ConveyLinx ERSC

Complete Guide
Version 5.1 — 15 April 2022

Copyright © 2022 PULSEROLLER

Table of Contents
1. About This Manual ................................................................................................................ 8

2. Glossary of T
Ter
erms
ms ................................................................................................................ 12

3. Getting Started .................................................................................................................... 16

4. Module Har
Hardwar
dware
e ................................................................................................................. 18
4.1. Identifying Module Components .................................................................................. 19
4.2. Mounting Dimensions .................................................................................................. 21
4.3. Motor Ports ................................................................................................................. 24
4.4. Sensor & Control Ports ................................................................................................ 25
4.5. Ethernet Ports ............................................................................................................. 27
4.6. Module Internal Fusing ................................................................................................ 28
4.7. Over-Voltage Protection............................................................................................... 29
4.8. LED Status Indicators .................................................................................................. 30
4.9. Power and Network Connections ................................................................................. 34
4.10. Power Supply Sizing .................................................................................................. 35
4.11. Technical Specifications............................................................................................. 36

5. Auto
Auto-Configuration
-Configuration...............................................................................................................
............................................................................................................... 41
5.1. Linear Conveyor .......................................................................................................... 42
5.1.1. Device Connections to Modules ...........................................................................43
5.1.2. Examples that will generate errors ......................................................................45
5.1.3. Motor Rotation Definition ..................................................................................... 46
5.2. Procedure.................................................................................................................... 47
5.3. Auto-Configuration Examples ...................................................................................... 50
5.4. Expected Results......................................................................................................... 51
5.5. What to do if things go wrong ..................................................................................... 53

6. Default Settings and Operation ............................................................................................

............................................................................................54
54
6.1. Singulation Release Mode ........................................................................................... 55
6.2. Flex Zone Recognition ................................................................................................. 56
6.3. Jam Conditions ............................................................................................................ 58
6.3.1. Arrival Jam........................................................................................................... 59
6.3.2. Sensor Jam .......................................................................................................... 61
6.4. Hard-Wired Interlocks.................................................................................................. 63
6.4.1. Upstream Interlock (Wake Up) ............................................................................. 64
6.4.2. Downstream Interlock (Lane Full) ........................................................................67
6.4.3. Local Zone Accumulate........................................................................................ 69
6.4.4. Interlocks with Single Zone Module .....................................................................70
6.4.5. Interlock Input versus Local Accumulate Input .....................................................72
6.4.6. Using a Photoeye for Wake-Up ............................................................................. 74
6.4.7. Using a Photoeye for Lane Full............................................................................. 75
6.4.8. SE Breakout Module............................................................................................. 77
6.5. Automatic Module Replacement .................................................................................. 80
6.6. Reset to Factory Default Settings ................................................................................ 82

7. SE Br
Break
eakout
out Module ............................................................................................................. 84
7.1. Typical Output Connection........................................................................................... 86
7.2. Typical Input Connections............................................................................................ 87
7.3. Input Circuit Blocking Diode Jumpers...........................................................................88
7.4. Notes on SE Module Revisions ..................................................................................... 90

8. EasyR
EasyRoll
oll Sof
Softwar
tware
e ................................................................................................................ 93
8.1. Installing EasyRoll on your PC ..................................................................................... 94
8.2. ConveyLinx Ethernet Definition ................................................................................... 95
8.3. Connecting your PC to ConveyLinx .............................................................................. 97
8.4. Using Discover Function .............................................................................................. 99
8.5. Main Screen .............................................................................................................. 100
8.5.1. Node Navigation ................................................................................................ 102
8.5.2. Node Identification ............................................................................................ 103
8.5.3. ZPA Upstream/Downstream Zone Settings ......................................................... 104
8.5.3.1. ZPA Release Mode...................................................................................... 105
8.5.3.1.1. Singulation Release ............................................................................ 106
8.5.3.1.2. Train Release ...................................................................................... 107
8.5.3.1.3. GAP Train Release .............................................................................. 108
8.5.3.2. T-Zone Settings.......................................................................................... 109
8.5.3.3. ZPA Error and Information .......................................................................... 112
8.5.3.4. Accumulate Control from Main Screen........................................................ 113
8.5.3.5. Settings Checkboxes .................................................................................. 114
8.5.3.5.1. Disable Reset Delays .......................................................................... 115
8.5.3.5.2. Disable Sensor Jam Auto Clear ........................................................... 116
8.5.3.5.3. Disable Arrival Timeout ...................................................................... 117
8.5.3.5.4. Disable Manual Operation .................................................................. 118
8.5.3.5.5. Dynamic Release................................................................................ 120
8.5.4. Motor Settings ................................................................................................... 122
8.5.4.1. Motor Type ................................................................................................. 123
8.5.4.2. Brake Method............................................................................................. 124
8.5.4.3. Speed Control Method................................................................................ 126
8.5.4.4. Speed ........................................................................................................ 128
8.5.4.5. Rotation Direction ...................................................................................... 130
8.5.4.6. Acceleration/Deceleration .......................................................................... 131
8.5.4.7. Motor Jog and Error Indicators .................................................................... 133
8.5.4.8. Motor Pulse to Distance Calculation ........................................................... 136
8.5.5. Diagnostic Window ............................................................................................ 137
8.6. Advanced Dialog ....................................................................................................... 139
8.6.1. Look Ahead and Timing Tab ............................................................................... 140
8.6.1.1. Look Ahead Slowdown Feature ................................................................... 141
8.6.1.2. Jam Auto Clear Timers................................................................................ 144
8.6.1.3. Run After Time/Distance............................................................................. 145
8.6.1.4. Induct Forward Time/Distance .................................................................... 147
8.6.1.5. Induct Reverse Time/Distance .................................................................... 149
8.6.1.6. Sensor Debounce ....................................................................................... 151
8.6.1.7. Reversing Control in ZPA Mode................................................................... 153
8.6.2. Upgrade Tab ...................................................................................................... 156
8.6.3. Connections Tab ................................................................................................ 159
8.6.4. Network Services Tab ........................................................................................ 162
8.6.4.1. Discover and IP Address Set....................................................................... 163
8.6.4.2. Position and DHCP ..................................................................................... 166
8.6.4.3. Network Lock Feature ................................................................................ 169
8.6.4.4. Backup and Restore ................................................................................... 171
8.6.5. Special Services Tab .......................................................................................... 174
8.6.5.1. Motor Slave Function ................................................................................. 177
8.6.6. Control Ports Tab ............................................................................................... 182
8.6.6.1. Control Port Inputs ..................................................................................... 183
8.6.6.2. Control Port Outputs .................................................................................. 185
8.6.6.3. Upstream/Downstream Accumulation......................................................... 187
8.6.6.4. Lane Full Interface ..................................................................................... 188
8.6.6.5. PLC Control of Control Ports ....................................................................... 189
8.6.7. Flex Zone Tab .................................................................................................... 190
8.6.8. Sensors Tab ....................................................................................................... 193
8.6.9. Extensions Tab................................................................................................... 194

9. ConveyMer
ConveyMerge
ge.....................................................................................................................
..................................................................................................................... 198
9.1. ConveyMerge Prerequisites and Requirements .......................................................... 200
9.2. Network Architecture ................................................................................................ 201
9.3. Sensor Placement ..................................................................................................... 203
9.4. Merge Zone Module .................................................................................................. 205
9.5. Merging Lines............................................................................................................ 208
9.6. Merge Configurations ................................................................................................ 210
9.7. Merge Priority ........................................................................................................... 211
9.8. T-Merge Settings ....................................................................................................... 212
9.9. Configuring Dynamic Priority Release ........................................................................ 214
9.10. Enabling ConveyMerge from EasyRoll ...................................................................... 217
9.11. Conventional Spur Merge Example .......................................................................... 219
9.12. T-Merge Example..................................................................................................... 221
9.13. Merge Line Full Example.......................................................................................... 223
10. ConveyStop ..................................................................................................................... 225
10.1. Benefits of ConveyStop ........................................................................................... 228
10.2. Using ConveyStop in an Integrated Stop System ..................................................... 229
10.3. ConveyStop Architecture ......................................................................................... 233
10.4. ConveyStop Software .............................................................................................. 235
10.4.1. User Accounts ................................................................................................. 236
10.4.2. Creating a New Project .................................................................................... 237
10.4.3. Discovering Modules........................................................................................ 238
10.4.4. Creating Stop Groups....................................................................................... 240
10.4.5. Add Stop and Start Buttons ............................................................................. 243
10.4.6. Commit All Button ........................................................................................... 245
10.4.7. Status Monitoring ............................................................................................ 247
10.5. Issuing a Stop Command ......................................................................................... 248
10.5.1. Other Conditions that cause Stop .................................................................... 250
10.5.2. Indications a Stop is Active .............................................................................. 252
10.5.3. ERSC Functions Affected by Stop Command..................................................... 254
10.5.4. CNIP Functions Affected by Stop Command...................................................... 256
10.6. ConveyLinx Function at Stop Group Boundaries....................................................... 257
10.7. Issuing a Start Command ........................................................................................ 258
10.7.1. Indications Start is Active ................................................................................ 260
10.8. Using a PLC with ConveyStop .................................................................................. 261
10.8.1. ConveyStop Status Register............................................................................. 263
10.8.2. ConveyStop Command Register ....................................................................... 264
10.9. Wiring Examples ..................................................................................................... 265
10.9.1. ERSC with Stop Button..................................................................................... 266
10.9.2. ERSC with Start Button .................................................................................... 267
10.9.3. CNIP with Stop Button...................................................................................... 268
10.9.4. CNIP with Start Button ..................................................................................... 269

11. ERSC PLC Developers Guide

Guide.............................................................................................
............................................................................................. 270
11.1. Network Architecture .............................................................................................. 271
11.2. Understanding Assemblies ...................................................................................... 272
11.2.1. Modbus Assembly Instance Structure .............................................................. 273
11.2.2. Ethernet I/P Assembly Instance Structure ........................................................ 275
11.2.3. Profinet IO Assembly Instance Structrure ......................................................... 276
11.2.4. Assembly Register Chart Legend ..................................................................... 277
11.3. ZPA Mode Control .................................................................................................... 278
11.3.1. PLC Inputs for ZPA Mode .................................................................................. 279
11.3.1.1. Local Zone Status .................................................................................... 283
11.3.1.2. Arrival/Departure Counts.......................................................................... 285
11.3.1.3. Module Status .......................................................................................... 286
11.3.1.4. Tracking and Release Counts.................................................................... 288
11.3.1.5. Forward and Reverse Tracking.................................................................. 289
11.3.1.6. Port Inputs and ConveyStop Status .......................................................... 290
11.3.2. PLC Outputs for ZPA Mode ............................................................................... 291
11.3.2.1. Set Local Tracking .................................................................................... 296
11.3.2.2. Accumulation Control ............................................................................... 298
11.3.2.3. Speed Control .......................................................................................... 300
11.3.2.4. Release and Status .................................................................................. 301
11.3.2.5. Induct Tracking Forward and Reverse ....................................................... 302
11.3.2.6. Set Outputs and Motor Clear .................................................................... 303
11.3.2.7. ConveyStop and Clear Jams ..................................................................... 305
11.3.2.8. Direction and Accumulation Mode ............................................................ 306
11.3.2.9. ConveyMerge Interface ............................................................................ 308
11.3.3. ZPA Examples .................................................................................................. 309
11.3.3.1. Basic Accumulate and Release with Tracking Data ...................................310
11.3.3.2. Conveyor Setup for Simple Bar Code Reader ............................................313
11.3.3.3. Upstream Accept Interface ....................................................................... 315
11.3.3.4. Downstream Discharge Interface ............................................................. 317
11.3.3.5. Simple Divert Example ............................................................................. 319
11.3.3.6. Merge onto ZPA Main Line ........................................................................ 321
11.3.4. Reduced Size ZPA Mode Assemblies................................................................. 323
11.4. PLC I/O Mode Control............................................................................................... 326
11.4.1. Setting PLC I/O Mode in EasyRoll ..................................................................... 327
11.4.2. Optional Clear Connections Choice .................................................................. 328
11.4.3. Configuring Action for Loss of Communication .................................................330
11.4.4. Lock PLC Mode ................................................................................................ 331
11.4.5. Load ConveyLogix Program.............................................................................. 332
11.4.6. PLC Inputs for PLC I/O Mode............................................................................. 334
11.4.6.1. ConveyStop Status................................................................................... 338
11.4.6.2. Sensor & Control Ports ............................................................................. 339
11.4.6.3. Left Motor Status ..................................................................................... 340
11.4.6.4. Right Motor Status ................................................................................... 342
11.4.6.5. Motor Ports Digital Status ........................................................................ 343
11.4.6.6. Upstream / Downstream Status & Tracking...............................................344
11.4.6.7. Servo Control Status ................................................................................ 345
11.4.7. PLC Outputs for PLC I/O Mode .......................................................................... 346
11.4.7.1. ConveyStop Command & Clear Motor Error ..............................................351
11.4.7.2. Motor & Control Port Digital Output .......................................................... 352
11.4.7.3. Left Motor Control .................................................................................... 353
11.4.7.4. Right Motor Control .................................................................................. 355
11.4.7.5. Set Status & Tracking ............................................................................... 357
11.4.7.6. Set Sensor & Control Port Input Mask ....................................................... 359
11.4.7.7. Servo Control ........................................................................................... 361
11.4.7.7.1. Servo Control Example ..................................................................... 363
11.4.8. Reduced Size PLC I/O Mode Assemblies ........................................................... 368
11.5. ConveyLogix Interface............................................................................................. 370
11.5.1. ConveyLogix Assembly Inputs to PLC ............................................................... 371
11.5.2. ConveyLogix Assembly Outputs from PLC ........................................................ 372
11.6. Assemblies with Reset Protection ............................................................................ 373
11.6.1. ZPA Mode Assembly Inputs with Reset Protection ............................................374
11.6.2. ZPA Mode Assembly Outputs with Reset Protection ..........................................375
11.6.3. Reduced Size ZPA Mode Assemblies with Reset Protection ...............................377
11.6.4. PLC I/O Mode Assembly Inputs with Reset Protection .......................................379
11.6.5. PLC I/O Mode Assembly Outputs with Reset Protection.....................................381
11.6.6. Reduced Size PLC I/O Mode Assemblies with Reset Protection..........................383
11.6.7. How to use Assemblies with Reset Protection ..................................................384
11.7. Motor Port as Digital I/O .......................................................................................... 385
11.8. ODVA Compliant Cross-Reference ............................................................................ 387
11.8.1. ZPA Mode Assembly Inputs .............................................................................. 388
11.8.2. ZPA Mode Assembly Outputs ........................................................................... 389
11.8.3. ZPA Mode Reduced Size ................................................................................... 391
11.8.4. PLC I/O Mode Assembly Inputs ......................................................................... 393
11.8.5. PLC I/O Mode Assembly Outputs ...................................................................... 394
11.8.6. PLC I/O Mode Reduced Size.............................................................................. 396
11.8.7. Reset Protection for ZPA Mode Assembly Inputs...............................................397
11.8.8. Reset Protection for ZPA Mode Assembly Outputs ............................................398
11.8.9. Reset Protection for Reduced Size ZPA Assemblies ..........................................400
11.8.10. Reset Protection for PLC I/O Mode Assembly Inputs........................................402
11.8.11. Reset Protection for PLC I/O Mode Assembly Outputs .....................................404
11.8.12. Reset Protection for PLC I/O Mode Reduced Size ............................................406

12. Setting Up Dual Motor Zones ........................................................................................... 407

12.1. 2 MDRs Mechanically Coupled ................................................................................. 408
12.1.1. ZPA Mode ........................................................................................................ 409
12.1.1.1. For Firmware 4.25/5.02 ............................................................................ 410
12.1.1.2. For Firmware 4.27/5.07 and EasyRoll 4.21 ................................................414
12.1.2. PLC I/O Mode ................................................................................................... 415
12.1.2.1. For Firmware 4.25/5.02 ............................................................................ 416
12.1.2.2. For Firmware 4.27/5.07 and EasyRoll 4.21 ................................................418
12.1.3. ConveyLogix Program ...................................................................................... 419
12.2. Two Motors in One Roller Tube ................................................................................. 420
12.2.1. ZPA Mode ........................................................................................................ 422
12.2.2. PLC I/O Mode ................................................................................................... 423
12.2.3. ConveyLogix Program ...................................................................................... 424
12.3. Two Motor Rollers in One Logical Zone Not Coupled.................................................425

13. Connecting to R
Rockwell
ockwell PLCs with Ether
Ethernet
net I/P .................................................................
.................................................................426
426
13.1. Selecting Your Connection Method based upon Assembly ........................................428
13.2. Using Generic Ethernet Module Method ................................................................... 429
13.3. Procedure for Connecting using Generic Ethernet Module........................................431
13.3.1. Parameters for Each Assembly......................................................................... 432
13.4. Procedure for using EDS Method ............................................................................. 435
13.5. Using ERSC Add On Instructions (AOI) with RSLogix 5000 ........................................437
13.5.1. AOI Tag Descriptions ........................................................................................ 439
13.5.1.1. ZPA Mode Inputs ...................................................................................... 440
13.5.1.2. ZPA Mode Outputs ................................................................................... 442
13.5.1.3. PLC I/O Mode Inputs ................................................................................. 445
13.5.1.4. PLC I/O Mode Outputs .............................................................................. 448
13.6. Using Logix 5000 MSG Instruction ........................................................................... 451
13.6.1. Read MSG Instruction ...................................................................................... 452
13.6.2. Write MSG Instruction ...................................................................................... 454
13.6.3. Reading ERSC Input Assembly with MSG Instruction ........................................456
13.7. EDS Module Data Type Cross Reference................................................................... 458

14. Connecting to Siemens PLC with P

Prrofinet IO .....................................................................
.....................................................................460
460
14.1. Preparing Your Programming Environment............................................................... 462
14.2. Modes of Operation ................................................................................................. 463
14.3. Understanding the Two Configuration Methods ........................................................ 465
14.4. Separate ConveyLinx Auto-Configuration ................................................................ 467
14.4.1. Profinet Name.................................................................................................. 468
14.4.2. Examples of Adding Modules ........................................................................... 469
14.4.2.1. Full ZPA.................................................................................................... 470
14.4.2.2. Full PLC Controlled ................................................................................... 473
14.4.2.3. Reduced ZPA ............................................................................................ 475
14.4.2.4. Reduced PLC ............................................................................................ 477
14.4.2.5. Merger Mode............................................................................................ 479
14.4.2.6. PLC Controlled with ConveyLogix Interface ..............................................480
14.5. Integrated PLC Topology Configuration .................................................................... 483
14.5.1. Profinet Name.................................................................................................. 484
14.5.2. Adding Modules ............................................................................................... 485
14.5.3. Topology Example............................................................................................ 486
14.5.3.1. Connecting 1st Subnet of Modules ........................................................... 489
14.5.3.2. Connecting 2nd Subnet of Modules .......................................................... 490
14.5.4. Module Configuration....................................................................................... 491
14.5.4.1. ZPA/Reduced ZPA Modes .......................................................................... 492
14.5.4.1.1. Upstream/Downstream Zones........................................................... 494
14.5.4.1.2. Upstream/Downstream Zone Timing .................................................496
14.5.4.1.3. Connection to Merger Module ........................................................... 497
14.5.4.2. PLC/Reduced PLC Mode ............................................................................ 498
14.5.4.3. Merger Mode............................................................................................ 500
14.5.4.4. ConveyLogix Mode ................................................................................... 501
14.6. Accessing Data from ConveyLinx Modules ............................................................... 502
14.6.1. Raw Unmapped Data Direct from Module......................................................... 504
14.6.2. Module Data Elements Mapped to Tags ............................................................ 507
14.6.3. Module Data Instances Mapped to User Defined Types (UDTs)..........................511
14.6.3.1. Installing UDTs into Programming Environment ........................................512
14.6.3.2. Selecting the correct UDT for the Module’s Assigned DAP ........................514
14.6.3.3. UDT Assignment Example ........................................................................ 517
14.6.3.3.1. Add feeder Module ........................................................................... 519
14.6.3.3.2. Add workstation Module ................................................................... 521
14.6.3.3.3. Add remaining Modules .................................................................... 523
14.7. User Data Types (UDTs) ........................................................................................... 525
14.7.1. UDTs for ConveyLinx-ERSC Family .................................................................... 526
14.7.1.1. Full ZPA Mode Inputs ................................................................................ 528
14.7.1.2. Full ZPA Mode Outputs ............................................................................. 532
14.7.1.3. Reduced ZPA Mode Inputs ........................................................................ 535
14.7.1.4. Reduced ZPA Mode Outputs ..................................................................... 538
14.7.1.5. Full PLC I/O Mode Inputs........................................................................... 541
14.7.1.6. Full PLC I/O Mode Outputs ........................................................................ 546
14.7.1.7. Reduced PLC I/O Mode Inputs................................................................... 551
14.7.1.8. Reduced PLC I/O Mode Outputs ................................................................ 554
PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

1. About This Manual

ConveyLinx ERSC Complete Guide V Version

ersion 5.1 includes
* functionality for Conveylinx-
5.07.
Conveylinx-ERSC
ERSC Fir
irmwar
mware
e versions 4.27 /

For ConveyLinx-
ConveyLinx-ERSC
ERSC Fir
irmwar
mwaree versions 4.25 / 5.02 please
refer to ConveyLinx ERSC Complete Guide Manual V
Version
ersion
5.0

Products Cover
Covered
ed in this Manual

ConveyLinx-
ConveyLinx-ERSC
ERSC
Article Number
3010-0000

Page 8 of 557
PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

ConveyLinx-
ConveyLinx-HTF
HTF
Article Number
3010-3000

ConveyLinx-
ConveyLinx-ERSC
ERSC-E
-E
Article Number
3110-0000

ConveyLinx-
ConveyLinx-HTF
HTF-E
-E
Article Number
3110-3000

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

Page 9 of 557
PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

Important User Infor

Information
mation

! 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, Pulseroller
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 Pulseroller is prohibited

Not Included in this Manual

! Because system applications vary; this manual assumes users and application
engineers have properly sized their power distribution capacity per expected
motor loading and expected operational duty cycle. Please refer to conveyor
equipment and/or motor roller manufacturer’s documentation for power supply
sizing recommendations

Page 10 of 557
PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

How to Contact Us
Technical Support North & South America: [email protected]
Sales Support North & South America: [email protected]
Technical Support Global: [email protected]
Sales Support Global: [email protected]
Web Site: www.pulseroller.com

Page 11 of 557
PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

2. Glossary of T
Ter
erms
ms
Ter
ermm Definition

A separate (usually wrapped or boxed) object to be transported by the

Carton conveyor. The terms tray, tote, load, or product may also be used
interchangeably in this document.

Conveyor controls architecture based upon modular distributed devices

ConveyLinx
connected via Ethernet network.

Conveyor control module that is part of the ConveyLinx family. Each module
ConveyLinx-Ai / can accommodate up to 2 MDR conveyor zones. The modules allow
ConveyLinx-Ai2 / connection for Senergy-Ai platform motor rollers and gear drives. The term
ConveyLInx-Ai3 Module will be used within this document and will refer to the ConveyLinx-Ai2
device

Dynamic Host Configuration Protocol A protocol for assigning IP addresses to

DHCP devices on a network from a pool of available IP’s. A dynamic IP address
changes each time the device connects to the network

Ethernet Roller Speed Control module – Conveyor control module that is part
of the ConveyLinx family. Each ERSC can accommodate up to 2 MDR
ERSC
conveyor zones. In this document the term module will be synonymous with
ERSC

Designed to “break-out” the RJ11 connection for easy installation. The

module has an amplifier to the output giving it up to 100mA output
ERSC
ERSC-SE4
-SE4 capabilities. Configurable diodes for the inputs to minimize leakage current to
and from the ERSC. Module also allows for external power source connection
for auxiliary devices.

Special sensor embedded within the brushless DC motor of an MDR used to

Hall Effect Sensor
provide motor rotor position feedback to the motor controller

The IP Code (International Protection Marking) specifies the device’s degree

of resistance to intrusions, dust and water. IP54 certified device must be fully
IP54
protected from splashed water, dust particles and completely protected from
contact

This is the name of a particular connector manufacturer that produces a

specific plug/socket arrangement for MDR connection to control cards. This
JST
name is accepted within the conveyor and MDR industry as a simple
description of the particular socket style used on ERSC hardware.

Light Emitting Diode – In the context of this document, LED’s are used on the
LED
ConveyLinx-Ai2 to provide visual indication of module status

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PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

Term used to describe how the signaling output circuit of a photo-sensor is

configured when it detects its reflected light. A photo-sensor that is light
Light / Dark
energized will activate its output circuit when it detects its reflected light. A
Ener
Energized
gized
dark energized photo-sensor will activate its output circuit when it does not
detect its reflected light

This is the type of a connector, which has four connector pins and is used on
M8
the ConveyLinx Ai2 modules for both sensor connectors and MDR connectors

Motorized Drive Roller or Motor Driven Roller – Brushless DC motor and

MDR
gearbox assembly integrated into a single conveyor roller

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Control logic terminology to define the state of the output of a Boolean “on”
or “off” device. The term specifically describes the state of the output circuit
when the device’s sensing circuit is un-energized. In the context of photo-
sensors; a normally open wired sensor would have its output circuit
Nor
Normally
mally Open /
energized when it detected its reflected light and its output circuit would be
Nor
Normally
mally Closed
de-energized when it did not detect its reflected light. Conversely a photo-
sensor wired normally closed would energize its output circuit when it did not
see its reflected light and it would de-energize its output circuit when it did
detect its reflected light

Electronics term that indicates the type of transistor circuit used for a logical
input or output for controllers. NPN devices will provide a common or ground
NPN / PNP
connection when activated and a PNP device will provide a logic voltage
connection when activated

A device, mounted near the end of the conveyor zone to sense the presence
Photo
Photo-sensor
-sensor
of a carton on the zone

Programmable Logic Controller – A wide variety of industrial computing

PLC
devices that control automatic equipment

Pulse Width Modulation – a control scheme that utilizes high speed switching
PWM transistors to efficiently deliver power in a controlled fashion from the
ConveyLinx controller to MDR

Term used to describe the two basic types of photo-sensors. Retro-reflective

photo-sensors utilize a reflective target that must be aligned with the photo-
sensor such that the light emitted by the photo-sensor is reflected back to it.
Retr
etro
o-r
-reflective
eflective /
‘Reflex (or sometimes known as proximity) type photo-sensors emit light to
Refle
eflexx
be reflected back from an object located sufficiently close to the sensor. ‘For
both types of photo-sensors, when they detect their reflected light source,
their signaling output circuit changes state.

