Zone
5
10 Run, Transport Zone
6
11 Run, NO Sensor Input
6
12 Zone Release On Signal
7
13 Automatic End Of The Line Zone Dump
7
1
Introduction
Thank you for purchasing a Bastian Automation Engineering (BAE) ZiPline material handling system! The following
manual will serve as a guide for setting up the Standard ZiPline 9006 Drive Card in various different operation modes.
9006 Drive Card
1
2
Base Configuration
The card is set to allow the zone to act in its most basic functionality. The speed potentiometer is entirely based upon the
needs for the system. The rest of the settings are the "typical" placement for the majority of applications. The Accel and
Decel potentiometers can be adjusted per use. The direction of rotation is set assuming product flow according to the
arrow shown. The upstream and downstream communication cables can be crossed in conjunction with turning DIP switch
2 to "ON" to reverse the direction of the product flow.
3
Zone Stop
The card is set to allow the zone to stop product when it reaches the sensor. The speed potentiometer is entirely based
upon the needs for the system. The rest of the settings are the "typical" placement for the majority of applications. The
Accel and Decel potentiometers can be adjusted per use. The direction of rotation is set assuming product flow according
to the arrow shown. The upstream and downstream communication cables can be crossed in conjunction with turning DIP
switch 2 to "ON" to reverse the direction of the product flow.
With the PLC connections made as shown, the photoeye status is such that ON is blocked. This makes the PLC Output
such that a high signal is used to stop the zone.
If this zone is the last zone, then it is recommended that a high signal is given to (6) Smart 1/FWD Input to serve as a
discharge signal to release the product. This will hold product back in the event of an E-stop or loss of signal.
9006 Drive Card
2
4
Slug Release
The card is set to allow the zones to release simultaneously. The speed potentiometer is entirely based upon the needs for
the system. The rest of the settings are the "typical" placement for the majority of applications. The Accel and Decel
potentiometers can be adjusted per use. The direction of rotation is set assuming product flow according to the arrow
shown. The upstream and downstream communication cables can be crossed in conjunction with turning DIP switch 2 to
"ON" to reverse the direction of the product flow.
5
Slaved, NO Photoeye
The card is set to allow the zone to be connected to the adjacent zone, serving as one large zone. The speed potentiometer
is entirely based upon the needs for the system. The rest of the settings are the "typical" placement for the majority of
applications. The Accel and Decel potentiometers can be adjusted per use. The direction of rotation is set assuming product
flow according to the arrow shown. The upstream and downstream communication cables can be crossed in conjunction
with turning DIP switch 2 to "ON" to reverse the direction of the product flow.
This configuration works in conjunction with the Master Head End Zone. The (6) Smart 1/FWD Input of the slaved zone
should be connected to the Motor Run (3) port of the master zone. This connection serves as the communication between
the two conjoined zones.
9006 Drive Card
3
6
Master Head End Zone
The card is set to allow the zone to be connected to the adjacent zone, serving as one large zone. The speed potentiometer
is entirely based upon the needs for the system. The rest of the settings are the "typical" placement for the majority of
applications. The Accel and Decel potentiometers can be adjusted per use. The direction of rotation is set assuming product
flow according to the arrow shown. The upstream and downstream communication cables can be crossed in conjunction
with turning DIP switch 2 to "ON" to reverse the direction of the product flow.
This configuration works in conjunction with the Slaved, NO Photoeye Zone. The (6) Smart 1/FWD Input of the slaved
zone should be connected to the Motor Run (3) port of the master zone. This connection serves as the communication between
the two conjoined zones. The upstream and downstream communication ports should be connected to the adjacent master
zones as needed, otherwise a PLC signal to the (6) Smart 1/FWD Input will be needed to release the zone.
7
Base Configuration and PLC Monitor Input
The card is set to allow the zone to have the most basic functionality with PLC inputs. The speed potentiometer is entirely
based upon the needs for the system. The rest of the settings are the "typical" placement for the majority of applications.
