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About This Manual
About This Manual
Products Covered in this Manual ConveyLinx-ERSC Article Number 3010-0000 ConveyLinx-HTF Article Number 3010-3000 ConveyLinx-ERSC-E Article Number 3110-0000 ConveyLinx-HTF-E Article Number 3110-3000 Symbol…
Motor Pulse to Distance Calculation
EasyRoll Software » Main Screen » Motor Settings » Motor Pulse to Distance Calculation
For the Senergy motor there are 30 pulses per revolution of the motor shaft. The formula to calculate the linear distance the roller would turn in one pulse is: mm/pulse = (π × Roller Diameter) / (30 × Gear Ratio) *Roller Diameter and Gear Ratio values for…
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…
ERSC PLC Developers Guide
ERSC PLC Developers Guide
This section defines the data connectivity available between ConveyLinx Modules 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…
EasyRoll Software
EasyRoll Software
The EasyRoll Software Configuration Tool is a PC based application that provides the ability to change each module’s default parameters that are otherwise not accessible from the module’s built-in Auto-Configuration routine. Learn About: How to Install…
Control Ports Tab
EasyRoll Software » Advanced Dialog » Control Ports Tab
The Control Ports tab provides you with the ability modify the function of one or both of the Control Ports. This tab is organized in the following areas: Control Port Inputs Control Port Outputs Upstream/Downstream Accumulation Lane Full Interface PLC Control…
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…
Motor Settings
EasyRoll Software » Main Screen » Motor Settings
The motor settings for the current selected module can be modified on the Main Screen Change Motor Type Change Brake Method Change Speed Control Method Change Speed Setting Change Rotation Direction Change Acceleration/Deceleration *Please note that…
Module Hardware
Module Hardware
ConveyLinx Modules are designed to be installed and integrated into the conveyor’s mechanical side frame assembly. The ConveyLinx Module is a controller for up to 2 Motorized Drive Roller (MDR) conveyor zones. Each ConveyLinx Module provides connection points for 2…
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 Network Lock/Unlock Backup and Restore Firmware Upgrade
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*
ZPA Upstream/Downstream Zone Settings
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings
On the main screen there are areas to configure the Upstream and Downstream Zone settings. The Upstream and Downstream settings are set independent of one another so you can customize your ZPA functionality based upon your specific needs. ZPA Release…
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…
Merger Mode
Connecting to Siemens PLC with Profinet IO » Integrated PLC Topology Configuration » Module Configuration » Merger Mode
The Merger DAP is essentially a Full ZPA mode module with an added parameter to configure the merger. So the General, Upstream/Downstream Zones, and Upstream/Downstream Zone Timing parameters are the same as previously described. Merger Configuration An example…
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 that does not require a PC or PC based software to implement. The Auto-Configuration of Linear Conveyor feature of…
AOI Tag Descriptions
Connecting to Rockwell PLCs with Ethernet I/P » Using ERSC 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
Basic Accumulate and Release with Tracking Data
ERSC 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 ERSC 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 has arrived, how to…
Hard-Wired Interlocks
Default Settings and Operation » Hard-Wired Interlocks
Once your linear conveyor has been Auto-Configured and running in ZPA mode; the ConveyLinx Modules will attempt to convey all items from upstream to downstream in the direction of flow. The next logical step that you will want to do is Interlock with the most upstream…
Upstream/Downstream Zones
Connecting to Siemens PLC with Profinet IO » Integrated PLC Topology Configuration » Module Configuration » ZPA/Reduced ZPA Modes » Upstream/Downstream Zones
Set zone’s release mode of operation Timer value when using GAP Train Release Change the logical polarity of the Sensor Configure Sensor port to accept Push Pull type sensor Change motor’s…
