Version 2.

0
January 2016

For Firmware versions 4.25 and 5.2

ConveyLinx module firmware and functionality is protected by U.S. and international patents.
For complete patent information visit www.pulseroller.com/patents

Publication ERSC-1520
Symbol Conventions 3

SYMBOL CONVENTIONS
This symbol indicates that special attention should be paid in order to ensure correct use
as well as to avoid danger, incorrect application of product, or potential for unexpected
results

This symbol indicates important directions, notes, or other useful information for the
proper use of the products and software described herein.

IMPORTANT USER INFORMATION

ConveyLinx ERSC modules contain ESD (Electrostatic Discharge) sensitive parts and
components. Static control precautions are required when installing, testing, servicing or
replacing these modules. Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures, reference any applicable
ESD protection handbook. Basic guidelines are:
• Touch a grounded object to discharge potential static
• Wear an approved grounding wrist strap
• Do not touch connectors or pins on component boards
• Do not touch circuit components inside the equipment
• Use a static-safe workstation, if available
• Store the equipment in appropriate static-safe packaging when not in use

Because of the variety of uses for the products described in this publication, those
responsible for the application and use of this control equipment must satisfy themselves
that all necessary steps have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws, regulations, codes,
and standards
The illustrations, charts, sample programs and layout examples shown in this guide are
intended solely for purposes of example. Since there are many variables and requirements
associated with any particular installation, Insight Automation Inc. does not assume
responsibility or liability (to include intellectual property liability) for actual use based on
the examples shown in this publication

Reproduction of the contents of this manual, in whole or in part, without written

permission of Insight Automation Inc. is prohibited.

Publication ERSC-1520 Rev 2.0 – January 2016

4 PLC Developer’s Guide

SUMMARY OF CHANGES
The following table summarizes the changes and updates made to this document since the last revision

Revision Date Change / Update

1.0 September 2014 Initial Release
2.0 January 2016 Major revision for firmware updates 4.25 and 5.2

GLOBAL CONTACT INFORMATION

Publication ERSC-1520 Rev 2.0 – January 2016

Table of Contents 5

TABLE OF CONTENTS
Symbol Conventions................................................................................................................................................... 3
Important User Information ........................................................................................................................................ 3
Summary of Changes ................................................................................................................................................. 4
Global Contact Information ........................................................................................................................................ 4
Table of Contents ........................................................................................................................................................ 5
Preface ......................................................................................................................................................................... 6
Who Should Use This Manual? ............................................................................................................................ 6
Prerequisites ........................................................................................................................................................... 6
Not Included in This Manual ................................................................................................................................. 6
Introduction .................................................................................................................................................................. 7
Ethernet I/P Guidelines .......................................................................................................................................... 7
Selecting Your Connection Method based upon Assembly ............................................................................. 8
Using Generic Ethenret Module Method ................................................................................................................. 9
ODVA Compliant Firmware 5.2 ............................................................................................................................ 9
General Procedure for Connecting using Generic Ethernet Module ............................................................ 10
Example for ERSC in ZPA Mode ....................................................................................................................... 10
Parameters for Each Assembly .......................................................................................................................... 14
For Firmware 4.24 and Earlier........................................................................................................................14
For Firmware 4.25 ............................................................................................................................................14
For Firmware 5.2 ..............................................................................................................................................15
Using EDS File Method ............................................................................................................................................ 16
Installing ConveyLinx EDS File into RSLogix5000 .......................................................................................... 17
Creating a ZPA Mode ERSC Module in the Ethernet Tree ............................................................................ 19
Note ① - Data Type Size ...............................................................................................................................24
Note ② - RPI Settings ....................................................................................................................................24
Creating Other Connection Types ..................................................................................................................... 25
Using ERSC Add On Instructions (AOI) with RSLogix 5000 .............................................................................. 27
Installing the AOIs into RSLogix 5000 ............................................................................................................... 27
Example for Assigning AOI to ERSC Modules in Your Project ..................................................................... 29
Assigning New Modules to AOI .......................................................................................................................... 29
Enabling the Module for Operation .................................................................................................................... 33
ZPA AOI Tag Descriptions .................................................................................................................................. 35
PLC I/O AOI Tag Descriptions ............................................................................................................................ 37
Using Logix5000 MSG Instruction .......................................................................................................................... 39
Message Configuration for Reading Data from ERSC ................................................................................... 39
Message Configuration for Writing Data To ERSC ......................................................................................... 40
Notes: ......................................................................................................................................................................... 41

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6 PLC Developer’s Guide

PREFACE

WHO SHOULD USE THIS MANUAL?

This manual is intended for users who need to utilize a Rockwell PLC equipped with Ethernet I/P capability to
connect to a ConveyLinx Ethernet network to access module status and control conveyor operation.

PREREQUISITES
You should have reviewed and understood either the ConveyLinx PLC Developer’s Guide (Insight Automation
publication ERSC-1500) or ConveyLinx-Ai PLC Developer’s Guide (Insight Automation publication ERSC-1510) before
utilizing this manual’s instructions to physically connect your Rockwell PLC to a ConveyLinx network.

This manual also assumes you have a solid working knowledge of both Rockwell PLC’s and the RSLogix 5000 /
RSLogix Designer development environments.

NOT INCLUDED IN THIS MANUAL

Because system applications vary; this manual assumes users and application engineers
have properly sized their PLC’s Ethernet port capacity to accommodate the quantity of
ConveyLinx module connections desired. Please refer to you particular PLC’s
specifications.

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Introduction 7

INTRODUCTION
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 import and use AOIs
• Use MSG Instruction

All three methods can be used for ConveyLinx modules in ZPA mode and in PLC I/O mode. However, the MSG
Instruction method does not maintain a constant connection to a ConveyLinx module and should not be used for
“time critical” operations.

ETHERNET I/P GUIDELINES

Each Allen-Bradley PLC has 2 metrics for limiting maintained Ethernet I/P communications to remote devices:

• Fixed quantity of TCP connections available on its Ethernet Port

• Fixed quantity of I/O data table memory available for connected devices

If the limit of either of these quantities is reached, the PLC processor will indicate I/O communications fault on one
or more instances of device declaration. For ERSC device declarations utilizing either ZPA or PLC I/O Mode
instances, in general the PLC limitation on TCP connections will be reached before I/O data table memory limit is
realized.