The Accel and Decel potentiometers can be adjusted per use. The direction of rotation is set assuming product flow
according to the arrow shown. The upstream and downstream communication cables can be crossed in conjunction with
turning DIP switch 2 to "ON" to reverse the direction of the product flow.
9006 Drive Card
4
8
Entry Zone with Wake-Up Eye
The card is set to allow the zone to run when product triggers the wake-up eye prior to the zone. This functionality is only
intended for entry zones, the first zone in a line of conveyor. The speed potentiometer is entirely based upon the needs for
the system. The rest of the settings are the "typical" placement for the majority of applications. The Accel and Decel
potentiometers can be adjusted per use. The direction of rotation is set assuming product flow according to the arrow
shown. The upstream and downstream communication cables can be crossed in conjunction with turning DIP switch 2 to
"ON" to reverse the direction of the product flow.
9
Run, Entry Zone
The card is set to allow the zone to run constantly while being able to accumulate product. This functionality is only
intended for entry zones, the first zone in a line of conveyor. Confirm with BAE when converting a zone from another
preset to a constant run functionality that the MDR is sufficient for such applications given the product specifications. The
speed potentiometer is entirely based upon the needs for the system. The rest of the settings are the "typical" placement for
the majority of applications. The Accel and Decel potentiometers can be adjusted per use. The direction of rotation is set
assuming product flow according to the arrow shown. The upstream and downstream communication cables can be
crossed in conjunction with turning DIP switch 2 to "ON" to reverse the direction of the product flow.
9006 Drive Card
5
10
Run, Transport Zone
The card is set to allow the zone to run constantly. This functionality is only intended for transport zones, all excluding the
first zone in a line of conveyor. Confirm with BAE when converting a zone from another preset to a constant run
functionality that the MDR is sufficient for such applications given the product specifications. The speed potentiometer is
entirely based upon the needs for the system. The rest of the settings are the "typical" placement for the majority of
applications. The Accel and Decel potentiometers can be adjusted per use. The direction of rotation is set assuming product
flow according to the arrow shown. The upstream and downstream communication cables can be crossed in conjunction
with turning DIP switch 2 to "ON" to reverse the direction of the product flow.
11
Run, NO Sensor Input
The card is set to allow the zone to constantly run. Confirm with BAE when converting a zone from another preset to a
constant run functionality that the MDR is sufficient for such applications given the product specifications. The speed
potentiometer is entirely based upon the needs for the system. The rest of the settings are the "typical" placement for the
majority of applications. The Accel and Decel potentiometers can be adjusted per use. The direction of rotation is set
assuming product flow according to the arrow shown. The upstream and downstream communication cables can be
crossed in conjunction with turning DIP switch 2 to "ON" to reverse the direction of the product flow.
9006 Drive Card
6
12
Zone Release On Signal
The card is set to allow the zone to act similarly to a zone stop, but the downstream zone is not told when product has been
accepted. With this setup, the zone will only release when given the signal to from the PLC. The speed potentiometer is
entirely based upon the needs for the system. The rest of the settings are the "typical" placement for the majority of
applications. The Accel and Decel potentiometers can be adjusted per use. The direction of rotation is set assuming product
flow according to the arrow shown. The upstream and downstream communication cables can be crossed in conjunction
with turning DIP switch 2 to "ON" to reverse the direction of the product flow.
13
Automatic End Of The Line Zone Dump
The card is set to allow the zone to automatically release the product when it reaches the photoeye. The speed
potentiometer is entirely based upon the needs for the system. The rest of the settings are the "typical" placement for the
majority of applications. The Accel and Decel potentiometers can be adjusted per use. The direction of rotation is set
assuming product flow according to the arrow shown. The upstream and downstream communication cables can be
crossed in conjunction with turning DIP switch 2 to "ON" to reverse the direction of the product flow.
9006 Drive Card
7