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ConveyLinx-Ai Family Complete Guide
3.0
3.0
2.1
2.0
1.7
Table of Contents
ConveyLinx-Ai Family Complete Guide
3.0
ConveyLinx-Ai Family Complete Guide — 3.0
ConveyLinx-Ai Family Complete Guide — 2.1
ConveyLinx-Ai Family Complete Guide — 2.0
ConveyLinx-Ai Family Complete Guide — 1.7
1.
About This Manual
2.
Glossary of Terms
3.
Getting Started
4.
Module Hardware
4.1.
Module Hardware Revisions
4.2.
Identifying Module Components
4.2.1.
ConveyLinx-Ai2 / ConveyLinx-Ai2-48
4.2.2.
ConveyLinx-Ai3-24-FC / ConveyLinx-Ai3-48-FC
4.2.3.
ConveyLinx-Ai3-24-RC
4.3.
Mounting Dimensions
4.3.1.
ConveyLinx-Ai2 / ConveyLinx-Ai2-48
4.3.2.
ConveyLinx-Ai3-24-FC / ConveyLinx-Ai3-48-FC
4.3.3.
ConveyLinx-Ai3-24-RC
4.4.
Module Power Connections
4.4.1.
ConveyLinx-Ai2 / ConveyLinx-Ai2-48
4.4.2.
ConveyLinx-Ai3-24-FC
4.4.3.
ConveyLinx-Ai3-48-FC
4.4.4.
ConveyLinx-Ai3-24-RC
4.4.5.
Assembly Instructions
4.5.
Motor and Logic Power Distribution
4.5.1.
ConveyLinx-Ai2
4.5.2.
ConveyLinx-Ai3-24-FC
4.5.3.
ConveyLinx-Ai3-24-RC
4.5.4.
ConveyLinx-Ai2-48
4.5.5.
ConveyLinx-Ai3-48-FC
4.6.
Proper Motor Grounding Practice
4.7.
Power Supply Sizing
4.7.1.
Motor Power for 24V Models
4.7.2.
Motor Power for 48V Models
4.7.3.
Logic Only Power
4.8.
Motor Ports
4.9.
Sensor Ports
4.9.1.
Electrical Connections for Sensor Port Aux I/O
4.10.
Ethernet Ports
4.11.
LED Status Indicators
4.12.
Technical Specifications
5.
Auto-Configuration
5.1.
Device Connections to Modules
5.1.1.
Examples that will generate errors
5.2.
Motor Rotation Definition
5.3.
Node Connections for a Subnet
5.4.
ConveyLinx Ethernet Definition
5.5.
Connecting Your PC to the Network
5.6.
Auto-Configuration Procedure
5.7.
Expected Results
5.8.
What to do if things go wrong
6.
Default Settings and Operation
6.1.
Singulation Release Mode
6.2.
Flex Zone Recognition
6.3.
Jam Conditions
6.3.1.
Arrival Jam
6.3.2.
Sensor Jam
6.4.
Automatic Module Replacement
6.5.
Reset to Factory Default Settings
7.
EasyRoll Software
7.1.
Installing EasyRoll
7.2.
Main Screen
7.2.1.
Node Navigation
7.2.2.
Node Identification
7.2.3.
ZPA Upstream/Downstream Zone Settings
7.2.3.1.
Release Mode
7.2.3.1.1.
Singulation Release
7.2.3.1.2.
Train Release
7.2.3.1.3.
GAP Train Release
7.2.3.2.
T-Zone Settings
7.2.3.3.
ZPA Error and Information
7.2.3.4.
Accumulate Control from Main Screen
7.2.3.5.
Settings Checkboxes
7.2.3.5.1.
Disable Reset Delays
7.2.3.5.2.
Disable Sensor Jam Auto Clear
7.2.3.5.3.
Disable Arrival Timeout
7.2.3.5.4.
Disable Manual Operation
7.2.4.
Motor Settings
7.2.4.1.
Motor Type
7.2.4.2.
Brake Method
7.2.4.3.
Speed
7.2.4.4.
Rotation Direction
7.2.4.5.
Acceleration/Deceleration
7.2.4.6.
Motor Jog and Error Indicators
7.2.4.7.
PGD Motor Pulse Distance Calculation
7.2.5.
Diagnostic Window
7.3.
Advanced Dialog
7.3.1.
Look Ahead and Timing Tab
7.3.1.1.
Look Ahead Slowdown Feature
7.3.1.2.
Jam & Auto Clear Timers
7.3.1.3.
Run After Time/Distance
7.3.1.4.
Induct Forward Time/Distance
7.3.1.5.
Sensor Debounce
7.3.2.
Upgrade Tab
7.3.3.
Connections Tab
7.3.4.
Network Services Tab
7.3.4.1.
Discover & IP Address Set
7.3.4.2.