For example, for a CompactLogix L3x series processor, the documented quantity of TCP connections available on
its Ethernet Port is 32. The processor always keeps one TCP connection in reserve for programming terminal
access, etc. An L3x series processor can accept 31 full-time ERSC Connections as generic I/O modules utilizing any
combination of ZPA mode and PLC I/O Mode instances.

When an ERSC is attached as a “full-time generic I/O module” to the PLC, the connection is continually maintained
and data exchanged at a minimum RPI value and if the PLC cannot communicate with the ERSC for any reason, the
PLC’s I/O tree will register a fault. It is possible for the PLC to communicate via Ethernet I/P with any ERSC it can
physically reach over its Ethernet port without the ERSC being “full-time connected as a generic I/O module”. This
is accomplished with a Logix5000 MSG instruction.

Reserve Ethernet I/P TCP connections for ERSC’s in PLC I/O Mode and for key ZPA Mode
ERSCs where permanent accumulate/query/release functionality is required.
Use MSG Instruction to gather less time-critical data for things such as status and
diagnostics.
For more information on determining the design and capacity of your Ethernet I/P
network; please refer to Allen-Bradley document EtherNet/IP Performance Application
Solution (publication ENET-AP001D-EN-P).

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8 PLC Developer’s Guide

SELECTING YOUR CONNECTION METHOD BASED UPON ASSEMBLY

As described in our PLC Developer’s Guide (publication ERSC 1500), the data that you exchange with your PLC and a
given ERSC module 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 depending on the assembly, will dictate whether you can
connect to an ERSC with for a given assembly using the EDS file method or the Generic Ethernet Module method.

All available assemblies can be connected utilizing the Generic Ethernet Module method. Only a selected few
assemblies are available from the EDS file installation

All available assemblies can be connected utilizing the Generic Ethernet

Module method. Only a selected few assemblies are available from the
EDS file installation.

Available as
Available from
Generic
Assembly Pair EDS File
Ethernet
Installation
Module
ZPA Mode Assembly Inputs
ZPA Mode Assembly Outputs  
ZPA Mode Assembly Inputs with Reset Protection
ZPA Mode Assembly Outputs with Reset Protection  
Reduced Size ZPA Mode Assembly Inputs
Reduced Size ZPA Mode Assembly Outputs 
Reduced Size ZPA Mode Assembly Inputs with Reset Protection
Reduced Size ZPA Mode Assembly Outputs with Reset Protection 
PLC I/O Mode Assembly Inputs
PLC I/O Mode Assembly Outputs  
PLC I/O Mode Assembly Inputs with Reset Protection
PLC I/O Mode Assembly Outputs with Reset Protection  
Reduced Size PLC I/O Mode Assembly Inputs
Reduced Size PLC I/O Mode Assembly Outputs 
Reduced Size PLC I/O Mode Assembly Inputs with Reset Protection
Reduced Size PLC I/O Mode Assembly Outputs with Reset Protection 
ConveyLogix Assembly Inputs
ConveyLogix Assembly Outputs  

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Using Generic Ethenret Module Method 9

USING GENERIC ETHENRET MODULE METHOD

When using the Generic Ethernet Module construct in RSLogix 5000, you must supply configuration information
about the device you are trying to connect. The following sections show the step by step procedure to connect a
module for each set of I/O Assemblies described in the PLC Developer’s Guides.

ODVA COMPLIANT FIRMWARE 5.2

Insight Automation has been granted a Certificate of Conformity from ODVA for ConveyLinx firmware version 5.2.
The main difference between firmware 5.2 and previous versions (4.xx, 3.xx) as it pertains to connecting to ODVA
compliant Ethernet I/P (EIP) PLC devices is that these previous versions utilized Instance Identifiers that were
classified as “reserved” by the ODVA specification.

All Firmware 5.xx versions have re-assigned these identifiers into the allowable range for ODVA compliance. The
actual data registers and functionality of all EIP assemblies has remained unchanged from the published
assemblies in our PLC Developer’s Guide. The only thing that has changed in version 5.xx is the value used for the
Instance Identifiers when connecting to the PLC. Firmware 4.25 recognizes both the previous and ODVA values for
backward compatibility if you happen to upgrade ERSC firmware from 4.24 (or earlier) to 4.25. The following chart
is a reference showing all the available assemblies and their respective Instance Values used when connecting as a
Generic Ethernet Device.

Pre 4.25 4.25

Recognized Recognized 5.2 Recognized
Assembly
Instance Instance Instance Values
Values Values
ZPA Mode Assembly Inputs 5 5 & 105 105
ZPA Mode Assembly Outputs 6 6 & 106 106
ZPA Mode Assembly Inputs with Reset Protection 25 25 & 305 305
ZPA Mode Assembly Outputs with Reset Protection 26 26 & 306 306
Reduced Size ZPA Mode Assembly Inputs 19 19 & 119 119
Reduced Size ZPA Mode Assembly Outputs 20 20 & 120 120
Reduced Size ZPA Mode Assembly Inputs with Reset Protection 39 39 & 319 319
Reduced Size ZPA Mode Assembly Outputs with Reset Protection 40 40 & 320 320
PLC I/O Mode Assembly Inputs 7 7 & 107 107
PLC I/O Mode Assembly Outputs 8 8 & 108 108
PLC I/O Mode Assembly Inputs with Reset Protection 27 27 & 307 307
PLC I/O Mode Assembly Outputs with Reset Protection 28 28 & 308 308
Reduced Size PLC I/O Mode Assembly Inputs 17 17 & 117 117
Reduced Size PLC I/O Mode Assembly Outputs 18 18 & 118 118
Reduced Size PLC I/O Mode Assembly Inputs with Reset Protection 37 37 & 317 317
Reduced Size PLC I/O Mode Assembly Outputs with Reset Protection 38 38 & 318 318
ConveyLogix Assembly Inputs Not Available 121 121
ConveyLogix Assembly Outputs Not Available 122 122

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10 PLC Developer’s Guide

GENERAL PROCEDURE FOR CONNECTING USING GENERIC ETHERNET MODULE

All assembly pairs can be connected to a single ERSC using the same procedure within RSLogix 5000 environment:

1. Create a New Module in your Ethernet Tree

2. Select Generic Ethernet Module from the list of devices
3. Enter name and I.P. Address
4. Select the correct Comm Data type
5. Enter Input Assembly Instance Value and Size
6. Enter Output Assembly Instance Value and Size
7. Enter desired RPI value

For example if you need to attach to 5 ERSC modules that are in ZPA Mode, each module will have to have a
unique name and I.P. address (step 3) and steps 4, 5, 6, and 7 will use the same values for each ERSC.

