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ConveyLinx-Ai Family Complete Guide
3.1
3.1
3.0
2.1
2.0
1.7
Table of Contents
ConveyLinx-Ai Family Complete Guide
3.1
ConveyLinx-Ai Family Complete Guide — 3.1
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.
ConveyLinx-Ai Family Controllers
1.1.
About This Manual
1.2.
Glossary of Terms
2.
Getting Started
3.
Module Hardware
3.1.
Module Hardware Revisions
3.2.
Identifying Module Components
3.2.1.
ConveyLinx-Ai2 / ConveyLinx-Ai2-48
3.2.2.
ConveyLinx-Ai3-24-FC / ConveyLinx-Ai3-48-FC
3.2.3.
ConveyLinx-Ai3-24-RC
3.3.
Mounting Dimensions
3.3.1.
ConveyLinx-Ai2 / ConveyLinx-Ai2-48
3.3.2.
ConveyLinx-Ai3-24-FC / ConveyLinx-Ai3-48-FC
3.3.3.
ConveyLinx-Ai3-24-RC
3.3.4.
ConveyLinx-Ai3-24-FCM / ConveyLinx-Ai3-48-FCM
3.4.
Module Power Connections
3.4.1.
ConveyLinx-Ai2 / ConveyLinx-Ai2-48
3.4.2.
ConveyLinx-Ai3-24-FC & FCM
3.4.3.
ConveyLinx-Ai3-48-FC & FCM
3.4.4.
ConveyLinx-Ai3-24-RC
3.4.5.
Assembly Instructions
3.5.
Motor and Logic Power Distribution
3.5.1.
ConveyLinx-Ai2
3.5.2.
ConveyLinx-Ai3-24-FC & FCM
3.5.3.
ConveyLinx-Ai3-24-RC
3.5.4.
ConveyLinx-Ai2-48
3.5.5.
ConveyLinx-Ai3-48-FC & FCM
3.6.
Proper Motor Grounding Practice
3.7.
Power Supply Sizing
3.7.1.
Motor Power for 24V Models
3.7.2.
Motor Power for 48V Models
3.7.3.
Logic Only Power
3.8.
Motor Ports
3.8.1.
Motor Ports as Digital Outputs
3.9.
Sensor Ports
3.9.1.
Electrical Connections for Sensor Port Aux I/O
3.10.
Ethernet Ports
3.10.1.
ConveyLinx-Ai3-24-FCM / ConveyLinx-Ai3-48-FCM
3.11.
LED Status Indicators
3.12.
Technical Specifications
3.12.1.
Certifications & Standards
4.
Auto-Configuration
4.1.
Device Connections to Modules
4.1.1.
Examples that will generate errors
4.2.
Motor Rotation Definition
4.3.
Node Connections for a Subnet
4.4.
ConveyLinx Ethernet Definition
4.5.
Connecting Your PC to the Network
4.6.
Auto-Configuration Procedure
4.7.
Expected Results
4.8.
What to do if things go wrong
5.
Default Settings and Operation
5.1.
Singulation Release Mode
5.2.
Flex Zone Recognition
5.3.
Jam Conditions
5.3.1.
Arrival Jam
5.3.2.
Sensor Jam
5.4.
Automatic Module Replacement
5.5.
Reset to Factory Default Settings
6.
EasyRoll Software
6.1.
Installing EasyRoll
6.2.
Main Screen
6.2.1.
Node Navigation
6.2.2.
Node Identification
6.2.3.
ZPA Upstream/Downstream Zone Settings
6.2.3.1.
Release Mode
6.2.3.1.1.
Singulation Release
6.2.3.1.2.
Train Release
6.2.3.1.3.
GAP Train Release
6.2.3.2.
T-Zone Settings
6.2.3.3.
ZPA Error and Information
6.2.3.4.
Accumulate Control from Main Screen
6.2.3.5.
Settings Checkboxes
6.2.3.5.1.
Disable Reset Delays
6.2.3.5.2.
Disable Sensor Jam Auto Clear
6.2.3.5.3.
Disable Arrival Timeout
6.2.3.5.4.
Disable Manual Operation
6.2.3.5.5.
Last Zone Recommendation
6.2.4.
Motor Settings
6.2.4.1.
Motor Type
6.2.4.2.
Brake Method
6.2.4.3.
Speed
6.2.4.4.
Rotation Direction
6.2.4.5.
Acceleration/Deceleration
6.2.4.6.
Motor Jog and Error Indicators
6.2.4.7.
PGD Motor Pulse Distance Calculation
6.2.5.
Diagnostic Window
6.3.
Advanced Dialog
6.3.1.
Look Ahead and Timing Tab
6.3.1.1.
Look Ahead Slowdown Feature
6.3.1.2.
Jam & Auto Clear Timers
6.3.1.3.