Registered Jack Style 11 / 12 – Standard connector / receptacle format

utilizing 4 or 6 pin connections. The typical standard connection for
RJ
RJ-11
-11 / RJ
RJ-12
-12
telephones. RJ-11 utilizes 4 pins and RJ-12 utilizes 6 pins but both styles use
the same physical size.

Registered Jack Style 45 – Standard connector / receptacle format utilizing 8

RJ
RJ-45
-45 pin connections. The typical standard for computer network cable
connections

PulseRoller brand proprietary motor control platform that provides electronic

intelligence inside the motor that can be read by ConveyLinx-Ai Family and
Sener
Senergy
gy-Ai
-Ai
MotionLinx-Ai Family control modules. The connection from the motor to the
controller is via 4-Pin M8 style connector

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Conveyor control method for zoned controlled conveyor that dictates that
Singulation when a zone is discharging its carton, the upstream carton waiting to enter
Release must wait until the discharged carton is completely clear before it is allowed
to enter

A set of non-motorized conveyor rollers mechanically linked to an MDR. The

MDR and slave rollers make up a physical zone. All of the slave rollers in a
Slave R
Rollers
ollers
zone rotate at the same speed and direction as the MDR because of their
mechanical linkage

Transport Control Protocol / Internet Protocol – IP is the protocol which

oversees the transmission of information packets from device to device on an
TCP
CP/IP
/IP Ethernet network. TCP makes sure the packets have arrived and that the
message is complete. These two protocols are the basic language of the
Internet and are often referred to together as TCP/IP.

Conveyor control method for zone configured conveyor that dictates that
Train R
Release
elease when a zone is discharging, the upstream zone’s carton can move in unison
with the discharging carton.

A basic (linear or curved) cell of the conveyor consisting of a set of slave

Zone
rollers driven by one or more MDR’s and a single photo-sensor.

Zero Pressure Accumulation – Term that describes the conveyor controls and
ZP
ZPA
A mechanical scheme that will cause loads to queue on a conveyor in discrete
zones such that loads do not touch each other

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3. 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 software tool and provide instructions to configure and modify
parameters

Who Should Use this Manual?

This manual is intended for users who need basic product information and simple application
procedures to implement Modules to control simple linear conveyor.
You should have a basic understanding of electrical circuitry and familiarity with relay logic,
conveyor equipment, photo-sensors, etc. If you do not, obtain the proper training before using
this product.

What do you want to do?

The Basics

Learn about module hardware ports

Learn about power supply sizing
How to Auto-Configure your network of modules
Find out about what all the LED states mean
Learn about the different release modes and how to change them
Learn about Flex Zone
Learn about jam conditions
How to reset a module back to factory default
How to wire up a Hardwired Interlock
How to Auto-Replace a module

Basic things you can do with EasyR

EasyRoll
oll

Learn about basic navigation through EasyRoll

Learn about ZPA settings and how to change them
How to change motor direction, speed, accel/decel, etc.
Learn about motor status and error indicators
How to change Jam Timers and Auto-Clear Timers
How to change how the module logic uses the block/clear output from your sensors

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How to change your Control Port Inputs to match the signals you are using

Some advanced things you can do with EasyR

EasyRoll
oll

Learn how to discover modules on your network and change IP addresses

How to set up Look Ahead Slow Down feature
How to disable Flex Zone Recognition and why you may want to
How to set up an Extension or slave module
How to connect two separate networks together to operate in ZPA
How to backup and restore module settings
How to upgrade module firmware

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4. Module Har
Hardwar
dware
e
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
MDR units with their corresponding 2 photo-sensors as well as upstream and downstream
network and discreet interconnections to form a complete control system for zoned MDR
conveyors.

* The “left” and “right” naming convention for the module ports is based upon
facing the front of the ConveyLinx Module and is not to be confused with
direction of product flow on the conveyor. Product flow will be designated as
“upstream” and “downstream”

Learn more:

Identif
Identifying
ying ConveyLinx Module Components
Mounting Dimensions
Motor P Ports
orts
Sensor & Contr
Control
ol P
Ports
orts
Ether
Ethernet
net PPorts
orts
ConveyLinx Module InterInternal
nal F
Fusing
using
LED Status Indicators

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4.1. Identif
Identifying
ying Module Components

Item Description

24VDC Power Connector

Install Button – Used for Auto-Configuration Procedure and Auto Module

Replacement

& Motor Left and Motor Right 9-pin JST style header for MDR/PGD connection

Left Sensor Port and Right Sensor Port RJ-12 style jack for zone photo-sensor
& connection

Link Left and Link Right RJ-45 style Ethernet network communication
& connection between modules

Left Control Port and Right Control Port RJ-12 style ports for discreet hard-
& wired signal connections for non-networked interface interlocks and zone
control

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& Motor Left LED & Motor Right LED – Motor status indicators

Module Status LED Indicator

Module Network Status LED Indicator

& Left Link & Right Link Status LED Indicators

& Left Sensor & Right Sensor Status LED Indicators

& Control Port Left & Control Port Right Status LED Indicators

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4.2. Mounting Dimensions

ConveyLinx (3010-0000) and ConveyLinxE (3110-0000)

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ConveyLinx-
ConveyLinx-HTF
HTF (3010-3000) and ConveyLinxE-
ConveyLinxE-HTF
HTF
(3110-3000)

Conveyor F
Frame
rame P
Prreforations Dimensions

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Optional Mounting Brack

Bracket
et
Pulseroller Order Type: BRK
BRKT
T-UNIV Order Code: 099-1002

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4.3. Motor P
Ports
orts
Both the Left and the Right Motor Ports utilize a 9-pin JST brand female receptacle. Each
receptacle is mechanically keyed to assure proper orientation upon plugging in. The motor
connector pin-outs are as shown

Pin Description

1 GND

2 Vcc – Hall Effect Sensor Power

3 Motor Winding U

4 Motor Winding V

5 Motor Winding W

6 Hall Effect Sensor U

7 Hall Effect Sensor V

8 Hall Effect Sensor W

9 Optional – Mechanical Holding Brake Control

* Please note the JST connector is keyed so you cannot plug it in upside down

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4.4. Sensor & Contr

Control
ol P
Ports
orts

Each Sensor and Control Port is a standard RJ-12 style jack.

Sensor P
Port
ort P
Pin
in Out
Pin Signal Description

1 Not Used

2 GND Module DC Common

Digital Input for Sensor’s error output – Auto detect for NPN or
3 Sensor Error
PNP

Digital Input for Sensor’s state output – Auto detect for NPN or
4 Sensor State
PNP

5 Vcc Module 24VDC Supply

6 Not Used

! Shorting Pins 2 & 5 (Vcc and Gnd) may damage the port’s Sensor Detect circuit.
If this circuit is damaged, the module will no longer properly detect a connected
sensor and will not properly Auto-Configure.

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Contr
Control
ol P
Port
ort P
Pin
in Out
Pin Signal Description

Digital Output for Upstream/Downstream Interlock, SE Module

1 Output E
recommended

2 GND Module DC Common

Optional Local Accumulate Digital Input – Auto detect for NPN

3 P3 Input
or PNP

4 P4 Input Optional Interlock Digital Input – Auto detect for NPN or PNP

5 Vcc Module 24VDC Supply

Digital Output for Upstream/Downstream Interlock, SE Module

6 Output C
recommended

! Single output signal flows between Pin 1 and Pin 6. This signal is very low power
(@ 2mA). An SE Breakout Module is recommended when using of this signal.

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4.5. Ether
Ethernet
net P
Ports
orts
Both of these ports are standard RJ-45 jacks conforming to standard Ethernet connection pin-
out.

RJ-45 Cable and Ethernet Port RJ-45 Cable Plugged in

Both Left & Right RJ-45 Cables Plugged In

! All Hardware Revision 1 ConveyLinx Module must use Ethernet shielded

crossover style cables. Hardware Revision 2 and later modules can use straight
or crossover shielded Ethernet cables. Failure to use SHIELDED cables may result
in data loss and unexpected results

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4.6. Module Inter

Internal
nal F
Fusing
using
Because the ConveyLinx Module utilizes a single external power connection for both control
power and MDR power; the ConveyLinx Module includes internal re-settable fusing to protect
the control power from the MDR power. The overall control power fuse is rated at 300 mA and
this is the source for CPU, LED’s, sensor ports, control ports, etc. From this circuit, the Sensor
and Control port pairs share their own separate 100 mA fuses.

ConveyLinx-ERSC Internal Fusing Diagram

! User’s must take care in the types of sensors and devices that need to connect
to a given ConveyLinx Module and assure that the current draw on any Sensor/
Control port pair does not exceed the fuse ratings. If any of the 100 mA fuses
trips, there is no direct indication of this state. An indirect indication could be to
see if a connected sensor is powered when plugged into either port.

! If the 300 mA fuse trips, upon the automatic reset of the fuse, the ConveyLinx
Module should reboot on its own. However, the ConveyLinx Module may require
the power to be cycled manually to fully restart

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4.7. Over
Over-V
-Voltage
oltage P
Prrotection
There are two sources of potential excess voltage:

1. Over-voltage coming from the power supply

2. Over-voltage generated by an over-driven motor

Power Supply
The ConveyLinx Module utilizes an SMBJ30A “clamp down” chip on the power input to detect
any voltage coming in that is greater than 33.3V. If this is detected, it shorts the +24V to GND
to protect the remaining electronics on the module. This chip serves a dual function as it also
helps filter ESD voltage spikes as well.

Over
Over-Driven
-Driven Motor
The ConveyLinx Module firmware monitors the motor voltage and if it rises above 30V, it
automatically shunts the motor driver transistors together (the same as in normal braking) so
that the energy is contained within the motor coils and away from the controller electronics.
The inherent nature of motor coil geometry and construction allow for this driven state to be
tolerated for several seconds or even minutes before there is any potential damage to the
motor coil circuit. When the voltage drops below 29V, the ConveyLinx Module firmware allows
the motor power transistors to switch back to their normal operation.

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4.8. LED Status Indicators

ConveyLinx Module status is indicated by several LED’s. All LED’s with the exception of the
Ethernet Link and Activity LEDs are multi-colored and context sensitive. The following sections
indicate the various meanings of all LED indicators.

* By definition Blinking is approximately 1⁄2 second on/off cycle and Flashing is

approximately 1⁄4 second on/off cycle.

If you need help finding where LED Items are located on the ConveyLinx Module

Communications
Indicator Item LED State Description

OFF No connection established

Ether
Ethernet
net L
Lef
eftt
Solid Green Connection is established
Link
Blinking Green When data transmission activity is occurring

OFF No connection established

Ether
Ethernet
net
Solid Green Connection is established
Right Link
Blinking Green When data transmission activity is occurring

Motors
Indicator Item LED State Description

OFF Motor is not running and no faults detected

Solid Green Motor is running

Flashing Green Motor is being moved or rotated by external

Motor Left & (intermittent) force
Motor Right &
Solid Red Motor is not connected or motor is stalled

Blinking Red Motor is overloaded or over-heated

Motor Stopped: Short circuit detected between

Flashing Red
at least two of the phase windings

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Motor Running: Over-current condition

Network & Module Status

Indicator Item LED State Description

Module is booting up or during Auto-

Solid Red Replacement procedure, module is attempting
to retrieve data from neighbor module(s)

Blinking Red Module is starting task processes

Blinking Green Module is ready

Module Flashing Green & Auto-replace procedure has been properly

Status Blinking Red triggered

Flashing Red &

Failsafe Mode
Blinking Green

Flashing Red Auto Configure Mode is active

Blinking Amber Performing firmware upgrade check

Solid Amber Firmware upgrade in progress

Solid Red Starting Inter-module communications

Network
Blinking Red Establishing inter-module connections
Status
Blinking Green Inter-module communications established

Sensors
Indicator Item LED State Description

Solid Green Sensor is Blocked

Solid Red Sensor Error State (Pin 3) is Active

Sensor L
Lef
eftt
& Right & Blinking Red Arrival Jam or missing sensor

Blinking Green/
Sensor Jam
Amber

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When Sensor is blocked, indicates external

Flashing Green device (PLC/PC controller or EasyRoll) has
accumulated the zone and inhibiting release

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Contr
Control
ol P
Ports
orts
Indicator Item LED State Description

If acting as Upstream Port: Wake-up signal is

logically enabled on Pin 4

If acting as Downstream Port: Lane Full signal is

Solid Green
logically enabled
Contr
Controlol P
Port
ort
& If Module is in PLC I/O Mode: Signal on Pin 4 is
Lef
eftt & Right
logically enabled

Local Accumulate signal (Pin 3) is logically

Solid Red
enabled

Flashing Red Module configuration error

Special Cases
Indicator Item LED State Description

All Sensor,
Control Port Flashing Red Module in stopped state
& Motor

Left Sensor,
Left Control ZPA zone on left side of module is in
Flashing Green
Port, & Left Maintenance Mode*
Motor

Right
Sensor,
ZPA zone on right side of module is in
Right Control Flashing Green
Maintenance Mode*
Port, & Right
Motor

* *Maintenance mode only accessible via remote PLC.

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4.9. 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
(Hardware Rev.1 modules must use shielded crossover Ethernet cables) and each module
needs to receive a 24VDC power connection. The Power Plug connection is the power source for
all logic, photo-sensors, and MDR’s.
Multiple power supplies should have their DC Common terminals connected together as shown:

! This document assumes the user is aware of MDR power requirements for the
application and that the user and/or installer have properly sized 24VDC power
supplies and wiring based upon all applicable codes and standards. This
document also assumes installation will follow proper equipment grounding
practices. “DC common or -”on all power supplies should always be connected to
ground. Improper power supply sizing and/or improper grounding practices will
produce unexpected results.

Learn about power supply sizing

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4.10. Power Supply Sizing

The current loading on the power supply for a group of ConveyLinx Modules depends upon the
Motor Type selected. Each of the motor types available has an associated rated current that the
motor will draw at rated torque and maximum speed. Each motor type also has an associated
allowed current draw that is available for a period of time upon the initial starting of the motor.
Theses current values and starting times are shown in the following chart:

BOOST
ECO BOOST
8

Power supply load per Motor P

Port
ort at rated torque at maximum
2.5 A 3.5 A 3.5 A
speed

Power supply load per Motor P

Port
ort during motor starting period 3.0 A 5.0 A 8.0 A

Duration of motor starting period 5.0 sec 1.5 sec 3.0 sec

* Please note that BOOST 8 is only available on ConveyLinx-ERSC-HTF module. You

can select BOOST 8 in EasyRoll for a ConveyLinx-ERSC module, but it will not
deliver the BOOST 8 current

* Please note that the current values shown are per Motor Port, so if both Motor
Ports are being used on a given ConveyLinx Module, the current load seen by the
power supply for that module will be double the value shown.

* The current values are at rated speed and at rated torque. The current will be
less if rated torque is not required by the motor.

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4.11. Technical Specifications

These specifications cover ConveyLinx ERSC Hardware Revisions 3 and above and Serial
numbers 137101 and higher.

Power Connector
Power connector is included with the ConveyLinx Module when shipped from the factory

ERSC Phoenix Contact PN: 1827127 MCVR 1,5/2-ST-3,81

ERSC-HTF Phoenix Contact PN: 1912841 MVSTBW 2,5 HC/ 2-ST-5,08

Electrical R
Ratings
atings
Power supply voltage 24.0V +/- 10%

Standby current consumption < 120mA

Motor Starting Current ≤ 5.5A ERSC / ≤ 8A ERSC-HTF

Motor Rated Current ≤ 4A ERSC / ≤ 5A ERSC-HTF

Motor PWM Frequency 10 kHz +/- 0.1%

Maximum R
Ratings
atings

! Operating outside these parameters may result in permanent ConveyLinx Module

failure or unexpected device behavior

Minimum Operating Voltage 21V

Maximum Operating Voltage 30V

Storage temperature -40ºC to 150º C ( -40ºF to 300ºF)

Ambient Operating temperature (ERSC) 0ºC to 40ºC ( 32°F to 104°F)

Ambient Operating temperature (HTF) -30ºC to 45ºC ( -22ºF to 113°F)

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Humidity 5% to 95% non-condensing

Vibration 0.152 mm (0.006 in.) displacement, 1G peak

Mechanical Shock 20G peak for 10ms duration (1.0 ms)

Enclosure IP Rating IP20

Maximum peak current 21.5A*

Maximum motor start current 12A

*This is the maximum current that will be allowed by the hardware over current protection
circuitry. On board firmware limits the amount of current based on the quantity and motor
types connected

Certifications & Standar

Standards
ds
Programmable controllers — Part 2: Equipment requirements and
BDS EN 61131-2:2008
tests

Electromagnetic compatibility (EMC) — Part 6-2: Generic standards

BDS EN 61000-6-2:2006
– Immunity for industrial environments

Electromagnetic compatibility (EMC) — Part 6-4: Generic standards

BDS EN 61000-6-4:2007
– Emission standard for industrial environments

Specification for radio disturbance and immunity measuring

BDS EN
apparatus and methods Part 2-1 Methods of measurement of
55016-2-1+A1:2006
disturbances and immunity. Conducted disturbance measurements

Electromagnetic compatibility – Requirements for household

BDS EN 55014-1:2007
appliances, electric tools and similar apparatus — Part 1: Emission

BDS EN Electromagnetic compatibility (EMC) Part 4-2: Electromagnetic

61000-4-2+A1+A2:2004 discharge Immunity test

Electromagnetic compatibility (EMC) Part 4-3 Radiated radio-

BDS EN 61000-4-3/A1:2008
frequency, electromagnetic field immunity test.

Electromagnetic compatibility (EMC) Part 4-4 Electrical fast

BDS EN 61000-4-4:2006
transient/burst immunity test.

BDS EN 61000-4-5:2007 Electromagnetic compatibility (EMC) Part 4-5 Surge immunity test.

Electromagnetic compatibility (EMC) Part 4-6 Immunity to

BDS EN 61000-4-6:2007
conducted disturbances, induced by radio-frequency field

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Electromagnetic compatibility (EMC) Part 4-11 Voltage dips, short

BDS EN 61000-4-11:2006
interruptions and voltage variations immunity tests

Sensor & Contr

Control
ol P
Port
ort I/O

Inputs

The Sensor and Control port

both have 2 inputs each.
Sensor and Control port
inputs are auto-sensing for
the connected circuit type.
Input function as either PNP
or NPN. Please note that
both sourcing and sinking
current will activate the
input

Minimum ON current 1.5 mA

Maximum OFF current 0.4 mA

Outputs

The Control Port output is

an NPN transistor whose
Emitter (Pin 1) and Collector
(Pin 6) are made available
to be connected either as
sourcing or sinking device in
the user’s input circuit

Minimum ON current 2 mA

Maximum ON current 8 mA

OFF current < 100 nA

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Sensor & Contr

Control
ol P
Port
ort P
Power
ower P
Pins
ins

Pin 5 of all RJ-12 ports provides 24V for powering up a photo-eye or for biasing the output
transistor found on the control port. The current that those pins can supply is limited internally.
Each side of the module is fused separately and each side’s control port and sensor port share
a solid-state fuse rated at 100 mA. For example, If there is one photo-eye plugged into the left
sensor port and one photo-eye plugged in the left control port, then the combined consumption
of the two photo eyes must not exceed 100mA.

! Current in excess of 100mA drawn from the sensor port’s 24V pin may cause
permanent damage to the sensor detection circuit. Care should be taken to avoid
excess loads, short circuits and miss-wiring of the sensor port

Motor P
Port
ort
Supported motor types 3 phase BLDC motors with 3 Hall Effect sensors

PWM frequency 10 kHz +/- 0.1%

Maximum starting current 8A

Maximum rated current 5A

Coil-to-coil short, coil-to-Vcc short, overheating, over-voltage,

Motor Protection*
under-voltage, stall sensing and protection

Brake output type PNP (high side switch)

Brake output current 0.5A (1 A peak)

! *During normal operation as an MDR port, the internal protection circuitry is not
capable of detecting a short-circuit between a BLDC coil output and ground. Such
a short-circuit will cause damage to the high-side bridge transistors. When
operating these outputs as general purpose outputs, the high-side transistors are
disabled, so a pin-to-ground short-circuit is not an issue

Motor P
Ports
orts in Digital IO Mode as Outputs

Motor Coil P
Pins
ins 3, 4, & 5

In certain modes of operation (PLC I/O and ConveyLogix PLC), Pins 3,4, and 5 can each be
independently switched on and off as general purpose digital outputs. Any individual pin can

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sink up to 1A to gr
ground
ound in these modes, but the total for all 3 pins combined cannot e
exxceed
1.5A
1.5A. In general purpose I/O mode, these pins cannot source current.

Brak
Brake
e Output P
Pin
in 9

As of firmware version 4.19 and later, the brake output pin can be configured through remote
PLC to operate as a general purpose output even if an MDR is connected to the port. This
situation requires a special cable or break-out board to be used and the MDR in use cannot
have and internal mechanical brake, as that mechanical brake requires a connection to pin 9
for proper operation. The brake-output pin 9 is a 24V high side switch (PNP) that can source up
to 0.5A continuously and 1A peak.

Ether
Ethernet
net
• 3 port integrated switch ( 2 external ports and 1 port for the on-board processor)
• Automatic speed setup (10Base-T / 100Base-TX)
• Automatic duplex configuration (Full / Half)
• Automatic straight/crossover cable detection ( Auto MDI/MDI-X)
• PAUSE frame support
• Back pressure flow control support
• Maximum segment length: 100m / 328ft

Supported P
Prrotocols

• Modbus/TCP
• EtherNet/IP
• Profinet IO
• CC-Link IE Field Basic (FW 4.27 and later and ODVA FW 5.07 and later)

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5. Auto
Auto-Configuration
-Configuration
The purpose of Auto
Auto-Configuration
-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
Auto-Configuration
-Configuration of Linear Conveyor feature of ConveyLinx
requires only the proper interconnection of each module and the press of a button on the most
upstream module to complete.

* A networked ConveyLinx solution is capable of controlling more complex

conveyor paths that include diverting and merging equipment. However, this
requires configuration with a PC and software.

Lear
earnn about:
Linear Conveyor
Auto
Auto-Configuration
-Configuration Examples
Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree
Expected Auto
Auto-Configuration
-Configuration RResults
esults
What to do if things go wr
wrong
ong with Auto
Auto-Configuration
-Configuration

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5.1. 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 zone.

Example of a Linear Conveyor

Lear
earnn about:

Device Connections to Modules

Examples that will generate errors
Motor rotation definition

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5.1.1. Device Connections to Modules

Before the Auto
Auto-Configuration
-Configuration PPrrocedur
oceduree can be performed; each individual ConveyLinx Module
needs to have its associated MDR’s and photo-sensors connected in the proper way for
expected operational results.
In general, each ConveyLinx Module detects which Sensor P Ports
orts have a device connected and
will use this to determine its specific configuration once it has been instructed to self-configure
by the Auto
Auto-Configuration
-Configuration PPrrocedur
oceduree.
Before starting to configure your system to operate, each MDR and photo-sensor needs to be
properly connected to the ConveyLinx Modules mounted on the conveyor. Modules will
determine how to operate based upon how the photo-sensors and MDR’s are connected.

* The number of Sensors connected will determine the total number of Zones.
Once Auto
Auto-Configuration
-Configuration is complete, this number of Zones cannot be modified
or over-ridden without performing another Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree.

A single ConveyLinx Module can operate as a:

2 zone contr
controller
oller
with 2 MDR
MDR’s’s and
2 photo
photo-sensors
-sensors

1 zone contr
controller
oller
with 1 MDR and 1
photo
photo-sensor
-sensor on
Lef
eftt or Right Side

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1 zone contr
controller
oller
with 2 MDR
MDR’s’s and
1 photo
photo-sensor
-sensor
with Sensor on
Lef
eftt or Right Side

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5.1.2. Examples that will generate er

errrors

* These examples are not necessarily invalid and will not cause the Auto
Configuration P
Prrocedur
oceduree to fail or abort, but they will result in module errors or
cause interruption in the flow of items on the conveyor.

This module will This module will

configure as a configure as a
two zone module two zone module
but will generate but will generate
a motor a motor
connection error connection error
for the missing for the missing
motor on the motor on the
Right side Left side

This module will This module will

configure as a configure as a
single zone single zone
module on the module on the
Right side but Left side but will
will generate a generate a
motor motor
connection error connection error
for the missing for the missing
motor on the motor on the
Right Side Left Side

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5.1.3. Motor R
Rotation
otation Definition
The ConveyLinx Module uses a Clock-W
Clock-Wise
ise (CW) and Counter Clock-W
Clock-Wise
ise ((CCW
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 automatically adjust the motor rotation direction based
upon the flow established by the procedure as long as the cable end of the roller
is on the same side of the conveyor as the ConveyLinx Module. If the rotation
direction is not correct after the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree completes, you
can change it in EasyR
EasyRoll
oll. How to change the motor rotation direction

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5.2. Procedur
oceduree
The ConveyLinx Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree routine will detect which photo-sensors are
connected in order to configure a given ConveyLinx Module as a 1 or 2 zone controller. The
physical order of module connections; from upstream to downstream, dictate the MDR direction
and product flow logic.