EXAMPLE FOR ERSC IN ZPA MODE

This section will provide the set-by-step procedure for creating an instance of an ERSC into the I/O configuration
for an Allen-Bradley CompactLogix processor in RSLogix 5000 software.

Step #1
Add a New Module to the processor’s I/O configuration
by highlighting the processor’s local Ethernet port in the
I/O configuration tree.
Right-clicking will show the context menu. Select “New
Module…”

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Using Generic Ethenret Module Method 11

Step #2
From the Select Module pop-up
window, expand the
Communications tree and select
“Generic Ethernet Module” and
click OK, which will open up the
New Module window

Step #3 thru #6
Fill in the Name field. This will
be the ModuleName that will
appear in your program Tag ❸
Database for any addressing. ③
❺
Select Comm Format to be
③
❻
“Data – INT” and fill in the I.P.
❹ ③
address of the ERSC.
③
Fill in the Connection ❸
Parameters as shown. ③
Configuration parameter is
always Instance 1 and Size 0

It is very important to select Comm Format data type to be INT

or interface to ERSC will not operate correctly!

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12 PLC Developer’s Guide

Step #7
Set RPI to a value no lower than 10ms.
200 ms is typical for ZPA Interface. ❼
You may also optionally select Unicast
Connection.
Click “Apply” to update the value and
then “OK” to exit the window.

Once you have completed the configuration of your ERSC, you can see the input and output registers in your
Controller Tags screen. The register format and order within their respective Input/Outpus arrays match up
exactly with the Assembly descriptions provided in the PLC Developer’s Guide.

For our example, we created an ERSC named “ERSC_Conveyor_1”. Figure 1 and Figure 2 show the Input and
Output register arrays for this module. You can access the data registers directly in your user program.

FIGURE 1 - GENERIC MODULE ERSC INPUT DATA ARRAY

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Using Generic Ethenret Module Method 13

FIGURE 2 - GENERIC MODULE ERSC OUTPUT DATA ARRAY

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14 PLC Developer’s Guide

PARAMETERS FOR EACH ASSEMBLY

Please note that for all Assemblies and all versions of firmware the
Instance value for the “Configuration” parameter is always “1” and its size
is always “0”.

FOR FIRMWARE 4.24 AND EARLIER

Assembly Type Instance Value Size Value
Input 5 21
ZPA Mode Assembly
Output 6 24
Input 25 21
ZPA Mode Assembly with Reset Protection
Output 26 24
Input 7 23
PLC I/O Mode Assembly
Output 8 27
Input 27 23
PLC I/O Mode Assembly with Reset Protection
Output 28 27

FOR FIRMWARE 4.25

Assembly Type Instance Value Size Value
Input 5 21
ZPA Mode Assembly
Output 6 25
Input 25 21
ZPA Mode Assembly with Reset Protection
Output 26 25
Input 19 12
Reduced Size ZPA Mode Assembly
Output 20 15
Input 39 12
Reduced Size ZPA Mode Assembly with Reset Protection
Output 40 15
Input 7 23
PLC I/O Mode Assembly
Output 8 27
Input 27 23
PLC I/O Mode Assembly with Reset Protection
Output 28 27
Input 17 9
Reduced Size PLC I/O Mode Assembly
Output 18 9
Input 37 9
Reduced Size PLC I/O Mode Assembly with Reset Protection
Output 38 9
Input 121 16
ConveyLogix Assembly
Output 122 16

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Using Generic Ethenret Module Method 15

FOR FIRMWARE 5.2

Assembly Type Instance Value Size Value
Input 105 21
ZPA Mode Assembly
Output 106 25
Input 305 21
ZPA Mode Assembly with Reset Protection
Output 306 25
Input 119 12
Reduced Size ZPA Mode Assembly
Output 120 15
Input 319 12
Reduced Size ZPA Mode Assembly with Reset Protection
Output 320 15
Input 107 23
PLC I/O Mode Assembly
Output 108 27
Input 307 23
PLC I/O Mode Assembly with Reset Protection
Output 308 27
Input 117 9
Reduced Size PLC I/O Mode Assembly
Output 118 9
Input 317 9
Reduced Size PLC I/O Mode Assembly with Reset Protection
Output 318 9
Input 121 16
ConveyLogix Assembly
Output 122 16

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16 PLC Developer’s Guide

USING EDS FILE METHOD

This section is applicable for ERSC’s with firmware 4.25 and later as well as
firmware 5.2 and later. If you are using firmware 4.24 and earlier, please
refer to Version 1.0 of this document and utilize the previous versions of
EDS files.

For best results, you should remove any previous ERSC EDS file(s) you may
have installed in your RSLogix 5000 environment before installing the
version described in this section.

Also, delete all unused module data types from your program especially if
you are modifying or starting with an existing program
Installing the EDS file provided by Insight Automation into your RSLogix 5000 environment will allow you to select
the ERSC module from your list of known devices without having to use the Generic Ethernet Module method. The
EDS file contains the Instance and size parameters so you do not have to fill in this information. When you connect
to an ERSC, the data is arranged in assembled registers as described in the PLC Developer’s Guide with the data
appearing in your Controller Tags similarly to how the data appears when you connect to an ERSC as a Generic
Ethernet Module.

From the pulseroller.com website, you need to download the following file:

ConveyLinx_V5_2.eds

This is the filename as of the publication of this document. Please go to

pulseroller.com to download the latest versions of this EDS file.

Please note that in Version 1.0 of this document, there were two EDS files required
depending on whether your ERSC needed to be in ZPA mode or PLC I/O mode. The EDS
file referenced in this section includes connection settings for both ERSC modes of
operation including options for reset protection and ConveyLogix interface.

