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Accumulation Control
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode » Accumulation Control
Register Name / Module Address Assembled Address for PLC Description Accumulation Control for Local Upstream Zone 4:0104 M: 4:1604 E: O.Data [4] P: Byte 8 (Hi) Byte 9 (Lo) Bitwise Values: bit 00 = Set/Clear…
Speed Control
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode » Speed Control
Register Name / Module Address Assembled Address for PLC Description Set Left Motor Speed 4:0040 M: 4:1606 E: O.Data [6] P: Byte 12 (Hi) Byte 13 (Lo) Value in mm/sec for MDR or RPM x 10 for PGD: Range: Depends upon…
Left Motor Control
PLC Developers Guide » PLC I/O Mode Control » PLC Outputs for PLC I/O Mode » Left Motor Control
Register Name / Module Address Assembled Address for PLC Description Left Motor Run / Reverse 4:0260 M: 4:1804 E: O.Data [4] P: Byte 8 (Hi) Byte 9 (Lo) Bit 0: 1 = Run Command 0 = Stop Command Bit 8: 0 =…
Right Motor Control
PLC Developers Guide » PLC I/O Mode Control » PLC Outputs for PLC I/O Mode » Right Motor Control
Register Name / Module Address Assembled Address for PLC Description Right Motor Run / Reverse 4:0270 M: 4:1807 E: O.Data [7] P: Byte 14 (Hi) Byte 15 (Lo) Bit 0: 1 = Run Command 0 = Stop Command Bit 8: 0…
Direction and Accumulation Mode
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode » Direction and Accumulation Mode
Register Name / Module Address Assembled Address for PLC Description Direction & Accumulation Mode Control for Local Upstream Zone 4:0365 M: 4:1622 E: O.Data [22] P: Byte 44 (Hi) Byte 45 (Lo) Used to change direction of flow…
Speed
EasyRoll Software » Main Screen » Motor Settings » Speed
The Speed setting value is in meters per second (m/s). The Senergy-Ai motor roller contains data as to its gear reduction ratio and roller diameter that is readable by the ConveyLinx-Ai Family Modules. EasyRoll then uses this information to indicate whether the speed…
Motor & Control Port Digital Output
PLC Developers Guide » PLC I/O Mode Control » PLC Outputs for PLC I/O Mode » Motor & Control Port Digital Output
Register Name / Module Address Assembled Address for PLC Description Set Left Motor Port Digital Control 4:0060 M: 4:1801 E: O.Data [1] P: Byte 2 (Hi) Byte 3 (Lo) Bitwise values bit 00 = Reserved bit 01 =…
Motor and Logic Power
Module Hardware » Motor and Logic Power
Regardless of the specific ConveyLinx-Ai Family Modules, each is equipped with the ability to separate the Motor power from the Logic power. Connecting only Motor Power *Connecting only to Motor Power will provide power to both the motor circuits and the logic…
Motor Jog and Error Indicators
EasyRoll Software » Main Screen » Motor Settings » Motor Jog and Error Indicators
Motor Jog (Run) Function In EasyRoll, the Left and Right motors have their own Run buttons on the Main Screen. These are used to temporarily run the motors for verification of function and diagnostics. Click the Run icon to turn on the motor* …
Set Outputs and Motor Clear
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode » Set Outputs and Motor Clear
Register Name / Module Address Assembled Address for PLC Description Clear Motor Error 4:0022 M: 4:1616 E: O.Data [16] P: Byte 32 (Hi) Byte 33 (Lo) Logical 1 or 0: 1 = send reset command 0 = clear reset…
Motor Ports
Module Hardware » Motor Ports
Both ports utilize a 4-pin M8 male receptacle. Each receptacle is mechanically keyed to assure proper orientation upon plugging in. M8 4 Pin Male Motor Port with Senergy Ai Motor Female Connector
Motor Settings
EasyRoll Software » Main Screen » Motor Settings
The motor settings for the current selected module can be modified on the Main Screen *Please note that the Motor Settings grouped by motor plugged into the physical Left and Right sides of the module and are not based upon Upstream or Downstream product…
Motor Type
EasyRoll Software » Main Screen » Motor Settings » Motor Type
The Motor Type pull-down box lists all motor brand and types whose profiles are available for the module. Senergy-Ai ECO is the default setting upon completion of the Auto-Configuration Procedure. The new settings are downloaded to the selected Node upon selecting a…