PLC Outputs for PLC I/O Mode
ERSC PLC Developers Guide » PLC I/O Mode Control » PLC Outputs for PLC I/O Mode
This chart shows the assembled registers for the data from the PLC to the ConveyLinx Module in PLC I/O Mode: Register Name / Module Address Assembled Address for PLC Links ConveyStop Command 4:0020 M: 4:1800 E: O.Data[0] P: …
Reduced Size ZPA Mode Assemblies
ERSC 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…
PLC Inputs for PLC I/O Mode
ERSC PLC Developers Guide » PLC I/O Mode Control » PLC Inputs for PLC I/O Mode
This chart shows the assembled registers for the data coming from the ConveyLinx Module in PLC I/O Mode and provided as input to the PLC: Register Name / Module Address Assembled Address for PLC Links ConveyStop Status Word 4:0019 M: …
PLC Inputs for ZPA Mode
ERSC PLC Developers Guide » ZPA Mode Control » PLC Inputs for ZPA Mode
This Assembly contains the output from the ERSC in ZPA Mode that is provided as input to the PLC. Register Name / Module Address Assembled Address for PLC Links Local Status Upstream Zone 4:0116 M: 4:1500 E: I.Data[0] P: Byte…
PLC Outputs for ZPA Mode
ERSC 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 when in ZPA Mode. Register Name / Module Address Assembled Address for PLC Links Set Local Upstream Zone Tracking Word 1 4:0132 M: 4:1600 E: …
Reduced Size PLC I/O Mode Assemblies
ERSC 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…
Linear Conveyor
Auto-Configuration » Linear Conveyor
A Linear Conveyor arrangement is defined as a single uninterrupted path of conveyor with no merge or diverts mechanisms. A Linear Conveyor can include curved sections, but the flow of cartons or totes on the conveyor is continuous from in-feed zone to discharge…
Jam Conditions
Default Settings and Operation » Jam Conditions
There are two (2) types of Jam conditions detected by the ConveyLinx Module: Sensor Jam Arrival Jam *Both of these Jam conditions utilize a single Jam Timer that has to expire in order for the condition to be active. Once either of these jam conditions becomes…
Connecting your PC to ConveyLinx
EasyRoll Software » Connecting your PC to ConveyLinx
You can connect your PC to a ConveyLinx network with a standard RJ-45 Ethernet cable at either end of the string of modules. OR What do you want to do next? The Subnet has already been Auto-Configured, my PC gets IP address form DHCP server, and I want to…
Downstream Discharge Interface
ERSC 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…
Upstream/Downstream Zone Timing
Connecting to Siemens PLC with Profinet IO » Integrated PLC Topology Configuration » Module Configuration » ZPA/Reduced ZPA Modes » Upstream/Downstream Zone Timing
Change zone’s Run After Timer from its default value Change zone’s Induct Forward and Reverse Timer values Change zone’s Jam Timer from its default value Configure zone’s Look Ahead…
UDT Assignment Example
Connecting to Siemens PLC with Profinet IO » Accessing Data from ConveyLinx Modules » Module Data Instances Mapped to User Defined Types (UDTs) » UDT Assignment Example
To use UDTs, you create your own tag in the Default tag table as shown in the previous section and instead of using one of the elementary Data types, you select one of the UDTs we generated. So for the feeder module, we know from the previous section that its starting…
Full ZPA Mode Outputs
Connecting to Siemens PLC with Profinet IO » User Data Types (UDTs) » UDTs for ConveyLinx-ERSC Family » Full ZPA Mode Outputs
CLX_ERSC_ZPA_OUT Element Name Sub Element Data Type Link InductTrackingOnUpstreamZone DWord More Info InductTrackingOnDownstreamZone DWord AccumulateControlUpstream …
PLC I/O Mode
Setting Up Dual Motor Zones » Two Motors in One Roller Tube » PLC I/O Mode
After Auto-Configuration is complete, you can reconnect the opposite motor cable and place the ConveyLinx Module into PLC I/O mode with EasyRoll. For Firmware 4.25 or ODVA Firmware 5.02 You have the same options as described in section Mechanically Coupled 2 Motor…
For Firmware 4.27/5.07 and EasyRoll 4.21
Setting Up Dual Motor Zones » 2 MDRs Mechanically Coupled » PLC I/O Mode » For Firmware 4.27/5.07 and EasyRoll 4.21
Functionality is provided within the defined PLC I/O Assembly. See the Left Motor Control topic to configure the Left Motor as a slave and see the Right Motor Control topic to configure the Right Motor as a slave.