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Using EDS File Method 17

INSTALLING CONVEYLINX EDS FILE INTO RSLOGIX5000

Step 1
With RSLogix5000 open, select Tools
from the menu and EDS Hardware
Installation Tool

Step 2
Select the Register an EDS file(s) radio
button and click next

Step 3
Select the register a single file radio
button and click Browse and then browse
to the location on your PC where you
downloaded the EDS file. In this example
we are installing the ZPA version. Click
Next to continue.

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18 PLC Developer’s Guide

Step 4
This window should appear with the
green check indicating there were no
errors. Click Next to continue

Step 5
A window appears indicating the graphic
image included in the EDS file. This
image will be used if you want to show
network topology in RSNetworx. You can
change to your own icon if you wish.
Click Next to Continue

Step 6
RSLogix5000 asks if you want to complete
the installation. Click Next to proceed.

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Using EDS File Method 19

Step 7
RSLogix5000 lets you know when it is
done by showing this window. Click
Finish.

Please refer to applicable Rockwell Software documentation for further details and
information for removing and installing EDS files.

CREATING A ZPA MODE ERSC MODULE IN THE ETHERNET TREE

Once you have installed the EDS file into your RSLogix 5000 environment, you can now add specific instances of
ERSC modules into your project. You follow a similar procedure as described for the Generic Ethernet Module
method.

We are going to show adding a ZPA mode ERSC to your program as an example.

Step 1
Right click on your Ethernet
Tree and select New Module
to open the Select Module
Type window.

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20 PLC Developer’s Guide

Step 2
In the Select Module Type
window, locate the ERSC
catalog number. In this
example we cleared the
vendor filter and checked
Insight Automation. Once you
select ERSC, click the Create
button to open the New
Module window.
Note: Your list may look different
depending on what you have already
installed in your RSLogix5000
environment.

Step 3
For our example, we entered
the Name and IP address
information as shown. You
can choose whatever name
you desire and enter the
proper IP address for your
application. Then you must
click the Change button to
open the Module Definition
window.

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Using EDS File Method 21

Step 4
In the Module Definition
window you will see the
default settings from the EDS
file. The EDS file only allows
SINT data type to be default.
This needs to be changed to
INT.

See Note ① below.

Click the right of the Size box

to show a drop down box and
then select INT

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22 PLC Developer’s Guide

Once you have selected INT as

the data size, you will notice
the input and output sizes
now reflect the register
quantities as described in the
PLC Developer’s Guide for ZPA
mode. Click OK.

Step 5
When you click OK, a warning
will appear to tell you that you
are changing the default
parameters. Click Yes.

Step 6
You should be back to the
New Module window. You
can change the RPI of the
connection to your ERSC by
clicking the Connection tab.

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Using EDS File Method 23

In our example, we changed

the RPI to 200 ms because we
are in ZPA mode. Note that
the EDS file limits your RPI
range to between 8 and 500
ms.
Click OK and your ERSC is
ready to use in your program
See Note ② - RPI Settings for
more details.

For our example, Figure 3 and Figure 4 show the PLC’s Controller tags generated when the ERSC was created. You
can see that the quantities of INT registers corresponds with the registers defined in the PLC Developer’s Guide for
ZPA mode.

FIGURE 3 - ZPA MODE CONTROLLER TAGS FOR INPUTS

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24 PLC Developer’s Guide

FIGURE 4 - ZPA MODE CONTROLLER TAGS FOR OUTPUTS

NOTE ① - DATA TYPE SIZE

As noted, the EDS specification only allows for SINT data type as default. You can leave SINT as the default data
type if this fits your particular programming preferences. However, keep in mind the documented register types in
the PLC Developer’s Guide are described as 16 bit INT and this could lead to cross-referencing confusion.
Furthermore, if you also wish to use Insight Automation’s Add On Instructions (AOIs – described in the next
section), you must change the data type to INT because these items are written expecting INT data type.

NOTE ② - RPI SETTINGS

Please note that RPI settings do not affect the ERSC nearly as much as the PLC’s Ethernet port’s throughput. A
combination of the quantity of ERSC connections along with small RPI values can create a bottleneck at the PLC’s
Ethernet port. A higher quantity of ERSC connections coupled with a small RPI for each can result in dropped
connections to devices (ERSC and other connected Ethernet devices). This is not an issue with the ERSC (or other
device); it is an issue with the PLC. It is always recommended to use the largest RPI value you can for a given
connection while maintaining reasonable device response. For example, 10 msec RPI for a module in ZPA mode
will not necessarily produce noticeable operation difference when compared to 100 msec. The rule of thumb is to
reserve your 10 msec RPI settings for PLC I/O modules only.

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Using EDS File Method 25

CREATING OTHER CONNECTION TYPES

The steps are basically the same as for adding a ZPA mode ERSC, with the exception of changing the default
connection type of ZPA in Step 4 to the connection you need for the particular ERSC you are connecting.

In Step 4, click on the right

side of the Name area to show
a drop down box of the
available connection types
and select.
You still need to change the
data type from SINT to INT
regardless of which
connection type you select.

You need to verify that the particular ERSCs you are connecting to be set
to the proper corresponding mode. If your connection is PLC I/O mode,
the ERSC must be placed in PLC I/O mode using EasyRoll. Similarly for
ConveyLogix Interface connection, the ERSC must both be in PLC I/O mode
and have a ConveyLogix program installed.

Connection type mismatch (PLC I/O connection to ERSC in ZPA mode for
example) may not indicate any specific errors but it will produce
unexpected results.

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Using ERSC Add On Instructions (AOI) with RSLogix 5000 27

USING ERSC ADD ON INSTRUCTIONS (AOI) WITH RSLOGIX 5000

Insight Automation has authored and made available Add On Instructions (AOI) in order to make your
programming easier to follow. In this document up until this section, when connecting to an ERSC module
regardless of mode; you PLC program needs to directly access the register data array tags created when you
created the ERSC instance. The AOIs attach to created ERSC’s register data arrays and maps the data into user tags
and functions with meaningful names. There are two separate AOIs for use depending on the mode of the ERSC
you want to connect: a ZPA mode AOI and a PLC I/O AOI.

Please note that the use of AOI(s) is purely optional. However, you must
install the EDS file as previously described before you can use either AOI.