Befor
Before
eYYou
ou Begin
• All sensors should be clear. Auto
Auto-Configuration
-Configuration assumes tak
takes
es for granted that the state
of each sensor is the “zone empty” state so that the module can auto-learn the block/
clear states for both retro-reflective and diffuse type sensors
• Make sure you have no more than 221 ConveyLinx Modules connected. Auto Auto--
Configuration will not configure past 221 ConveyLinx Modules in one network
• Make sure that there are no other Ethernet devices or switches connected in your string
of ConveyLinx Modules. After Auto
Auto-Configuration
-Configuration is complete and successful, you can
interrupt the Ethernet string with other devices and/or switches as needed.

The direction of flow of the conveyor dictates where to begin the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree.
The ConveyLinx Module located at the most upstream or in-feed end of the conveyor is the
module where the procedure must be initiated.. Because of its physical location on the
conveyor path and physical location in the Ethernet connection chain; the most upstream

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ConveyLinx Module will automatically connect to all downstream ConveyLinx Modules and set
their I.P. address for communication. Then the routine automatically sets the direction of flow.

Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree

1. Press and hold INSTALL button on the most upstream/in-feed end ConveyLinx Module and
keep it held for 5 seconds
2. After 5 seconds the Module Status LED will flash RED
3. Once Module Status LED begins flashing RED, the INSTALL button must be released within
2 seconds. If held for longer than 2 seconds; the procedure is cancelled
4. Once the INSTALL button has been released within the 2 second time window, the
ConveyLinx Module will be initiated as most upstream module and the Auto-Configuration
Procedure routine will begin.
5. Observe that all of the LED’s (with the exception of the Left Link and Right Link LEDs) will
flash on and off RED on all the ConveyLinx Modules in the network string

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https://www.youtube.com/embed/XDJkC8jpZIM?rel=0

! In order for the Auto-Configuration to work properly, all loads, totes, product,
containers, cartons, etc. must be removed from the entire conveyor path and all
photo-sensors must be aligned and adjusted so that none are detecting that their
respective zone is occupied. Failure to meet these conditions will produce
unexpected results.

* Please note that once a network has been configured; pressing and holding the
Install button on any module that has neighboring ConveyLinx Modules on both
sides of it will not initiate a new Auto-Configuration Procedure. The module will
detect that it is not the most upstream unit and abort the procedure. However,
the ConveyLinx Module will perform its local re-booting procedure. This
procedure will take a few seconds to complete

! Please note that pressing and holding the Install button on the most
DOWNSTREAM ConveyLinx Module WILL initiate a new Auto-Configuration
Procedure and attempt to establish the flow in the opposite direction

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5.3. Auto
Auto-Configuration
-Configuration Examples

* Please note that the Flow is based upon the Ethernet cable routing during the
Auto
Auto-Configur
-Configure
ePPrrocedur
oceduree. The Flow direction cannot be changed or over-ridden.
The only way to change the Flow direction is to perform another Auto
Auto--
Configuration P
Prrocedur
oceduree

Lef
eftt to Right
Flow Example

Right to L
Lef
eftt
Flow Example

Lef
eftt to Right
Flow with
Opposite Side
Module Example

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5.4. Expected R
Results
esults
When the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree routine is complete, each ConveyLinx Module will
automatically reboot. When a ConveyLinx Module has been successfully configured and
rebooted, its Module and Network Status LEDLED’s
’s will blink on and off green.

When the module has been

pr
properly
operly configur
configured
ed and is
operational, both its Module
and Network Status LEDLEDss
will blink on and off Gr
Green
een

* Please note that the time to complete the Auto

Auto-Configuration
-Configuration P
Prrocedur
ocedure
dependent on the number of ConveyLinx Modules being configured. Larger
networks will take more time than smaller networks
e is

How to verif
verifyy success

Conveyor Operation

Place a carton on your empty conveyor so that it blocks the most upstream zone’s sensor. It
should convey all the way to the discharge end and the last most downstream zone should try
to convey it off the end of its zone. If this does not happen, then at the point where the carton
stops, check that module’s motor connection is sound and that the zone’s sensor is properly
aligned. If the sensor was not properly plugged in and powered when the Auto Auto-Configuration
-Configuration
Procedur
oceduree was performed, you will have to perform the procedure again. If the sensor was
powered but is misaligned when the Auto Auto-Configuration
-Configuration PPrrocedur
oceduree was performed, you can
either perform the procedure again or use EasyREasyRoll
oll to change the logical polarity of that
particular sensor.

Examine the Network

While the Auto

Auto-Configuration
-Configuration P
Prrocedur
oceduree is in process, you should see all of your modules’ LEDs

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flashing on and off red. If this is not the case, then check your Ethernet cables and connections
and power connections.

To verify that all the modules you expected to be configured are in fact configured, with
EasyR
EasyRoll
oll you can connect to your newly configured ConveyLinx Module network and perform a
Discover function. The Discover function will display all modules that it finds and from the list
your most upstream ConveyLinx Module should have the 4th octet of its IP Address as .20 and
you should see each module you configured in the list.

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5.5. What to do if things go wr

wrong
ong
Here are some troubleshooting tips:

Une
Unexpected
xpected 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 procedure is performed.
• Make sure you have the correct motor type setting in EasyRoll. How to change Motor
Type
• Make sure that there are no motor errors. How to jog motor and look for errors

Network and Module Status LED

LEDss Blinking Gr
Green
een with une
unexpected
xpected rresults
esults

• Check that all sensors are operational and that all zones are clear then perform
procedure again. How to change block/clear sensor logic without having to perform
another Auto-Configuration
• Check all network and power connections and make sure there is 24V on each
ConveyLinx Module then try the Auto-Configuration procedure again
• Verify that all of the module sensor/motor combinations are valid. Check here to find
out what module set-ups are invalid

Either or both Network and Module Status LED

LEDss ar
aree Blinking or Flashing R
Red
ed

• Make sure there are no other Ethernet devices (PC’s, Switches, Scanners, etc.)
connected between any of the module on your network. The Auto-Configuration
procedure aborts when it encounters a non ConveyLinx device along the network path
before reaching the last module. ConveyLinx Module up to that point should be
configured properly but the remaining modules will not.
• When removing a ConveyLinx Module from an existing configured network that is
already operational; be sure to wait 1 or 2 minutes to allow the Ethernet Switches on
the modules to reset their MAC Address ARP table before attempting a new Auto-
Configuration procedure

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6. 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 zone and see that it conveys to the
discharge zone. If it does, then the Auto-Configuration Procedure is successful.

Lear
earnn About:

Singulation R
Release
elease Mode
Fle
Flexx Zone R
Recognition
ecognition
Jam Conditions
Har
Hard-W
d-Wir
ired
ed Interlocks
Automatic Module R Replacement
eplacement
How to R
Reset
eset to F
Factory
actory Defaults

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6.1. Singulation R
Release
elease 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 ar
aree accumulated

Carton 1 rreleases
eleases – Cartons 2
and 3 rremain
emain accumulated

When Carton 1 clears PE1

then Carton 2 rreleases
eleases

* View other ZPA Release Modes and how to change them

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6.2. Fle
Flexx Zone R
Recognition
ecognition
ConveyLinx Modules will automatically detect that a given carton is longer than one zone
length and automatically adjust accumulation control so that the longer carton occupies two
logical zones and will keep the next upstream carton from conveying into the longer carton.

! Flex Zone mode only functions in singulation release mode

All 3 Cartons ar
aree accumulated and the Zone at PE3 has Fle
Flexx Zone enabled

Carton 1 R
Releases
eleases – Even though PE3 is clear, because it has Fle
Flexx Zone enabled, Carton 2 rremains
emains
accumulated

When Carton 1’s leading edge rreaches

eaches PE1, Fle
Flexx Zone is clear
cleared
ed fr
from
om the Zone at PE3 and Carton
2 rreleases
eleases

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! Please note that Flex Zone mode operates for carton lengths up to 2 zone
lengths only. Operating conveyor system with cartons whose lengths are in
excess of 2 zone lengths may produce undesirable results such as excessive
detected jam conditions and faults.

How to disable Flex Zone operation with EasyRoll

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6.3. Jam Conditions

There are two (2) types of Jam conditions detected by the ConveyLinx Module:

Sensor Jam

Ar
Arrival
rival 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
active; they will automatically clear in the logic after the Auto Clear Time has
expired. Both the Jam Time and Auto Clear Time values are 5 seconds each by
default. Please see How to Change Jam and Auto Clear Timers

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6.3.1. Ar
Arrival
rival 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 at
this upstream zone while this upstream zone is waiting for a downstream arrival confirmation,
the new carton will accumulate on this upstream zone. If the upstream zone does not receive
this confirmation within the Jam T
Timer
imer interval, the ConveyLinx Module will produce an Ar
Arrival
rival
Jam fault. Once an Arrival Jam occurs, the ConveyLinx Module will automatically hold any new
carton at the upstream zone for a pre-determined Auto Clear T Time
ime Timer value and then
resume normal ZPA function. By default, the Jam T Timer
imer and the Auto Clear Timer values are set
to 5 seconds for each. This condition will be indicated on the corresponding Sensor LED on the
module

Carton 1 has lef

leftt PE1 and is on its way
to PE2 and because PE1 is clear,
Carton 2 is entering Zone 1

Carton 1 disappears but the Zone 2

motor continues to run for the Jam
Time period (5 sec. by default).
During this time Carton 2 ar
arrives
rives at
PE1 but Zone 1 stops because Jam
Timer is still timing

When the Jam T Timer

imer e
expir
xpires,
es, the
Sensor LED blinks to indicate an
Ar
Arrival
rival Jam and k keeps
eeps blinking for the
Auto Clear TTime
ime (5 sec. by default).
When Auto Clear T Time
ime eexpir
xpires,
es, the
Ar
Arrival
rival Jam is rreset
eset and Carton 2 will
release if Zone 2 is empty

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* How to Disable Arrival Jam

* How to change the Jam and Auto Clear Timers

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6.3.2. 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 here.

Carton 1 is leaving Zone 1 but has got

stuck. Zone 1 and Zone 2 motors arare
e
running but PE1 is rremaining
emaining block
blocked
ed

When the Jam T Timer

imer has e
expir
xpired
ed (5
sec. by default) Zone 1 and Zone 2
motors stop and Zone 1 Sensor LED
flashes gr
green/amber
een/amber for the Auto
Clear T
Time
ime (5 sec. by default)

When the Auto Clear T Timer

imer has
expir
xpired,
ed, Zone 1 will start perfor
performing
ming
the Sensor Jam Auto Clear pr procedur
oceduree

Her
Here
e is what happens when Sensor Jam Auto Clear pr
procedur
ocedure
e occurs

1. Run the zone motor in reverse until the sensor is clear or 1 second has elapsed,
whichever happens first
2. Wait for the Auto Clear Timer to expire
3. Run the zone motor forward to attempt discharge to the downstream zone (Attempt
#1 complete)
4. If sensor is still blocked after discharge attempt, the zone motor runs in reverse until

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the sensor is clear or 1 second has elapsed, whichever happens first

5. Wait for the Auto Clear Timer to expire
6. Run the zone motor forward to attempt discharge to the downstream zone (Attempt
#2 complete)
7. If sensor is still blocked after discharge attempt, the zone motor runs in reverse until
the sensor is clear or 1 second has elapsed, whichever happens first
8. Wait for the Auto Clear Timer to expire
9. Run the zone motor forward to attempt discharge to the downstream zone (Attempt
#3 complete)
10. If sensor is still blocked after Attempt #3, the sensor must be cleared manually to
reset the Sensor Jam condition. Please note that if any of the discharge to
downstream attempts (steps 3, 6, or 9) are successful, the Sensor Jam condition is
automatically reset.

* If item is still blocking the sensor after Sensor Jam Auto Clear procedure is
complete you have to physically clear the jam by removing the item or you can
attempt another Auto Clear procedure

* The 5 second Jam Timer and Auto Clear Timer values are default settings. How to
change Jam and Auto Clear Timers in EasyRoll

* How to Disable Sensor Auto Clear Function

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6.4. Har
Hard-W
d-Wir
ired
ed 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 and/or
downstream zones and perhaps interrupt flow in a zone somewhere in the middle.

Contr
Control
ol P
Ports
orts P
Prrovide Interlock F
Function
unction

By default after configuration, each control port provides:

• An input for an Interlock Signal (Pin 4)

• An input for Local Zone Accumulate (Pin 3)
• An output that indicates if zone is occupied (Pins 1/6 Circuit)

* The Interlock Input (Pin 4) will act as either a Wak

akee Up or a Lane F
Full
ull depending
on whether the Control Port is configured on the Upstream or Downstream side of
the module. When each ConveyLinx Module has been Auto-Configured, either its
Left or Right side will be configured as the Upstream side and the other will be
the Downstream side depending on the flow established during Auto-
Configuration.

! Wak
akee Up interlock should only be used on the MOST Upstr
Full interlock should only be used on then MOST Downstr
Downstream
eam zone and the Lane
Upstream
eam zone of any given
subnet.

Lear
earnn About:

Upstr
Upstream
eam Interlock (W
(Wak
akee Up)
Downstr
Downstream
eam Interlock (Lane F Full)
ull)
Local Zone A Accumulate
ccumulate
Interlocks with a Single Zone Module
Interlock Input versus LLocal
ocal A
Accumulate
ccumulate Input
Using a Photoeye for W Wak
ake
e Up
Using a Photoeye for Lane F Full
ull
SE-4 Br
Break
eakout
out Module

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6.4.1. Upstr
Upstream
eam Interlock (W
(Wak
ake
e Up)

Interlock with the most upstream zone to get an input to see if is clear and then turn on an
output (Wak
akee Up) to tell it to run to accept a new item

Whichever Control Port (Left or Right) is on the Upstr

Upstream
eam Side of the module will accept a Wak ake
e
Up signal input on its interlock input Pin 4. If the zone is unoccupied, when a digital signal is
applied to Pin 4, the zone will run its motor to accept an item.

! For an Upstream Side Control Port the motor will continue to run as long as the
signal is being applied to Pin 4 and the zone sensor remains unblocked. If the
signal is removed, the zone will continue to run for Jam Timer setting (5 seconds
by default) and then stop

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When NOT to use P in 4 as a Wak

Pin ake
e Up

Only use the Interlock Pin 4 signal for Wak

ake
e Up on the most upstr
upstream
eam zone of a network. Do
not use the Pin 4 signal on any of the other zones on modules with an upstream connection to
another ConveyLinx Module – You may get unexpected results because signal may or may not
over-ride the status coming from upstream over the network.

Wak
ake
e Up Interlock with Handshak
Handshake
e

The external controls providing the Wak

akee Up signal to Pin 4 will sometimes also require an
output signal from the ConveyLinx Module that will indicate when this upstream zone is
occupied in order to implement a handshake. This zone occupied signal is provided by the
Control Port’s output signal.

Upstr
Upstream
eam Contr
Control
ol P
Port
ort Output is OFF
and PLC signal to Upstr
Upstream
eam Contr
Control
ol
Port P
Pin
in 4 is OFF
OFF.. When Carton 1
reaches PLC connected PEx, the PLC
ener
energizes
gizes its output signal to
Upstr
Upstream
eam Contr
Control
ol P
Port
ort P
Pin
in 4 and
Zone 1 Motor starts to run

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When Carton 1 clears PLC

connected PEx, the PLC tur
turns
ns off its
output signal to Upstr
Upstream
eam Contr
Control
ol
Port P
Pin
in 4

When Carton ararrives

rives at Zone 1 PE1,
the Upstr
Upstream
eam Contr
Control
ol P
Port
ort Output is
ON to indicate that Zone 1 is
occupied. The PLC can connect this
signal to a digital input to use in its
logic to stop its conveyor if another
carton ar
arrives
rives at PEx

* How to hook up PLC I/O to Control Port

* How to Wake Up the Upstream zone with a single sensor

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6.4.2. Downstr
Downstream
eam Interlock (Lane F
Full)
ull)

Interlock with the most downstream zone to turn on an output tell it to stop when something shows
up (Lane F
Full
ull) 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 signals, if
an item is on the conveyor, it will convey to the last downstream zone and try to continue on.
Whichever Control Port (Left or Right) is on the Downstream Side of the ConveyLinx Module will
accept a Lane F
Full
ull signal input on its interlock input Pin 4. When a digital signal is applied to Pin
4, the zone will still run its motor to accept an item but it will stop and accumulate when the
item reaches the sensor.

PLC output signal to Downstr

Downstream
eam
Contr
Control
ol Port Pin 4 is ON because PEx
Port
is blocked. Because Pin 4 is ON, when
blocked.
Carton 1 ararrives
rives at PE1 it will stop and
accumulate. Downstr
Downstream
eam Contr
Controlol P
Port
ort
Output is ON when Carton 1 is
blocking PE1

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When PLC output signal to Pin 4 is

OFF
OFF,, Zone 1 motor runs and Carton 1
dischar ges. Module is waiting for Pin 4
discharges.
to tur
turnn ON in or
order
der to avoid an Ar
Arrival
rival
Jam. When PE1 is clear, Downstr
Downstream
eam
Contr
Control
ol Port Output is OFF
Port

When Carton 1 ar arrives

rives at PEx, the PLC
tur ns ON its output signal to Pin 4
turns
indicating to the module that Carton 1
ar
arrived
rived so Zone 1 will not generate an
Ar
Arrival
rival Jam. If another carton conveys
into Zone 1, it will accumulate as long
as Pin 4 signal is ON

* When Pin 4 is used on a Downstream Control Port the cycling off and on of this
signal generates an “Arrival” in the module logic and thus prevents an Arrival
Jam

* How to hook up PLC I/O to Control Port

* How to add Lane Full to the most Downstream zone with a single sensor

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6.4.3. Local Zone A

Accumulate
ccumulate
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 accumulate an

item when it arrives in a zone, you energize the Local Zone A
Accumulate
ccumulate signal on Pin 3 of the
Control Port for the zone.

! If you re-energize the Pin 3 signal while the item is in transit and still blocking
the zone sensor, the item will stop and if left like this, the zone will eventually
generate an Arrival Jam. You can modify the function of the Pin 3 operation by
making it active only upon leading edge of the zone sensor

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6.4.4. Interlocks with Single Zone Module

When you have a single zone ConveyLinx Module (one sensor and one or two motors);
whichever side of the ConveyLinx Module (Left or Right) that has the Sensor attached will
always be the Upstr eam Zone of the ConveyLinx Module and that same side’s Control Port Pin 4
Upstream
will provide the Wak
akee Up function.

Single Zone ConveyLinx Module with Sensor on RIGHT Side

Single Zone ConveyLinx Module with Sensor on LEF

LEFTT Side

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6.4.5. Interlock Input versus L

Local
ocal
Accumulate Input
By default, energizing the Interlock Signal Pin 4 on a Control Port on the Downstream side of a
ConveyLinx Module will cause that zone to accumulate an item when it arrives on the zone
sensor. You get the same result if you energize the Local Accumulate Signal on Pin 3. So if all
you want to do is accumulate a zone, which signal should you use and does it make any
difference? The answer is yes it can mak
makee a differ
difference
ence

* To accumulate the most downstr

downstream
eam zone, use the Interlock Input P
Pin
in 4

* To accumulate any other zone, use the L

Local
ocal A
Accumulate
ccumulate Input P
Pin
in 3

What happens if you use P

Pin
in 3 when you should use P
Pin
in 4?

Suppose you want to control the release of multiple items by toggling the Pin 3 signal. After
you release the first one, you will get an Arrival Jam because the module is looking for the Pin 4
signal to be energized in order to “confirm the downstream arrival” of the item. So, by using
Pin 3 in this case, you will have to wait the Jam Time plus the Auto Clear Time between release
of each item.

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Downstr
Downstream
eam Contr
Control
ol Port Pin 3 is ON
Port
and Carton 1 accumulates when it
ar
arrives
rives

When Pin 3 is tur

turned
ned OFF
OFF,, Zone 1
will run to convey Carton 1 on
downstr
downstream
eam

When Carton 1 clears PE1, Pin 3

signal is tur
turned
ned back ON. Because
Pin 3 is ON, Carton 2 will stop upon
ar rival at PE1 however because
arrival
ther
there e is no signal to PPin
in 4 to indicate
ar
arrival
rival downstr
downstream,
eam, Zone 1 will
generate an Ar Arrival
rival Jam !!!

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6.4.6. Using a Photoeye for W

Wak
ake-Up
e-Up

Because standar
standardd RJ
RJ-11/12
-11/12
Sensors put their block
blocked/
ed/
clear output on P
Pin
in 4; this
type of Sensor can be
plugged into the Upstr
Upstream
eam
Contr
Controlol P
Port
ort and pr
provide
ovide
the P
Pin
in 4 WWak
akee Up signal

When PEx is plugged into

the Right Contr
Control
ol P
Port
ort and
its output is ON, Zone 1
will W
Wak
ake
e Up if it is
unoccupied. If Zone 1 is
occupied, Zone 1 will not
wak
wake
e up and run

* If you do not have a Sensor with RJ-11/12 connector; you can use an SE-4 module
to wire you sensor to the Control Port

* By default, your Sensor has to energize its output when it is blocked. You can
change Pin 4 to accommodate a Sensor that de-energizes its output when it is
blocked

! If your sensor has an Error or Health Output signal, you need to cut the signal
wire for this on the RJ-12 connector in order to keep this signal from
inadvertently energizing Pin 3

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6.4.7. Using a Photoeye for Lane F

Full
ull

Because standar
standard
d RJ
RJ-11/12
-11/12
Sensors put their block
blocked/
ed/
clear output on PPin
in 4; this
type of Sensor can be
plugged into the
Downstr
Downstreameam Contr
Control
ol P
Port
ort
and pr
provide
ovide the P
Pin
in 4 Lane
Full signal.

When PEx is plugged into

the Right Contr
Control
ol P
Port
ort and
its output is ON, Zone 1
will see a Lane F
Full
ull
condition and stop any
item that ar
arrives
rives at PE1. If
PEx output is OFF
OFF,, Zone 1
will continue to run and
convey item downstr
downstream
eam

* If you do not have a Sensor with RJ-11/12 connector; you can use an SE module
to wire you sensor to the Control Port

* Block and Clear Timer function for the Lane Full Sensor

* By default, your Sensor has to energize its output when it is blocked to make
Lane F
Full
ull operate. You can change Pin 4 to accommodate a Sensor that de-
energizes its output when it is blocked

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! If your sensor has an Error or Health Output signal, you need to cut the signal
wire for this on the RJ-12 connector in order to keep this signal from
inadvertently energizing Pin 3

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6.4.8. SE Br
Break
eakout
out Module
The SE breakout module provides convenient wiring terminals for access to Pin 3 and Pin 4
inputs as well as the Control Port’s output. SE Inputs (Pin 3 and Pin 4) are PNP-NPN auto-
sensing so you can use sourcing or sinking PLC output modules. The terminals P3 and P4 on the
SE-4 correspond to Pin 3 and Pin 4 respectively

PLC Sour
Sourcing
cing Output to P3 or P4

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PLC Sinking Output to P3 or P4

SE OUT to PLC Sinking Input

! Please note that the Control Port output (OUT) signal on the SE is always PNP and
is subject to the power limitations of the module’s internal fusing

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SE OUT with Exter

External
nal P
Power
ower

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6.5. Automatic Module R

Replacement
eplacement
Once a linear conveyor has been commissioned by AutoAuto-Configuration
-Configuration P
Prrocedur
oceduree, 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 parameters modified by the EasyRoll software. The ConveyLinx Module firmware uses this
feature to allow for easy module replacement so that the entire linear conveyor does not have
to be Auto-Configured again in order to replace a single ConveyLinx Module.

! For Automatic Module R

Replacement
eplacement to work:
● The modules initially must have been pr
properly
operly Auto
Auto--
Configur
Configured
ed
● None of the modules have had their I.P
I.P.. A
Addr
ddresses
esses
changed manually
● None of the Ether
Ethernet
net cables have been rre-r
e-routed
outed
since initial Auto
Auto-Configuration
-Configuration

Module Auto R
Replacement
eplacement P
Prrocedur
oceduree

1. Disconnect existing module’s motor(s), network, photo-sensor(s), hardware, and

power connections. The order of disconnection does not matter.

2. Connect new module’s motor(s), sensor(s), hardware, and network connections only.
DO NOT CONNECT POWER YET.

3. Press and hold INSTALL button. While holding the INSTALL button pressed; connect
module power.

4. Observe the Module Status LED. About 1 second after applying power; the Module
Status LED will start blinking red. DO NOT RELEASE THE INSTALL BUTTON YET. After
another second, you will see that the Module Status LED will start to blink both RED
and GREEN. This is the indication that the Auto Replace Procedure is starting and you
MUST release the Install Button NOW. Releasing the Install Button before you see the
Module Status LED flashing both red and green will result in cancelling the Auto
Replace Procedure.

5. To tell if the Auto R

Replace
eplace P
Prrocedur
oceduree has been properly initiated, the replaced module
will turn its Sensor and Control Port LEDs on solid red. Also, all modules on the
network will briefly flash their sensor and control port LEDs. This is normal and they
will return to normal operation within a few seconds.

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6. Wait for at least 3 minutes before using the system or cycling power or plugging or
unplugging any Ethernet connections. The module being replaced will automatically
upgrade or downgrade its firmware if needed and restore its configuration settings.
This will involve multiple automatic restarts of the module. Do NOT cycle power to the
module during this 3-minute period.

7. When both the Module Status and Network LED’s are blinking green, then the module
replacement has been a success.

! Once the Auto Replacement procedure has started; if power is lost on the
replacing module, it may become inoperable. In this case, you may need to reset
it back to factory default settings before attempting to use it as a replacement
module. If it does not return to factory default settings, you may need to return it
to PULSEROLLER to be repaired. How to reset a module back to factory default
settings

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6.6. Reset to F
Factory
actory Default Settings
There may be instances when you want to return a ConveyLinx Module to its “factory default”
state. The procedure to do this is the following:

1. Unplug all sensors, devices, motors, and network cables such that the only thing
connected is power
2. Press and hold the Install Button until the Module LED begins to flash
3. When the Module Status and Network Status LEDs both blink green, the procedure is
complete

! If the module you wish to reset was installed in a subnet that was subsequently
Locked from EasyRoll; then this module must first be Unlocked using EasyRoll
before you can perform the procedure to reset to factory default setting.

