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ConveyLinx ERSC Complete Guide
4.9
5.1
5.0
4.9
Table of Contents
ConveyLinx ERSC Complete Guide
4.9
ConveyLinx ERSC Complete Guide — 5.1
ConveyLinx ERSC Complete Guide — 5.0
ConveyLinx ERSC Complete Guide — 4.9
1.
About This Manual
2.
Glossary of Terms
3.
Getting Started
4.
Module Hardware
4.1.
Identifying Module Components
4.2.
Mounting Dimensions
4.3.
Motor Ports
4.4.
Sensor & Control Ports
4.5.
Ethernet Ports
4.6.
Module Internal Fusing
4.7.
Over-Voltage Protection
4.8.
LED Status Indicators
4.9.
Power and Network Connections
4.10.
Power Supply Sizing
4.11.
Technical Specifications
5.
Auto-Configuration
5.1.
Linear Conveyor
5.1.1.
Device Connections to Modules
5.1.2.
Examples that will generate errors
5.1.3.
Motor Rotation Definition
5.2.
Procedure
5.3.
Auto-Configuration Examples
5.4.
Expected Results
5.5.
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.
Hard-Wired Interlocks
6.4.1.
Upstream Interlock (Wake Up)
6.4.2.
Downstream Interlock (Lane Full)
6.4.3.
Local Zone Accumulate
6.4.4.
Interlocks with Single Zone Module
6.4.5.
Interlock Input versus Local Accumulate Input
6.4.6.
Using a Photoeye for Wake-Up
6.4.7.
Using a Photoeye for Lane Full
6.4.8.
SE Breakout Module
6.5.
Automatic Module Replacement
6.6.
Reset to Factory Default Settings
7.
SE Breakout Module
7.1.
Typical Output Connection
7.2.
Typical Input Connections
7.3.
Input Circuit Blocking Diode Jumpers
7.4.
Notes on SE Module Revisions
8.
EasyRoll Software
8.1.
Installing EasyRoll on your PC
8.2.
ConveyLinx Ethernet Definition
8.3.
Connecting your PC to ConveyLinx
8.4.
Using Discover Function
8.5.
Main Screen
8.5.1.
Node Navigation
8.5.2.
Node Identification
8.5.3.
ZPA Upstream/Downstream Zone Settings
8.5.3.1.
ZPA Release Mode
8.5.3.1.1.
Singulation Release
8.5.3.1.2.
Train Release
8.5.3.1.3.
GAP Train Release
8.5.3.2.
T-Zone Settings
8.5.3.3.
ZPA Error and Information
8.5.3.4.
Accumulate Control from Main Screen
8.5.3.5.
Settings Checkboxes
8.5.3.5.1.
Disable Reset Delays
8.5.3.5.2.
Disable Sensor Jam Auto Clear
8.5.3.5.3.
Disable Arrival Timeout
8.5.3.5.4.
Disable Manual Operation
8.5.3.5.5.
Dynamic Release
8.5.4.
Motor Settings
8.5.4.1.
Motor Type
8.5.4.2.
Brake Method
8.5.4.3.
Speed Control Method
8.5.4.4.
Speed
8.5.4.5.
Rotation Direction
8.5.4.6.
Acceleration/Deceleration
8.5.4.7.
Motor Jog and Error Indicators
8.5.4.8.
Motor Pulse to Distance Calculation
8.5.5.
Diagnostic Window
8.6.
Advanced Dialog
8.6.1.
Look Ahead and Timing Tab
8.6.1.1.
Look Ahead Slowdown Feature
8.6.1.2.
Jam Auto Clear Timers
8.6.1.3.
Run After Time/Distance
8.6.1.4.
Induct Forward Time/Distance
8.6.1.5.
Induct Reverse Time/Distance
8.6.1.6.
Sensor Debounce
8.6.1.7.
Reversing Control in ZPA Mode
8.6.2.
Upgrade Tab
8.6.3.
Connections Tab
8.6.4.
Network Services Tab
8.6.4.1.
Discover and IP Address Set
8.6.4.2.
Position and DHCP
8.6.4.3.
Network Lock Feature
8.6.4.4.
Backup and Restore
8.6.5.
Special Services Tab
8.6.6.
Control Ports Tab
8.6.6.1.
Control Port Inputs
8.6.6.2.
Control Port Outputs
8.6.6.3.
Upstream/Downstream Accumulation
8.6.6.4.
Lane Full Interface
8.6.6.5.
PLC Control of Control Ports
8.6.7.
Flex Zone Tab
8.6.8.
Sensors Tab
8.6.9.
Extensions Tab
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.
ConveyStop
10.1.
Benefits of ConveyStop
10.2.
Using ConveyStop in an Integrated Stop System
10.3.
ConveyStop Architecture
10.4.
ConveyStop Software
10.4.1.
User Accounts
10.4.2.
Creating a New Project
10.4.3.
Discovering Modules
10.4.4.
Creating Stop Groups
10.4.5.
Add Stop and Start Buttons
10.4.6.
Commit All Button
10.4.7.
Status Monitoring
10.5.
Issuing a Stop Command
10.5.1.
Other Conditions that cause Stop
10.5.2.
Indications a Stop is Active
10.5.3.
ERSC Functions Affected by Stop Command
10.5.4.
CNIP Functions Affected by Stop Command
10.6.
ConveyLinx Function at Stop Group Boundaries
10.7.
Issuing a Start Command
10.7.1.
Indications Start is Active
10.8.
Using a PLC with ConveyStop
10.8.1.
ConveyStop Status Register
10.8.2.
ConveyStop Command Register
10.9.
Wiring Examples
10.9.1.
ERSC with Stop Button
10.9.2.
ERSC with Start Button
10.9.3.
CNIP with Stop Button
10.9.4.
CNIP with Start Button
11.
ERSC 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 & Control 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 & Control 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 & Control 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
11.8.
ODVA Compliant Cross-Reference
11.8.1.
ZPA Mode Assembly Inputs
11.8.2.
ZPA Mode Assembly Outputs
11.8.3.
ZPA Mode Reduced Size
11.8.4.
PLC I/O Mode Assembly Inputs
11.8.5.
PLC I/O Mode Assembly Outputs
11.8.6.
PLC I/O Mode Reduced Size
11.8.7.
Reset Protection for ZPA Mode Assembly Inputs
11.8.8.
Reset Protection for ZPA Mode Assembly Outputs
11.8.9.
Reset Protection for Reduced Size ZPA Assemblies
11.8.10.
Reset Protection for PLC I/O Mode Assembly Inputs
11.8.11.
Reset Protection for PLC I/O Mode Assembly Outputs
11.8.12.
Reset Protection for PLC I/O Mode Reduced Size
12.
Setting Up Dual Motor Zones
12.1.
2 MDRs Mechanically Coupled
12.1.1.
ZPA Mode
12.1.2.
PLC I/O Mode
12.1.3.
ConveyLogix Program
12.2.
Two Motors in One Roller Tube
12.2.1.
ZPA Mode
12.2.2.
PLC I/O Mode
12.2.3.
ConveyLogix Program
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 ERSC 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 ERSC 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 ConveyLinx-ERSC 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 I/O Mode Inputs
14.7.1.6.
Full PLC I/O Mode Outputs
14.7.1.7.
Reduced PLC I/O Mode Inputs
14.7.1.8.
Reduced PLC I/O Mode Outputs
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