INSTALLING THE AOIS INTO RSLOGIX 5000

From the pulseroller.com website, you need to download one or both the following files depending on your needs:

ERSC_ZPA_5_2.L5X
ERSC_PLCIO_5_2.L5X

These are the filenames as of the publication of this document. Please go to

pulseroller.com to download the latest versions of these AOI files.

After your EDS files have been installed; the next procedure is to install the Add On Instruction (AOI) files that you
downloaded.

Step 1
Right click on the Add On Instruction
folder in the explorer tree. From the
pop-up menu select Import Add On
Instruction…

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28 PLC Developer’s Guide

Step 2
Navigate to the folder location where
you downloaded your AOIs, select the
file then click import. In this example
we are importing the AOI for ZPA mode.

Step 3
A window will appear indicating the
details about the AOI you are about to
import. There should be no errors or
warnings. Click OK to proceed with the
import.

Simply repeat this process to import the other AOI for the ERSC in PLC I/O mode.

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Using ERSC Add On Instructions (AOI) with RSLogix 5000 29

When you are done, these AOIs will

appear in the explorer tree as shown.

EXAMPLE FOR ASSIGNING AOI TO ERSC MODULES IN YOUR PROJECT

For our example, we are going to add one ZPA mode ERSC and one PLC I/O mode ERSC to our current project.
These were added following the steps outlined in section Creating a ZPA Mode ERSC Module in the Ethernet Tree
beginning on page 19. For our example we are assuming these have been configured with I.P. addresses
192.168.200.22 for the ZPA module and 192.168.200.23 for the PLC I/O module. Also, the ZPA ERSC is attached
using the ZPA with Reset Protection connection and the PLC I/O mode ERSC is attached with the PLCIO with Reset
Protection connection as outlined in section Creating Other Connection Types on page 25.

Insight Automation provided AOI’s require connections to be “with Reset

Protection”. Please refer to Creating Other Connection Types on page 25
for details on creating these connections. Also refer to the PLC
Developer’s Guide for details on Reset Protection assemblies.

ASSIGNING NEW MODULES TO AOI

Now that we have our ERSC’s defined with their correct connection types and the AOI instructions installed into
our RSLogix5000 project; the next step is to create an instance of the appropriate AOI for each physical ERSC.

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30 PLC Developer’s Guide

Step 1
Locate the AOIs and place in your
ladder diagram. For our example we
are selecting the ERSC_ZPA
instruction

Step 2
Once the instruction has been added
to the ladder, we need to create a tag
that will be how you access the
modules data.
For our example we entered
“Node_01” and then created the new
tag

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Using ERSC Add On Instructions (AOI) with RSLogix 5000 31

Step 3
This is the typical New Tag window
you invoke from the ladder diagram
screen. Note that the DataType
defaults to the AOI’s data type. Click
Create to create the new tag

Step 4
The AOI requires two other
parameters; “ERSC_IN” for the data
coming from the module and
“ERSC_OUT for data coming from the
PLC to the module. These will be
from the physical modules we
previously added. Here we will add
the ERSC_IN parameter by clicking
the drop down box arrow will
automatically show all tags that
match the data type for the ERSC_IN
parameter. In this case, “ERSC_1” is
the only ZPA module we created, so it
is the only selection. Double click this
and it will be assigned to the
Node_01 instance of our ZPA AOI’s
“ERSC_IN” parameter.

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Step 5
Similarly to Step 4, we need to do the
select the physical module for the
ERSC_OUT parameter. Clicking the
drop down box arrow will show all
physical modules that have the
matching data type for the ERSC_OUT
parameter.
Double click this and it will be
assigned to the Node_01 instance of
our ZPA AOI’s “ERSC_OUT”
parameter.

At this point, the AOI has been set up

to use in your logic program. All of
the tags associated with using the
ERSC_1 in ZPA mode are in the
structured tag “Node_01”.

You simply follow this same 5 step procedure for creating a new instance of the ERSC_PLCIO AOI. The drop down
for the data types for the ERSC_IN and ERSC_OUT parameters will automatically display only the ERSCs you have
installed with a PLC I/O connection.

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Using ERSC Add On Instructions (AOI) with RSLogix 5000 33

ENABLING THE MODULE FOR OPERATION

Before using the AOI in your program, you need to add some logic to enable the outputs on the physical module.
Both the ZPA and PLC I/O connections defined in the EDS file use the “with reset Protection” assemblies that
require the PLC to instruct the ERSC module to process output data coming from the PLC.

The Reset Protection topic is covered in PLC Developer’s Guide

Another function that is built-in when you created the module is indication of whether the PLC is communicating
with the module. For example, for the ZPA module we created (ERSC_1); if you look in the Controller tags for the
input data coming from the module, there is a Boolean value that indicates “Connection Faulted”.

From our example, when you expand the

“ERSC_1:I” structure, there is a BOOL that
indicates “Connection Faulted”. This tag
can be used in your logic to assure
connection is OK prior to enabling the
module.

We recommend a simple rung of logic for each module that will allow the module to be enabled when its
connection is OK and when “the system” is OK to start. This “system OK” state is wholly up to you as the
programmer to determine or omit as desired.

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For our example, we added a N.C. contact for the module’s “ConnectionFaulted” tag, a N.C. contact for the AOI’s
tag that indicates that the module is not enabled, and a N.O. contact for the programmer’s “System_OK_to_Run”
condition as previously described. When this logic becomes true, then AOI’s input to “EnableModule” is
energized. When the module becomes enabled, the “ModuleEnabled” contact becomes true so that the
“EnableModule” input to the AOI does not need to be held ON to keep the module enabled.
Simply repeat this rung of logic for each instance of the AOI. Also, these same tags are utilized for the ERSC_PLCIO
AOI, so this same type of rung is needed to enable these.

If you do not include some logic to set the “O_EnableModule” bit in your
program, the ERSC will NOT respond to any data written to it by the PLC.

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Using ERSC Add On Instructions (AOI) with RSLogix 5000 35

ZPA AOI TAG DESCRIPTIONS

The following chart lists each tag made available in the ERSC-ZPA AOI along with the register reference from the
PLC Developer’s Guide 4.7 and later or ConveyLinx-Ai PLC Developer’s Guide version 1.0 and later.