How to unlock a module with EasyRoll

Factory Default Settings

Item Value or Setting

IP: 192.168.202.20

IP Address Settings Subnet Mask: 255.255.128.0

Default Gateway: 192.168.202.1

Senergy ECO

Normal Braking

Closed Loop

Left & Right Motor Settings 100% Speed

CW Direction

100 Pulses Acceleration

50 Pulses Deceleration

ZPA – 2 Zone – Left to Right Flow

Module Mode Singulation Release Mode

All Settings Options Unchecked

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JAM Timer = 5.00

Auto Clear Timer = 5.00

Look Ahead & Timing
Run After Timer = 5.00
Settings
Sensor Debounce = 0.10

All Induct Timers = 0.00

Control Ports All Options Unchecked

Sensors are “ON is Blocked”

Sensors
Sensor Health are “ON is Error”

Connections All are Cleared

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7. SE Br
Break
eakout
out Module
The SE Br
Break
eakout
out Module is used to provide convenient screw terminal wiring access to the
RJ-12 ports (Sensor and Control) on the ConveyLinx Module. The SE BrBreak
eakout
out Module utilizes an
RJ-12 to RJ-12 interface cable to connect to the ConveyLinx Module.

* This module is typically sold as the SE Br

Break
eakout
out Module Kit (Order Code
8087-0017). This kit includes the modules and an 8 inch RJ-12 cable to connect
the SE to the ConveyLinx Module

Additional F
Functionality
unctionality

Blocking Diodes

In addition to providing simple wiring connectivity to the ConveyLinx Module RJ-12 pins, the SE

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Breakout Module also provides blocking diodes for both the Local Zone Accumulate input signal
(Pin 3) and the Interlock input signal (Pin 4). The SE module’s diodes are equipped with user
settable jumpers to allow configurations for both sourcing and sinking solid state PLC output
modules.

Output Amplifier with Optional Exter

External
nal P
Power
ower Sour
Source
ce

The SE Breakout Module also includes an amplifier for the Control Port’s output circuit (Pin 1
and Pin 6) to allow up to 100mA of current load. This feature will allow the Control Port output
to drive a small inductive load such as a relay coil as well as a PLC input. Because of current
restrictions on each pair of Sensor and Control Ports, you can optionally connect an external
+24V power source to the “+24V” terminal on the SE Breakout Module to provide power to
connected devices. The SE Module’s output can accommodate up to 500 mA with this external
power. The SE Module also contains circuitry to prevent a connected external power source
from back-feeding into the ConveyLinx Module’s power bus.

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7.1. Typical Output Connection

! If using optional external power supply, this external supply’s DC common MUST
be connected to ERSC power supply DC common

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7.2. Typical Input Connections

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7.3. Input Cir

Circuit
cuit Blocking Diode Jumpers
A typical situation for using an SE breakout Module is to connect a PLC’s digital output to one
of the ERSC’s input signals for interlock control. Some solid state digital output circuits for
some PLC models can provide false inputs to the ERSC module because of the module’s
PNP/NPN auto-detection circuitry. Some PLC solid state digital outputs can provide an electrical
path to ground when powered off. This can result in the ERSC module’s NPN auto-detection
circuit to interpret this condition as a positive NPN signal and thus energize its input circuit.
The SE Breakout module provides jumper selectable diodes in order to block this opposite flow
in order to keep from false triggering an ERSC input.

* Please note that NOT ALL PLC SOLID STATE OUTPUTS present this behavior.

! For relay or dry contact signals to the P3/P4 inputs, leave both jumpers installed

Both the P3 and P4 inputs on the SE Breakout Module has a pair of user removable jumpers to
allow configuration to block a ground path when connecting a PNP input signal and to block a
voltage when connecting an NPN input signal.

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* Please note that if both jumpers remain installed, the ERSC Module will auto
detect PNP/NPN operation and there will be no protection from reverse current
path from Solid State devices

! At least one jumper MUST remain installed. If BOTH jumpers are removed then
there will be NO SIGNAL (PNP nor NPN) connected to the ERSC

Examples

For a solid state PLC output module SOUR

SOURCING
CING 24V
24V::

For P4 – remove Jumper 1 and leave Jumper 2 installed

For P3 – remove Jumper 3 and leave Jumper 4 installed

For a solid state PLC Output module SINKING 0V

0V::

For P4 – remove Jumper 2 and leave Jumper 1 installed

For P3 – remove Jumper 4 and leave Jumper 3 installed

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7.4. Notes on SE Module R

Revisions
evisions
Because there have been a handful of revisions to the SE breakout module since its
introduction, this section documents the changes and updates made for each revision.

Part Number and Cir

Circuit
cuit Boar
BoarddR
Revision
evision
Customers have been confused (and rightly so) because initially Pulseroller changed the Part
Number for the SE module upon each revision because these revisions changed the
functionality of the module. It was often interpreted by customers that the markings on the
Printed Circuit Board (PCB) were the part number. Actually, the markings on the PCB are the
PCB’s revision level. For part numbers SE-2, SE-3, and SE-4; the PCB revision matched the part
number because there were functional changes with each revision. However since the SE-4 PCB
revision ther
theree have been no functional changes to the SE br
break
eakout
out module and no part number
change.

* PCB revisions greater than SE-4 are functionally equivalent to the SE-4 part
number. As of the date of this publication the current PCB revision is SE-6. This

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PCB revision is functionally equivalent to SE-4

SE-4.

Revision History
In order to support previous revisions to the SE Breakout Module, the following items describe
the functionality and possible limitations of each revision.

Part Number ERSC

ERSC-SE2
-SE2

Original design providing bias diodes for the Pin 3 and Pin 4 inputs to allow solid state PLC
output modules to operate without inadvertently triggering the PNP/NPN auto detect feature of
the ERSC. This design also provided the Control Port Output amplifier to allow higher current
devices to be connected to this output. The OUT signal is PNP only.

! Because the Control Port Output is in an indeterminate state upon ERSC boot up;
the OUT signal could possibly momentarily energize upon initial power up or re-
boot of the ERSC. Users must take proper care when using the OUT signal in their
control system logic.

! The 24V terminal on the ERSC-SE2 is directly connected to the ERSC’s Control
port power. If users connect an external power source to the 24V terminal on the
SE2; this will back-feed power into the ERSC. If this is done, when the main
power to the ERSC is disconnected; the ERSC could still power up. User must
take care to not connect external power source to the 24V terminal.

Part Number ERSC

ERSC-SE3
-SE3

This version contains a modification to block the OUT signal from energizing during the ERSC’s
initial power-up or re-boot sequence. Thus, users no longer have to worry about an inadvertent
OUT signal being energized during initialization or reboot of the ERSC. For convenience; an LED
has been added that illuminates when the OUT signal is being energized.

! The 24V terminal on the ERSC-SE3 is directly connected to the ERSC’s Control
port power. If users connect an external power source to the 24V terminal on the
SE3; this will back-feed power into the ERSC. If this is done, when the main
power to the ERSC is disconnected; the ERSC could still power up. User must
take care to not connect external power source to the 24V terminal.

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Part Number ERSC

ERSC-SE4
-SE4

This version contains a diode circuit that blocks an external power source from back-feeding
into the ERSC’s Control Port power. Users can now provide external power for devices
connected to the Control Port in cases where these device’s power requirements exceed the
maximum limits of the port.

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8. EasyR
EasyRoll
oll Sof
Softwar
tware
e
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.

Lear
earnn About:

How to Install EasyR

EasyRoll
oll
Getting to know the Main Scr
Screen
een
ZP
ZPA
A Upstr
Upstream/Downstr
eam/Downstream
eam Settings
Motor Settings
Diagnostic W
Window
indow
Advanced Dialog

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8.1. Installing EasyR

EasyRoll
oll on your PC
The files for EasyR
EasyRoll
oll can be download for free at www
www.pulser
.pulseroller
oller.com
.com and will be typically in a
compressed (i.e. “.zip”) format. Once you have extracted the contents of the compressed file;
the result will be a folder named with the format “EasyRoll_Vx_nn” where x is the main version
number and the nn is the revision level. Inside this folder is a file named “Setup.exe”. Double
click this file to begin the install procedure. EasyRoll installs like any standard Windows
application and you will be prompted for typical Windows prompts. By accepting the defaults
for the prompts; EasyRoll will install on your local Operating System drive under the “ \Program
Files (x86)\Industrial Software\EasyRoll\” or “ \Program Files\Industrial Software\EasyRoll\

! Please note that some anti-virus and/or security updates block the usage of
WinPcap utility which is used by EasyRoll. It is recommended that when you run
“Setup.exe” that you “Run as Administrator”

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8.2. ConveyLinx Ether

Ethernet
net Definition
All ConveyLinx Modules communicate over Ethernet network and use TCP/IP based protocols for
normal function. All TCP/IP protocols require that each device on a network have a unique I.P.
address assigned to it in order to function properly.
An I.P. address is in the format of: A A A.BBB.CCC.DDD where A A A, BBB
BBB, CCC
CCC, and DDD are
numerical values between 0 and 255.

* For the purposes of ConveyLinx; the A A A.BBB.CCC portion of the I.P. address
taken together is defined as the Subnet
is defined as the Node
Node.
Subnet. The DDD value of the address minus 19

For example; if a module has an I.P. address of “192.168.25.20” then its Subnet address is
“192.168.25” and its Node is 1 (i.e. 20-19 = 1)

At the factory, each and every module is assigned an I.P. address that is used by automated
testing equipment and fixtures so that every module is verified prior to shipment. When a
module is taken “out of the box” it will still have this I.P. address stored in its memory.

When the Auto Configuration P Prrocedur

oceduree is initiated; one of the many things that occur is that
each module is automatically assigned a new I.P. address. This I.P. address for all modules is
determined by the Subnet of the I.P. address already stored inside the most upstream module.
Even if all downstream modules from the most upstream have the same or different Subnet or
Node values; these downstream modules will have their Subnet changed to the existing Subnet
of the most upstream module. Furthermore, when the Auto Configuration Procedure occurs; the
most upstream module will also have its DDD octet value changed to 20. All downstream
Modules will then have their respective DDD values automatically set beginning with 21.

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An Example

Here is a 4-module network with possible I.P. addresses that could have been on the module
from the factory. Note that their Subnets could be different as well as there could be duplicate
addresses.

Once the Most Upstr

Upstream
eam Module is identified and the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree is
performed; all 4 modules will have their I.P. address configured as shown.

* The Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree will assign Nodes up to and including DDD
octet 240. Therefore, each Subnet is limited to 221 module Nodes

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8.3. 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 ne

next?
xt?

The Subnet has alr

already
eady been Auto
Auto-Configur
-Configured,
ed, my PC gets IP addr
address
ess for
formm DHCP server, and I
want to connect with EasyR
EasyRoll
oll and change default settings

• If you know the Subnet address of you modules, go to the Main Screen and enter in

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the Subnet address at the top and click Refresh.

• If you do not know the Subnet address of your modules, go to the Advanced Dialog
and use the Discover function to view all connected modules to see which Subnet
address you want to connect to and then go to the Main Screen and enter the Subnet
address at the top and click Refresh

The Subnet has alr

already
eady been Auto
Auto-Configur
-Configured,
ed, I need to manually set my IP addr
address
ess on my
PC, and I want to connect with EasyR
EasyRoll
oll and change default settings

If you know the Subnet address of you modules, set your PC’s IP Address withing the same
subnet and subnet mask as your modules. Then go to the Main Screen and enter in the Subnet
address at the top and click Refresh. If you do not know the Subnet address of your modules,
go to the Advanced Dialog and use the Discover function to view all connected modules to see
which Subnet address you want to connect and set you PC’s IP Address within the same subnet
and subnet mask. Then go to the Main Screen and enter the Subnet address at the top and
click Refresh

I want to change the IP addr

address
ess of my Auto
Auto-Configuration
-Configuration master module and then perfor
performm an
Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree

Go to the Advanced Dialog and use the Discover function to view all connected modules. You
will need to locate the specific module whose address you want to change. Double click this
module from the list and its information will appear to the right side of the dialog. Enter in the
IP Address and Subnet Mask you want to use and then click the Set button

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8.4. Using Discover F

Function
unction
The Discover function is often one of the first activities you will need or want to do when you
connect to your ConveyLinx network with EasyRoll. The Discover function tells EasyRoll to look
out on the network and report back a list of all ConveyLinx modules it finds, regardless of what
subnet they are in or their IP address.

* Because the Discover function does not use TCP/IP connections to find
ConveyLinx modules, your PC does not have to have its IP address and subnet
mask set to match any ConveyLinx module IP addresses. However, in order to
eventually connect to any module and make any changes with EasyRoll, you will
need to make sure your PC and the ConveyLinx network you want to connect to
are in the same IP address subnet.

What you can do with the Discover Function

• See the IP address, serial number, and firmware version of each connected module
• Change the IP address and Subnet Mask for any module
• Enable/Disable DHCP server for Auto Configuration Master module

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8.5. Main Scr

Screen
een

Indicator Description

Network IP – This is where you enter the Subnet of the particular ConveyLinx
network you wish to connect

Node No. – This is where you enter a range of Nodes in which to connect.
Entering values here will cause the “Refresh” button to enable. Clicking this
button will cause the rest of the items (3, 4, and 5) to be populated

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Upstream Zone / Downstream Zone – These selections allow you to change

the ZPA mode of the particular zone as well as several check boxes to change
the default operation of certain jam conditions, etc.

Upstream Zone / Downstream Zone – Selector to cause the local zone to

Accumulate if a carton arrives and to cause the local zone to be in
Accumulate mode upon power up of the module

Left MDR / Right MDR – Selections for MDR type, speed control, acceleration,
deceleration, etc.

Left MDR / Right MDR – Selector to click to jog the MDR, click again to stop

Left MDR / Right MDR – Visual indicators for various MDR status and
diagnostics information

Diagnostic Window – Click the graphic image to open a details Diagnostics

window

* Please note that some of the detailed information shown in this figure may be
different for your particular system and that most of these fields will be blank
until you actually initiate communications

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8.5.1. Node Navigation

Whatever value is entered in the From Node #
box will be the particular module Node data
shown in the remainder of the main screen.

The value entered in the To Node # box does

not have to be the actual “last” Node of the
network, it can define a range of Nodes you
want to work with.

Clicking the + and – buttons will increment /

decrement the Node value in the From Node #
box and display the module data for the new
Node selected. Please note that if you
increment past the value of the last physical
Node installed, you will receive an error
message

* Anywhere on the Main Screen where you see a Set All button next to a
parameter or data entry selection, all the nodes in the range entered in the From
Node # and To Node # will be updated with the same parameter or data entry
selection when you click the associated Set All button. A dialog box will appear
to confirm your selection.

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8.5.2. Node Identification

* EasyRoll main screen has a feature identified as “Blink & Wink” that allows you
to visually verify the Node you have selected

If a valid Node is selected in the From Node #

text box and its information is displayed on the
main screen; clicking the Blink & W
Wink
ink switch
icon will signal the selected module to blink on
and off all of its LED indicators. Click the Blink &
Wink switch again to turn this off

! Please note that when Blink & Wink is active, the module stops all motors

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8.5.3. ZP
ZPA
A Upstr
Upstream/Downstr
eam/Downstream
eam 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.

ZP
ZPA
A Release Mode
T-Zone Settings
ZP
ZPAA Er
Errror and Infor
Information
mation
Accumulate Contr
Control
ol fr
from
om
Main Scr
Screen
een
Settings Checkbo
Checkbox
xes

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8.5.3.1. ZP
ZPA
ARRelease
elease Mode

Selecting the pull-down bo

box
x
for ZP
ZPA
A 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 for the range of nodes
entered in the Node No. text boxes, then click the Set All button. Similarly, you
can do the same operation in the “Downstream Zone” portion of the main
screen.

* Singulation Release Mode is the default setting and it is described in the Default
Settings and Operation section

* Please note that Singulation and Train Release Modes are configurable per Zone
and can be mixed on the same network

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8.5.3.1.1. Singulation R
Release
elease

* Singulation Mode is the default setting and it is described in the Default Settings
and Operation section

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8.5.3.1.2. Train R
Release
elease

All 3 Cartons ar
aree
Accumulated

When Carton 1
releases –
Cartons 2 and 3
also rrelease
elease at
the same time

Select Train fr
from
om
the pull-down bobox
x
for T
Train
rain Mode

! Please note that starting many zones in Train Release mode particularly with
heavy loads can cause voltage drops on your power supplies. Be sure to take
care in sizing your power supply needs. You should consider GAP Train Release
Mode if power supply sizing is a concern

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8.5.3.1.3. GAP T
Train
rain R
Release
elease

All 3 Cartons ar
areeA
Accumulated
ccumulated

When Carton 1 rreleases

eleases and Zone
2’s GAP time has e
expir
xpired,
ed, Carton 2
will begin to rrelease.
elease. Carton 3
remains accumulated

When Carton 2 rreleases

eleases and Zone
3’s GAP timer has e expir
xpired,
ed, Carton 3
will begin to rrelease
elease

When you select Gap T Train

rain fr
from
om the
ZP
ZPAA Mode dr
drop-down
op-down bo
box;
x; the Gap
Timer data entry bo
box
x and Set button
ar
are
e enabled. Simply enter the desir
desired
ed
time value and click the Set button to
update the value in the selected
Node. In this e
example
xample we enter
entereded
0.35 seconds.

! Please note the GAP time does not create a gap or cause any delay when items
are in transportation. The gap timer is only activated when a given zone
accumulates an item and then it is allowed to release

* If more than one consecutive zone is configured as Gap Train; then each of these
zones will in turn require that their respective gap timers expire. If the time value
is long enough, the result may appear to be Singulation Release mode or even
Singluation Release with extra time delay. 0.2 to 0.3 seconds are typical values
used when you want to help balance the loading on your power supplies but still
have the operation be very close to Train Release Mode

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8.5.3.2. T-Zone Settings

In conveyor applications, transferring a carton at a right angle from one conveyor to another
often requires special lifting and lowering mechanisms. In certain applications, one conveyor
can simply drive its carton off of its downstream zone directly onto the upstream zone of
another conveyor that is perpendicularly oriented. This type configuration is commonly defined
as a T-Zone arrangement. ConveyLinx contains the logic to control a T-Zone arrangement
without requiring any external control interface or programming.

! Material handling considerations such as discharge conveyor speed and load

weight have to be analysed prior to implementing a T-Zone configuration. Be
sure to verify your mechanical design and carton characteristics before utilizing
a T-Zone arrangement.

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T-Zone Between 2 Separate Modules

! This example assumes both Module A and Module B are in the same Subnet.
Otherwise you will need to use EasyRoll to establish connections between
Module A and Module B.

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T-Zone on a Single Module

Enter the value, for e

example
xample 0.200 for
200 milliseconds and click the Set
button. Whether to change the
Upstr
Upstream
eam Zone or Downstr
Downstream
eam Zone
value on the main scr
screen
een is
dependent upon which zone is the
accepting zone. In our eexample
xample we
enter
entered
ed 1.5 seconds

! The T-zone Accept time is always applied to the accepting zone

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8.5.3.3. ZP
ZPA
A Er
Errror and Infor
Information
mation
There is an Er
Errror and Infor
Information
mation area in the upper right corner in both the Upstream and
Downstream Zone areas of the Main Scr Screen
een. There is an indicator that shows if a Jam condition
is active (either Ar
Arrival
rival Jam or Sensor Jam). There is a numerical indicator of all occurrences of
any Jam conditions since the last module power cycle. There is also a Clear button to allow you
to clear a Sensor Jam if it is active.

* The Clear button is a convenience so you do not have to go the zone in question
and remove or otherwise clear the item from the zone sensor. If Sensor Jam Auto
Clear is enabled, clicking the Clear button will re-initiate this procedure.

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8.5.3.4. Accumulate Contr

Control
ol fr
from
om Main
Scr
Screen
een
Clicking the Accumulate switch icon will place the zone in accumulation mode and the next
carton that arrives at that zone will stop and remain until you click the switch again to turn off
the accumulation mode

Clicking the icon will initiate

the A
Accumulate
ccumulate function
and the icon will highlight
and change state

Clicking the icon again will

tur
turnn off the A
Accumulate
ccumulate
function

* When you set Accumulate from EasyRoll, this is saved to the module’s flash
memory so that when you cycle power on the module, it will power up in the
accumulated state.

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8.5.3.5. Settings Checkbo

Checkbox
xes
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
module nodes.

Disable R
Reset
eset Delays
Disable Sensor Jam Auto Clear
Disable Ar
Arrival
rival T
Timeout
imeout
Disable Manual Operation
Dynamic R Release
elease Contr
Control
ol

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8.5.3.5.1. Disable R
Reset
eset 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-bo
check-boxxes will cause the
zone’s logic to ignor
ignoree the
Auto Clear TTime
ime delay for
the particular jam condition

! Selecting either of these options will not eliminate the detection of the particular
jam condition; it simply eliminates the default Auto Clear Time delay the logic
utilizes before automatically clearing the condition.

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8.5.3.5.2. 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 disable
this functionality

Clicking the Disable Sensor

Jam Auto Clear check bo
box
x
will disable the 3 attempts
to clear the Sensor Jam and
will cause the zone to
remain in the jam state until
the sensor is clear
cleared
ed
manually

* You can also attempt to clear a Sensor Jam using the Clear button for the Zone

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8.5.3.5.3. Disable Ar
Arrival
rival T
Timeout
imeout
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 disable this
functionality

Clicking the Disable Ar Arrival

rival
Timeout check bo boxx will
pr
prevent
event the dischar
discharging
ging
zone frfrom
om rregistering
egistering an
Ar
Arrival
rival Jam condition.
Upstr
Upstream
eam cartons will not
wait to enter the
dischar
discharging
ging zone once a
carton has lefleftt the
dischar
discharging
ging zone

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8.5.3.5.4. Disable Manual Operation

In normal ZPA operation, if a zone is in Accumulation (either by external device or Local Zone
Accumulation control by Pin 3 on the Control Port) and the carton is subsequently manually
removed from the conveyor; the zone downstream of the accumulated zone will run in an
attempt to “find the lost carton”. In certain applications or situations where manually removing
cartons from accumulated zones is expected; you can disable the running of the downstream
zone to “find the lost carton”

Carton accumulated in
Upstr
Upstream
eam Zone by L
Local
ocal
Accumulate signal on P Pin
in 3
or e
exter
xternal
nal network signal

If carton is rremoved
emoved fr
from
om
Upstr
Upstream
eam Zone, the
Downstr
Downstream
eam Zone will run
to “find the missing carton
carton”.
”.
Run time is the duration of
the Jam TTimer
imer setting (5
sec. by default)

If you check the Disable

Manual Operations check-
bo
boxx for the Downstr
Downstream
eam
Zone, then it will not run
when upstr
upstream
eam carton is
removed

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You first navigate the main scr

screen
een to
the zone you want to pr
prevent
event fr
from
om
running when it’s upstr
upstream
eam
neighboring zone has its carton
removed. Clicking the Disable Manual
Operations check bo
box
x will pr
prevent
event this
zone fr
from
om running when its upstr
upstream
eam
neighbor has an accumulated carton
manually rremoved
emoved

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8.5.3.5.5. Dynamic R
Release
elease
Some conveyor applications may require that you be able to switch a defined quantity of zones
between singulation and train release modes depending on operational conditions. Dynamic
Release allows you to utilize Contr
Control
ol P
Port
ort signals to remotely perform this switching. There are
two zones that require configuration in order to use Dynamic R Release
elease. The most downstream
zone in the range of zones you wish to control is the Dynamic R Release
elease Contr
Control
ol zone and the
most upstream zone in the range of zones you wish to control is the Dynamic R Release
elease
Ter
ermination
mination zone. The Dynamic R Release
elease Contr
Control
ol zone requires you to energize its Contr
Control
ol P
Port
ort
Pin 3 signal to toggle between release modes. If the default release mode for the range is
Singulation, then energizing Pin 3 will switch the range to Train. If the default release mode is
Train, then energizing Pin 3 will switch the range to Singulation.

5 Zone Dynamic R
Release
elease Example

For our example, we want to dynamically switch Zones A through E between Singulation
Release and Train RRelease
elease modes. All Zone’s default setting in our example is Singulation
Release mode. Zone A will be the Dynamic R Release
elease Contr
Control
ol zone and Zone E will be the
Dynamic RRelease
elease T
Ter
ermination
mination zone. We will wire our signal to Zone A Control Port Pin 3 to to
make this work. When we energize the signal, Zones A thru E will operate in Train Release
Mode and when the signal is de-energized, Zones A thru E will operate in Singulation Release
mode.

You first navigate the main

scr
screen
een to the most
downstr
downstreameam zone of the
Dynamic R Release
elease range
(Zone A). Clicking the
Dynamic R Release
elease Contr
Controlol
check-bo
check-box x will set this
zone’s Contr
Control
ol P
Port
ort to look
for Pin 3 ener
energized
gized to switch
the rrelease
elease mode

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Then you navigate the main

scr
screen
een to the upstr
upstream
eam
zone of the Dynamic
Release range (Zone E).
Clicking the Dynamic
Release T Ter
ermination
mination check-
bo
boxx will set this zone as the
“ter
“termination
mination”” of the
Dynamic R Release
elease range

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8.5.4. Motor Settings

The motor settings for the current selected module can be modified on the Main Scr
Screen
een

Change Motor T
Type
ype
Change Brak
Brake
e Method
Change Speed Contr
Control
ol Method
Change Speed Setting
Change R
Rotation
otation Dir
Direction
ection
Change AAcceleration/
cceleration/
Deceleration

* Please note that the Motor Settings grouped by motor plugged into the physical
Left and Right sides of the module and are not based upon Upstream or
Downstream product flow.