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…
PLC/Reduced PLC Mode
Connecting to Siemens PLC with Profinet IO » Integrated PLC Topology Configuration » Module Configuration » PLC/Reduced PLC Mode
General There is no equivalent setting in EasyRoll because these are determined by the Auto-Configuration procedure Change Upstream ConveyLinx Connection. If you want to perform the EasyRoll equivalent of selecting “None”…
Adding Modules
Connecting to Siemens PLC with Profinet IO » Integrated PLC Topology Configuration » Adding Modules
You add modules using the exact same procedures as depicted in the Separate ConveyLinx Auto Configuration section. The main difference is that you must use the DAPs created for Integrated PLC Topology Configuration. Update Time The DAPs for Integrated PLC Topology…
Full PLC Controlled
Connecting to Siemens PLC with Profinet IO » Separate ConveyLinx Auto-Configuration » Examples of Adding Modules » Full PLC Controlled
STEP 1: Add the Module to the PLC Network From the Catalog window, drag and drop the ConveyLinx-Ai DAP into the Network View window To attach the module to the PLC, click on the Not Assigned link and select the desired Profinet Interface of the…
Reduced ZPA
Connecting to Siemens PLC with Profinet IO » Separate ConveyLinx Auto-Configuration » Examples of Adding Modules » Reduced ZPA
STEP 1: Add the Module to the PLC Network From the Catalog window, drag and drop the ConveyLinx-Ai in reduced ZPA mode DAP into the Network View window To attach the module to the PLC, click on the Not Assigned link and select the desired…
Reduced PLC
Connecting to Siemens PLC with Profinet IO » Separate ConveyLinx Auto-Configuration » Examples of Adding Modules » Reduced PLC
STEP 1: Add the Module to the PLC Network From the Catalog window, drag and drop the ConveyLinx-Ai in reduced ZPA mode DAP into the Network View window To attach the module to the PLC, click on the Not Assigned link and select the desired…
Full PLC I/O Mode Outputs
Connecting to Siemens PLC with Profinet IO » User Data Types (UDTs) » UDTs for ConveyLinx-ERSC Family » Full PLC I/O Mode Outputs
CLX_ERSC_PLC_OUT Element Name Sub Element Data Type Link ConveyStopControl Word More Info LeftMotorAsDIO ClearPortError Bool More Info Bit09 Bool Bit10 Bool …
Reduced ZPA Mode Outputs
Connecting to Siemens PLC with Profinet IO » User Data Types (UDTs) » UDTs for ConveyLinx-ERSC Family » Reduced ZPA Mode Outputs
CLX_ERSC_ZPA_Reduced_OUT Element Name Sub Element Data Type Link AccumulateControlUpstream AccumUpstreamToThisZone Bool More Info SetArrival Bool JogZoneFwd Bool …
Simple Divert Example
ERSC 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 ERSC from generating…
What to do if things go wrong
Auto-Configuration » What to do if things go wrong
Here are some troubleshooting tips: Unexpected Motor Behavior If ConveyLinx Module was previously configured and its motor settings were changed in EasyRoll including rotation direction, these setting are not changed to default when a new Auto-Configuration…
Merge onto ZPA Main Line
ERSC 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 ERSC 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 B…
ZPA/Reduced ZPA Modes
Connecting to Siemens PLC with Profinet IO » Integrated PLC Topology Configuration » Module Configuration » ZPA/Reduced ZPA Modes
General There is no equivalent setting in EasyRoll because these are determined by the Auto-Configuration procedure Set up for master/slave motor rollers in a belted zone. There is no equivalent setting in EasyRoll Sensor…
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…
PLC I/O Mode
Setting Up Dual Motor Zones » 2 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 either control each motor independently with…
Full PLC I/O Mode Inputs
Connecting to Siemens PLC with Profinet IO » User Data Types (UDTs) » UDTs for ConveyLinx-ERSC Family » Full PLC I/O Mode Inputs
CLX_ERSC_PLC_IN Element Name Sub Element Data Type Link ConveyStopStatus StopOnLeft Bool More Info StopOnRight Bool StopActiveCommandPLC Bool Bit11 Bool …
Using a Photoeye for Lane Full
Default Settings and Operation » Hard-Wired Interlocks » Using a Photoeye for Lane Full
Because standard RJ-11/12 Sensors put their blocked/clear output on Pin 4; this type of Sensor can be plugged into the Downstream Control Port and provide the Pin 4 Lane Full signal. When PEx is plugged into the Right Control Port and its…
Ethernet I/P Assembly Instance Structure
ERSC PLC Developers Guide » Understanding Assemblies » Ethernet I/P Assembly Instance Structure
When an ConveyLinx Module 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 describing…
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…
ZPA Mode
Setting Up Dual Motor Zones » Two Motors in One Roller Tube » ZPA Mode
Once Auto-Configure is complete with the opposite motor cable unplugged, you can reconnect this motor cable. For Firmware 4.25 or ODVA Firmware 5.02 You follow the same procedures as described for ZPA Mode in section Mechanically Coupled 2 Motor Roller – ZPA…
PLC Controlled with ConveyLogix Interface
Connecting to Siemens PLC with Profinet IO » Separate ConveyLinx Auto-Configuration » Examples of Adding Modules » PLC Controlled with ConveyLogix Interface
STEP 1: Add the Module to the PLC Network From the Catalog window, drag and drop the ConveyLinx-Ai in PLC mode with ConveyLogix DAP into the Network View window To attach the module to the PLC, click on the Not Assigned link and select the…