Developer’s
Data
Tag Name Guide Bit Description
Type
Register
Arrival at Local Upstream Zone – Only active if zone
I_ArrivalUPZn BOOL 4:0116 AOI Logic
becomes occupied and it has been set to accumulate
Arrival at Local Downstream Zone – Only active if zone
I_ArrivalDNZn BOOL 4:0196 AOI Logic
becomes occupied and it has been set to accumulate
I_ControlPortPin3_Left BOOL 4:0035 1 Left Control Port Pin 3 Energized
I_ControlPortPin3_Right BOOL 4:0035 3 Right Control Port Pin 3 Energized
I_ControlPortPin4_Left BOOL 4:0035 5 Left Control Port Pin 4 Energized
I_ControlPortPin4_Right BOOL 4:0035 7 Right Control Port Pin 4 Energized
I_ConveyStopByLeftControlPort BOOL 4:0020 8 ConveyStop Activated at Local Left Control Port
I_ConveyStopByLostConnection BOOL 4:0020 6 ConveyStop Activated because of Lost Connection
I_ConveyStopByPLCCmd BOOL 4:0020 7 ConveyStop Activated because of PLC Command
I_ConveyStopByPLCDisconnect BOOL 4:0020 10 ConveyStop Activated because of Lost PLC Connection
I_ConveyStopByRemoteModule BOOL 4:0020 5 ConveyStop Activated by another module in Stop Group
I_ConveyStopByRightControlPort BOOL 4:0020 9 ConveyStop Activated at Local Right Control Port
4:0201 (MSW) Current Forward Tracking Value at Induct to Local
I_GetForwardTracking DINT -
4:0202 (LSW) Upstream Zone
I_Heartbeat BOOL 4:0035 15 Module Heartbeat
I_JamAtUPZn BOOL 4:0088 5 Sensor Jam at Local Upstream Zone
I_JamAtDNZn BOOL 4:0089 5 Sensor Jam at Local Downstream Zone
I_ModuleEnabled BOOL - - Local ERSC Module Output are Enabled
4:0088 Module Fault Active (Logical OR of bits 2,4,and 7 from 5-
I_ModuleFault BOOL AOI Logic
4:0089 6 and bits 2 and 7 from 5-7
4:0088 (MSW)
I_ModuleStatus DINT Modules Status Words 1 and 2
4:0089 (LSW)
I_MtrError_Left BOOL 4:0088 3 Left Motor Error is Active
I_MtrError_Right BOOL 4:0089 3 Right Motor Error is Active
I_SensorPortPin3_Left BOOL 4:0035 0 Left Sensor Port Pin 3 Energized
I_SensorPortPin3_Right BOOL 4:0035 2 Right Sensor Port Pin 3 Energized
I_SensorPortPin4_Left BOOL 4:0035 4 Left Sensor Port Pin 4 Energized
I_SensorPortPin4_Right BOOL 4:0035 6 Right Sensor Port Pin 4 Energized
4:0199 (MSW) Current Tracking Value for Arrival at Local Downstream
I_TrackingDNZn DINT -
4:0200 (LSW) Zone
4:0119 (MSW) Current Tracking Value for Arrival at Local Upstream
I_TrackingUPZn DINT -
4:0120 (LSW) Zone
I_ZoneStatusDnZn SINT 4:0196 Lo Byte Zone Status Local Downstream Zone Forward Direction
I_ZoneStatusUpZn SINT 4:0116 Lo Byte Zone Status Local Uptream Zone Forward Direction
O_AccForArrivalDNZn BOOL 4:0184 0 Set Local Downstream Zone to Accumulate
O_AccForArrivalUPZn BOOL 4:01046-4 0 Set Local Upstream Zone to Accumulate
Accumulate Adjacent Upstream to Local Downstream
O_AccumAdjUpstreamToDNZn BOOL 4:0184 8
Zone
O_AccumAdjUpstreamToUPZn BOOL 4:0104 8 Accumulate Adjacent Upstream to Local Upstream Zone
O_ClearJamDNZn BOOL 4:0189 0 Clear Jam at Local Upstream Zone
O_ClearJamUPZn BOOL 4:0109 0 Clear Jam at Local Downstream Zone
O_ClearMotorError BOOL 4:0022 0 Clear Motor Error Left & Right
Confirm Downstream Arrival for Local Downstream
O_ConfArrivalAdjDownstreamToDNZn BOOL 4:0184 9
Zone
O_ConfArrivalAdjDownstreamToUPZn BOOL 4:0104 9 Confirm Downstream Arrival for Local Upstream Zone
O_ControlPortOutputLeft BOOL 4:0063 1 Set Left Control Port Output

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36 PLC Developer’s Guide

Developer’s
Data
Tag Name Guide Bit Description
Type
Register
O_ControlPortOutputRight BOOL 4:0063 3 Set Right COntrol Port Output
O_ConveyMerge_DisableCenter BOOL 4:0387 4 Set to disable center release
O_ConveyMerge_DisableLeft BOOL 4:0387 5 Set to disable left release
O_ConveyMerge_DisableRight BOOL 4:0387 6 Set to disable right release
O_ConveyMerge_EnablePLCCtrl BOOL 4:0387 15 Set to enable PLC over-ride of configured ConveyMerge
O_ConveyMergePriority SINT 4:0387 - Numerical value to set merge priority
O_ConveyStopCommand INT 4:0020 - Set Local ConveyStop Command Word
Direction & Accumulation Mode Command Byte for
O_DAModeCmdDNZn SINT 4:0375 Lo Byte
Downstream Zone
Direction & Accumulation Mode Command Byte for
O_DAModeCmdUPZn SINT 4:0365 Lo Byte
Upstream Zone
Direction & Accumulation Mode Data Byte for
O_DAModeValueDNZn SINT 4:0375 Hi Byte
Downstream Zone
Direction & Accumulation Mode Data Byte for Upstream
O_DAModeValueUPZn SINT 4:0365 Hi Byte
Zone
O_EnableModule BOOL - AOI Logic Enable Output to ERSC
O_JogFwdDNZn BOOL 4:0184 10 Jog Forward for Local Downstream Zone
O_JogFwdUpZn BOOL 4:0104 10 Jog Forward for Local Upstream Zone
O_JogRevDNZn BOOL 4:0184 11 Jog Reverse for Local Downstream Zone
O_JogRevUPZn BOOL 4:0104 11 Jog Reverse for Local Upstream Zone
Release and Accumulate on Next at Downstream Zone –
O_ReleaseDNZn BOOL 4:0105 AOI Logic
Automatically increments release counter
Release and Accumulate on Next at Upstream Zone –
O_ReleaseUPZn BOOL 4:0185 AOI Logic
Automatically increments release counter
O_SpeedLeftMtr INT 4:0040 - Set Left Motor Speed Reference
O_SpeedRightMtr INT 4:0064 - Set Right Motor Speed Reference
O_StatusDownstreamDischarge INT 4:0232 - Set Downstream Discharge Zone Status Value
O_StatusUpstreamInduct INT 4:0134 - Set Upstream Induct Zone Status Value
4:0212 (MSW)
O_TrackingDNZn DINT - Set Tracking Value for Local Downstream Zone
4:0213 (LSW)
4:0139 (MSW)
O_TrackingInductFwd DINT - Set Forward Induct Tracking Value
4:0140 (LSW)
4:0132 (MSW)
O_TrackingUPZn DINT - Set Tracking Value for Local Upstream Zone
4:0133 (LSW)
O_WakeUpDNZn BOOL 4:0184 12 Wakeup Local Downstream Zone
O_WakeUpUPZn BOOL 4:0104 12 Wakeup Local Upstream Zone