Backup & Restore
7.3.5.
Special Services Tab
7.3.6.
Flex Zone Tab
7.3.7.
Sensors Tab
7.3.8.
Extensions Tab
7.3.9.
Pin 2 Usage Tab
7.3.9.1.
Most Downstream Zone
7.3.9.2.
Most Upstream Zone
7.3.9.3.
Accumulate Intermediate Zone
7.3.9.4.
Lane Full Interface
7.3.9.5.
Most Upstream Zone Handshake Interlock
7.3.9.6.
Most Downstream Zone Handshake Interlock
7.3.9.7.
Inverting the Pin 2 Signals
8.
EasyRoll+ Software
9.
ConveyMerge
9.1.
ConveyMerge Prerequisites and Requirements
9.2.
Network Architecture
9.3.
Sensor Placement
9.4.
Merge Zone Module
9.5.
Merging Lines
9.6.
Merge Configurations
9.7.
Merge Priority
9.8.
T-Merge Settings
9.9.
Configuring Dynamic Priority Release
9.10.
Enabling ConveyMerge from EasyRoll
9.11.
Conventional Spur Merge Example
9.12.
T-Merge Example
9.13.
Merge Line Full Example
10.
IOX Interface Module
10.1.
Wake up and/or Lane Full Interface
10.2.
Wake up/Lane Full with Wired Terminals
10.3.
Wake up/Lane Full with Discrete Signals
10.4.
Wake up/Product on Zone Handshake Interlock
10.5.
Downstream/Product on Zone Handshake Interlock
10.6.
Pin 2 Output on Aux I/O M8
10.7.
Pin 2 Output on Wired Terminals
11.
PLC Developers Guide
11.1.
Network Architecture
11.2.
Understanding Assemblies
11.2.1.
Modbus Assembly Instance Structure
11.2.2.
Ethernet I/P Assembly Instance Structure
11.2.3.
Profinet IO Assembly Instance Structrure
11.2.4.
Assembly Register Chart Legend
11.3.
ZPA Mode Control
11.3.1.
PLC Inputs for ZPA Mode
11.3.1.1.
Local Zone Status
11.3.1.2.
Arrival/Departure Counts
11.3.1.3.
Module Status
11.3.1.4.
Tracking and Release Counts
11.3.1.5.
Forward and Reverse Tracking
11.3.1.6.
Port Inputs and ConveyStop Status
11.3.2.
PLC Outputs for ZPA Mode
11.3.2.1.
Set Local Tracking
11.3.2.2.
Accumulation Control
11.3.2.3.
Speed Control
11.3.2.4.
Release and Status
11.3.2.5.
Induct Tracking Forward and Reverse
11.3.2.6.
Set Outputs and Motor Clear
11.3.2.7.
ConveyStop and Clear Jams
11.3.2.8.
Direction and Accumulation Mode
11.3.2.9.
ConveyMerge Interface
11.3.3.
ZPA Examples
11.3.3.1.
Basic Accumulate and Release with Tracking Data
11.3.3.2.
Conveyor Setup for Simple Bar Code Reader
11.3.3.3.
Upstream Accept Interface
11.3.3.4.
Downstream Discharge Interface
11.3.3.5.
Simple Divert Example
11.3.3.6.
Merge onto ZPA Main Line
11.3.4.
Reduced Size ZPA Mode Assemblies
11.4.
PLC I/O Mode Control
11.4.1.
Setting PLC I/O Mode in EasyRoll
11.4.2.
Optional Clear Connections Choice
11.4.3.
Configuring Action for Loss of Communication
11.4.4.
PLC Inputs for PLC I/O Mode
11.4.4.1.
ConveyStop Status
11.4.4.2.
Sensor Ports
11.4.4.3.
Left Motor Status
11.4.4.4.
Right Motor Status
11.4.4.5.
Motor Ports Digital Status
11.4.4.6.
Upstream / Downstream Status & Tracking
11.4.4.7.
Servo Control Status
11.4.5.
PLC Outputs for PLC I/O Mode
11.4.5.1.
ConveyStop Command & Clear Motor Error
11.4.5.2.
Motor & Sensor Port Digital Output
11.4.5.3.
Left Motor Control
11.4.5.4.
Right Motor Control
11.4.5.5.
Set Status & Tracking
11.4.5.6.
Set Sensor Port Input Mask
11.4.5.7.
Servo Control
11.4.5.7.1.
Servo Control Example
11.4.6.
Reduced Size PLC I/O Mode Assemblies
11.5.
ConveyLogix Interface
11.5.1.
ConveyLogix Assembly Inputs to PLC
11.5.2.
ConveyLogix Assembly Outputs from PLC
11.6.
Assemblies with Reset Protection
11.6.1.
ZPA Mode Assembly Inputs with Reset Protection
11.6.2.