Right Motor Status
PLC Developers Guide » PLC I/O Mode Control » PLC Inputs for PLC I/O Mode » Right Motor Status
Register Name / Module Address Assembled Address for PLC Description Right Motor Current 4:0079 M: 4:1708 E: I.Data [8] P: Byte 16 (Hi) Byte 17 (Lo) Integer Value in mA for the current the motor is drawing Example: 1900…
Motor Rotation Definition
Auto-Configuration » Motor Rotation Definition
The ConveyLinx-Ai Family Modules uses a Clock-Wise (CW) and Counter Clock-Wise (CCW) motor rotation definition. The reference for this distinction is based upon viewing the MDR from the cable exit end of the roller. Motor Rotation Definition *Auto Configuration…
Left Motor Status
PLC Developers Guide » PLC I/O Mode Control » PLC Inputs for PLC I/O Mode » Left Motor Status
Register Name / Module Address Assembled Address for PLC Description Left Motor Current 4:0055 M: 4:1704 E: I.Data [4] P: Byte 8 (Hi) Byte 9 (Lo) Integer Value in mA for the current the motor is drawing Example: 1900 =…
Motor Ports Digital Status
PLC Developers Guide » PLC I/O Mode Control » PLC Inputs for PLC I/O Mode » Motor Ports Digital Status
Register Name / Module Address Assembled Address for PLC Description Left Motor Port Digital I/O Status 4:0060 M: 4:1712 E: I.Data [12] P: Byte 24 (Hi) Byte 25 (Lo) Bitwise Value – Read Only: bit 12 = Short Circuit…
Servo Control
PLC Developers Guide » PLC I/O Mode Control » PLC Outputs for PLC I/O Mode » Servo Control
Register Name / Module Address Assembled Address for PLC Description Left Motor Servo Command Word 4:0009 M: 4:1824 E: O.Data [24] P: Byte 48 (Hi) Byte 49 (Lo) Bit 0: Reset Command 1 = Set Current Pulse Count to…
Setting Up Dual Motor Zones
Setting Up Dual Motor Zones
This section describes how to set up conveyor zones with two motor rollers in scenarios involving ZPA Mode, PLC I/O Mode, and ConveyLogix program control. The details of the set up are also governed by the mechanical construction of the conveyor zone. Solution Matrix…
Servo Control Status
PLC Developers Guide » PLC I/O Mode Control » PLC Inputs for PLC I/O Mode » Servo Control Status
Register Name / Module Address Assembled Address for PLC Description Left Motor Servo Position 4:0062 M: 4:1719 E: I.Data [19] P: Byte 38 (Hi) Byte 39 (Lo) Signed integer value that indicates the current position of the Left…
ZPA Mode Control
PLC Developers Guide » ZPA Mode Control
When an ConveyLinx-Ai Family Modules is in its default ZPA mode, an external networked PLC or PC controller can connect to the ConveyLinx-Ai Family Modules and perform the following: Instruct either or both the upstream and downstream zone to accumulate the next…
Servo Control Example
PLC Developers Guide » PLC I/O Mode Control » PLC Outputs for PLC I/O Mode » Servo Control » Servo Control Example
For our example, we want to perform the following cycle using PLC control of the Left MDR on an ConveyLinx-Ai Family Modules: Establish a zero or home position by external input to the module form a PLC (sensor or operator button) Rotate in the CCW direction for…
ConveyStop Command & Clear Motor Error
PLC Developers Guide » PLC I/O Mode Control » PLC Outputs for PLC I/O Mode » ConveyStop Command & Clear Motor Error
Register Name / Module Address Assembled Address for PLC Description ConveyStop Command Word 4:0020 M: 4:1800 E: O.Data [0] P: Byte 0 (Hi) Byte 1 (Lo) Integer Value 0= No Command 1 = Command local module’s Stop Group…
Motor Port as Digital I/O
PLC Developers Guide » Motor Port as Digital I/O
!Motor port as digital I/O is only applicable for a ConveyLinx-Ai Family Modules in PLC I/O Mode Each motor port can provide 1 or 2 independently controlled digital outputs and each of these outputs can be energized simultaneously for a total of 4 outputs available…
Accumulate Control from Main Screen
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » Accumulate Control from Main Screen
Clicking the Accumulate switch icon will place the zone in accumulation mode and the next carton that arrives at that zone will stop and remain until you click the switch again to turn off the accumulation mode Clicking the icon will initiate the Accumulate…