Run After Time/Distance
6.3.1.4.
Induct Forward Time/Distance
6.3.1.5.
Sensor Debounce
6.3.2.
Upgrade Tab
6.3.3.
Connections Tab
6.3.4.
Network Services Tab
6.3.4.1.
Discover & IP Address Set
6.3.4.2.
Backup & Restore
6.3.5.
Special Services Tab
6.3.6.
Flex Zone Tab
6.3.7.
Sensors Tab
6.3.8.
Extensions Tab
6.3.9.
Pin 2 Usage Tab
6.3.9.1.
Most Downstream Zone
6.3.9.2.
Most Upstream Zone
6.3.9.3.
Accumulate Intermediate Zone
6.3.9.4.
Lane Full Interface
6.3.9.5.
Most Upstream Zone Handshake Interlock
6.3.9.6.
Most Downstream Zone Handshake Interlock
6.3.9.7.
Inverting the Pin 2 Signals
7.
EasyRoll+ Software
8.
ConveyMerge
8.1.
ConveyMerge Prerequisites and Requirements
8.2.
Network Architecture
8.3.
Sensor Placement
8.4.
Merge Zone Module
8.5.
Merging Lines
8.6.
Merge Configurations
8.7.
Merge Priority
8.8.
T-Merge Settings
8.9.
Configuring Dynamic Priority Release
8.10.
Enabling ConveyMerge from EasyRoll
8.11.
Conventional Spur Merge Example
8.12.
T-Merge Example
8.13.
Merge Line Full Example
9.
IOX Interface Module
9.1.
Wake up and/or Lane Full Interface
9.2.
Wake up/Lane Full with Wired Terminals
9.3.
Wake up/Lane Full with Discrete Signals
9.4.
Wake up/Product on Zone Handshake Interlock
9.5.
Downstream/Product on Zone Handshake Interlock
9.6.
Pin 2 Output on Aux I/O M8
9.7.
Pin 2 Output on Wired Terminals
10.
PLC Developers Guide
10.1.
Network Architecture
10.2.
Understanding Assemblies
10.2.1.
Modbus Assembly Instance Structure
10.2.2.
Ethernet I/P Assembly Instance Structure
10.2.3.
Profinet IO Assembly Instance Structrure
10.2.4.
Assembly Register Chart Legend
10.3.
ZPA Mode Control
10.3.1.
PLC Inputs for ZPA Mode
10.3.1.1.
Local Zone Status
10.3.1.2.
Arrival/Departure Counts
10.3.1.3.
Module Status
10.3.1.4.
Tracking and Release Counts
10.3.1.5.
Forward and Reverse Tracking
10.3.1.6.
Port Inputs and ConveyStop Status
10.3.2.
PLC Outputs for ZPA Mode
10.3.2.1.
Set Local Tracking
10.3.2.2.
Accumulation Control
10.3.2.3.
Speed Control
10.3.2.4.
Release and Status
10.3.2.5.
Induct Tracking Forward and Reverse
10.3.2.6.
Set Outputs and Motor Clear
10.3.2.7.
ConveyStop and Clear Jams
10.3.2.8.
Direction and Accumulation Mode
10.3.2.9.
ConveyMerge Interface
10.3.3.
ZPA Examples
10.3.3.1.
Basic Accumulate and Release with Tracking Data
10.3.3.2.
Conveyor Setup for Simple Bar Code Reader
10.3.3.3.
Upstream Accept Interface
10.3.3.4.
Downstream Discharge Interface
10.3.3.5.
Simple Divert Example
10.3.3.6.
Merge onto ZPA Main Line
10.3.4.
Reduced Size ZPA Mode Assemblies
10.4.
PLC I/O Mode Control
10.4.1.
Setting PLC I/O Mode in EasyRoll
10.4.2.
Optional Clear Connections Choice
10.4.3.
Configuring Action for Loss of Communication
10.4.4.
PLC Inputs for PLC I/O Mode
10.4.4.1.
ConveyStop Status
10.4.4.2.
Sensor Ports
10.4.4.3.
Left Motor Status
10.4.4.4.
Right Motor Status
10.4.4.5.
Motor Ports Digital Status
10.4.4.6.
Upstream / Downstream Status & Tracking
10.4.4.7.
Servo Control Status
10.4.5.
PLC Outputs for PLC I/O Mode
10.4.5.1.
ConveyStop Command & Clear Motor Error
10.4.5.2.
Motor & Sensor Port Digital Output
10.4.5.3.
Left Motor Control
10.4.5.4.
Right Motor Control
10.4.5.5.
Set Status & Tracking
10.4.5.6.
Set Sensor Port Input Mask
10.4.5.7.
Servo Control
10.4.5.7.1.
Servo Control Example
10.4.6.