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8.5.4.1. Motor T
Type
ype
The Motor TType
ype drop-down box lists all motor brand and types whose profiles are available for
the module. Sener
Senergy
gy ECO is the default setting upon completion of the Auto
Auto-Configuration
-Configuration
Procedur
oceduree. The new settings are downloaded to the selected Node upon selecting a new item
from the list.

Selecting a Motor T
Type
ype from the drop
down box immediately makes the
change for the current Node.
Clicking Set All will download the
selected setting to the Left MDR of
all modules entered in the range of
Nodes at the top of the main screen
in the From Node # / T To
o Node #
boxes. In our example, the From
Node # / TTo
o Node # boxes have the
values of 2 and 6. Changing the
selection in the Motor T Type
ype drop
down will change Node 2 and then
by clicking Set All it will change
Nodes 3 thru 12 to the same setting
as Node 2

* Please note that if you change the Motor TType

ype and this module goes through
another Auto Configuration procedure, the Motor T Type
ype setting will not reset back
to default. It will remain unchanged at the last selected setting.

! Please consult your particular MDR’s documentation and review your application
if you are unsure as to which motor-type setting to use

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8.5.4.2. Brak
Brake
e Method
The Brak
Brake
e Method drop-down box lists all the holding brake methods available for the module.
Nor
Normal
mal is the default setting upon completion of the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree. The new
settings are downloaded to the selected Node upon selecting a new item from the list.

Selecting a Brak
Brake
e Method from the
drop down box immediately makes
the change for the current Node.
Clicking Set All will download the
selected setting to the Left MDR of
all modules entered in the range of
Nodes at the top of the main screen
in the From Node # / T To
o Node #
boxes. In our example, the From
Node # / TTo
o Node # boxes have the
values of 2 and 6. Changing the
selection in the Brak
Brake e Method drop
down will change Node 2 and then
by clicking Set All it will change
Nodes 3 thru 12 to the same setting
as Node 2

Method >Description

Once the controls have decelerated the rotor to a stop, the motor coil are internally
connected. The permanent magnet forces in the rotor and the mechanical inertia of the
Nor
Normal
mal gearbox holds the rotor in place. This is the MDR industry standard holding brake
method and is often termed short circuit or shunt. Nor
Normal
mal is the default factory setting
for all module zones from the Auto-Configuration Procedure

Once the controls have decelerated the rotor to a stop, the motor coils are internally
Free
disconnected and only the mechanical gearbox inertia holds the rotor in place

When the controls have decelerated the rotor to a stop, the processor notes the Hall
Servo Effect sensor status. If the Hall Effect sensor status changes indicating a change in
Brak
Brake
e 1 position of the rotor, the controls will inject current into 2 of the 3 motor coils in the
proper sequence to move the rotor back to its original stop position

When the controls have decelerated the rotor to a stop, the processor notes the Hall
Servo Effect sensor status. If the Hall Effect sensor status changes indicating a change in
Brak
Brake
e 2 position of the rotor, the controls will inject current into all 3 of the motor coils in the
proper sequence to move the rotor back to its original stop position

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* Please note that if you change the Brak

Brake
e Method and this module goes through
another Auto Configuration procedure, the Brak
Brakee Method setting will not reset
back to default. It will remain unchanged at the last selected setting.

! Servo Brake 1 and 2 are functionally equivalent. Servo Brake 2 utilizes more
power and provides more holding torque. Consequently, because Servo 2 uses
more current, the potential for heat build-up is present depending on your
application. If Servo Brake 1 provides enough holding torque for the application,
it is recommended using it in lieu of Servo Brake 2. Servo Brake 2 should only be
used when Servo Brake 1 does not provide enough holding torque for the
application

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8.5.4.3. Speed Contr

Control
ol Method
You can change the Speed Control Method between Open L
Loop
oop and Closed L
Loop
oop

Closed L
Loop
oop
Closed LLoop
oop speed control utilizes a proportional – integral (PI) algorithm to regulate MDR
speed. When enabled, the module motor control processor accepts the input from the Hall
Effect sensors to measure rotor speed and will adjust the motor output accordingly to attempt
to regulate speed. The value entered is in percent of the motor’s rated speed. Closed L Loop
oop
speed regulation can be used for applications where you need to maintain constant speed with
varying carton weights. The default setting is for Closed LLoop
oop to be enabled.

Checking the Closed L Loop

oop check box
enables Closed L Loop
oop speed control
method. You can also use the Set All
button to set the selected speed
control method for each motor in the
From Node # / T To
o Node # boxes. In
this example the Left MDRs from
nodes 2 thru 12 will each get the
same Speed Control Method speed
setting.

* Also note that when Closed Loop is enabled; the units for Acceleration and
Deceleration change from time-based (seconds) to distance-based (pulses).
Motor pulses can be converted to linear distance based upon knowing the
particular speed code of your MDR and its tube diameter. Please refer to Motor
Pulse to Distance Calculation for details and an example of calculating this
distance.

! Closed Loop speed control will provide PWM voltage to the MDR up to the limit of
the particular MDR’s selected profile and/or the current limits allowed by the
module’s built in protection algorithms and circuitry. To avoid unexpected results,

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please review your particular mechanical application along with the published
MDR performance data prior to implementing Closed Loop speed control

Open L
Loop
oop
Open LLoop
oop speed control does not utilize any such feedback to regulate speed. The value
entered is the percent PWM waveform (or “throttle”) that is output to the motor and the actual
rotor speed will fluctuate depending on the mechanical loading on the motor

Unchecking the Closed L Loop

oop check
box disables Closed Loop speed
control method and enables Open
Loop speed control method. You can
also use the Set All button to set the
selected speed control method to
each motor in the From Node # / T To
o
Node # boxes. In this example, all of
the Left MDRs from nodes 2 thru 12
will each get the same Speed
Control Method speed setting.

* Please note that if you change the Speed Contr

Control
ol Method and this module goes
through another Auto Configuration procedure, the Speed ContrControl
ol Method setting
will not reset back to default. It will remain unchanged at the last selected
setting.

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8.5.4.4. Speed
The definition of the Speed setting value depends upon the Speed Contr
Control
ol Method and Motor
Type selected:

Closed L
Loop
oop

Closed L
Loop
oop is the default Speed Contr
Control
ol Method and the value entered is in percent of the
motor rated speed based upon the Motor T Type
ype selected. The ConveyLinx module will adjust the
motor output based upon fluctuating motor loading in order to maintain this set speed.

Type in the desired speed as a

percentage. Valid values are from 1
to 100. You can also use the Set All
button to set the entered speed to
each motor in the From Node # / T To
o
Node # boxes. In this example we
set the speed to be 80% for Node 2
and when we click the Set All button,
the Left MDRs from nodes 2 thru 12
will each get the same speed setting

Open L
Loop
oop

Open LLoop
oop value entered is in % of the selected Motor T
Type’s
ype’s rated Pulse Width Modulation
(PWM) voltage. With this Speed Contr
Control
ol Method, the PWM voltage being fed to the motor
remains constant and the actual measured motor speed will fluctuate depending upon motor
load.

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Type in the desired speed as a

percentage. Valid values are from 1
to 100. You can also use the Set All
button to set the entered speed to
each motor in the From Node # / TTo
o
Node # boxes. In this example we
set the speed to be 80% for Node 2
and when we click the Set All button,
the Left MDRs from nodes 2 thru 12
will each get the same speed setting

* Please note that if you change the Speed and this module goes through another
Auto Configuration procedure, the Speed setting will not reset back to default. It
will remain unchanged at the last selected setting.

! Please consult your particular motor brand and model’s documentation for
determining the actual speed of the MDR’s for your application. The actual
mechanical speed of the MDR is determined by the mechanical gearing attached
to the motor. All Senergy MDR’s have identical motors but will run at very
different speeds and have very different torque characteristics depending on the
mechanical gearing used.

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8.5.4.5. Rotation Dir

Direction
ection
This setting is either Clock-Wise (CW
CW) or Counter-Clock Wise (CCW
CCW)and is determined for each
module based upon the Auto-Configuration Procedure results. Please refer to section Motor
Rotation Definition for details on how to determine rotation direction with respect to MDR
installed orientation.

Selecting a direction from the drop-

down box immediately sets the
rotation direction. You can also use
the Set All button to set the selected
rotation direction to each motor in
the From Node # / TTo
o Node # boxes.
In this example the Left MDRs from
nodes 2 thru 6 will each get the
same CW/CCW rotation direction
setting

* Please note that if you change the Rotation Dir

Direction
ection and this module goes
through another Auto Configuration procedure, the Rotation Dir Direction
ection setting will
not reset back to default. It will remain unchanged at the last selected setting.

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8.5.4.6. Acceleration/Deceleration
Acceleration and Deceleration settings are fields you enter values similar to Speed. The units of
the value you enter are dependent upon which Speed Contr
Control
ol Method you have selected.

When in Closed L
Loop
oop
In Closed L
Loop
oop, the units shown are Motor P
Pulses
ulses which means the control will accelerate and
decelerate in terms of motor rotor distance based upon Hall Effect sensor state change and the
controller’s current limits and the mechanical limits of the connected drive train. Because the
module does not have any data regarding the gear reduction ratio of the installed MDR, you
will need to work with the Motor Pulse to Distance Calculation to find out the amount of linear
distance the particular acceleration or deceleration will take

Type in the desired accel and decel

values in motor pulses
pulses. You can also
use the Set All button to set the
entered values to each motor in the
From Node # / T To
o Node # boxes. In
this example we set the accel to 300
and the decel to 0 for Node 2 and
when we click the Set All button, the
Left MDRs from nodes 2 thru 12 will
each get the same speed setting

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When in Open L
Loop
oop
Units shown are seconds which means that the control will accelerate and decelerate for the
time specified within the controller’s current limits and the mechanical limits of the connected
drive train

Type in the desired accel and decel

values in seconds
seconds. You can also use
the Set All button to set the entered
values to each motor in the From
Node # / TTo
o Node # boxes. In this
example we set the accel to 0.30
and the decel to 0 for Node 2 and
when we click the Set All button, the
Left MDRs from nodes 3 thru 12 will
each get the same speed setting

* Please note that if you change either of the Accel/Decel values and this module
goes through another Auto Configuration procedure, the Accel/Decel settings will
not reset back to default. They will remain unchanged at their last selected
settings.

! Please note that very small deceleration values can cause the module to indicate
a Short Circuit Error. This can happen at speeds greater than 75% and
deceleration values less than 0.1 seconds (in Open Loop) or 50 pulses (in Closed
Loop) with Servo Brake 1 or Servo Brake 2 enabled.

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8.5.4.7. Motor Jog and Er

Errror Indicators
Motor Jog (R
(Run)
un) F
Function
unction
In EasyRoll, the Left and Right motors have their own Run buttons on the Main Screen. These
are used to temporarily run the motors for verification of function and diagnostics.

Click the R
Run
un icon to tur
turnn on
the motor

When R Run
un is activated the
icon highlights. Click the
icon again to tur
turnn the motor
off

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* Please note the Motor Jog (R(Run)

indicated by the Rotation Dir
un) F
Function
unction rotates the motor in the direction
Direction
ection selection which may or may not be the
direction of flow established by the Auto Configuration procedure.

Er
Errror Indicators
In EasyRoll, the Left and Right motors have their own status indicators on the Main Screen.
These are used to provide visual indication of certain conditions. There are also status
indicators for the Sensors connected to the Left and Right sides of the modules.

Indicators ar
aree Gr
Green
een when
the condition does not eexist
xist
and will be R
Red
ed when the
condition does e exist.
xist.

Indicator Description

Sensor Connection Occurs when the particular side of the module was Auto Configured as a
Error zone and the sensor is unplugged or otherwise not drawing power

Occurs when the sensor health/gain signal on pin 3 of the Sensor port
Sensor Gain Error
changes state from its Auto-Configuration state

A running numerical counter that increments for each occurrence of

Error Counter
connection or gain errors. Counter resets to 0 upon power cycle

Motor Connection Occurs when a motor that is expected to be connected becomes

Error disconnected by either unplugging or internal damage

Voltage drop [<18V] Occurs if the incoming power to the module drops below 18 volts

Motor short circuit Occurs if the module detects a short circuit condition

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Indicator turns Yellow if the motor is delivering the maximum torque

Max. Torque
according to the selected motor profile

Occurs if motor is commanded to run and is not rotating sufficiently for

Overload
at least 20 seconds

Occurs when the motor is commanded to run and the rotor is not
Motor Stalled
turning

Occurs if one or more of the 3 Hall Effect Sensors does not produce a
Motor Sensor Error
signal or does not change state when motor is running

Occurs when the calculated motor temperature has exceeded 105°C or

Overheat
the module temperature has exceeded 90°C

A running numerical counter that increments for each occurrence of any

Motor Error Counter
of the motor error conditions. Counter resets to 0 upon power cycle

Overvoltage [>30V] Occurs when the incoming power to the module exceeds 30V

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8.5.4.8. Motor P
Pulse
ulse 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 R

Ratio
atio)

* Roller Diameter and Gear Ratio values for specific roller diameters and speed
codes are found in our Pulseroller Global Motor Roller Technologies Product
Catalog available at www.pulseroller.com

For example, we have a standard Senergy roller with a diameter of 48.6 mm (standard 1.9”
tube) and our speed code is 60. From the chart on page 10 (2019 edition of the Catalog)
indicates that the Gear ratio for a 60-speed code is 11. From this information we plug in the
values into our formula:

(π × 48.6) / (30 × 11) = 0.463 mm per pulse

For this 60-speed code Senergy roller, when you set the Deceleration in Closed Loop mode to
50 pulses; the roller will decelerate for a distance of:

0.463 _ mm/pulse_ × 50 pulses ≅ 23 mm

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8.5.5. Diagnostic W
Window
indow

Indicator Description

You can navigate to the next or previous module’s Diagnostic Window by clicking
the + and – buttons

Displays the current ZPA status of the zone and the state of the sensor

Displays the status of the upstream and downstream zones to the selected
module. Note that the values depicted below the text (“00 00” in the example)
indicate the contents of the Tracking Registers. Please refer to ConveyLinx ERSC
PLC Developers Guide for details on how to use the Tracking Registers

Displays the current input voltage to the module as well as the count of the
number of times the power supply went below 18 volts but did not completely
shut off. This is useful for diagnosing possible power supply issues

Displays the current state of each Sensor Port and Control Port input signals

Displays current status of each motor. Please note that this data is also shown on
the main screen as well

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Accumulation Status

If a carton is accumulated on a particular zone, the Diagnostic Window will indicate a reason for
the accumulated state. Also note that in situations where an external device (PLC or PC
controller) or the Accumulate icon on the Main Screen has been activated; the Sensor LED on
the module for the stopped carton’s zone will be fast blinking green. You can then consult the
Diagnostic Window for more detailed information on the exact reason

As shown in this e
example,
xample,
for the downstr
downstream
eam zone
on the selected Module, it
shows ““PPin3 Contr
Control
ol P
Port
ort
Accumulation
ccumulation”” as the
reason a carton is stopped
at this zone even though
the zone that is
downstr
downstream
eam of this
module is empty

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8.6. Advanced Dialog

The Advanced Dialog is where you can make further changes to module operation and access
utilities to help maintain your system of modules.

To invoke the ConveyLinx Advanced Dialog you can do any of the following:

• Click Advanced Dialog button

• Press F2
• Simultaneously press [Ctrl] [Shift] U

The ConveyLinx
Advanced Dialog
pops up over the
Main scr
screen
een
display and
defaults to show
the Look Ahead &
Timing tab

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8.6.1. Look Ahead and T

Timing
iming T
Tab
ab
The Look Ahead and Timing Tab contains 4 sections of settings pertaining to ZPA functionality:

Look Ahead
Jam & Auto Clear TTimers
imers
Run A
Affter & Induct
Sensor Debounce
Debounce*

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8.6.1.1. Look Ahead Slowdown F

Featur
eaturee
The Look Ahead feature configures the logic to “look ahead” to its next downstream zone and if
it is occupied when a carton is entering its zone, the module will dynamically adjust the MDR to
the selected speed. This feature in intended to be used in higher speed applications were
increased stopping distance is required to keep cartons from over-travelling their stop
positions. This function can be applied per zone or for multiple zones

A carton is
accumulated
and stopped at
Zone 1 and
another carton is
conveying at
nor
normal
mal set
speed

When carton
reaches end of
Zone 3, Zone 2
will wak
wake
e up and
run at the L
Look
ook
Ahead Speed

Click the checkbox to enable the Look Ahead feature for the selected Node.
Clicking the Set buttons will download the setting to the respective zone on the
selected Node. The value entered for the slowdown speed is in percent of the
Node’s normal speed as set on the main screen. In this example, the Look
Ahead speed will be proportional to 80% of 90% PWM current. If the PWM
speed on the main screen was set to 70% PWM, then the slowdown speed
would be “80% of 70% PWM”. Also note there is a Set All button that will apply
the settings to the range of Nodes entered

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Fast R
Release
elease T
Time
ime

The Fast R
Release
elease T
Time
ime option allows you to set a delay before the Look Ahead Slowdown speed
is engaged for the slow-down zone

When Zone 2
wak
wakeses up it will
run at nor
normal
mal
set speed until
the FFast
ast R
Release
elease
Time has
expir
xpired,
ed, then it
will switch to run
at the LLook
ook
Ahead Slowdown
speed

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To use the Fast

Response T Time
ime
option, click the
Fast Release
Time checkbox
and enter a time
value (in
seconds) into
the value entry
box. In this
example we
entered 0.5
seconds. Click
Set to write the
changes to the
module and use
the Set All
feature as
desired

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8.6.1.2. Jam Auto Clear T

Timers
imers
The Jam TTimer
imer for a given Upstream or Downstream zone is used for both detecting an Arrival
Jam and a Sensor Jam. The Jam T Timer
imer 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 nuisance jam
occurrences. The default value for the Jam Timer is 5 seconds and the valid range of values is
from 1 seconds to 65 seconds.

The Auto Clear TTimer

imer is the amount of times that the logic maintains the jam condition before
auto resetting the jam. The default value for the Auto Clear Timer is 5 seconds and the valid
range of values is from 0 seconds to 65 seconds

Enter new values for either or

both the Jam T Timer
imer and/or Auto
Clear T
Timer
imer and click the
corresponding Set button for
each. The Set All button will
apply these same settings for
the range of modules indicated
at the top of the dialog

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8.6.1.3. Run A
Affter T
Time/Distance
ime/Distance
The Run AAffter time value is used by the logic for normal zone discharge. This is the amount of
time the zone’s MDR will continue run after its photo-sensor has been clear when discharging
to the next downstream zone.

This extra run time allows the zone to

run so that the trailing edge of the
carton can completely pass the photo-
sensor and fully enter the next zone.
This value is adjustable to
compensate for special conditions
where a zone photo-sensor is required
to be placed farther upstream or
downstream

* Please note that Run After does not affect throughput rate. A longer Run After
time will not prevent an upstream item from entering the zone.

Run A
Affter T
Time
ime

Enter new values for upstream and/

or downstream Run A Affter time and
click the corresponding Set button.
The default is 5 seconds and the
valid range is 0 to 65 seconds. The
Set All button will apply these same
settings for the range of modules
indicated at the top of the dialog

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Run A
Affter Distance

EasyRoll provides the option to change the Run A

Affter metric to be distance based instead of
time based. When the metric is distance, the value entered is motor pulses instead of seconds

Select Distance from the drop-down

box and enter new values for
upstream and/or downstream Run
After pulses and click the
corresponding Set button. The
default is 5000 pulses and the valid
range is 0 to 65,535. The Set All
button will apply these same
settings for the range of modules
indicated at the top of the dialog

* See Motor Pulse to Distance Calculation for details on figuring out the distance
traveled

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8.6.1.4. Induct F
Forwar
orwarddT
Time/Distance
ime/Distance
Induct F
Forwar
orward
d value is used to cause the MDR to continue to run after the zone’s photo-sensor
has been blocked when receiving a carton from upstream.

This value is adjustable per zone to

compensate for special conditions
when for example a zone’s photo-
sensor needs to be placed farther
upstream from the discharge end of
the zone

Induct F
Forwar
orwarddT
Time
ime

Enter new values for upstream and/

or downstream Induct F Forwar
orwardd time
and click the corresponding Set
button. The default is 0 seconds and
the valid range is 0 to 65 seconds. In
opur example we entered 0.5
seconds. The Set All button will
apply these same settings for the
range of modules indicated at the
top of the dialog

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Induct F
Forwar
orwardd Distance

Select Distance from the drop down

box and enter new values for
upstream and/or downstream Induct
Forwar
orwardd pulses and click the
corresponding Set button. The
default is 0 pulses and the valid
range is 0 to 65,535 pulses. In our
example we entered 300 pulses. The
Set All button will apply these same
settings for the range of modules
indicated at the top of the dialog

* See Motor Pulse to Distance Calculation for details on figuring out the distance
traveled

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8.6.1.5. Induct R
Reverse
everse T
Time/Distance
ime/Distance

* Induct R
Reverse
everse is only applicable for Reversing Control in ZPA Mode

Induct R
Reverse
everse 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 blocked when receiving a carton from upstream with reference to the
“reverse” direction.

* Typically for Reversing Control, the Sensor is mounted in the center of the zone
and the Induct RReverse
everse TTime/Distance
ime/Distance is equal to the Induct F
Forwar
orward
dTTime/
ime/
Distance. These are adjusted separately so you can compensate for situations
when you cannot put the Sensor in the center of the zone

Induct R
Reverse
everse T
Time
ime

Enter new values for upstream and/

or downstream Induct RReverse
everse time
and click the corresponding Set
button. The default is 0 seconds and
the valid range is 0 to 65 seconds. In
our example we entered 0.5
seconds. The Set All button will
apply these same settings for the
range of modules indicated at the
top of the dialog

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Induct R
Reverse
everse Distance

Select Distance from the drop down

box and enter new values for
upstream and/or downstream Induct
Reverse pulses and click the
corresponding Set button. The
default is 0 pulses and the valid
range is 0 to 65,535 pulses. In our
example we entered 300 pulses. The
Set All button will apply these same
settings for the range of modules
indicated at the top of the dialog

* See Motor Pulse to Distance Calculation for details on figuring out the distance
traveled

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8.6.1.6. Sensor Debounce

Sensor Debounce setting is the time the logic holds the state of its Sensor inputs after a
change of state. Keep in mind this is not a delay prior to detecting a carton when it first blocks
the sensor.

The module will detect the leading edge of a carton and hold this state for the
Sensor Debounce time period. Similarly, when the trailing edge of the carton
clears the sensor, the logic holds this state for the Sensor Debounce time
period

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Enter the desired value in seconds

and click the Set button. The default
is 0.1 seconds and the valid range is
0 to 2 seconds. Please note this
setting applies to both the Lef
eftt and
Right Sensor ports. In our example
we entered 0.2 seconds. The Set All
button will apply these same
settings for the range of modules
indicated at the top of the dialog

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8.6.1.7. Reversing Contr

Control
ol in ZP
ZPA
A Mode
There is a checkbox on the Look Ahead & T Timing
iming tab for Enable R
Reversing
eversing Conveyor Contr
Control
ol on
Downstr
Downstream
eam Contr
Control
ol P
Port
ort located at the bottom of the dialog. Reversing conveyor control
applies to an entire subnet of modules and the Control Port used for this functionality is always
assigned to the Downstream zone of the most UpstrUpstream
eam module.

This checkbox
should only be
checked on the
module that is the
most upstr
upstream
eam in
a subnet

Practical P
Prrer
erequisites
equisites for R
Reversing
eversing ZP
ZPA
A Contr
Control
ol
• Sensors should be located very close to or in the center of each zone
• Length of all products should be identical or very close to identical
• Induct F
Forwar
orward
d and Induct R
Reverse
everse need to be set

Reversing Contr
Control
ol Example

Reversing conveyor utilizing hard-wired signal to Control Ports is enabled in EasyRoll as

indicated in section Reversing Control on page 91. Figure 61 depicts a simple 8 zone example

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and indicates which signals on which Control Ports will provide the control. Reversing function
applies to all modules in a subnet will work for any number of zones up to the maximum that
can be included in a single subnet.

* Please note that you can utilize reversing control for a portion of a subnet by
utilizing a remote PLC via the Ethernet network. See how to use a PLC for
reversing ZPA control

Sequence of Operation

Forwar
orwardd Dir
Direction
ection

• All signals are OFF on Downstream Control Port – A of the xxx.xxx.xxx.20 module
• You can use the Upstream Control Port to wake up the most upstream zone
• You can use the Downstream Control Port-B to hold and accumulate the most
downstream zone

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Switching to R
Reverse
everse Dir
Direction
ection

Energize Pin 3 on Downstream Control Port-A to cause all zones in the subnet to accumulate
Wait for all zones to stop and accumulate (time value dependent upon zone length and speed –
2 or 3 seconds is typical) Energize Pin 4 on Downstream Control Port-A to logically switch the
direction to Reverse De-energize Pin 3 on the Downstream Control Port-A to remove
accumulation for all zones in subnet to start reversing operation Note that the Upstream
Control Port and Downstream Control Port-B have also reversed their respective functions.
Upstream Control Port now provides the Downstream Interlock (lane full) function and the
Downstream Control Port-B provides the Upstream Interlock (wake-up) function

Switching Back to F
Forwar
orwardd Dir
Direction
ection

Energize Pin 3 on Downstream Control Port-A to cause all zones in the subnet to accumulate
Wait for all zones to stop and accumulate (time value dependent upon zone length and speed –
2 or 3 seconds is typical) De-energize Pin 4 on Downstream Control Port-A to logically switch
the direction to Forward De-energize Pin 3 on the Downstream Control Port-A to remove
accumulation for all zones in subnet to start forward operation

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8.6.2. Upgrade T
Tab
ab
The Upgrade tab screen gives access to the module firmware utility. Over time, enhancements
and features may be added to the ConveyLinx family of products. These features and
enhancements are typically made available to customers in the form of firmware upgrade files
that need to be uploaded to your modules. These files are available for download from our
website. Once you have downloaded the desired file, the Upgrade utility allows you to browse
for it and then select a single Node or group of Nodes to upload

* VER
VERYY COOL
COOL:: Please note that if you upgrade firmware, all of each module’s
settings (motors, speeds, ZPA options, etc.) are preserved

! Please note that if module power is lost during a fir

the module may become inoperable.
firmwar
mware
e upgrade,

If this occurs, the module must be rretur

eturned
ned to the factory in or
order
der to
be rrecover
ecovered.
ed.