Add workstation Module
Connecting to Siemens PLC with Profinet IO » Accessing Data from ConveyLinx Modules » Module Data Instances Mapped to User Defined Types (UDTs) » UDT Assignment Example » Add workstation Module
From our Default tag table, create a new tag and let’s call it workstation_Inputs. From the chart in the UDT Assignment Example topic, we know that the workstation module is in Full PLC I/O mode. Select CLXAiPLC_IN as the Data type. …
Local Zone Accumulate
Default Settings and Operation » Hard-Wired Interlocks » Local Zone Accumulate
On a newly Auto-Configured linear conveyor without any intervention from external signals, items will not stop on any zones in the middle unless the next downstream zone is occupied. To cause either the upstream or downstream zone on a ConveyLinx Module to…
ZPA Mode
Setting Up Dual Motor Zones » 2 MDRs Mechanically Coupled » ZPA Mode
In general, when you perform an Auto-Configure procedure, ConveyLinx 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 both…
Full ZPA Mode Inputs
Connecting to Siemens PLC with Profinet IO » User Data Types (UDTs) » UDTs for ConveyLinx-ERSC Family » Full ZPA Mode Inputs
CLX_ERSC_ZPA_IN Element Name Sub Element Data Type Link LocalUpstreamZoneStatus_Rev Byte More Info LocalUpstreamZoneStatus_Fwd Byte LocalDownstreamZoneStatus_Rev Byte …
Reduced PLC I/O Mode Inputs
Connecting to Siemens PLC with Profinet IO » User Data Types (UDTs) » UDTs for ConveyLinx-ERSC Family » Reduced PLC I/O Mode Inputs
CLX_ERSC_PLC_Reduced_IN Element Name Sub Element Data Type Link PortInputs Bit08 Bool More Info Bit09 Bool Bit10 Bool Bit11 Bool Bit12 Bool …
Reduced PLC I/O Mode Outputs
Connecting to Siemens PLC with Profinet IO » User Data Types (UDTs) » UDTs for ConveyLinx-ERSC Family » Reduced PLC I/O Mode Outputs
CLX_ERSC_PLC_Reduced_OUT Element Name Sub Element Data Type Link LeftMotorAsDIO ClearPortError Bool More Info Bit09 Bool Bit10 Bool Bit11 Bool Bit12 Bool …
For Firmware 4.27/5.07 and EasyRoll 4.21
Setting Up Dual Motor Zones » 2 MDRs Mechanically Coupled » ZPA Mode » For Firmware 4.27/5.07 and EasyRoll 4.21
This is automatically handled when you utilize the Slave Function in EasyRoll
ConveyLogix Program
Setting Up Dual Motor Zones » Two Motors in One Roller Tube » ConveyLogix Program
Follow the exact procedure as described in section Mechanically Coupled 2 Motor Roller – ConveyLogix Program
Upstream Accept Interface
ERSC 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…
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 Module will detect a Sensor Jam. This will be indicated on the corresponding Sensor LED on the module as shown…
Singulation Release
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » ZPA Release Mode » Singulation Release
*Singulation Mode is the default setting and it is described in the Default Settings and Operation section
Module Data Elements Mapped to Tags
Connecting to Siemens PLC with Profinet IO » Accessing Data from ConveyLinx Modules » Module Data Elements Mapped to Tags
*This method is not recommended in applications where you need to access more than one or two data elements from a module because you have to manually create individual tags for each element you want to access This method allows you to create your own global tags with…
Accessing Data from ConveyLinx Modules
Connecting to Siemens PLC with Profinet IO » Accessing Data from ConveyLinx Modules
There are 3 methods to access data from your modules: 1. Raw Unmapped Direct from the Module This method allows you to access the raw data to/from the array of I/O data defined in the DAP directly from within one of you program blocks. You then initiate the…
Train Release
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » ZPA Release Mode » Train Release
All 3 Cartons are Accumulated When Carton 1 releases – Cartons 2 and 3 also release at the same time Select Train from the pull-down box for Train Mode !Please note that starting many zones in Train Release mode…
ConveyStop Command & Clear Motor Error
ERSC 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…
Add remaining Modules
Connecting to Siemens PLC with Profinet IO » Accessing Data from ConveyLinx Modules » Module Data Instances Mapped to User Defined Types (UDTs) » UDT Assignment Example » Add remaining Modules
The remaining modules are added in similar fashion. We go to the Device view for each of the modules to see the starting byte addresses for their respective input and output data and use this when we create our tags for these modules. For the spur module, when…
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…
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…
Merger Mode
Connecting to Siemens PLC with Profinet IO » Separate ConveyLinx Auto-Configuration » Examples of Adding Modules » Merger Mode
The Merge function is configured in EasyRoll. Follow the exact same steps as for a Full ZPA module to add a module that will eventually be configured as merging zone in EasyRoll
ConveyLogix Mode
Connecting to Siemens PLC with Profinet IO » Integrated PLC Topology Configuration » Module Configuration » ConveyLogix Mode
The ConveyLogix DAP is essentially the same as a Full PLC mode module, so the previous topic for PLC/Reduced PLC Mode is identical for the ConveyLogix DAP.