Reduced Size PLC I/O Mode Assemblies
10.5.
ConveyLogix Interface
10.5.1.
ConveyLogix Assembly Inputs to PLC
10.5.2.
ConveyLogix Assembly Outputs from PLC
10.6.
Assemblies with Reset Protection
10.6.1.
ZPA Mode Assembly Inputs with Reset Protection
10.6.2.
ZPA Mode Assembly Outputs with Reset Protection
10.6.3.
Reduced Size ZPA Mode Assemblies with Reset Protection
10.6.4.
PLC I/O Mode Assembly Inputs with Reset Protection
10.6.5.
PLC I/O Mode Assembly Outputs with Reset Protection
10.6.6.
Reduced Size PLC I/O Mode Assemblies with Reset Protection
10.6.7.
How to use Assemblies with Reset Protection
10.7.
Motor Port as Digital I/O
11.
Connecting to Rockwell PLCs with Ethernet I/P
11.1.
Selecting Your Connection Method based upon Assembly
11.2.
Using Generic Ethernet Module Method
11.3.
Procedure for Connecting using Generic Ethernet Module
11.3.1.
Parameters for Each Assembly
11.4.
Procedure for using EDS Method
11.5.
Using Add On Instructions (AOI) with RSLogix 5000
11.5.1.
AOI Tag Descriptions
11.5.1.1.
ZPA Mode Inputs
11.5.1.2.
ZPA Mode Outputs
11.5.1.3.
PLC I/O Mode Inputs
11.5.1.4.
PLC I/O Mode Outputs
11.6.
Using Logix 5000 MSG Instruction
11.6.1.
Read MSG Instruction
11.6.2.
Write MSG Instruction
11.6.3.
Reading an Input Assembly with MSG Instruction
11.7.
EDS Module Data Type Cross Reference
12.
Connecting to Siemens PLC with Profinet IO
12.1.
Preparing Your Programming Environment
12.2.
Modes of Operation
12.3.
Understanding the Two Configuration Methods
12.4.
Separate ConveyLinx Auto-Configuration
12.4.1.
Profinet Name
12.4.2.
Examples of Adding Modules
12.4.2.1.
Full ZPA
12.4.2.2.
Full PLC Controlled
12.4.2.3.
Reduced ZPA
12.4.2.4.
Reduced PLC
12.4.2.5.
Merger Mode
12.4.2.6.
PLC Controlled with ConveyLogix Interface
12.5.
Integrated PLC Topology Configuration
12.5.1.
Profinet Name
12.5.2.
Adding Modules
12.5.3.
Topology Example
12.5.3.1.
Connecting 1st Subnet of Modules
12.5.3.2.
Connecting 2nd Subnet of Modules
12.5.4.
Module Configuration
12.5.4.1.
ZPA/Reduced ZPA Modes
12.5.4.1.1.
Upstream/Downstream Zones
12.5.4.1.2.
Upstream/Downstream Zone Timing
12.5.4.1.3.
Sensor Port Pin 2 Usage
12.5.4.1.4.
Connection to Merger Module
12.5.4.2.
PLC/Reduced PLC Mode
12.5.4.3.
Merger Mode
12.5.4.4.
ConveyLogix Mode
12.6.
Accessing Data from ConveyLinx Modules
12.6.1.
Raw Unmapped Data Direct from Module
12.6.2.
Module Data Elements Mapped to Tags
12.6.3.
Module Data Instances Mapped to User Defined Types (UDTs)
12.6.3.1.
Installing UDTs into Programming Environment
12.6.3.2.
Selecting the correct UDT for the Module’s Assigned DAP
12.6.3.3.
UDT Assignment Example
12.6.3.3.1.
Add feeder Module
12.6.3.3.2.
Add workstation Module
12.6.3.3.3.
Add remaining Modules
12.7.
User Data Types (UDTs)
12.7.1.
UDTs for Ai2 Family
12.7.1.1.
Full ZPA Mode Inputs
12.7.1.2.
Full ZPA Mode Outputs
12.7.1.3.
Reduced ZPA Mode Inputs
12.7.1.4.
Reduced ZPA Mode Outputs
12.7.1.5.
Full PLC Mode Inputs
12.7.1.6.
Full PLC Mode Outputs
12.7.1.7.
Reduced PLC Mode Inputs
12.7.1.8.
Reduced PLC Mode Outputs
12.8.
Troubleshooting
Download as PDF
9.2.
Wake up/Lane Full with Wired Terminals
9.1.
Wake up and/or Lane Full Interface
9.3.
Wake up/Lane Full with Discrete Signals
IOX Interface Module
/
Wake up/Lane Full with Wired Terminals
9.1.
Wake up and/or Lane Full Interface
9.3.
Wake up/Lane Full with Discrete Signals