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Using ERSC Add On Instructions (AOI) with RSLogix 5000 37

PLC I/O AOI TAG DESCRIPTIONS

The following chart lists each tag made available in the ERSC-PLCIO AOI along with the register reference from the
PLC Developer’s Guide 4.7 and later or ConveyLinx-Ai PLC Developer’s Guide version 1.0 and later.

Developer’s
Tag Name Data Type Bit Decription
Guide Register
I_ControlPortPin3_Left BOOL 4:0019 1 Port Inputs
I_ControlPortPin3_Right BOOL 4:0035 3 Port Inputs
I_ControlPortPin4_Left BOOL 4:0035 5 Port Inputs
I_ControlPortPin4_Right BOOL 4:0035 7 Port Inputs
I_ConveyStopByLeftControlPort BOOL 4:0019 8 ConveyStop
I_ConveyStopByLostConnection BOOL 4:0019 6 ConveyStop
I_ConveyStopByPLCDisconnect BOOL 4:0019 7 ConveyStop
I_ConveyStopByPLCCmd BOOL 4:0019 10 ConveyStop
I_ConveyStopByRemoteModule BOOL 4:0019 5 ConveyStop
I_ConveyStopByRightControlPort BOOL 4:0019 9 ConveyStop
I_DigitalMtrOverCurrent_Left BOOL 4:0060 14 Left Motor Port as Digital
I_DigitalMtrOverCurrent_Right BOOL 4:0084 14 Right Motor Port as Digital
I_DigitalMtrShortCkt_Left BOOL 4:0060 12 Left Motor Port as Digital
I_DigitalMtrtShortCkt_Right BOOL 4:0084 12 Right Motor Port as Digital
I_DownstreamModuleStatus SINT 4:0232 Lo Byte Module Status
I_Heartbeat BOOL 4:0035 15 Port Inputs
I_ModuleEnabled BOOL - - Module Status
I_ModuleVoltage REAL 4:0024 - Module Status
I_MtrCurrent_Left REAL 4:0055 - Left Motor Status
I_MtrCurrent_Right REAL 4:0079 - Right Motor Status
I_MtrFreq_Left INT 4:0056 - Left Motor Status
I_MtrFreq_Right INT 4:0080 - Right Motor Status
I_MtrRunningCCW_Left BOOL 4:0058 AOI Logic Left Motor Status
I_MtrRunningCCW_Right BOOL 4:0082 AOI Logic Right Motor Status
I_MtrRunningCW_Left BOOL 4:0058 AOI Logic Left Motor Status
I_MtrRunningCW_Right BOOL 4:0082 AOI Logic Right Motor Status
I_MtrStatus_Left INT 4:0058 - Left Motor Status
I_MtrStatus_Right INT 4:0082 - Right Motor Status
I_SensorDetectLeftPort BOOL 4:0036 1 Sensor Port Status
I_SensorDetectRightPort BOOL 4:0036 0 Sensor Port Status
I_SensorPortPin3_Left BOOL 4:0035 0 Port Inputs
I_SensorPortPin3_Right BOOL 4:0035 2 Port Inputs
I_SensorPortPin4_Left BOOL 4:0035 4 Port Inputs
I_SensorPortPin4_Right BOOL 4:0035 6 Port Inputs
I_ServoCmdStatus_Left BOOL 4:0011 2 Left Servo Function
I_ServoCmdStatus_Right BOOL 4:0016 2 Right Servo Function
I_ServoLastCmdComplete_Left BOOL 4:0011 0 Left Servo Function
I_ServoLastCmdComplete_Right BOOL 4:0016 0 Right Servo Function
I_ServoPosition_Left INT 4:0062 Left Servo Function
I_ServoPosition_Right INT 4:0086 Right Servo Function
I_ServoResetStatus_Left BOOL 4:0011 1 Left Servo Function
I_ServoResetStatus_Right BOOL 4:0016 1 Right Servo Function
I_TemperatureCalculated_Left SINT 4:0057 Hi Byte Left Motor Status
I_TemperatureCalculated_Right SINT 4:0081 Hi Byte Right Motor Status
I_TemperatureOnBoard_Left SINT 4:0057 Lo Byte Left Motor Status
I_TemperatureOnBoard_Right SINT 4:0081 Lo Byte Right Motor Status
I_UpstreamModuleStatus SINT 4:0134 Lo Byte ZPA Status