PLC I/O Mode Control
PLC Developers Guide » PLC I/O Mode Control
When an ConveyLinx-Ai Family Modules is in PLC I/O mode, all automatic functions of detecting loads and running motors are suspended by the local ConveyLinx-Ai Family Modules’s on-board logic and the external controller must explicitly read inputs and write data…
Two Motor Rollers in One Logical Zone Not Coupled
Setting Up Dual Motor Zones » Two Motor Rollers in One Logical Zone Not Coupled
In this mechanical scenario, the motor rollers are not coupled together as shown. ZPA Mode In ZPA Mode with this mechanical configuration, it will not work properly because the module will never monitor and adjust the Slave Motor’s speed. Because they are…
Release and Status
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode » Release and Status
Register Name / Module Address Assembled Address for PLC Description Release and Accumulate on Next Arrival for Local Upstream Zone 4:0105 M: 4:1608 E: O.Data [8] P: Byte 16 (Hi) Byte 17 (Lo) When bit 0 of Accumulation…
Default Settings and Operation
Default Settings and Operation
After Auto-Configuration, the modules on your newly configured network are in ZPA mode and set to Singluation Release. If all module and/or Network Status LED’s are blinking green; then to fully verify configuration is to place a single carton onto the most upstream…
ZPA Error and Information
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » ZPA Error and Information
There is an Error and Information area in the upper right corner in both the Upstream and Downstream Zone areas of the Main Screen. There is an indicator that shows if a Jam condition is active (either Arrival Jam or Sensor Jam). There is a numerical indicator of all…
ConveyMerge Prerequisites and Requirements
ConveyMerge » ConveyMerge Prerequisites and Requirements
Please Note – ConveyMerge works for ALL ConveyLinx Family Modules Module Firmware ConveyLinx-ERSC 4.25 and later ConveyLinx-HTF 4.25 and later ConveyLinx-Ai2 4.20 and later ConveyLinx-Ai3-24-xx 4.20 and…
Tracking and Release Counts
PLC Developers Guide » ZPA Mode Control » PLC Inputs for ZPA Mode » Tracking and Release Counts
Register Name / Module Address Assembled Address for PLC Description Current Upstream Zone Tracking Word 1 4:0119 M: 4:1508 E: I.Data [8] P: Byte 16 (Hi) Byte 17 (Lo) When Carton is accumulated in UPSTREAM…
Forward and Reverse Tracking
PLC Developers Guide » ZPA Mode Control » PLC Inputs for ZPA Mode » Forward and Reverse Tracking
Register Name / Module Address Assembled Address for PLC Description Get Tracking Forward Direction Word 1 4:0201 M: 4:1514 E: I.Data [14] P: Byte 28 (Hi) Byte 29 (Lo) When ERSC is discharging to Non-ConveyLinx controlled…
ConveyStop and Clear Jams
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode » ConveyStop and Clear Jams
Register Name / Module Address Assembled Address for PLC Description ConveyStop Command Word 4:0020 M: 4:1619 E: O.Data [19] P: Byte 38 (Hi) Byte 39 (Lo) Integer Value: 0 = No Command 1 = Command local…
Look Ahead and Timing Tab
EasyRoll Software » Advanced Dialog » Look Ahead and Timing Tab
The Look Ahead and Timing Tab contains 4 sections of settings pertaining to ZPA functionality: Look Ahead Jam & Auto Clear Timers Run After & Induct Sensor Debounce
Port Inputs and ConveyStop Status
PLC Developers Guide » ZPA Mode Control » PLC Inputs for ZPA Mode » Port Inputs and ConveyStop Status
Register Name / Module Address Assembled Address for PLC Description Sensor & Control Port Inputs 4:0035 M: 4:1518 E: I.Data [18] P: Byte 36 (Hi) Byte 37 (Lo) Bitwise Value – Read Only: bit 0 = Left Sensor Port…
Induct Tracking Forward and Reverse
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode » Induct Tracking Forward and Reverse
Register Name / Module Address Assembled Address for PLC Description Set Induct Tracking Forward Direction Word 1 4:0139 M: 4:1612 E: O.Data [12] P: Byte 24 (Hi) Byte 25 (Lo) Only used when local module is accepting loads…
Merge onto ZPA Main Line
PLC Developers Guide » ZPA Mode Control » ZPA Examples » Merge onto ZPA Main Line