Reduced ZPA Mode Inputs
Connecting to Siemens PLC with Profinet IO » User Data Types (UDTs) » UDTs for ConveyLinx-ERSC Family » Reduced ZPA Mode Inputs
CLX_ERSC_ZPA_Reduced_IN Element Name Sub Element Data Type Link LocalUpstreamZoneStatus_Rev Byte More Info LocalUpstreamZoneStatus_Fwd Byte LocalDownstreamZoneStatus_Rev Byte …
Using a Photoeye for Wake-Up
Default Settings and Operation » Hard-Wired Interlocks » Using a Photoeye for Wake-Up
Because standard RJ-11/12 Sensors put their blocked/clear output on Pin 4; this type of Sensor can be plugged into the Upstream Control Port and provide the Pin 4 Wake Up signal When PEx is plugged into the Right Control Port and its output is…
Two Motors in One Roller Tube
Setting Up Dual Motor Zones » Two Motors in One Roller Tube
!THIS SECTION ONLY APPLIES TO FIRMWARE 4.25 AND OLDER AND 5.02 AND OLDER. FOR FIRMWARE 4.27 / 5.07 AND NEWER THIS FUNCTIONALITY IS PROVIDED AUTOMATICALLY THROUGH SET UP IN EASYROLL Some Pulseroller models are available with two motors in one tube as…
Downstream Interlock (Lane Full)
Default Settings and Operation » Hard-Wired Interlocks » Downstream Interlock (Lane Full)
Interlock with the most downstream zone to turn on an output tell it to stop when something shows up (Lane Full) and then get an input to see if the last downstream zone is occupied On a newly Auto-Configured linear conveyor without any intervention from external…
ERSC with Stop Button
ConveyStop » Wiring Examples » ERSC with Stop Button
Stop Button with SE Breakout Module Stop Button with RJ-12 Pigtail Cable ! Please note that you cannot use an indicator light with RJ-12 pigtail cable. You must use SE Breakout Module for an indicator light
ERSC with Start Button
ConveyStop » Wiring Examples » ERSC with Start Button
Start Button with SE Breakout Module Start Button with RJ-12 Pigtail Cable ! Please note that you cannot use an indicator light with RJ-12 pigtail cable. You must use SE Breakout Module for an indicator light
Add feeder Module
Connecting to Siemens PLC with Profinet IO » Accessing Data from ConveyLinx Modules » Module Data Instances Mapped to User Defined Types (UDTs) » UDT Assignment Example » Add feeder Module
From our Default tag table, create a new tag and let’s call it feeder_Inputs. Select CLXAiZPA_IN as the Data type. Because we know from Module Data Elements Mapped to Tags section example that the feeder module starts at Input byte…
Induct Reverse Time/Distance
EasyRoll Software » Advanced Dialog » Look Ahead and Timing Tab » Induct Reverse Time/Distance
*Induct Reverse is only applicable for Reversing Control in ZPA Mode Induct Reverse value is used in conjunction with Induct Forward when you are setting up Reversing Conveyor in ZPA Mode to cause the MDR to continue to run after the zone’s photo-sensor has been…
Right Motor Status
ERSC 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…
Network Architecture
ERSC PLC Developers Guide » Network Architecture
Each ConveyLinx Module communicates to its adjacent modules and to any connected PC or PLC via Ethernet physical media. ConveyLinx Modules recognize (3) TCP/IP based protocols: Modbus TCP, Profinet I/O, and Ethernet I/P. Modbus TCP is the “native” protocol for…
Connection to Merger Module
Connecting to Siemens PLC with Profinet IO » Integrated PLC Topology Configuration » Module Configuration » ZPA/Reduced ZPA Modes » Connection to Merger Module
These settings are only used if this given module is discharging onto another ConveyLinx module that is configured as a Merger. In EasyRoll this operation is performed when connected to the Merger module’s Merge Zone. The difference here is that you enter…
Expected Results
Auto-Configuration » Expected Results
When the Auto-Configuration Procedure routine is complete, each ConveyLinx Module will automatically reboot. When a ConveyLinx Module has been successfully configured and rebooted, its Module and Network Status LED’s will blink on and off green. When the…
