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Disable Arrival Timeout
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » Settings Checkboxes » Disable Arrival Timeout
Arrival Jam describes how default zone to zone logic utilizes the Jam Time value for the discharging zone to wait for the accepting zone to indicate successful arrival of the carton into the accepting zone. In certain applications for a given zone, you may want to…
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…
Arrival/Departure Counts
PLC Developers Guide » ZPA Mode Control » PLC Inputs for ZPA Mode » Arrival/Departure Counts
Register Name / Module Address Assembled Address for PLC Description Arrival Count Local Upstream Zone 4:0106 M: 4:1502 E: I.Data [2] P: Byte 4 (Hi) Byte 5 (Lo) Unsigned Integer Value: • Increments by 1 each time a…
Disable Reset Delays
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » Settings Checkboxes » Disable Reset Delays
Any individual zone or group of zones can be configured to ignore the Auto Clear Time delay for either or both of the Arrival Jam and Sensor Jam. Clicking either or both check-boxes will cause the zone’s logic to ignore the Auto Clear Time delay for the…
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…
Disable Sensor Jam Auto Clear
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » Settings Checkboxes » Disable Sensor Jam Auto Clear
Sensor Jam Auto Clear Procedure describes how the logic will make 3 attempts to clear a Sensor Jam if one occurs. There may be instances at specific zones or range of zones where you do not want this functionality to happen. There is a check box that allows you to…
Settings Checkboxes
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » Settings Checkboxes
Both the Upstream and Downstream ZPA Zones have Settings check boxes to allow you to customize some of the ZPA behavior. These settings can apply to only the zone you are connected to and viewing or you can apply the same settings to multiple modules in a range of…
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…
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…
PLC Inputs for ZPA Mode
PLC Developers Guide » ZPA Mode Control » PLC Inputs for ZPA Mode
This Assembly contains the output from the ERSC that is provided as input to the PLC. You can select which area of the assembly to view below. Local Zone Status Arrival/Departure Counts Module Status Tracking and Release Counts Forward and Reverse Tracking Port…
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…
Lane Full Interface
EasyRoll Software » Advanced Dialog » Pin 2 Usage Tab » Lane Full Interface
A special case of the accumulate signal for the most downstream zone is referred to as Lane Full Interface. When Lane Full Interface is used on the most downstream zone; the input signal is treated with a block and clear timer such that when the signal is energized,…
Jam Conditions
Default Settings and Operation » Jam Conditions
There are two (2) types of Jam conditions detected by the ConveyLinx-Ai Family Modules: Sensor Jam Arrival Jam *Both of these Jam conditions utilize a Jam Timer that has to expire in order for the condition to be active. Once either of these jam conditions…
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…
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…
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…
Jam & Auto Clear Timers
EasyRoll Software » Advanced Dialog » Look Ahead and Timing Tab » Jam & Auto Clear Timers
The Jam Timer for a given Upstream or Downstream zone is used for both detecting an Arrival Jam and a Sensor Jam. The Jam Timer should be set as the maximum expected time it takes for a carton to travel from one zone to the next plus a small addition to prevent…
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…
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…
Configuring Dynamic Priority Release
ConveyMerge » Configuring Dynamic Priority Release
In situations where the full status of a given merge line needs to determine merge priority, ConveyMerge provides the ability to monitor the status of one or all merging lines and base the release priority accordingly. EasyRoll provides the option to select a given…
Pin 2 Usage Tab
EasyRoll Software » Advanced Dialog » Pin 2 Usage Tab
Pin 2 on each of the two Sensor port’s M8 connector on the Module is configurable as to its potential function. This pin can function as either an input or an output. The default “out-of-the-box” usage for Pin 2 is “Not Used”. Using the Pin 2 Usage screen…
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…
ConveyMerge Interface
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode » ConveyMerge Interface
Register Name / Module Address Assembled Address for PLC Description ConveyMerge Interface 4:0387 M: 4:1624 E: O.Data [24] P: Byte 48 (Hi) Byte 49 (Lo) ONLY AVAILABLE for FIRMWARE 4.25 and HIGHER Used to…
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: …
Assemblies with Reset Protection
PLC Developers Guide » Assemblies with Reset Protection
For control system applications where the Ethernet I/P PLC needs to take specific action to recover from a loss of communications due to a module that has had its power cycled off and on; there is an additional set of instances implemented that provides 2 new registers…
ZPA Mode Inputs
Connecting to Rockwell PLCs with Ethernet I/P » Using Add On Instructions (AOI) with RSLogix 5000 » AOI Tag Descriptions » ZPA Mode Inputs
Tag Name Data Type Module Register Bit Description I_Arrival_DnZone BOOL 4:0116 AOI Logic Accumulated Arrival Downstream – Only Active When Local Accumulate Bit is Set I_Arrival_UpZone BOOL 4:0196 AOI…
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…