This example shows how to perform a simple merge with only a single module connection to the PLC. In this example the PLC only needs to connect to Module C and from this connection, the PLC can monitor conditions on Module A as well as “wake-up” Module C / Module…
Basic Accumulate and Release with Tracking Data
PLC Developers Guide » ZPA Mode Control » ZPA Examples » Basic Accumulate and Release with Tracking Data
Here is a typical arrangement of an upstream or downstream zone on an ConveyLinx-Ai Family Modules in ZPA mode that is not the most upstream or most downstream zone in a given network. This example will show how to cause a Carton to accumulate, how to detect a Carton…
Simple Divert Example
PLC Developers Guide » ZPA Mode Control » ZPA Examples » Simple Divert Example
This example shows how to use a PLC to control a simple divert mechanism to divert a Carton from a ZPA zone and capture its tracking. This example also illustrates how to use the set downstream arrival function with the PLC to keep the discharging module from…
Downstream Discharge Interface
PLC Developers Guide » ZPA Mode Control » ZPA Examples » Downstream Discharge Interface
This example shows how to control the discharge of a Carton from the most downstream zone of a ConveyLinx controlled conveyor. This example also shows how to properly accept the tracking data from the ConveyLinx module. For this example, the PLC must establish a…
PLC Outputs for ZPA Mode
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode
This Assembly contains the output from the PLC that is provided as input to the ERSC. You can select which area of the assembly to view below. Set Local Tracking Accumulation Control Speed Control Release and Status Induct Tracking Forward and Reverse Set Outputs and…
Reduced Size ZPA Mode Assemblies
PLC Developers Guide » ZPA Mode Control » Reduced Size ZPA Mode Assemblies
For some PLC controllers, the data size footprint required for a given assembly can be a limiting factor on how many devices can connect to a given controller. ConveyLinx includes input/output assemblies with fewer registers that contain basic functions in…
Glossary of Terms
Glossary of Terms
Term Definition Carton A separate (usually wrapped or boxed) object to be transported by the conveyor. The terms tray, tote, load, or product may also be used interchangeably in this document. ConveyLinx Conveyor controls architecture…
ZPA Mode Assembly Outputs with Reset Protection
PLC Developers Guide » Assemblies with Reset Protection » ZPA Mode Assembly Outputs with Reset Protection
Module Address Register Name Ethernet I/P Tag Modbus PLC Holding Register 4:0132 Set Local Upstream Zone Tracking Word 1 E: I.Data [0] M: 4:3600 4:0133 Set Local Upstream Zone Tracking Word 2 E: I.Data [1] M: …
PLC I/O Mode
Setting Up Dual Motor Zones » Two Ai MDRs Mechanically Coupled » PLC I/O Mode
In PLC I/O mode there is no ZPA logic operating in the module, so the motors are independently controlled by default when the module is placed in PLC I/O mode. With a remote PLC you can connect to the PLC I/O Assemblies and configure either the Left or the Right motor…
Reduced Size PLC I/O Mode Assemblies
PLC Developers Guide » PLC I/O Mode Control » Reduced Size PLC I/O Mode Assemblies
For some PLC controllers, the data size footprint required for a given assembly can be a limiting factor on how many devices can connect to a given controller. ConveyLinx includes input/output assemblies with fewer registers that contain basic functions in…
Reduced Size ZPA Mode Assemblies with Reset Protection
PLC Developers Guide » Assemblies with Reset Protection » Reduced Size ZPA Mode Assemblies with Reset Protection
Inputs to PLC Module Address Register Name Ethernet I/P Tag Modbus PLC Holding Register 4:0116 Local Status Upstream Zone E: I.Data [0] M: 4:4900 4:0196 Local Status Downstream Zone E: I.Data [1] M: …
PLC I/O Mode Assembly Outputs with Reset Protection
PLC Developers Guide » Assemblies with Reset Protection » PLC I/O Mode Assembly Outputs with Reset Protection
Module Address Register Name Ethernet I/P Tag Modbus PLC Holding Register 4:0020 ConveyStop Command E: O.Data [0] M: 4:3800 4:0060 Set Left Motor Port Digital Control E: O.Data [1] M: …
Reduced Size PLC I/O Mode Assemblies with Reset Protection