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…
Module Data Instances Mapped to User Defined Types (UDTs)
Connecting to Siemens PLC with Profinet IO » Accessing Data from ConveyLinx Modules » Module Data Instances Mapped to User Defined Types (UDTs)
*Using the UDTs is the recommended method of data access with ConveyLinx modules because these have been tested and verified by Pulseroller. User Data Types (UDTs) are used to generate structured data type blocks within the PLC programming environment for each…
Motor Rotation Definition
Auto-Configuration » Linear Conveyor » Motor Rotation Definition
The ConveyLinx Module 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 will…
Singulation Release Mode
Default Settings and Operation » Singulation Release Mode
Singulation Release is the mode where the ConveyLinx Module requires that its neighboring downstream zone must be clear before it releases an item. All 3 Cartons are accumulated Carton 1 releases – Cartons 2 and 3 remain…
ZPA Release Mode
EasyRoll Software » Main Screen » ZPA Upstream/Downstream Zone Settings » ZPA Release Mode
Selecting the pull-down box for ZPA Mode will show the available selections. Singulation is the default configuration *Selecting a new setting from the ZPA Mode drop down box immediately changes the zone’s mode. If you want to set all Upstream zones…
Separate ConveyLinx Auto-Configuration
Connecting to Siemens PLC with Profinet IO » Separate ConveyLinx Auto-Configuration
!This section applies ONLY when you use Separate ConveyLinx Auto-Configuration (EasyRoll or ConveyLinx module Install button) Adding ConveyLinx Modules to Your Project Once you have installed the GSDXML file into your environment, ConveyLinx devices are available to…
ConveyStop Status
ERSC 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 0 – 4 Reserved …
Motor Ports Digital Status
ERSC 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…
Power and Network Connections
Module Hardware » Power and Network Connections
Once MDR’s and photo-sensors have been connected based upon the desired conveyor arrangement (1 zone, 2 zone, dual motor zone, etc.); all the ConveyLinx Modules that make up the linear conveyor arrangement need to be interconnected with shielded Ethernet cables…
Understanding Assemblies
ERSC PLC Developers Guide » Understanding Assemblies
The Modbus Holding Registers described above will be defined as Module Register Addresses and are used for the function of the ConveyLinx Module regardless of if any remote PLC or PC is connected. There are 512 Module Register Addresses that are used for the operation…
Speed
EasyRoll Software » Main Screen » Motor Settings » Speed
The definition of the Speed setting value depends upon the Speed Control Method and Motor Type selected: Closed Loop Closed Loop is the default Speed Control Method and the value entered is in percent of the motor rated speed based upon the Motor Type selected. The…
Connecting to Siemens PLC with Profinet IO
Connecting to Siemens PLC with Profinet IO
!This section assumes you have a solid working knowledge of both Siemens PLC’s and the TIA Portal or Step7 manager development environments. !This section applies to all ConveyLinx Family modules. Figures and software screenshots may only show ConveyLinx-Ai Family…
Automatic Module Replacement
Default Settings and Operation » Automatic Module Replacement
Once a linear conveyor has been commissioned by Auto-Configuration Procedure, the ConveyLinx Module store configuration data about its upstream and downstream neighboring modules. This configuration data is automatically updated even if the linear conveyor has had its…
Control Port Outputs
EasyRoll Software » Advanced Dialog » Control Ports Tab » Control Port Outputs
!Control Port outputs are very low power. You need to use an SE Module to connect your external device. The default Control Port Output configuration signal is “ON” or logical “1” to indicate to external controls that it is associated zone is…