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 Assembly Inputs with Reset Protection
PLC Developers Guide » Assemblies with Reset Protection » ZPA Mode Assembly Inputs with Reset Protection
Module Address Register Name Ethernet I/P Tag Modbus PLC Holding Register 4:0116 Local Status Upstream Zone E: I.Data [0] M: 4:3500 4:0196 Local Status Downstream Zone E: I.Data [1] M: …
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…
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: …
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…
Merge Priority
ConveyMerge » Merge Priority
EasyRoll provides the ability to adjust which of the merging lines receives priority. EasyRoll Priority Selection Description First Come First Served The logic monitors the arrival status in each of the zones that discharge in to the MergeZone.…
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…
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…
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…
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…
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…
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…
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…
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 & 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 =…
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…
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…
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…
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…
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…
ConveyStop Status
PLC Developers Guide » PLC I/O Mode Control » PLC Inputs for PLC I/O Mode » ConveyStop Status
Register Name / Module Address Assembled Address for PLC Description ConveyStop Status Word 4:0019 M: 4:1700 E: I.Data [0] P: Byte 0 (Hi) Byte 1 (Lo) Bitwise Value – Read Only: bit 00 – 04 Reserved …
Sensor Ports
PLC Developers Guide » PLC I/O Mode Control » PLC Inputs for PLC I/O Mode » Sensor Ports
Register Name / Module Address Assembled Address for PLC Description Sensor Port Inputs 4:0035 M: 4:1701 E: I.Data [1] P: Byte 2 (Hi) Byte 3 (Lo) Bitwise Value – Read Only bit 00 = Left Sensor Port – Aux…
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…
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 =…
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…
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…
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…
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…
Set Local Tracking
PLC Developers Guide » ZPA Mode Control » PLC Outputs for ZPA Mode » Set Local Tracking
Register Name / Module Address Assembled Address for PLC Description Set Local Upstream Zone Tracking Word 1 4:0132 M: 4:1600 E: O.Data [0] P: Byte 0 (Hi) Byte 1 (Lo) Write value for 16-bit integer tracking data word #1 for…
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…
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…
Set Status & Tracking
PLC Developers Guide » PLC I/O Mode Control » PLC Outputs for PLC I/O Mode » Set Status & Tracking
Register Name / Module Address Assembled Address for PLC Description Set Status to Downstream Module 4:0196 M: 4:1817 E: O.Data [17] P: Byte 34 (Hi) Byte 35 (Lo) Used to write this module’s ZPA Status to its…
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…
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…
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…
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…
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…
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…
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…
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…
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…
Set Sensor Port Input Mask
PLC Developers Guide » PLC I/O Mode Control » PLC Outputs for PLC I/O Mode » Set Sensor Port Input Mask
Register Name / Module Address Assembled Address for PLC Description Sensor Port Input Signal Condition Mask 4:0034 M: 4:1819 E: O.Data [19] P: Byte 38 (Hi) Byte 39 (Lo) Bitwise Value: bit 00 = Left Sensor Port…
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…
Selecting Your Connection Method based upon Assembly
Connecting to Rockwell PLCs with Ethernet I/P » Selecting Your Connection Method based upon Assembly
As described in the PLC Developer’s Guide section, the data that you exchange with your PLC and a given ConveyLinx-Ai Family Modules depends on the mode of the module and how you want to use it. The I/O data to be exchanged are arranged in register Assemblies and…
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…
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…
Configuring Action for Loss of Communication
PLC Developers Guide » PLC I/O Mode Control » Configuring Action for Loss of Communication
When changing the mode of a given ConveyLinx-Ai Family Modules to PLC I/O mode in EasyRoll, you are given the option to select the behavior of the ConveyLinx-Ai Family Modules’s outputs upon loss of communications with the PLC. Select “Don’t Change” if…
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
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…
Ethernet I/P Assembly Instance Structure
PLC Developers Guide » Understanding Assemblies » Ethernet I/P Assembly Instance Structure
When an ConveyLinx-Ai Family Modules is attached to an external Ethernet I/P controller (Logix 5000 based PLC), it is done so as a Generic Ethernet I/O device or by installing EDS file(s) provided by Pulseroller. *For purposes of working with assemblies, we will be…
AOI Tag Descriptions
Connecting to Rockwell PLCs with Ethernet I/P » Using Add On Instructions (AOI) with RSLogix 5000 » AOI Tag Descriptions