PLC Developers Guide » Assemblies with Reset Protection » Reduced Size PLC I/O Mode Assemblies with Reset Protection
Inputs to PLC Module Address Register Name Ethernet I/P Tag Modbus PLC Holding Register 4:0035 Sensor & Control Port Inputs E: I.Data [0] M: 4:4700 4:0036 Sensor Detect E: I.Data [1] M: …
PLC Inputs for PLC I/O Mode
PLC Developers Guide » PLC I/O Mode Control » PLC Inputs for PLC I/O Mode
These Topics show the data coming from the ConveyLinx-Ai Family Modules and provided as input to the PLC: ConveyStop Status Sensor & Control Ports Left Motor Status Right Motor Status Motor Ports Digital Status Upstream / Downstream Status & Tracking Servo Control…
Power Supply Sizing
Module Hardware » Power Supply Sizing
The current loading on the power supply for a group of ConveyLinx-Ai Family Moduless depends upon the Motor Type selected. Each of the motor types available has an associated rated current that the motor will draw at rated torque and maximum speed. Each Motor Type also…
ConveyLogix Program
Setting Up Dual Motor Zones » Two Ai MDRs Mechanically Coupled » ConveyLogix Program
Similar to PLC I/O Mode example, you populate either the Left Motor Slave Mode (4:0262) register or the Right Motor Slave Mode (4:0272) register according to the desired control. It is recommended you use the FirstLadderExec controller tag Boolean in a rung that…
Acceleration/Deceleration
EasyRoll Software » Main Screen » Motor Settings » Acceleration/Deceleration
Acceleration and Deceleration settings are fields you enter values similar to Speed. The units of the value you enter are in mm which means that the control will accelerate and decelerate for the distance specified within the controller’s current limits and the…
Write MSG Instruction
Connecting to Rockwell PLCs with Ethernet I/P » Using Logix 5000 MSG Instruction » Write MSG Instruction
For this example, we have created a ConveyLinx-Ai Family Modules in our Ethernet Tree and added a MSG Instruction to a ladder rung. We named this MSG block “WriteSpeed” and created the Controller Tag for it. With this MSG Instruction we are going to write…
Module Status
PLC Developers Guide » ZPA Mode Control » PLC Inputs for ZPA Mode » Module Status
Register Name / Module Address Assembled Address for PLC Description Module Status Word 1 4:0088 M: 4:1506 E: I.Data [6] P: Byte 12 (Hi) Byte 13 (Lo) Bitwise Value – Read Only bit 0 = Module Reset Flag – 1…
PLC Developers Guide
PLC Developers Guide
This section defines the data connectivity available between ConveyLinx-Ai Family Moduless and remote control devices such as PLCs and PCs Click Links to Learn More Network Architecture Understanding Assemblies ZPA Mode Control PLC I/O Mode Control ConveyLogix…
Getting Started
Getting Started
Purpose of this Manual The purpose of this manual is to: Identify the components and ports available on a module Provide guidelines for proper installation and wiring Provide examples on basic inter-module connections for linear conveyor Introduce the EasyRoll…
Two Ai Motors in One Roller Tube (Dual Drive)
Setting Up Dual Motor Zones » Two Ai Motors in One Roller Tube (Dual Drive)
Some Pulseroller-Ai models are available with two motors in one tube as shown. ZPA Mode This mechanical configuration is not supported with Ai-Family controls. !Attempting to use a Dual Drive MDR in ZPA Mode with a Ai-Family controller could result in damage to…
Technical Specifications
Module Hardware » Technical Specifications
*Unless otherwise stated, all specification data is identical for ConveyLinx-Ai2, ConveyLinx-Ai3-24-FC, and ConveyLInx-Ai3-24-RC Power Connection ConveyLinx-Ai2 Power connector is Degson DG245-5.0, 12 AWG (4.0 mm 2) Max wire size, 5-6 mm strip length …
Diagnostic Window
EasyRoll Software » Main Screen » Diagnostic Window
Diagnostic Window Example Indicator Description You can navigate to the next or previous module’s Diagnostic Window by clicking the + and – buttons Displays the current ZPA status of the zone and the state of the…
T-Zone Settings
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » T-Zone Settings