Upon selecting the Upgrade screen

tab, EasyRoll fills in the I.P. address
of the range of Nodes entered on the
main screen. Click the Browse
button to open a file selection dialog
window

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With the Open dialog displayed,

navigate to the location on your PC
where you placed the firmware
upgrade file you received. Select the
file and click Open

In this example, we clicked Upload

ALL so the selected firmware
upgrade file will be sent to all 6
Nodes. The Output window will
update the progress of the file
uploading process. The time it takes
for this process will vary depending
upon how many Nodes are being
uploaded

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When all Nodes report back to the

Output window with a status of
Done; then the upload is complete
and you can close the ConveyLinx
Advanced Dialog window

* Please note that you typically arrive at the Upgrade tab from the Network
Services tab where you select the modules first and click the Upgrade button
there. That will automatically take you to the Upgrade tab and populate the
Selected Devices list box on the Upgrade tab with your selection from the
Network Services tab

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8.6.3. Connections T
Tab
ab
The Connections utility uses EasyRoll to instruct a given module to make a logical connection
to another module that it otherwise would not have made during the Auto-Configuration
Procedure. For applications where you have more than one Subnet, this would be the way to
logically connect the most downstream Node of one Subnet to the most upstream Node of
another Subnet

Connecting T
Two
wo Subnets T
Together
ogether

Here is a typical boundary between two Subnets. The most downstream Node
of the first Subnet has an I.P. address of 192.168.25.34 and the most upstream
Node of the second Subnet has an I.P. address of 192.168.26.20.

By simply connecting an Ethernet cable between these two boundary Nodes

and then using EasyRoll to establish the “logical” connection between the two
Subnets; you can achieve seamless flow between the two networks. The
procedure requires that you have to instruct Node at 192.168.25.34 to convey
cartons to Node at 192.168.26.20, and likewise you have to instruct Node at
192.168.26.20 to accept cartons from Node at 192.168.25.34

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Navigate to Node 15 of the

192.168.25 subnet (i.e.
192.168.20.34). Notice that the
module’s network data appears in
the center. Also notice that the
Downstream connection for this
Node is None

Enter 192.168.26.20 as the I.P.

address for Node 15’s new
Downstream connection. Click Apply
to make the change. Please note
that it will take a few seconds for
this to complete

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Navigate to Node 1 of the

192.168.26 subnet (i.e.
192.168.26.20). Notice that the
module’s network data appears in
the center. Also notice that the
Upstream connection for this Node is
None

Enter 192.168.25.34 as the I.P.

address for Node 1’s new Upstream
connection. Click Apply to make the
change. Please note that it will take
a few seconds for this to complete

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8.6.4. Network Services T

Tab
ab
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

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8.6.4.1. Discover and IP A

Addr
ddress
ess Set
One of the features of EasyRoll is that it has a utility called Discover that allows your PC to go
and find any modules that may be physically connected to you network regardless of the I.P.
address settings of your PC or the I.P. address settings of the modules

Clicking the Discover button

will cause the list box to
populate with all the modules in
all Subnets that your PC can
see out on the network. In this
example you can see that 112
Nodes were discovered.

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The drop-down box at the top

of the list box lets you filter the
list by Subnet. In this example
we are selecting the
192.168.25 Subnet
Subnet.

Double-click any one of the line

items in the list to display its
properties. In this example we
double clicked the first item to
show its properties data.

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Once a modules data has been

selected, you can change its
properties. In this example we
changed the 3rd octet of the I.P.
address from 25 to 37. Once
you have edited the data, click
the Set button and the changes
are sent to the module.

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8.6.4.2. Position and DHCP

Position Identifier
Within the “Settings of the selected node” area, at the bottom, is a read-only box that shows
the position of the selected module within the network. This information is provided so you can
Subnet. The data shown is a position indicator or Flag. The possible
check the integrity of your Subnet
values are 1 -> First, 2 -> Last, and 0 -> unknown .

For a properly configured Subnet you must have:

• Only one Module with a 1 -> First position Flag

• Only one Module with a 2 -> Last position Flag
• All modules with the exception of the First and Last should indicate 0 -> unknown

With your list filtered so that it

shows only one Subnet , the
first item in the list should be
the .20 module of the Subnet
and its position Flag should
always indicate 1 -> First. In
our example we selected the
192.168.26.20 node and its
Flag is shown as_1 -> First_.

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The last module in the Subnet

should have a position Flag
value of 2 -> Last. In our
example we selected module
192.168.26.30 and we can see
its position Flag is 2 -> Last as
shown.

Any module that is not the First

or Last module in the Subnet
should have a Flag value of 0
-> unknown. In our example we
selected module 192.168.26.24
and we can see its position Flag
is 0 -> unknown as shown.

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! If you have more than one module in a Subnet with a First or Last Flag, or if there
is no First or Last module in the Subnet, your network will not properly preserve
its data for Automatic Module Replacement and the Subnet may have problems
negotiating Ethernet switches and routers for PLC connectivity. You MUST
properly Auto-Configure all Subnets so that these position Flags are correct!

DHCP Server
By default, the most upstream module of every Subnet (I.P. Address xxx.xxx.xxx.20) enables a
simple DHCP server as a convenience so that if your PC is set up to receive an IP address from
the network, your ConveyLinx Subnet will issue one. On larger systems with perhaps multiple
Subnets and/or customer managed network infrastructures, this DHCP server may interfere
with the function of the network. You can disable this DHCP server from the Network Services
tab.

Once you have double clicked

the module form the list, you
can check the Disable DHCP
checkbox to disable the DHCP
server. You have to click the Set
button to make the change to
the module.

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8.6.4.3. Network L
Lock
ock F
Featur
eaturee
The Lock FFeatur
eature
e allows you to “lock” a specific Subnet so that no accidental pressing of the
Install button on any of the modules will inadvertently cause an Auto Configuration Procedure
to be activated.

In this example, the 192.168.29

Subnet is selected and you can see
by the icons next to each module
entry in the list that they are
“Unlocked”

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By clicking the Lock Selected

Network button, all modules in the
Subnet listed will be “Locked” as
indicated by the icons in the list.
Clicking the Unlock Selected
Network button will “Unlock” all the
modules in the list

! Please note that this function applies to all the modules within a selected Subnet
and cannot be activated for an individual module

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8.6.4.4. Back
Backup
up and R
Restor
estoree
You have the ability to select a Subnet or all Subnets discovered and generate a Back Backup
up file
that will contain all the parameters and settings for each module included in the selection. This
means all motor settings (speed, acceleration, deceleration, braking, etc.), ZPA settings,
Advanced Dialog settings, etc. are captured in this file that can be saved on your PC.
Conversely you can use this Back
Backup
up file to Restor
estoree settings to a Subnet or all Subnets in the
event settings are inadvertently modified or you simply want to return your modules to a
previously known state

To perform a backup, click the Select

ALL button to select all the items in
the list. In this example we are going
to backup Subnet 192.168.29. Once
all modules are highlighted, click the
Back
Backup
up button. A “Save As” file
dialog will appear and you provide a
filename and location to save the file

A Save As dialog will appear and you

provide a filename and location to
save the file

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Conversely, if you have a Back

Backup
up file
that you want to use to get your
Subnet’s settings restored; click the
Select ALL button and then click the
Restor
estoree button. An “Open File”
dialog will appear for you to
navigate to the location of your
backup file

An “Open File” dialog will appear for

you to navigate to the location of
your backup file, select it and click
“Open”.

* Please note that the Restor

estore
e function will only restore settings to modules that
have a matching Serial Number in the Back
Backup
up file. For situations where module
serial number are different but functionality still needs to be restored, you will
need to use the Restor
estore
e by IP function

Restor
estoree by IP F
Function
unction

Because the default Restor

estoree function restores settings by module Serial Number only, in
situations such as duplicating a Subnet or restoring functionality from an older backup where
some of the modules were replaced since the BackBackup
up file was generated, you need to restore

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the settings by IP address instead of by module Serial Number. To do this you follow the same
restore procedure as previously shown except you click the Restor
estoree by IP button instead of the
Restore button

Back
Backup
up and R
Restor
estoreeR
Recommendations
ecommendations and T
Tips
ips

Sometimes there are situations where just because a software application will allow you to do
something does not always mean that you should. The BackBackup
up and Restor
estore
e functions in
EasyRoll can fall into this scenario. Even though you can technically create a backup file for a
few or even a single module from within a Subnet of many modules, it is not recommended
that you do so. ConveyLinx support engineer’s experience to date has indicated that when
customers perform Back
Backup
up and Restor
estore
e functions for, at a minimum, all modules in a Subnet
Subnet,
you will have fewer or no problems with your ConveyLinx networks. Systems that were once
working and then start producing unexpected results often stem from performing a Restor
estore
e
function to a small portion of modules instead of the entire Subnet and/or starting with a
backup file that did not include all modules in the Subnet
Subnet. So, here is a list of tips:

• When you perform a Back

Backup
up; at a minimum, select all modules in a given Subnet
• When you perform a Restor
estoree; at a minimum, select all modules in a given Subnet
• Perform a new Back
Backup
up after you make any settings changes to one or more modules in a
Subnet
• Perform a new Back
Backup
up after every time you perform an Auto Configure Procedure

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8.6.5. Special Services T

Tab
ab
Reset Operating T
Time
ime

Each module maintains a non-

volatile data register for each MDR
whose value is the number of
minutes the motor has been run.
This value is displayed as Operating
Time on the Main Screen. This
screen on the ConveyLinx Advanced
Dialog allows you to reset this meter
in the event you have to replace a
given MDR. Click either the Left
Motor or Right Motor buttons in the
Reset Operating Time area to reset
the corresponding value to 0.

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Clear Motor Short Cir

Circuit
cuit Er
Errror

Another function on the Special

Services tab is a button used to
clear an MDR short circuit error. This
particular error is not logically
cleared based upon an elapsed
period timeout or other such reset.
An MDR short circuit error requires
that either the module be powered
down and then powered back up or
by clicking the Reset button on this
tab. This function is made available
in EasyRoll as a convenience so you
don’t have to cycle the power on the
module.

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Touch & Go

The Touch & Go function is available

in ZPA mode and when activated
causes the MDR in the activated
zone to sense rotational movement
of the MDR in its default direction. If
this rotational movement (such as
someone pushing a carton onto the
zone) is of sufficient duration and
speed; the zone will “wake up” as if
its upstream interlock had been
energized. You enable this function
by checking the appropriate
Upstream or Downstream checkbox
in the Touch & Go area.

! Touch & Go is only applicable for ZPA mode. Do NOT use Touch & Go with Servo
Braking

* If you are using Firmware 4.27 and later or ODVA Firmware 5.07 and later and
EasyRoll version 4.21 or later; there is a Motor Slave function available on this
screen tab

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8.6.5.1. Motor Slave F

Function
unction

! The functionality in this topic requires Firmware 4.27 and later or ODVA Firmware
5.07 and later as well as EasyRoll version 4.21 or later

* The Motor Slave function from EasyRoll is only applicable to modules in ZP

mode that have been Auto-Configured as a single zone (only one sensor
connected) and two motors connected.
ZPA
A

* Motor Slave function automatically adjusts slave motor’s speed and performance
in Closed L
Loop
oop mode to properly assist the master motor

The purpose of the Slave FFunction

unction is to select one of the two motors (Left or Right) to be the
master and the other to to follow the run/stop and speed of the opposite motor. When you
select one of the motors to be the master, only its settings are accessible in EasyRoll and
whatever setting you modify (Speed, Accel, Decel, etc.) will also apply to the slave motor.

From the Special Services Tab, if you

have selected a Node that has been
Auto
Auto-Configur
-Configured
ed as a Single Zone
ZP
ZPAA , then the Slave F
Function
unction drop
down box is enabled for selection.

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Slave F
Function
unction Selections
Selection Description

No Slave Function is applied and Node functions as Auto-Configured as single zone

None ZPA. Both motors run together when the zone is activated and the two motors
have their settings independently accessible from EasyRoll

Left motor becomes the master and the Right motor becomes the slave. Only the
right is
Left motor’s settings are accessible in EasyRoll and the Right motor will utilize all
slaved to left
the settings made to the Left motor

right is in Identical to right is slaved to left except that when the Left motor runs, the Right
opposite motor runs in the opposite direction of the Left motor. This function is used for
direction Dual Drive MDRs

Right motor becomes the master and the Left motor becomes the slave. Only the
left is slaved
Right motor’s settings are accessible in EasyRoll and the Left motor will utilize all
to right
the settings made to the Right motor

left is in Identical to left is slaved to right except that when the Right motor runs, the Left
opposite motor runs in the opposite direction of the Right motor. This function is used for
direction Dual Drive MDRs

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Example

You have a single zone

ZP
ZPAA module where the
flow is from Lef
eftt to Right,
so lets make the Right
motor the master and the
Lef
eftt motor the slave

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From the Slave F

Function
unction
drop down selector, select
lef
leftt is slaved to right

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When you go back to the

Main Scr
Screen
een, you can see
that the Left motor
parameters are greyed out
and not accessible. Any
changes you make to the
Right motor will
automatically be applied
to the Left motor

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8.6.6. Contr
Control
ol P
Ports
orts T
Tab
ab
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 of Control Ports

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8.6.6.1. Contr
Control
ol P
Port
ort Inputs
Each of the two Control Ports on the module has a 2 input signals: Local Accumulation and
Infeed/Discharge Interlock. Each of these inputs has a default logical state (on or off) that
enables the function. The Contr
Control
ol P
Port
ort Inputs area contains check boxes to invert the logical
state of these inputs to accommodate your particular needs. Please note that these checkboxes
are for Lef
eftt and Right ports on the module and not the logical Upstr
Upstream
eam or Downstr
Downstream
eam zones

By default, the module interprets the

Infeed/Discharge input signal
(Interlock Pin 4 on RJ-12 Control Port
or P4 on a SE-4) when energized or
ON to mean a logical “1”. By clicking
the check box to invert the Infeed/
Discharge input signal, a de-
energized or “OFF” condition will
mean a logical “1” to the module for
the Interlock Pin 4 Control Port signal

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By default, the module interprets the

Accumulation input signal (Pin 3 on
RJ-12 Control Port or P3 on a SE-4)
when energized or ON to mean a
logical “1”. By clicking the check box
to invert the Accumulation input
signal, a de-energized or “OFF”
condition will mean a logical “1” to
the module for the Pin 3 Control Port
signal

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8.6.6.2. Contr
Control
ol P
Port
ort Outputs

! Control Port outputs are very low power. You need to use an SE Module to
connect your external device.

The default Contr

Control
ol P
Port
ort Output
configuration signal is “ON” or
logical “1” to indicate to external
controls that it is associated zone is
occupied. By clicking the associated
Invert check box, the module will
make the output “OFF” or logical “0”
when its associated zone is occupied

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The default operation of each

Contr
Control
ol P
Port
ort Output signal is to
indicate whether the zone is
blocked. You can change this
operation to indicate that the motor
is running instead of zone blocked
by clicking the Motor State
checkbox. Please note that the
Invert function applies to this option
as well

! Please note that if you select the Motor State option on a module that is an
Extension of another module, the Control Port Output will not energize. The
Motor State output only energizes on the module with the zone that is controlling
the Extension. See the Extensions Tab topic for more details.

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8.6.6.3. Upstr
Upstream/Downstr
eam/Downstream
eam
Accumulation
One of the Control Port input signals previously mentioned above is the Local Accumulate
signal (Pin 3 on RJ-12 Control Port or P3 on a SE-4). By default, this signal causes the local zone
to accumulate when its zone sensor is blocked. If this signal is removed when a carton is
blocking the sensor, the carton will discharge to the next downstream zone (if of course it is
clear). While the carton is discharging and still blocking the zone sensor, if the Accumulate
signal is re-energized, the zone will stop.

Accumulate on Sensor T
Trigger
rigger

In situations (like an operator workstation) where you for example want every carton to
accumulate upon its arrival, you would leave the Accumulate signal energized all the time and
then have an operator momentarily de-energize the signal to cause the carton to discharge. In
this situation you probably do not want the operator to have to watch and wait for the carton to
fully discharge from the zone in order for them to re-energize the Accumulate signal so that the
next carton will stop at the zone. The Accumulate on Sensor Trigger checkboxes for the
Upstream and Downstream zones allow you to tell either or both the Upstream or Downstream
zones on the module to remember that the Accumulate signal was momentarily de-energized
so the carton will discharge without any further operator intervention and automatically know
to accumulate the zone upon the arrival of the next carton.

Click the Accumulate on Sensor

Trigger checkbox so that a
momentary removal of the Pin 3
signal will release the carton from
the zone. If the Pin 3 signal comes
back on and the sensor is still
blocked, the control will still release
the carton and will not accumulate
again until the sensor becomes clear
and then blocked again

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8.6.6.4. Lane F
Full
ull Interface
The Control Ports tab provides selection and adjustment to the Pin 4 Interlock Signal on the
most Downstream zone to provide a Lane F Full
ull Interface that is typical in conveyor applications.
With Lane FFull
ull Interface checkbox checked; the Downstream Interlock will change its default
functionality to ignore the confirmation signal from the downstream controls and thus eliminate
the logical Arrival Jam condition. This will allow the downstream zone to continually release as
long as the sensor signal is OFF (default). This option also allows the user to set a block and
clear time for the Pin 4 signal for added flexibility

* The Lane F
Full
ull Interface Block and Clear Timer capability is designed so you can
plug a Sensor direct into the Control Port

When a sensor is plugged into the

downstr
downstream
eam Control Port, you can
check the Lane F Full
ull Interface
checkbox. This will cause the zone to
no longer require a downstream
arrival interlock (i.e. Ignore Arrival
Jam) and use the sensor signal to
stop and start releasing from the
zone. Block and Clear T Timers
imers are
provided to adjust the behavior of
product flow based upon the
blocking and clearing of the sensor.
In this example we entered 4
seconds for Block Time and 5
seconds for Clear Time.

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8.6.6.5. PLC Contr

Control
ol of Contr
Control
ol P
Ports
orts
If you have a PLC connected to a module while it is in ZPA mode, you have the option of
disabling the default ZPA functionality of either Control Port (or both) and allow your external
PLC to access the 2 input signals and the one output signal available on each port. This means
that when selected for a given zone’s Control Port; energizing either input signal will not
indicate Local Accumulation or Infeed/Discharge Interlock functions and the output signal will
not become energized when the zone is occupied. Your PLC program will have access to these
inputs and output to use as remote I/O over the ConveyLinx Ethernet network

You can select either or both the

Upstream and/or Downstream
Control Ports to be controlled by
your remote PLC over the
ConveyLinx Ethernet network.
Checking the appropriate checkbox
will immediately make the change. If
a checkbox is already checked,
unchecking it will return the
associated port back to its ZPA
functionality

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8.6.7. Fle
Flexx Zone T
Tab
ab
The Fle
Flex
x Zone feature is enabled by default when you perform the Auto Configure Procedure.
There can be certain situations such as higher speed applications and/or applications where a
large percentage of cartons are at a length very close to the zone length where a “false
triggering” of a flex zone condition can occur. In these situations, when product needs to
accumulate, you may see several zones unoccupied because of this false triggering. For these
applications where accumulation density is paramount, you can disable Flex Zone to eliminate
this false triggering situation.

! Please note that Flex Zone function has to be enabled or disabled for the entire
Subnet. It cannot be disabled or enabled on a per zone basis or for a group of
zones within the same subnet.

Click the appropriate button to

either Disable or Enable Flex Zone
based upon the subnet’s current
status as indicated. Because this
function applies to all modules in the
Subnet, it does not matter what
module you were connected to when
you invoked the Advance Dialog in
order to disable or enable Flex Zone

Inter Module Communication T

Time
ime
The Inter Module Communication T Time
ime value is used to adjust the behavior of the Flex Zone
operation. In situations where carton lengths can be close to the length of the zones (i.e.
distance between photoeyes), you may want to adjust Flex Zone operation so that it either
engages or not in these situations.

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Typically there are one or two driven rollers past the sensor in a Zone. If you
have cartons that encroach upon these rollers when accumulated in the
downstream zone, you may want Fle Flex
x Zone to engage so that the next
upstream carton will not enter the zone (Zone A in the example), thus not
running these rollers underneath the accumulated carton.

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The value entered is in msec and it

can be thought of as an amount of
time added to the logic after the
trailing edge of the sensor in order
to simulate increasing the carton
length. Please note that this value
will be set the same for each module
in the Subnet.

* Please note this value has nothing to do with speeding up or slowing down the
actual speed of communications between modules

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8.6.8. Sensors T
Tab
ab
The Sensors tab displays the status of how the two sensor signals were configured during the
Auto Configuration Procedure. If for some reason one or more of the sensors was not configured
properly during the Auto Configuration Procedure; for example they were not aligned with their
reflector or there was an obstruction blocking the sensor at the time the procedure was
performed, the Sensors Tab will allow you to change the sensor’s configuration without
requiring you to re-perform the Auto Configuration PPrrocedur
oceduree for the entire subnet. For
example, if all the sensors on the system are light energized normally open then the
corresponding zone’s sensor graphic on this tab will show Off Blocked. Similarly, if the sensor is
equipped with a separate health or low gain signal and this signal is on when there is no error,
the graphic on this tab will show Off Gain Error.

Click the appropriate icon to change

the sensor’s blocked and/or gain
error signal state. Note that you can
make the same change for a group
of modules by clicking the Set All
Sensors this Way button

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8.6.9. Extensions T
Tab
ab
The Extensions Tab allows you to extend or “slave” single or multiple zones to one “master”
zone. An example situation could be that you have for example certain length zones and on a
given conveyor line there is a need for an extra partial zone that is too short to be a functional
zone that accumulates a carton, but at the same time it is long enough that mechanically you
need to have an MDR in that zone. In this situation you would like to provide a module and an
MDR but no sensor and you want this zone to run its MDR when either its adjacent upstream or
downstream zone is also running. In essence you want to make this partial zone a logical
extension to one of its neighbors.

Example for Using Extensions for a Lif

Liftt Gate

A common use of the Extension mode configuration available from the Connections tab
selection is for a powered lift gate.

In this example the module on the lifting or gate portion of conveyor has an
MDR and no photo-sensors. Normal operation when the gate is down is for the
MDR on the gate to run when its immediate downstream zone runs so as to
create “one long logical zone”. This means that if a carton is accumulated on
the upstream zone of Node 192.168.26.24; a carton arriving at the downstream
zone of Node 192.168.26.22 will stop and accumulate and no loads will ever be
logically accumulated or stopped on the gate portion. In order to accomplish
this, all we need to do is instruct Node 192.168.26.23 to be an Extension of its
downstream neighbor Node 192.168.26.24

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In the Advanced Dialog, navigate to

Node 4 and click the Extensions Tab.
Notice that Node 4’s IP address
192.168.20.24 is filled in. In the
drop-down box, select Downstream
and click Apply. Note that this may
take a few seconds to complete

After clicking Apply, the screen will

update and show you that the
module has been configured as an
extension or “slave” of its
downstream neighbor

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Now if you navigate back to Node 3

and look at the Connections Tab, you
can see that the downstream
connection of Node 3 is now Node 5
instead of Node 4

And then when you navigate to

Node 5, you can see that its
upstream connection is now Node 3
instead of Node 4

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And when you navigate to Node 4,

you can see that it is configured as
an Extension of Node 5

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9. ConveyMer
ConveyMerge
ge
ConveyMer
ConveyMerge ge is an optional functionality layer built on top of ConveyLinx’s ZP
ZPAA logic. Users can
enable and configure it using EasyR
EasyRoll
oll software. ConveyMer
ConveyMerge
ge behaves the same as ZPA logic,
but allows you to define a special Mer
Mergege Zone that can have up to three upstream zones
connected to it. ConveyMer
ConveyMerge ge also has simple priority schemes for the multiple upstream zones
as well as the ability to dynamically change those priorities on-the-fly by utilizing the Mer
Merge
ge
Line F
Full
ull option. It also takes care of passing tracking information properly and has Jam
Condition detection.