The following links take you to the listings for each tag made available in the both the ERSC-ZPA AOI and the PLC I/O AOI. ZPA Mode Inputs ZPA Mode Outputs PLC I/O Inputs PLC I/O Outputs
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…
Network Services Tab
EasyRoll Software » Advanced Dialog » Network Services Tab
The Network Services screen provides multiple functions related to module and network management. These functions are: Discover and IP Address Set Backup and Restore Firmware Upgrade
Assembly Register Chart Legend
PLC Developers Guide » Understanding Assemblies » Assembly Register Chart Legend
All of the Assemblies are organized in charts that show: The Name of the register and its Module Address The Assembled Address for Modbus TCP, Ethernet IP, and Profinet Description of the register’s usage The Assembled Addresses are shown in specific…
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…
Identifying Module Components
Module Hardware » Identifying Module Components
The ConveyLinx-Ai Family of controllers have very similar module components, but there are small differences between the different models, so each module has its own page for component…
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 …
How to use Assemblies with Reset Protection
PLC Developers Guide » Assemblies with Reset Protection » How to use Assemblies with Reset Protection
When the PLC determines that it has a valid connection to the ConveyLinx-Ai Family Modules in question and is ready for it to respond to output data being written by the PLC: Your PLC program needs to move the value in the Current Module Reset Counter register into…
Advanced Dialog
EasyRoll Software » Advanced Dialog
The Advanced Dialog is where you can make further changes to module operation and access utilities to help maintain your system of modules. To invoke the ConveyLinx Advanced Dialog you can do any of the following: Click Advanced Dialog button Press…
Inverting the Pin 2 Signals
EasyRoll Software » Advanced Dialog » Pin 2 Usage Tab » Inverting the Pin 2 Signals
On this dialog, you can also invert the meaning of the electrical signal by checking the Invert box for either or both Pins. In this example, because we have the Invert box checked for both Pin signals, their respective functions will be activated when their…
Procedure for Connecting using Generic Ethernet Module
Connecting to Rockwell PLCs with Ethernet I/P » Procedure for Connecting using Generic Ethernet Module
All assembly pairs can be connected to a single ConveyLinx-Ai Family Modules using the same procedure within RSLogix 5000 environment: Create a New Module in your Ethernet Tree Select Generic Ethernet Module from the list of devices Enter name and I.P.…
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…
Modbus Assembly Instance Structure
PLC Developers Guide » Understanding Assemblies » Modbus Assembly Instance Structure
Each ConveyLinx-Ai Family Modules utilizes Modbus register architecture for remote data access over Ethernet. Modbus TCP is a simple protocol for data exchange based upon a query/response mechanism. Each ConveyLinx-Ai Family Modules’s memory structure contains a…
Device Connections to Modules
Auto-Configuration » Device Connections to Modules
Before the Auto-Configuration Procedure can be performed; each individual ConveyLinx-Ai Family Modules needs to have its associated MDR’s and photo-sensors connected in the proper way for expected operational results. In general, each ConveyLinx-Ai Family Modules…
Merge Configurations
ConveyMerge » Merge Configurations
The Merge Configurations available from within in EasyRoll are: Left Line Only with either Conventional (spur discharge) or T-Merge (90˚ discharge) Right Line Only with either Conventional (spur discharge) or T-Merge (90˚ discharge) Both Left and Right Lines…
Connecting to Rockwell PLCs with Ethernet I/P
Connecting to Rockwell PLCs with Ethernet I/P
This manual will provide instructions on how to connect your Rockwell Ethernet I/P capable PLC to a network of ConveyLinx modules. There are three basic methods for connecting ConveyLinx to Rockwell PLCs: Use Generic Ethernet Device Import EDS and optionally…
Upstream Accept Interface
PLC Developers Guide » ZPA Mode Control » ZPA Examples » Upstream Accept Interface
This example describes how to use a PLC to control the “wake-up” and passing of tracking data to the most upstream zone of a ConveyLinx controlled conveyor For this example, the PLC must establish a connection with Module A. When PLC is ready to transfer a…
Profinet IO Assembly Instance Structrure
PLC Developers Guide » Understanding Assemblies » Profinet IO Assembly Instance Structrure
Prior to connecting any modules to a Profinet IO capable (Siemens) PLC, a GSDXML configuration file needs to be installed in your PLC programming software (i.e. STEP 7 or TIA Portal). The GSDXML file contains, among other things, the definition of memory size required…
Enabling ConveyMerge from EasyRoll
ConveyMerge » Enabling ConveyMerge from EasyRoll
• Open EasyRoll • Connect and navigate to the ConveyLinx-Ai Family Modules that will control the Merge Zone. • Press CTRL+SHIFT+M to open the ConveyMerge Configuration Screen Item Description Navigation Buttons for Node…
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.),…
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…
Network Architecture
ConveyMerge » Network Architecture
All lines (Center, Left, and Right) must be on separate subnets of modules, as shown. Each subnet should be Auto-Configured separately and then connected together with an Ethernet switch. Keep in mind that the separate subnets will have to be able to communicate with…