In conveyor applications, transferring a carton at a right angle from one conveyor to another often requires special lifting and lowering mechanisms. In certain applications, one conveyor can simply drive its carton off of its downstream zone directly onto the…
Module Hardware
Module Hardware
ConveyLinx-Ai Family Moduless are designed to be installed and integrated into the conveyor’s mechanical side frame assembly. The ConveyLinx-Ai Family Modules is a controller for up to 2 Motorized Drive Roller (MDR) conveyor zones. Each ConveyLinx-Ai Family Modules…
Flex Zone Recognition
Default Settings and Operation » Flex Zone Recognition
ConveyLinx-Ai Family Moduless will automatically detect that a given carton is longer than one zone length and automatically adjust accumulation control so that the longer carton occupies two logical zones and will keep the next upstream carton from conveying into the…
Flex Zone Tab
EasyRoll Software » Advanced Dialog » Flex Zone Tab
The Flex Zone feature is enabled by default when you perform the Auto Configure Procedure. There can be certain situations such as higher speed applications and/or applications where a large percentage of cartons are at a length very close to the zone length where a…
LED Status Indicators
Module Hardware » LED Status Indicators
ConveyLinx-Ai Family Modules status is indicated by several LED’s. All LED’s with the exception of the Ethernet Link and Activity LEDs are multi-colored and context sensitive. The following sections indicate the various meanings of all LED indicators. *By…
Local Zone Status
PLC Developers Guide » ZPA Mode Control » PLC Inputs for ZPA Mode » Local Zone Status
Register Name / Module Address Assembled Address for PLC Description Local Status Upstream Zone Forward Direction 4:0116 M: 4:1500 (Lo Byte) E: I.Data [0] (Lo Byte) P: Byte 1 Unsigned Value of Byte: 0×01 = Zone sensor…
PLC I/O Mode Inputs
Connecting to Rockwell PLCs with Ethernet I/P » Using Add On Instructions (AOI) with RSLogix 5000 » AOI Tag Descriptions » PLC I/O Mode Inputs
Tag Name Data Type Module Register Bit Description I_ConveyStopByLostConnection BOOL 4:0019 6 Stop active due to lost communication connection I_ConveyStopByPLCCmd BOOL 4:0019 10 Stop active due to Stop…
ConveyLinx-Ai3-24-FC
Module Hardware » Identifying Module Components » ConveyLinx-Ai3-24-FC
Item Description Mounting Bracket with FC cable routing channels & Motor Left LED & Motor Right LED – Motor status indicators & Left Sensor & Right Sensor Status LED Indicators Module Status LED…
ConveyLinx-Ai3-24-RC
Module Hardware » Identifying Module Components » ConveyLinx-Ai3-24-RC
Item Description Mounting Bracket with RC wire routing channels & Motor Left LED & Motor Right LED – Motor status indicators & Left Sensor & Right Sensor Status LED Indicators Module Status LED…
ConveyLinx-Ai2
Module Hardware » Identifying Module Components » ConveyLinx-Ai2
Item Description 24VDC Power Terminals with separate connections for Logic and Motors & Motor Left LED & Motor Right LED – Motor status indicators & Left Sensor & Right Sensor Status LED…
ZPA Mode
Setting Up Dual Motor Zones » Two Ai MDRs Mechanically Coupled » ZPA Mode
In general, when you perform an Auto-Configure procedure, ConveyLinx-Ai2 modules will configure in ZPA mode. If one sensor is connected (either Left or Right) and two motors are connected, the module is automatically configured as a single logical zone and will run…
PLC I/O Mode Outputs
Connecting to Rockwell PLCs with Ethernet I/P » Using Add On Instructions (AOI) with RSLogix 5000 » AOI Tag Descriptions » PLC I/O Mode Outputs
Tag Name Data Type Module Register Bit Description O_Clear_Motor_Error BOOL 4:0022 0 Clear Motor Error Left & Right O_ConveyStop_Command INT 4:0020 - Set Local ConveyStop Command …
About This Manual
About This Manual
Products Covered in this Manual ConveyLinx-Ai2 – All Article Numbers 3022-xxxx ConveyLinx-Ai3-24-FC – Article Number 3023-0001 ConveyLinx-Ai3-24-RC – Article Number 3023-0002 Symbol Conventions !This symbol indicates that special…
Sensor Jam
Default Settings and Operation » Jam Conditions » Sensor Jam
While a zone is releasing a carton; if this carton remains blocking the photo-sensor for the Jam Timer period (default of 5 seconds), the ConveyLinx-Ai Family Modules will detect a Sensor Jam. This will be indicated on the corresponding Sensor LED on the module as…