ConveyMer
ConveyMerge
ge Components
ConveyMer
ConveyMergege can accommodate product merge control from one or two conveyor paths onto a
single take-away conveyor path as shown:

Component Description

Powered conveyor section that accepts an item from any one of the 3
Mer
Merge
ge Zone
possible upstream sources

Term to describe the 3 in-line conveyor sections – Center Line, Mer

Merge
ge Zone
Main Line
and Dischar
Discharge
ge Zone

Part of Center Line that is one of three possible sources of items that can flow
into the Mer
Merge
ge Zone. This term is used in the configuration screen of EasyR
EasyRoll
oll
Center Line
to designate the network that serves as the trunk line that contains the
Mer
Merge
ge Zone

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Part of the Center Line that is downstream of the Mer

Merge
ge Zone. This conveyor
Dischar
Discharge
ge Zone
section accepts the item from the Mer
Merge
ge Zone

One of the three possible conveyor sections that can discharge items into the
Lef
eftt Line
Mer
Merge
ge Zone

One of the three possible conveyor sections that can discharge items into the
Right Line
Mer
Merge
ge Zone

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9.1. ConveyMer
ConveyMerge
ge P
Prrer
erequisites
equisites and
Requir
equirements
ements
Please Note – ConveyMer
ConveyMerge
ge works for ALL ConveyLinx
Family Modules

Module Fir
irmwar
mware
e

ConveyLinx-ERSC 4.25 and later

ConveyLinx-HTF 4.25 and later

ConveyLinx-Ai2 4.20 and later

ConveyLinx-Ai3-24-xx 4.20 and later

The following items are the prerequisites and constraints required to provide a fully functioning
automatic conveyor merge:

• EasyR
EasyRoll
oll version 4.19 or greater
• Only (1) one Mer
Merge
ge Zone is allowed for any given single module
• Mer
Merge
ge Zone cannot have any Extension (slaved) zone
• Mer
Merge
ge Zone must be in ZP ZPA
A mode. Lef
eftt Line discharge, Right Line discharge, and Center
Line discharge can be in either ZPZPA
A mode or PLC I/O mode
• Left, Right, and Center Lines discharges cannot also be included in another instance of
ConveyMer
ConveyMerge ge

* If Lef
eftt Line discharge, Right Line discharge, or Center Line discharge modules are
in PLC I/O mode, you are responsible for programming logic to recognize and
respond to ZPA zone status values between the Mer Merge
ge Zone module for proper
jam free singulation control

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9.2. Network Ar
Architectur
chitecture
e
All lines (Center, Lef
eftt, and Right) should be on separate subnets of modules, as shown. Each
subnet should be Auto
Auto-Configur
-Configured
ed separately and then connected together with an Ethernet
switch. Keep in mind that the separate subnets will have to be able to communicate with each
other so special care must be taken when setting up the IP Network Mask before performing
the Auto
Auto-Configuration
-Configuration P Prrocedur
oceduree.

* A good starting point is the default mask of 255.255.128.0. With this setting you
can vary the third octet in the ranges 0-127 and 128-254 and all three lines will
be able to communicate with each other as long as the third octets of their IP
addresses are in the same range (either 0-127 or 128-254).

* Even though ConveyMer

ConveyMergege can work with all lines being in the same subnet, care
must be taken during Auto
Auto-Configuration
-Configuration to assure proper zone flow for all lines.
We recommend separate subnets in order to assure proper zone flow for all lines.

Ar
Architectur
chitecturee Summary
• The Center Line is a separate subnet of modules that have been Auto
Auto-Configur
-Configured
ed. The

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Mer
Mergege Zone and the Dischar
Discharge
ge Zone are part of this subnet. The Center Line can consist
of any number of ConveyLinx Modules and the actual position of the Mer Merging
ging Zone can be
on any ConveyLinx Module within the subnet
• The Dischar
Dischargege Zone has to be the zone immediately downstream of the Mer Merge
ge Zone.
However, the Dischar
Discharge
ge Zone can be on either the same ConveyLinx Module as the MerMerge
ge
Zone or on the adjacent downstream ConveyLinx Module from the Mer Merge
ge Zone’s
ConveyLinx Module
• The Lef
eftt Line is a separate subnet of modules and its most downstream zone has to
physically discharge on to the Mer
Merge
ge Zone
• The Right Line is a separate_* subnet*_ of modules and its most downstream zone has to
physically discharge on to the Mer
Merge
ge Zone
• All three subnets must be connected to a common Ethernet switch only after each subnet
has been Auto
Auto-Configur
-Configured
ed.

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9.3. Sensor Placement

! It is very important for the internal ConveyMer

by only one sensor at a time
ConveyMerge
ge logic, that the product is seen

Conventional Spur Mer

Merge
ge Sensor Placement

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90° T
T-Mer
-Merge
ge Sensor Placement

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9.4. Mer
Merge
ge Zone Module
Depending on the physical arrangement of actual zones on the Center Line, the Mer
Merge
ge Zone
can be assigned to either the Upstream or Downstream zone of its particular ConveyLinx
Module. It can also be assigned to a ConveyLinx Module that is configured as a single zone ZPA
controller.

In all 4 of these e xamples, Node 2 is the Mer

examples, Merge
ge Zone’s contr
controlling
olling
ConveyLinx Module

* Images show ConveyLinx-ERSC modules but functions are applicable to all

ConveyLinx Family modules

Mer
Merge
ge Zone on Upstr
Upstream
eam Zone

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Mer
Merge
ge Zone on Downstr
Downstream
eam Zone

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Single Zone Module

Whenever an ConveyLinx Module has been Auto
Auto-Configur
-Configured
ed as a single zone
zone; regardless of
whether the single zone is connected to the right side or left side of the ConveyLinx Module,
the logical designation for the zone on the this module is always the Upstream Zone. Shown
below are examples of a single zone module using the left and right sides of the module
respectively.

Merge Zone on a Single Zone Module's Left Side

Merge Zone on a Single Zone Module's Right Side

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9.5. Mer
Merging
ging Lines
The Lef
eftt Line and Right Line are set up in a similar fashion to the Center Line. Each of these
lines are in their own separate subnet that is both different from each other and different from
the Center Line. Regardless of whether these merging lines are an Conventional Spur
arrangement or a 90˚ T-Merge arrangement; the conveyor zone that discharges product onto
the Mer
Mergege Zone must be the most downstream zone if its particular subnet. The following
figures illustrate this for an Conventional Spur Left Line and a 90˚ T-Mer
-Merge
ge Left Line
respectively. The same would apply if these were Right Line examples as well.

* Images show ConveyLinx-ERSC modules but functions are applicable to all

ConveyLinx Family modules

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9.6. Mer
Merge
ge Configurations
The Mer
Merge
ge Configurations available from within in EasyR
EasyRoll
oll are:

• Lef
eftt Line Only with either Conventional (spur discharge) or T-Mer
-Merge
ge (90˚ discharge)
• Right Line Only with either Conventional (spur discharge) or T-Mer
-Merge
ge (90˚ discharge)
• Both Lefeftt and Right Lines with either Conventional (spur discharge) or T-Mer
-Merge
ge (90˚
discharge) for each

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9.7. Mer
Merge
ge P
Priority
riority
EasyR
EasyRoll
oll provides the ability to adjust which of the merging lines receives priority.

EasyR
EasyRoll
oll P
Priority
riority
Description
Selection

The logic monitors the arrival status in each of the zones that discharge in to
the Mer
MergeZone
geZone. The first product that arrives at any of these lines will be
First Come FFirst
irst
allowed to convey into the Mer
MergeZone
geZone. When the MerMergeZone
geZone is clear, the
Served
next line that has had a product arrive will be allowed to convey into the
Mer
MergeZone
geZone

The Center Line will be allowed to release as long as product arrives at the
Center Line’s zone sensor prior to the previously released product having not
cleared the Mer
MergeZone
geZone. When the MerMerge
ge Zone is clear and if there is no
Center Line
product sensed on the center line zone; then the Lef eftt and/or Right Lines will
Priority
be allowed to release if product has arrived at their respective sensors. As
long as no product is arriving on the Center Line, if Lef
eftt and Right Lines are
enabled, these will operate as First Come FFirst
irst Served between them

The Lefeftt Line will be allowed to release as long as product arrives at the Lefeftt
Line’s most downstream sensor prior to the previously released product
having not cleared the Mer MergeZone
geZone. When the Mer Merge
ge Zone is clear and if there
is no product sensed on the Lef eftt Line’s most downstream sensor; then the
Lef
eftt Line P
Priority
riority
Center and/or Right Line will be allowed to release if product has arrived at
their respective sensors. As long as no product is arriving on the Lef eftt Line, if
the Right Line is enabled, the Center and Right will operate as First Come
First Served between them

The Right Line will be allowed to release as long as product arrives at the
Right Line’s most downstream sensor prior to the previously released product
having not cleared the Mer MergeZone
geZone. When the Mer Mergege Zone is clear and if there
is no product sensed on the Right Line’s most downstream sensor; then the
Right Line P
Priority
riority
Center and/or Lef eftt Line will be allowed to release if product has arrived at
their respective sensors. As long as no product is arriving on the Right Line, if
the Lef
eftt Line is enabled, the Center and Lef eftt will operate as First Come FFirst
irst
Served between them

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9.8. T-Mer
-Merge
ge Settings
For a T-Mer
-Merge
ge, the discharging conveyor is arranged perpendicular to the Mer
Merge
ge Zone and this
discharging conveyor needs to “throw” the product across the Merge Zone’s rollers. In order to
mitigate carton alignment issues, the logic controls need to make sure that it keeps the Mer
Merge
ge
Zone’s rollers stopped until the discharging conveyor has completely finished “throwing” the
product onto the Mer
Mergege Zone. In order to accommodate various conveyor speeds and material
handling situations; EasyR
EasyRoll
oll provides some timer adjustments to facilitate proper T-Mer
-Merge
ge
functionality.

Accept T
Timeout
imeout

This timer specifies how much time the Mer

Merge
ge Zone will wait after its sensor is blocked until the
logic allows it’s motor to run. Once the timer has expired, the Merge Zone’s motor will be
allowed to run. Keep in mind that conditions downstream of the Mer
Merge
ge Zone also dictate if the
motor is allowed to run.

Send T
Timeout
imeout

This timer specifies how much time the discharging zone has to wait after the Mer Merge
ge Zone
sensor is clear before it is allowed to release the next product into the Mer
Merge
ge Zone. This timer
helps ensure that the Mer
Mergege Zone is clear when sensor placement cannot guarantee that the
zone is clear.

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9.9. Configuring Dynamic P

Priority
riority R
Release
elease
In situations where the full status of a given merge line needs to determine merge priority,
ConveyMer
ConveyMerge ge provides the ability to monitor the status of one or all merging lines and base the
release priority accordingly. EasyR
EasyRoll
oll provides the option to select a given upstream zone on a
given line as the Monitor Zone. When the Monitor Zone becomes occupied for a given time
value; its line will be given release priority into the Mer
Merge
ge Zone. There are two adjustable time
values for this function:

EasyR
EasyRoll
oll Selection Description

Specified the amount of time the Monitor Zone must be occupied before the
Monitor Zone’s line will receive priority to release into the Mer
Merge
ge Zone. This
Block T
Timeout
imeout timer starts when the Monitor Zone first becomes accumulated (sensor
blocked and motor stopped) and continues to time as long as the Monitor
Zone stays accumulated

Specified amount of time that the priority release will continue to be active
Clear T
Timeout
imeout once the priority release has begun. When this time value expires, the
priority setting will return to its original EasyR
EasyRoll
oll configured setting

* If multiple lines are configured for Dynamic P

Block T
Timers
imers have expired; ConveyMer
ConveyMerge
Priority
riority and each of their respective
ge logic will revert to the First Come F
Serve release mode until one or more of the releasing lines’ Clear T Timer
First
imer has
irst

expired

Dynamic P
Priority
riority R
Release
elease Example
Please refer to Figure A and Figure B below. In EasyR EasyRoll oll, Node 2 upstream zone of the Center
Line has been selected as the Mer Mergege Zone and the merge type is Up Left. The EasyR EasyRoll
oll setting
for priority is Center Line P Priority
riority. Also in EasyRoll, the MerMerge
ge Line F Full
ull function has been
enabled as assigned to Node 3 downstream zone of the Lef eftt Line.
With the Mer
Merge
ge Line F Full
ull feature enabled on the Lef eftt Line; once Left Line Node 3 downstream
zone remains accumulated for the Block T Timer’s
imer’s timeout (Figure A); priority will dynamically
change to the Lef eftt Line. This Left Line priority will remain in effect until the Clear T Timer’s
imer’s
timeout has expired (Figure B). When this occurs, the priority will automatically revert to the
EasyR
EasyRoll
oll configured priority (Center Line in this example).

In this example, if we did not enable the Mer

Merge
ge Line F
Full
ull function for the Lef
eftt Line and if there
was a steady flow of product on the Center Line; the Lefeftt Line would never be able to release
because the default priority in EasyRoll was set to Center Line.

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* Images show ConveyLinx-ERSC modules but functions are applicable to all

ConveyLinx Family modules

Figure A - Merge Line Full Block Timer

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Figure B - Merge Line Full Clear Timer

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9.10. Enabling ConveyMer

ConveyMerge
ge fr
from
om EasyR
EasyRoll
oll
• Open EasyR
EasyRoll
oll
• Connect and navigate to the ConveyLinx Module that will control the Mer
Merge
ge Zone.
• Press CTRL
CTRL+SHIF
+SHIFT+M
T+M to open the ConveyMer
ConveyMerge
ge Configuration Scr
Screen
een

Item Description

Navigation Buttons for Node selection

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Drop down selector for Mer

Merge
ge T
Type
ype – Left, Right, or Both

Drop down for Mer

Merge
ge P
Priority
riority

Display of IP Address for the ConveyLinx Module selected that will contain the Mer
Merge
ge
Zone

User button to click to apply the settings to the affected modules

User button to cancel any changes made and close the screen

Field to enter the IP Address of the Lef

eftt Line’s most downstream ConveyLinx Module

Checkbox to enable Mer

Merge
ge Line F
Full
ull functions

IP Address of the ConveyLinx Module that contains the zone being defined as the
Monitor Zone for the Mer
Merge
ge Line F
Full
ull function

Radio buttons to select whether the upstream or downstream zone of the ConveyLinx
Module identified in Item 9 will be used as the Monitor Zone

Field to enter the IP Address of the Right Line’s most downstream ConveyLinx Module

User checkbox to select T-Mer

-Merge
ge type

Graphical representation of the merge. Please note this will update and change as
settings and configuration is modified

Mer
Merge
ge Line F
Full
ull Block T
Timer
imer preset value

Mer
Merge
ge Line F
Full
ull Clear T
Timer
imer preset value

T-Mer
-Merge
ge A
Accept
ccept T
Timer
imer preset value

T-Mer
-Merge
ge Send T
Timer
imer preset value

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9.11. Conventional Spur Mer

Merge
ge Example
In this example we are going to configure the Lefeftt Line to be standard spur angle merge onto
the Center Line and we will set the Mer
Merge
ge P
Priority
riority to be First Come F
First
irst Served

* Images show ConveyLinx-ERSC modules but functions are applicable to all

ConveyLinx Family modules

The Mer
Merge
ge Zone is the upstream zone of the module at 192.168.25.28 and the most
downstream ConveyLinx Module for the Lef eftt Line is at 192.168.24.31. Here is the ConveyMer
ConveyMerge
ge
Configuration Scr
Screen
een with these values entered

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The last step is to click the Apply button to send the changes to the affected ConveyLinx
Modules

* Please note that after clicking the “Apply” button, if the configuration has
changed, the affected modules will reboot. It will take a few seconds for the
reboot to finish and some or all of the affected zones may briefly run their
motors

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9.12. T-Mer
-Merge
ge Example
In this example we are going to configure the Right Line to be a T-Mer
-Merge
ge onto the Center Line
and we will set the Mer
Merge
ge P
Priority
riority to be First Come F
First
irst Served

* Images show ConveyLinx-ERSC modules but functions are applicable to all

ConveyLinx Family modules

The Mer
Merge
ge Zone is the upstream zone of the module at 192.168.25.28 and the most
downstream ConveyLinx Module for the Right Line is at 192.168.26.58. Here is the
ConveyMer
ConveyMerge
ge Configuration Scr
Screen
een with these values entered

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9.13. Mer
Merge
ge Line F
Full
ull Example
In this example we have the Lef
eftt Line configured as standard spur angle merge and the Mer
Merge
ge
Priority to be Center Line

* Images show ConveyLinx-ERSC modules but functions are applicable to all

ConveyLinx Family modules

The Mer
Merge
ge Zone is the upstream zone of ConveyLinx Module 192.168.25.28 and the Lef eftt Line’s
most downstream node is 192.168.24.31 and we want this line to have the Mer Merge
ge Line F Full
ull
function enabled. On the Lef
eftt Line, we would like for the upstream zone of ConveyLinx Module
192.168.24.25 to be the Merge Line Full function’s Monitor Zone. We would also like that once
the Monitor Zone has been accumulated (or blocked) for 5 seconds, we want the Lef eftt Line to
release for 5 seconds and then return the priority to the Center Line. Here is the ConveyMer
ConveyMerge ge
Configuration Scr
Screen
een with the values entered for this example:

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10. ConveyStop
ConveyStop is a ConveyLinx function that establishes a network based means to signal all
ConveyLinx Modules with a Stop Command in order to physically stop their motion and/or
output functions and remain in a stopped state until a separate Start Command network signal
is received to return all connected modules back to their normal function. This is accomplished
by utilizing the built-in Ethernet network that already inter-connects the ConveyLinx control
system

Single Physical Network with 2 Stop Groups

In a similar fashion to how ConveyLinx modules establish logical connections based upon
conveyor flow; ConveyStop, when applied, establishes Stop Gr Group
oup connections between
modules such that only modules within a given Stop Gr Group
oup are affected by STOP and START
network commands. With ConveyStop, any given system can be segregated into as many Stop
Gr
Groups
oups as desired as long as all modules within a Stop Gr
Group
oup are physically connected over
Ethernet.

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Typical STOP Command Sources

Typical START Command Sources

Each Stop Gr
Group
oup is independent in that a Stop Command or Start Command occurring in one
Stop Gr
Group
oup does not affect the modules in another Stop Gr
Group
oup even if they are on the same
Ethernet network. In fact, modules within the same subnet that have logical conveyor flow
connections can be in different Stop Gr
Groups
oups. This means that a ConveyLinx-ERSC module in a

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non-stopped Stop Gr
Group
oup will automatically detect if it is discharging into a stopped Stop Gr
Group
oup
and automatically inhibit product flow.

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10.1. Benefits of ConveyStop

Replaces Separate Stop Cir
Circuit
cuit
One important feature of a ConveryLinx control system with ConveyStop enabled is that local
operator buttons or switches can wire directly to a nearby ERSC or CNIP module. With these
locally wired devices, anyone can initiate a controlled stop of a given Stop Gr
Group
oup without
requiring a separately wired stop circuit. Depending on system size and complexity, this can
result in substantial savings in both installation cost and implementation time.

Detects Network Connectivity L

Loss
oss
Another important feature of a ConveyStop enabled system is that loss of network
communication and/or loss of connection to a PLC (if originally connected) will automatically
cause a Stop Command to be initiated. Very often in large and/or complex network based
control systems; the loss of communications is not easily detected nor does adjacent
unaffected devices react in predictable ways. With ConveyStop, not only does every device
stop upon communication loss, there can be information taken from the modules to help pin-
point where the communication loss occurred.

Provides Mor
MoreeR
Reliable
eliable R
Recovery
ecovery
When any Stop Command is initiated in an ERSC module, not only is all motor commutation
stopped, but the ERSC retains pertinent data on its status at the time the Stop Command was
initiated. The ERSC will remember that it was discharging or accepting a package along with
the packages tracking data. Upon getting a Start Command, the ERSC will pick up where it left
off and attempt to finish what it was doing prior to the Stop Command.
This same scenario applies to situations when power is disconnected to all modules within a
Stop Gr
Group
oup. As part of the power loss procedure in all ERSC modules with ConveyStop enabled;
certain pertinent data regarding module status and package tracking is saved to flash memory
such that upon power-up and subsequent Start Command, each ERSC will attempt to complete
what it was doing at the time of initial power loss.

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10.2. Using ConveyStop in an Integrated

Stop System
The means and methods of stopping automated equipment in an integrated material handling
system are governed by many factors including, but not limited to:

• Location and usage of the equipment per the application

• Operator or non-maintenance personnel access to moving equipment
• Federal, State, and/or local ordinance or code
• Accepted electrical design practice
• Customer or end user preference

With all of these variables in play; ConveyStop cannot claim or be advertised as a de facto
“approved” stopping method for all conveyor system stopping situations including an
emergency stop situation. The purpose of this section is to define a recognized standard for
control system stop classifications or categories and describe how ConveyStop can be applied
for each.
It is the responsibility of the integrator of a ConveyLinx equipped system utilizing ConveyStop
to assess all of the aforementioned factors before deeming a ConveyStop generated Stop
Command as being applicable and suited for an emergency stop situation.

NFP
NFPA®
A® 79
The National Fire Protection Association (NFPA®) 79 Electrical Standard for Industrial Machinery
2012 Edition contains accepted definitions for stopping functionality and emergency operations
that are, in general, applicable to the conveyor and material handling industry.

Emer
Emergency
gency Operations
NFPA® 79 section 9.2.5.4 Emergency Operations is as follows:

(1) This section specifies the rrequir

equirements
ements for the emer
emergency
gency stop and the
emer
emergency
gency switching-off functions of the emer
emergency
gency operations, both of which ar
aree
initiated by a single human action

(2) Once active operation of an emer emergency

gency stop or emer
emergency
gency switching off actuator
has ceased following a command, the effect of this command shall be sustained until
it is rreset.
eset. This rreset
eset shall be
possible only at the location wher
where
e the command has been initiated. The rreset
eset of
the command shall not rrestart
estart the machinery but only per
permit
mit rrestarting
estarting

(3) It shall not be possible to rrestart

estart the machinery until all emer
emergency
gency stop

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commands have been rreset.

eset. It shall not be possible to rre-ener
e-energize
gize the machinery until
all emer
emergency
gency switching off commands have
been rreset.
eset.

How ConveyStop Applies to Emer

Emergency
gency Operations
The section 9.2.5.4 Item (1) criterion is met when physical buttons or switches are assigned
and enabled with ConveyStop. Please note that a networked PLC or PC can generate a Stop
Command and as such can occur programmatically and not necessarily by “single human
action”. In this case, the integrator would be responsible for assuring that the PLC or PC based
Stop Command is always initiated from a “single human action” integrated with said PLC or PC
controls.
The section 9.2.5.4 Item (2) criterion is met when physical buttons or switches are assigned
and enabled with ConveyStop and these devices are proper maintained contact type. As long
as the button or switch is in its “emergency” position; ConveyStop will not issue or respond to
any Start Command regardless of source (hard-wired button or networked PLC or PC). Also,
resetting the physical device to its “non-emergency” state will not restart the modules to
operation nor will this resetting of the device initiate any Start Command.
The section 9.2.5.4 Item (3) criterion is met in ConveyStop by design. If multiple physical
buttons or switches are assigned and enabled with ConveyStop; all have to be placed into their
“non-emergency” state before ConveyStop will issue or respond to any Start Command
regardless of source. This is true regardless of which device first initiated the stop.

Stop F
Function
unction
NFPA® 79 section 9.2.2 Stop Functions defines stop functionality as:

Stop functions shall operate by de-ener

de-energizing
gizing that rrelevant
elevant cir
circuit
cuit and shall over
override
ride rrelated
elated
start functions. The rreset
eset of the stop functions shall not initiate any hazar
hazardous
dous conditions.

This section further defines three (3) Categories for stop functionality:

Category 0 – An uncontr
uncontrolled
olled stop by immediately rremoving
emoving power to the machines actuators
Category 1 – A contr
controlled
olled stop with power to the machine actuators available to achieve the
stop then rremove
emove power when the stop is achieved
Category 2 – A contr
controlled
olled stop with power lef
leftt available to the machine actuators

ConveyStop and Stop F

Function
unction Definition

In general, ConveyStop follows the intent of the Stop Function definition for section 9.2.2. The
manner in which “de-energizing that relevant circuit” it is accomplished differs between the
ERSC and CNIP modules.

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CNIP and Stop F

Function
unction

Four of the six digital output circuits on the CNIP modules have their control power source
internally wired to a contact relay. When a Stop Command is active, this relay is de-energized
and control power is disconnected. In this state, the digital output circuit is de-energized
regardless of the state of the logical output. This is a common stop circuit design for PLC based
I/O systems.

ERSC and Stop F

Function
unction

In situations where a Stop Command is active and control power is maintained to an ERSC, the
de-energizing of the relevant circuit is accomplished by the on board processor. The ERSC
utilizes a single processor and this processor directly controls (among other things) the power
MOSFET transistor gates that commutate the motor. When a Stop Command is active, the
processor places all MOSFET gates in their open or non-conductive state and then by-passes
the task in the processor that produces motor commutation.

ConveyStop and Stop F

Function
unction Categories

Category 2

Utilizing ConveyStop as designed and intended adheres to the criterion of Category 2.

Maintaining control power to all ConveyLinx modules is desirable because they maintain their
“pre stopped” state making for faster and more reliable recovery. Another added benefit of
maintaining control power to all ConveyLinx modules is that the diagnostic features of both
ConveyLinx and ConveyStop are available to PLC and/or PC (including the ConveyStop PC
software monitoring capability) as an aid in troubleshooting and event logging.

Category 1 And Category 0

Both of these categories involve disconnecting power to ConveyLinx modules and either of
these can be implemented on a ConveyLinx system with or without ConveyStop being enabled.
If ConveyStop is implemented, the behavior would essentially be as described in section 0
Power Loss. ERSC modules will retain their state to flash memory as power is being dropped.
When power is restored; each Stop Gr Group
oup affected by the power disconnect will have to receive
a Start Command from either an assigned and enabled button or switch or from a network
source (PLC or PC).
For CNIP modules, each is equipped with separate power terminals. One set of terminals is for
module logic and input bus power and the other set powers only the output bus. In a Category
1 or Category 0 system, the motion producing control power can be disconnected from the
CNIP
CNIP’s
’s output bus while leaving logic and input control power on. This is a typical strategy
applied to PLC I/O systems and can be implemented with CNIP modules with or without
ConveyStop installed and enabled. It must be noted that this strategy requires 2 separate
power systems to be field wired.

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What Happens When Y

You
ou Do Not Use
ConveyStop?
Operationally, ConveyStop is not required for any ConveyLinx system to function. If
ConveyStop is not implemented, disconnecting power does cause all motor motion to stop for
ERSC’s and all outputs to be de-energized for CNIP’s. However it is important to note that
without ConveyStop enabled and when power is restored; ERSC modules will be enabled to run
and if conveyor conditions dictate, motors will run and packages will begin to move with no
other or separate start signal or command.
Another important note is that ConveyLinx devices are Ethernet based, and upon cycle of
power, modules will individually reinitialize at different rates making exact power up behavior
unpredictable.