ZPA Mode Assembly Outputs with Reset Protection
11.6.3.
Reduced Size ZPA Mode Assemblies with Reset Protection
11.6.4.
PLC I/O Mode Assembly Inputs with Reset Protection
11.6.5.
PLC I/O Mode Assembly Outputs with Reset Protection
11.6.6.
Reduced Size PLC I/O Mode Assemblies with Reset Protection
11.6.7.
How to use Assemblies with Reset Protection
11.7.
Motor Port as Digital I/O
12.
Setting Up Dual Motor Zones
12.1.
Two Ai MDRs Mechanically Coupled
12.1.1.
ZPA Mode
12.1.2.
PLC I/O Mode
12.1.3.
ConveyLogix Program
12.2.
Two Ai Motors in One Roller Tube (Dual Drive)
12.3.
Two Motor Rollers in One Logical Zone Not Coupled
13.
Connecting to Rockwell PLCs with Ethernet I/P
13.1.
Selecting Your Connection Method based upon Assembly
13.2.
Using Generic Ethernet Module Method
13.3.
Procedure for Connecting using Generic Ethernet Module
13.3.1.
Parameters for Each Assembly
13.4.
Procedure for using EDS Method
13.5.
Using Add On Instructions (AOI) with RSLogix 5000
13.5.1.
AOI Tag Descriptions
13.5.1.1.
ZPA Mode Inputs
13.5.1.2.
ZPA Mode Outputs
13.5.1.3.
PLC I/O Mode Inputs
13.5.1.4.
PLC I/O Mode Outputs
13.6.
Using Logix 5000 MSG Instruction
13.6.1.
Read MSG Instruction
13.6.2.
Write MSG Instruction
13.6.3.
Reading an Input Assembly with MSG Instruction
13.7.
EDS Module Data Type Cross Reference
14.
Connecting to Siemens PLC with Profinet IO
14.1.
Preparing Your Programming Environment
14.2.
Modes of Operation
14.3.
Understanding the Two Configuration Methods
14.4.
Separate ConveyLinx Auto-Configuration
14.4.1.
Profinet Name
14.4.2.
Examples of Adding Modules
14.4.2.1.
Full ZPA
14.4.2.2.
Full PLC Controlled
14.4.2.3.
Reduced ZPA
14.4.2.4.
Reduced PLC
14.4.2.5.
Merger Mode
14.4.2.6.
PLC Controlled with ConveyLogix Interface
14.5.
Integrated PLC Topology Configuration
14.5.1.
Profinet Name
14.5.2.
Adding Modules
14.5.3.
Topology Example
14.5.3.1.
Connecting 1st Subnet of Modules
14.5.3.2.
Connecting 2nd Subnet of Modules
14.5.4.
Module Configuration
14.5.4.1.
ZPA/Reduced ZPA Modes
14.5.4.1.1.
Upstream/Downstream Zones
14.5.4.1.2.
Upstream/Downstream Zone Timing
14.5.4.1.3.
Sensor Port Pin 2 Usage
14.5.4.1.4.
Connection to Merger Module
14.5.4.2.
PLC/Reduced PLC Mode
14.5.4.3.
Merger Mode
14.5.4.4.
ConveyLogix Mode
14.6.
Accessing Data from ConveyLinx Modules
14.6.1.
Raw Unmapped Data Direct from Module
14.6.2.
Module Data Elements Mapped to Tags
14.6.3.
Module Data Instances Mapped to User Defined Types (UDTs)
14.6.3.1.
Installing UDTs into Programming Environment
14.6.3.2.
Selecting the correct UDT for the Module’s Assigned DAP
14.6.3.3.
UDT Assignment Example
14.6.3.3.1.
Add feeder Module
14.6.3.3.2.
Add workstation Module
14.6.3.3.3.
Add remaining Modules
14.7.
User Data Types (UDTs)
14.7.1.
UDTs for Ai2 Family
14.7.1.1.
Full ZPA Mode Inputs
14.7.1.2.
Full ZPA Mode Outputs
14.7.1.3.
Reduced ZPA Mode Inputs
14.7.1.4.
Reduced ZPA Mode Outputs
14.7.1.5.
Full PLC Mode Inputs
14.7.1.6.
Full PLC Mode Outputs
14.7.1.7.
Reduced PLC Mode Inputs
14.7.1.8.
Reduced PLC Mode Outputs
14.8.
Troubleshooting
Download as PDF
14.5.4.1.3.
Sensor Port Pin 2 Usage
14.5.4.1.2.
Upstream/Downstream Zone Timing
14.5.4.1.4.
Connection to Merger Module
Select the operation and configuration of each Sensor Port’s
Pin 2
14.5.4.1.2.
Upstream/Downstream Zone Timing
14.5.4.1.4.
Connection to Merger Module