ZPA Mode Outputs
Connecting to Rockwell PLCs with Ethernet I/P » Using Add On Instructions (AOI) with RSLogix 5000 » AOI Tag Descriptions » ZPA Mode Outputs
Tag Name Data Type Module Register Bit Description O_Acc_Adj_UpStr_to_DnZn BOOL 4:0184 8 Accumulate Adlacent Upstream to Local Upstream Zone O_Acc_Adj_UpStr_to_UpZn BOOL 4:0104 8 Accumulate Adlacent…
Module Power Connections
Module Hardware » Module Power Connections
At a minimum, for any of the ConveyLinx-Ai Family Moduless, you must supply at least the Motor Power connection. The Logic Power connection is optional and used when you want to be able to disconnect motor power and yet maintain module communication…
Reset to Factory Default Settings
Default Settings and Operation » Reset to Factory Default Settings
There may be instances when you want to return a ConveyLinx-Ai Family Modules to its “factory default” state. The procedure to do this is the following: Unplug all sensors, devices, motors, and network cables such that the only thing connected is…
PLC I/O Mode Assembly Inputs with Reset Protection
PLC Developers Guide » Assemblies with Reset Protection » PLC I/O Mode Assembly Inputs with Reset Protection
Module Address Register Name Ethernet I/P Tag Modbus PLC Holding Register 4:0019 ConveyStop Status E: I.Data [0] M: 4:3700 4:0035 Sensor & Control Port Inputs E: I.Data [1] M: 4:3701 4:0036 Sensor…
Special Services Tab
EasyRoll Software » Advanced Dialog » Special Services Tab
Clear Motor Short Circuit Error Another function on the Special Services tab is a button used to clear an MDR short circuit error. This particular error is not logically cleared based upon an elapsed period timeout or other such reset. An MDR short circuit error…
Rotation Direction
EasyRoll Software » Main Screen » Motor Settings » Rotation Direction
This setting is either Clock-Wise (CW) or Counter-Clock Wise (CCW)and is determined for each module based upon the Auto-Configuration Procedure results. Please refer to section Motor Rotation Definition for details on how to determine rotation direction with respect…
Two Ai MDRs Mechanically Coupled
Setting Up Dual Motor Zones » Two Ai MDRs Mechanically Coupled
This scenario is perhaps the most common in that this would be the case for a two-motor roller used in an incline or decline application as shown. Please note that mechanically the two motor rollers can be coupled with just O-bands and with a full width belt. The…
Examples that will generate errors
Auto-Configuration » Device Connections to Modules » Examples that will generate errors
*These examples are not necessarily invalid and will not cause the Auto Configuration procedure to fail or abort, but they will result in module errors in ZPA Mode. This module will configure as a two zone module but will generate a motor connection error for…
ConveyLinx-Ai3-24-FC
Module Hardware » Module Power Connections » ConveyLinx-Ai3-24-FC
AS-I Cable for Powering Both Logic and Motors with One Cable One AS-I Cable Each for Separate Motor and Logic Power
Upstream / Downstream Status & Tracking
PLC Developers Guide » PLC I/O Mode Control » PLC Inputs for PLC I/O Mode » Upstream / Downstream Status & Tracking
Register Name / Module Address Assembled Address for PLC Description Upstream Module Status 4:0134 M: 4:1714 E: I.Data [14] P: Byte 28 (Hi) Byte 29 (Lo) Interger Value of Low or High Byte: 0×01 = Zone sensor…
Network Architecture
PLC Developers Guide » Network Architecture
Each ConveyLinx-Ai Family Modules communicates to its adjacent modules and to any connected PC or PLC via Ethernet physical media. ConveyLinx-Ai Family Moduless recognize (3) TCP/IP based protocols: Modbus TCP, Profinet I/O, and Ethernet I/P. Modbus TCP is the…
Brake Method
EasyRoll Software » Main Screen » Motor Settings » Brake Method
The Brake Method pull-down box lists all the holding brake methods available for the module. Normal is the default setting upon completion of the Auto-Configuration Procedure. The new settings are downloaded to the selected Node upon selecting a new item from the…
Look Ahead Slowdown Feature