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4:0139 (MSW)
I_UpstreamTracking DINT ZPA Tracking
4:0140 (LSW)
O_BrakeMethod_Left SINT 4:0261 Lo Byte Left Motor Control
O_BrakeMethod_Right SINT 4:0271 Lo Byte Right Motor Control
O_ClearMotorError BOOL 4:0022 Motor Control
O_ControlPortOutput_Left BOOL 4:0037 1 Left Motor Control
O_ControlPortOutput_Right BOOL 4:0037 3 Right Motor Control
O_ControlPortPin3Mask_Left BOOL 4:0034 1 Sensor/Control Port Configuration
O_ControlPortPin3Mask_Right BOOL 4:0034 3 Sensor/Control Port Configuration
O_ControlPortPin4Mask_Left BOOL 4:0034 5 Sensor/Control Port Configuration
O_ControlPortPin4Mask_Right BOOL 4:0034 7 Sensor/Control Port Configuration
O_ConveyStopCommand INT 4:0020 ConveyStop
4:0201 (MSW)
O_DischargeTracking DINT ZPA Tracking
4:0202 (LSW)
O_DownstreamStatus SINT 4:0196 Lo Byte ZPA Status
O_EnableModule BOOL - - Module Control
O_LeftMtrDigitalPin3 BOOL 4:0060 0 Left Motor Port Digital Control
O_LeftMtrDigitalPin4 BOOL 4:0060 1 Left Motor Port Digital Control
O_LeftMtrDigitalPin5 BOOL 4:0060 2 Left Motor Port Digital Control
O_MtrAccel_Left INT 4:0043 Left Motor Control
O_MtrAccel_Right INT 4:0067 Right Motor Control
O_MtrDecel_Left INT 4:0044 Left Motor Control
O_MtrDecel_Right INT 4:0068 Right Motor Control
O_RightMtrDigitalPin3 BOOL 4:0084 0 Right Motor Port Digital Control
O_RightMtrDigitalPin4 BOOL 4:0084 1 Right Motor Port Digital Control
O_RightMtrDigitalPin5 BOOL 4:0084 2 Right Motor Port Digital Control
O_RunMtrFwd_Left BOOL 4:0260 1 Left Motor Control
O_RunMtrFwd_Right BOOL 4:0270 1 Right Motor Control
O_RunMtrRev_Left BOOL 4:0260 8 Left Motor Control
O_RunMtrRev_Right BOOL 4:0270 8 Right Motor Control
O_SensorPortPin3Mask_Left BOOL 4:0034 0 Sensor/Control Port Configuration
O_SensorPortPin3Mask_Right BOOL 4:0034 2 Sensor/Control Port Configuration
O_SensorPortPin4Mask_Left BOOL 4:0034 4 Sensor/Control Port Configuration
O_SensorPortPin4Mask_Right BOOL 4:0034 6 Sensor/Control Port Configuration
O_ServoCmdPulses_Left INT 4:0008 Left Servo Function
O_ServoCmdPulses_Right INT 4:0013 Right Servo Function
O_ServoGoCmd_Left BOOL 4:0009 1 Left Servo Function
O_ServoGoCmd_Right BOOL 4:0014 1 Right Servo Function
O_ServoZero_Left BOOL 4:0009 0 Left Servo Function
O_ServoZero_Right BOOL 4:0014 0 Right Servo Function
O_SetLeftMtrPortDigital BOOL 4:0060 15 Left Motor Port Digital Control
O_SetRightMtrPortDigital BOOL 4:0084 15 Right Motor Port Digital Control
O_SpeedMethod_Left SINT 4:0262 Lo Byte Left Motor Control
O_SpeedMethod_Right SINT 4:0272 Lo Byte Right Motor Control
O_SpeedReference_Left INT 4:0040 Left Motor Control
O_SpeedReference_Right INT 4:0064 Right Motor Control
O_UpstreamStatus SINT 4:0116 Lo Byte ZPA Status

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Using Logix5000 MSG Instruction 39

USING LOGIX5000 MSG INSTRUCTION

This section appeared as Appendix C in PLC Developer’s Guide Version 4.6 and
earlier

Any ERSC on the network will respond to an appropriately configured Logix5000 MSG instruction without the ERSC
being attached as a Generic I/O instance to the PLC. The ERSC will allow a MSG instruction to read up to 30
contiguous Modbus registers in a single instruction. The ERSC will allow a MSG instruction to write 1 Modbus
register in a single instruction.

MESSAGE CONFIGURATION FOR READING DATA FROM ERSC

Read MSG Setup
• Select “CIP Generic” as the
Message Type
• Select “Get Attribute Single” and
the Service Type
• Class is always set to 64
• Instance is the Modbus register
address. In this example the
Instance is 88 indicating register
4:0088
• Attribute is the number of registers
to read. In this example it is set = 2.
This means the MSG instruction will
read Modbus registers 4:0088 and
4:0089
• Destination Element is the user
defined tag for the MSG instruction
to place the data it reads from the
ERSC. In this example,
“TempDiagStatus” is the user
defined tag.
The acceptable values for “Attribute” are from 0x1 to 0x1E which is 1 to 30 contiguous registers. In the above
example, the data being read is Module Status #1 and Module Status #2 registers (4:0088 and 4:0089). This same
MSG instruction could be duplicated for each ERSC in ZPA mode in a given conveyor system and used to populate
an array of ERSC status data that could in turn be used for example to feed an HMI diagnostic application.

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MESSAGE CONFIGURATION FOR WRITING DATA TO ERSC

Write MSG Setup

• Select “CIP Generic” as the Message

Type
• Select “Set Attribute Single” and the
Service Type
• Class is always set to 64
• Instance is the Modbus register
address. In this example the
Instance is 40 indicating register
4:0040
• Attribute is the number of registers
to write. This value is always set to 1
• Source Element is the PLC tag that
contains the data to be written to
the defined Modbus register.
Source Length is always set to 2

The above example illustrates how to set-up a MSG instruction to write a new speed reference to a specific ERSC’s
upstream zone (Modbus register 4:0040). The tag “NewSpeed” contains the value of speed reference for the
ERSC’s upstream zone.

Please note that the data type of each Modbus register is integer (INT). The user defined
controller tag used for “Destination Element” must of appropriate data type to accept the
MSG instruction data. Please consult Allen-Bradley documentation for full description of
MSG instruction usage.

Although a read MSG instruction can be used on an ERSC in PLC I/O mode, it is assumed
that any ERSC in PLC I/O will already be utilizing a permanent TCP connection and should
not ever need to be accessed with a read MSG instruction.

Refer to Allen-Bradley reference documentation for the particular PLC processor being
used as to the proper usage and expected performance loading on the processor
communication channels due to multiple MSG instructions executing simultaneously.

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Notes: 41

NOTES:

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Publication ERSC-1520 Rev 2.0 – January 2016