EasyRoll Software » Advanced Dialog » Look Ahead and Timing Tab » Look Ahead Slowdown Feature
The Look Ahead feature configures the logic to “look ahead” to its next downstream zone and if it is occupied when a carton is entering its zone, the module will dynamically adjust the MDR to the selected speed. This feature in intended to be used in higher speed…
T-Merge Settings
ConveyMerge » T-Merge Settings
For a T-Merge, the discharging conveyor is arranged perpendicular to the Merge Zone and this discharging conveyor needs to “throw” the product across the Merge Zone’s rollers. In order to mitigate carton alignment issues, the logic controls need to make sure…
Automatic Module Replacement
Default Settings and Operation » Automatic Module Replacement
Once a linear conveyor has been commissioned by Auto-Configuration Procedure, the ConveyLinx-Ai Family Modules store configuration data about its upstream and downstream neighboring modules. This configuration data is automatically updated even if the linear conveyor…
Backup & Restore
EasyRoll Software » Advanced Dialog » Network Services Tab » Backup & Restore
ou have the ability to select a Subnet or all Subnets discovered and generate a Backup file that will contain all the parameters and settings for each module included in the selection. This means all motor settings (speed, acceleration, deceleration, braking, etc.),…
What to do if things go wrong
Auto-Configuration » What to do if things go wrong
Module Status LEDs Blinking Green with unexpected results Check that all sensors are operational and that all zones are clear then perform procedure again. How to change block/clear sensor logic without having to perform another Auto-Configuration Check…
Disable Manual Operation
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » Settings Checkboxes » Disable Manual Operation
In normal ZPA operation, if a zone is in Accumulation (either by external device or if Aux I/O Pin 2 is set to Accumulate) and the carton is subsequently manually removed from the conveyor; the zone downstream of the accumulated zone will run in an attempt to “find…
Arrival Jam
Default Settings and Operation » Jam Conditions » Arrival Jam
When a carton leaves an upstream zone and is conveyed to its next downstream zone, this upstream zone expects positive confirmation of carton arrival from the downstream zone. This communication occurs automatically along the ConveyLinx network. If a new carton arrives…
Expected Results
Auto-Configuration » Expected Results
When the Auto-Configuration Procedure routine is complete, each ConveyLinx-Ai Family Modules will automatically reboot. When a ConveyLinx-Ai Family Modules has been successfully configured and rebooted, its Module Status LED will blink on and off green. When…
Auto-Configuration
Auto-Configuration
The purpose of Auto-Configuration for networked ConveyLinx controls is to provide a simple and easy procedure for linear conveyor system commissioning. The Auto-Configuration Procedure requires the use of EasyRoll on a PC. Connecting Devices to ConveyLinx-Ai Family…
Proper Grounding Practice
Module Hardware » Motor and Logic Power » Proper Grounding Practice
Whether logic and MDR are powered together or separately; the DC common (“-“) connections on all power supplies should be connected together. One of the power supplies should have its DC common connected to ground. Avoid connecting more than one power supply DC…
Conveyor Setup for Simple Bar Code Reader
PLC Developers Guide » ZPA Mode Control » ZPA Examples » Conveyor Setup for Simple Bar Code Reader
This example shows how to set up the conveyor control to easily singulate cartons through a bar code scanning region In this example, Module B must be logically configured as a single zone. This can be either a single long zone with one MDR and one sensor, or a…
Using Logix 5000 MSG Instruction
Connecting to Rockwell PLCs with Ethernet I/P » Using Logix 5000 MSG Instruction
Access to ConveyLinx-Ai Family Moduless is also available utilizing the Logix 5000 MSG instruction. The MSG instruction utilizes CIP Explicit Messaging. This means that the connection is not maintained as an implicit connection. Generic Ethernet Module and EDS…