Integrator R
Responsibility
esponsibility
By no means is NFPA® 79 the only specification or criteria for defining the stop function of an
automated system. The NFPA® 79 is a general standard for the USA and the descriptions
above are based upon general experience for US installations.
The bottom line is that it is always up to the integrator to understand and adhere to the
applicable specifications, codes, and standards on a per system basis. ConveyStop can be a
valuable tool to achieve desired system stop functionality, enhanced diagnostics, and lower
installed cost.

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10.3. ConveyStop Ar
Architectur
chitecturee
The ability to respond to Stop Commands and Start Commands is built in to every ERSC and
CNIP module. The activation of the ConveyStop function requires the ConveyStop PC software
package to first define one or more Stop Gr
Groups
oups of modules and then enable the ConveyStop
functions in these modules. When enabled, the modules create 2 logical network connection
rings within their configured Stop Gr
Group
oup as shown:

! Please note this is only a logical group of connections between modules.

ConveyLinx modules within a Stop Gr Group
oup are NOT physically connected in a
closed loop

These connections create two logical rings. Each module expects to get data and heartbeat
keep-alive messages every 200 ms over both connection rings. If any single module in the
group does not receive data or heartbeat message either of its neighbors; the module will
immediately disable the gates of its MOSFET transistors and sends a message to all other
module over the 2 connection rings to do the same. The disabling of the MOSFET gates
immediately halts any possible commutation and rotation of connected motors.

For ConveyLinx ERSC modules, the ConveyStop Stop Command causes all motor commutation
to immediately stop. For ConveyLinx ConveyNet I/P (CNIP
CNIP)) modules, the _*Stop* Command
causes the CNIP processor to de-energize the output bus relay, thus disconnecting control
power to the affected discrete outputs.

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Once a Stop GrGroup

oup has been stopped and any and all conditions that caused the Stop
Command have been cleared; the Stop Gr Group
oup has to be given a Start command to restart the
function of the logical ring connections.

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10.4. ConveyStop Sof

Softwar
tware
e
Before any ConveyStop functionality can be realized; you must first configure one or more Stop
Gr
Group*_s
oup*_s on your system. In or
order
der to do this, you must have the _*ConveyStop Software. This
section details how to:

• Install and enable the software

• Create a new Project
• Create Stop Gr
Groups
oups
• Assign STOP Command inputs
• Assign ST
STAR
ARTT Command inputs
• Utilize monitoring functions

The ConveyStop PC software connects to a ConveyLinx network and shows all available ERSC
and CNIP devices. From this list, the system integrator creates and populates one or more Stop
Gr
Groups
oups. Within each Stop Gr
Group
oup, one or more ERSC’s can be configured to have either its Left
or Right Control Port assigned to contain a hard-wired button or switch to issue a STOP
Command. Similarly, any CNIP module can be similarly assigned a hard-wired button or switch
to a specific dedicated input to issue a STOP Command. Also within each Stop Gr Group
oup, one or
more ERSC’s can be configured to have either its Left or Right Control Port assigned to contain
a hard-wired button or switch to issue a ST
STAR
ART
T Command. Similarly, any CNIP module can be
similarly assigned a hard-wired button or switch to a specific dedicated input to issue a ST
STAR
ARTT
Command.

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10.4.1. User A
Accounts
ccounts
Guest
Guest access allows access to ConveyStop software monitoring capabilities only and does not
allow any access to add, delete, or modify any items

Administrator
Only Administrator accounts are allowed to modify any configuration or assignments.
Administrator access is required to:

• Add or remove modules from a Stop Gr

Group
oup
• Add or Remove Stop Gr
Groups
oups
• Add or Remove STOP Command inputs
• Add or Remove ST
STAR
ARTT Command inputs

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10.4.2. Cr
Creating
eating a New P
Prroject
Create a new blank project by selecting “New” from the File menu.

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10.4.3. Discovering Modules

Starting with a blank project as shown below, click the “Discover and Redraw” button will cause
ConveyStop to search for any and all ConveyLinx devices it can find.

After a few seconds depending on the number of devices located, a list of discovered devices
will be displayed in the window on the far left. ConveyStop will also create a graphical image of
its discovery as shown:

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10.4.4. Cr
Creating
eating Stop Gr
Groups
oups
In this example, there are 3 subnets – one with 10 ERSC modules, one with 14 ERSC modules,
and one with 2 CNIP modules. We want to create 2 Stop GrGroups
oups – one with the 10 ERSC subnet
and the other one with the 14 ERSC subnet combined with the 2 CNIP subnet.

First Stop Gr
Group
oup

First we use the “Show devices on Subnet” to filter the list for the 10 ERSC subnet. Then we
select all the items in the list as shown:

Then drag the selection into the ConveyStop Groups list window as shown. This creates a Stop
Gr
Group
oup from the selected modules and automatically generates a group name.

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Right click on this name to give it as meaningful name for your project. In this example we will
call it “Line A”. You can also expand and collapse the detail of a Stop Gr
Group
oup by clicking the + or
– icon to the left of the group name:

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10.4.5. Add Stop and Start Buttons

Stop Button

In our example, we want to add a Stop Button to node 8 at address 192.168.26.27 and we want
the button to connect to the Left Control Port. You do this by right clicking on the desired node
and selecting the option from the pop-up menu as shown:

Start Button

In our example we want to add a Start button to the Right Control Port of the same node. Right
click on the node and select the desired option from the pop-up menu as shown:

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10.4.6. Commit All Button

Completing Our Example

By repeating the same procedures, we want to add a 2nd Stop Gr

Group
oup consisting of the
remaining unused devices from the Discover window. We want to rename this Stop GrGroup
oup as
“Line_B”. We then want a STOP Button on node 1 at I.P. Address 192.168.25.20 connected to
the Left Control Port and a ST
STAR
ART
T Button on the same node connected to the Right Control Port.
When this is complete it should look like as shown:

Commit All Button

The process is not complete because we have only configured ConveyStop within the software;
we still need to Commit the functionality to the physical ConveyLinx modules. Clicking the
“Commit All” button sends the current configuration of Stop Gr
Groups
oups, buttons, etc. to the actual
devices. When complete, ConveyStop screen displays the status of the connected devices.
Shown below is what the screen should look like for our example when both Stop Gr Groups
oups are
operational and have no stop conditions active and no stop groups awaiting Start:

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10.4.7. Status Monitoring

The ConveyStop screen gives indication when there is a Stop active and the individual node(s)
where the Stop was initiated. The System State area on the screen provides quick status at a
glance as to whether any group is in an active stopped state with the stop condition still true,
in a stopped state with the condition reset and awaiting Start, and whether at least one Stop
Group is started. Below shows our example system with Line_A in both a stopped state and the
stop condition is still active. It also shows Line_B in a started state with no stop conditions
active:

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10.5. Issuing a Stop Command

Typical methods for an operator or the control system to issue a Stop Command is either via
hardwired Stop push-button or via network command from PLC as shown:

Har
Hard-W
d-Wir
ired
ed P
Push-Button
ush-Button

ERSC Module

You can connect Stop Command buttons to either the Left or Right Control Ports on an ERSC in
the Stop Gr
Group
oup. Stop buttons require 2 sets of contacts and connect to the 2 inputs on the
control port. If ANY of these contacts become opened on a given module; it will generate a
STOP Command to ALL modules within the group over the 2 communication rings.

CNIP Module

For the CNIP module, there are dedicated inputs to use to connect a Stop Command button.
See Wiring Examples for details on the inputs reserved for this function

Remote PLC
If a PLC is connected to at least one module in a Stop Gr
Group
oup; it can issue a Stop Command to
that module and all modules within that group will recognize this as a Stop Command. Even if
the PLC is connected to more than one module in a Stop Gr Group
oup, it only has to issue the Stop

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Command to only one module in order to Stop the whole Stop Gr

Group
oup.

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10.5.1. Other Conditions that cause Stop

There are other conditions, not necessarily initiated by an operator or the control system, that
will cause a Stop Command to be interpreted by a given Stop Gr Group
oup

Missing Connection
If any single device (ERSC or ConveyNet I/P) is missing from a configured Stop Gr
Group
oup due to for
example unplugged or damaged cable; a Stop Command will be issued to all modules in the
Stop Gr
Group
oup

Missing PLC
If a PLC establishes a structur
structured
ed instance connection to any single device (ERSC or ConveyNet
I/P) within a Stop Gr
Group
oup and that connection is subsequently lost to the PLC, a Stop Command
will be issued to all modules in the Stop Gr
Group
oup

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Power L
Loss
oss
If any individual or multiple modules within a Stop Gr
Group
oup has its power disconnected; all
remaining powered modules within that Stop Gr Group
oup will recognize this as a Stop Command

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10.5.2. Indications a Stop is A

Active
ctive
ERSC Indicators
Any powered ERSC modules within a Stop Gr
Group
oup that has an active Stop Command will flash
Red LEDs on the Motor, Sensor, and Control Ports. Please note that the Link, Network, and
Status LEDs will be unaffected by the Stop Command

If a given ERSC within a Stop Gr

Group
oup has a Stop Button assigned; when a Stop Command is
active, the digital output on the Control Port for which the stop button is assigned will toggle on
and off. This signal can be used to illuminate an indicator light or be used as an input to a
remote PLC. See Wiring Examples for more details.

CNIP Indicators
Any powered CNIP modules within a Stop Gr
Group
oup that has an active Stop Command will flash
their Module and Network Status LEDs in Red. All other LEDs will remain unaffected.

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PLC Indication
In order for a PLC to be able to either initiate a Stop or Start Command ; it has to establish an
instance connection to at least one ERSC or CNIP within a given Stop GrGroup
oup. Each instance
assembly available for both the ERSC and CNIP provides an input register for ConveyStop
Status and an output register to issue ConveyStop Stop and Start Commands.
If the PLC is connected to multiple ERSC’s or CNIP’s in a given Stop Gr
Group
oup; any connected ERSC
or CNIP can provide ConveyStop status and can accept Stop and Start Commands from the PLC.

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10.5.3. ERSC F
Functions
unctions Affected by Stop
Command
Regardless of mode (ZPA, PLC I/O, ConveyLogix program); a Stop Command completely inhibits
any rotation of a motor connected to either Motor Port.

How the module’s digital outputs respond to a Stop Command is dependent upon what mode
the module is in and its settings in EasyR
EasyRoll
oll. When placing a module into PLC I/O Mode from the
Connections tab from the Advanced Dialog; there is a drop down box for the user to select how
to respond when there is a communications loss with the PLC. The choices are to turn off the
outputs of leave them in their last state. This setting also affects how the outputs respond
during a Stop Command

EasyRoll Connections Tab with PLC Disconnect Option

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Contr
Control
ol P
Port
ort Outputs
The state of the Control Port digital outputs during a Stop Command depends upon the
following:

Whether the module is in ZP

ZPA
A Mode or PLC I/O Mode
Whether or not a Stop Button was assigned during ConveyStop Stop Gr
Group
oup configuration
The selection of the * On PLC Disconnected* option from the Connections Tab in EasyR
EasyRoll
oll

The following chart indicates the state of the corresponding Left or Right Control Port digital
output while a Stop Command is Active based upon these factors:

Stop
ERSC Mode Button on Port Output State
Port

Unaffected by Stop Command. Output will

ZPA No
reflect the blocked/clear status of the zone

Energized while Stop Command is Active,

ZPA Yes
otherwise OFF

ZPA with PLC control of Control State determined by On PLC Disconnected

N/A
Port option enabled in EasyR
EasyRoll
oll option setting in EasyR
EasyRoll
oll

State determined by On PLC Disconnected

PLC I/O No
option setting in EasyR
EasyRoll
oll

Energized while Stop Command is Active,

PLC I/O Mode Yes
otherwise OFF

Motor P
Ports
orts in Digital I/O Mode
For the Left and Right Motor Ports in Digital Mode, the state of these outputs is determined by
the On PLC Disconnected setting on the Connections Tab in EasyRoll

! WARNING !!! Motor Port in Digital Mode output state upon STOP Command is
determined by On PLC Disconnected setting in EasyRoll and that these outputs
could remain energized during a STOP Command. In any case where output state
is determined by EasyRoll setting; it is up to the Integrator to insure that control
system programming understands that a STOP Command has no effect on these
outputs. It is possible that based upon this setting, any given digital output could
remain energized even though there is STOP Command active.

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10.5.4. CNIP F
Functions
unctions Affected by Stop
Command
Upon a Stop Command, the on-board relay is de-energized which in turn disconnects the
control power bus that feeds Outputs O2 through O5. This ensures that Outputs O2 thru O5 de-
energize during a Stop Command regardless of any logic instructing these outputs to remain
energized.

! Outputs O0 and O1 are unaffected by a Stop Command and will still respond to
any logic from either a remote PLC or on-board ConveyLogix program

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10.6. ConveyLinx F
Function
unction at Stop Gr
Group
oup
Boundaries
If a given system application utilizes multiple Stop Gr
Groups
oups (or non-ConveyStop configured
modules) that are physically and logically connected such as a conveyor system; ConveyLinx
has built in mechanisms for flow control. If the upstream or in feed end of a Stop Gr
Group
oup is being
fed by the discharge of ConveyLinx controlled conveyor; a Stop Condition will cause the most
upstream module of the Stop GrGroup
oup to indicate to its upstream zone to not allow any item to be
conveyed into the Stop Gr
Group’s
oup’s in feed zone.

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10.7. Issuing a Start Command

Typical methods for an operator or the control system to issue a Start Command is either via
hardwired Start push-button or via network command from PLC as shown:

Befor
Before
e a Start Command will work you must mak
make
e sur
sure:
e:
• All modules in the Stop Gr
Group
oup must be powered
• All Stop Buttons must be physically reset
• All expected communications between modules must be present
• All expected PLC connections to modules must be present

Har
Hard-W
d-Wir
ired
ed P
Push-Button
ush-Button

ERSC Module

You can connect Start Command buttons to either the Left or Right Control Ports on an ERSC in
the Stop Gr
Group
oup. Start buttons require a single momentary normally open (N.O.) contact. Once
the contact is closed, if all Start Command criteria are met, the Stop Gr
Group
oup will resume its
normal function.

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CNIP Module

For the CNIP module, there are dedicated inputs to use to connect a Start Command button.
See Wiring Examples for details on the inputs reserved for this function

Remote PLC
If a PLC is connected to at least one module in a Stop Gr
Group
oup; it can issue a Start Command to
that module and all modules within that group will recognize this as a Start Command. Even if
the PLC is connected to more than one module in a Stop Gr
Group
oup, it only has to issue the Start
Command to only one module in order to Start the whole Stop Gr
Group
oup.

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10.7.1. Indications Start is A

Active
ctive
ERSC Indication
Only ERSC modules that have Start Buttons assigned will give an active indication that
ConveyStop has been started. If a given ERSC has a Start Button assigned to a given Control
Port, then the digital output signal of that Control Port will energize when ConveyStop is started
and the Stop Gr
Group
oup is functioning. If any Stop Condition exists, then this output is de-energized

CNIP Indication
There are no active indicators on a CNIP module that ConveyStop has been started. Even for
modules that have a Start Button assigned; there is not default digital output on the module to
indicate a started condition

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10.8. Using a PLC with ConveyStop

All PLC communications assemblies for ConveyLinx modules include a reserved set of registers
for ConveyStop command output and status input. Please refer to Appendix B – PLC Instance
Usage for details on the particular PLC and instance connection you want to use.
Regardless of which network the PLC uses (Ethernet I/P, Modbus TCP, or Profinet), the data
transfer between ConveyLinx modules (ERSC or CNIP) is organized in blocks of registers
defined as Assembiles. Each Assembly is part of an input / output pair. The input assembly
provides status input data to the PLC to read and the output assembly is used by the PLC to
write data to the ConveyLinx module.
Within each Input Assembly is a ConveyStop Status R Register
egister and within each Output Assembly
is a ConveyStop Command R Register
egister. Regardless of PLC, each register is a 16-bit value.

Ether
Ethernet
net I/P
If a PLC establishes an Ethernet I/P assembly instance connection to at least one ERSC or CNIP
module within a Stop GrGroup
oup, then the ConveyStop control within the Stop GrGroup
oup will expect this
connection to always be present. If this connection is ever lost, then a Stop Condition is
triggered for the Stop Gr
Group
oup. If the PLC has established connections to multiple modules within
a Stop Gr
Group
oup; the loss of connection to any one of these connections will trigger a Stop
Condition for the Stop Gr
Group
oup.
Please Note: ERSC and CNIP modules will also respond to unsolicited MSG instruction requests
from the PLC. This form of communication does not require the ERSC or CNIP to be configured
as a “permanent” Ethernet module on the PLC’s logic Ethernet backplane. If the PLC
establishes communication with an ERSC or CNIP within a Stop Gr Group
oup with a MSG instruction
request; the ConveyStop control does not treat this as an expected connection and does not
generate a Stop Condition for any MSG instruction communication presence or loss.

Modbus TCP
Modbus TCP is a request/response type protocol and each ERSC or CNIP module acts as a
Modbus TCP server and will respond to holding register read/write requests. Holding Register
addresses 4:1000 and above are reserved for assembly instances. If a PLC establishes
communications to at least one module in a Stop Gr Group
oup to read/write to any block of holding
registers at address 4:1000 or above and these read/write communication requests from the
PLC is missing for more than 100 msec; a Stop Condition will be generated.
If a PLC establishes a connection to read/write to Holding Registers whose addresses are in the
range of 4:0001 thru 4:999; a loss of connection for this communication will not result in a Stop
Condition

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Profinet I/O
Profinet I/O connection works similarly to Ethernet I/P with ConveyStop. If a PLC establishes a
connection to one or more modules within a Stop Gr Group
oup; then the ConveyStop control within
the Stop Gr
Group
oup will expect all of these connections to always be present. If any one of these
connections is lost, then a Stop Condition is triggered for the Stop Gr
Group
oup

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10.8.1. ConveyStop Status R

Register
egister
The data in this register is to be interpreted bit wise regardless of the PLC protocol used. The
following chart lists the bit definitions for the ConveyStop Status R
Register
egister:

Bit Description

0 thru 4 Reserved

1 = Stop Command issued from a hardwired button on a module in the Stop Gr

Group
oup
5
0 = No Stop Command issued from a hardwired button on a module in the Stop Gr
Group
oup

1 = Stop Command issues because of loss of Ethernet connectivity

6
0 = Ethernet connectivity is OK

1 = Stop Command issued because of loss of connection to PLC

7
0 = PLC connectivity is OK

1 = Stop Command issued because Stop Button on local module’s Lef eftt Control Port (or
8 CNIP I0/I1)
0 = Stop button OK on local module’s Left Control Port(or CNIP I0/I1)

1 = Stop Command issued because Stop Button on local module’s Right Control Port
9 (or CNIP I0/I1)
0 = Stop button OK on local module’s Left Control Port(or CNIP I0/I1)

1 = Stop Command issued from PLC

10
0 = PLC is not issuing a stop command

11 thru
Reserved
15

* If all bits are reset (0) in the ConveyStop Status R

Condition active within the Stop Gr Group
oup
Register
egister then there is no Stop

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10.8.2. ConveyStop Command R

Register
egister
The PLC writes integer values to the ConveyStop Command R
Register
egister to issue either a Stop
Command or a Start Command .

Stop Command
Writing a value of “1” to the ConveyStop Command R
Register
egister will cause a Stop Command to be
issued to the STOP Group. In any module (ERSC or CNIP) that is connected to the PLC, bit10 will
be set in their corresponding ConveyStop Status R
Register
egister.

Start Command
Before issuing a Start Command, the PLC should first verify that the ConveyStop Status
Register is “0” indicating there is not an active STOP condition. One of these conditions is
indicated in Bit 10 of the ConveyStop Status R Register
egister. So the procedure for issuing a Start
Command is:

1. Write a 0 to the ConveyStop Command R Register

egister
2. Verify that the ConveyStop Status R
Register
egister is equal to 0
3. Write a 2 to the ConveyStop Command R Register
egister to issue the Start Command
4. Wait at least 500 msec and then write a 0 to the ConveyStop Command R Register
egister

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10.9. Wiring Examples

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10.9.1. ERSC with Stop Button

Stop Button with SE Br
Break
eakout
out Module

Stop Button with RJ

RJ-12
-12 P
Pigtail
igtail Cable

! Please note that you cannot use an indicator light with RJ-12 pigtail cable. You
must use SE Br
Break
eakout
out Module for an indicator light

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10.9.2. ERSC with Start Button

Start Button with SE Br
Break
eakout
out Module

Start Button with RJ

RJ-12
-12 P
Pigtail
igtail Cable

! Please note that you cannot use an indicator light with RJ-12 pigtail cable. You
must use SE Br
Break
eakout
out Module for an indicator light

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10.9.3. CNIP with Stop Button

Stop Button on Inputs I0 and I1

Stop Button on Inputs I2 and I3

! Indicator Light option is not available on CNIP Module

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10.9.4. CNIP with Start Button

Start Button on Input I0

Start Button on Inputs I2

! Indicator Light option is not available on CNIP Module

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11. ERSC PLC Developers Guide

This section defines the data connectivity available between ConveyLinx Modules and remote
control devices such as PLC
PLCss and PCs

Click Links to L
Lear
earn
n Mor
Moree

Network Ar
Architectur
chitecturee
Understanding Assemblies
ZP
ZPA
A Mode Contr
Control
ol
PLC I/O Mode Contr
Control
ol
ConveyL
ConveyLogix
ogix Interface
Assemblies with R Reset
eset P
Prrotection
Motor PPort
ort as Digital I/O
OD
ODVVA Compliant CrCross-R
oss-Refer
eference
ence

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11.1. Network Ar
Architectur
chitecture
e
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 CP,, P
Prrofinet I/O, and Ether
Ethernet
net I/P. Modbus TCP is the “native” protocol for
communications between ConveyLinx Modules and the EasyR EasyRoll
oll PC software. When ConveyLinx
Modules are used even for basic ZPA control with no external connections to a PC or PLC, they
utilize Modbus TCP for inter-module communication. Ether Ethernet
net I/P is recognized by ConveyLinx
Modules and any given ConveyLinx Module can be attached to an Ethernet I/P capable PLC
(Allen-Bradley ControlLogix or CompactLogix platforms) and be recognized as a Generic
Ether
Ethernet
net Module or explicitly as an ConveyLinx Module by using a Pulseroller provided EDS file.
Profinet I/O is recognized by ConveyLinx Modules and can be attached to any Profinet I/O
capable PLC (applicable Siemens platforms) using a Pulseroller provided GSDXML file.

* All protocols access the same internal data locations on a given ConveyLinx
Module.

Each ConveyLinx Module’s internal data structure is arranged and addressed as Modbus
Holding R
Registers
egisters. The on-board communication and control processes attach logical meanings
to each holding register and read and write data to specific registers to initiate and/or react to
events. Certain registers contain information as to how the ConveyLinx Module is configured
(MDR type, speed, direction, etc.) for its local controls. Other registers are used for inter-
module communications for conveyor operation. For example, when an upstream ConveyLinx
Module has a Carton ready to discharge to its neighboring downstream ConveyLinx Module, the
upstream ConveyLinx Module will write a specific value to a specific address in the downstream
ConveyLinx Module’s internal registers. The downstream ConveyLinx Module’s on board logic
monitors these registers and knows that a specific value means that an upstream Carton is
coming and to engage the proper control logic to convey the Carton.
Because ConveyLinx utilizes an open architecture (Modbus TCP) for inter-module
communications; with proper definition and expected usage of certain register address
locations, external control devices (PC’s and PLC’s) can easily interact with ConveyLinx
Modules to monitor and control various points along the conveyor path.

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11.2. Understanding Assemblies

The Modbus Holding Registers described above will be defined as Module R Register
egister A
Addr
ddresses
esses
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 of the
ConveyLinx Module and these can be thought of as “physical” module address locations.
However, many of these are not applicable, required, or should even be made available to a
remote PLC.

An Assembly is a grouping of some subset of these 512 Module registers based upon the
relevance of the data. For example, the ZPA Input Assembly groups together 21 Module
registers out of the 512 that are relevant for ZPA Inputs. This relevant data from within the
Module’s 512 registers are not necessarily in consecutive address locations and are scattered
throughout the 512 addresses. The Assembly groups them together so they can be read
efficiently all at once.

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11.2.1. Modbus Assembly Instance

Structur
Structuree
Each ConveyLinx Module utilizes Modbus register architecture for remote data access over
Ethernet. Modbus TCP is a simple protocol for data exchange based upon a query/response
mechanism. Each ConveyLinx Module’s memory structure contains a fixed array of internal
data locations that are constructed as Modbus Holding R Registers
egisters. Each ConveyLinx Module has
a fixed reserve of Holding RRegisters
egisters with each capable of holding a 16-bit numerical integer
value. Modbus TCP protocol provides for read/write access to any available Holding R Register
egister.
The structure of these registers allows for individual ConveyLinx Module’s to read from and
write to specific register address locations to achieve inter-module communications. Certain
registers are read from and written to by the EasyR
EasyRoll
oll software in order to monitor and/or
change default configuration values such as MDR speed, direction, type, etc.

* Modbus TCP addressing convention utilizes a “4:xxxx” notation. The “4:” in

Modbus protocol designates that the address is a Holding Register and the xxxx
is a numerical value representing the offset or index for a specific location. The
“xxxx” values used in this document are to be interpreted as if they are for a
Modbus PLC which means that the first register address is “4:0001” and that
there is no “4:0000” register. Some PLC data structures and PC development
environments utilize the “4:0000” designation and their indexes will be offset by
1. Please refer to your PLC or PC application documentation for the Modbus
convention used on their platforms.

Supported Modbus TCP Service Codes

Any Modbus TCP capable PC or PLC can connect to any ERSC visible on its network and access
Input and Output Holding Register Assemblies. The ERSC supports the following Modbus TCP
Service Codes:
• Service Code 3 – Read Holding Register (up to 45 registers per instruction)
• Service Code 6 – Write Single Register
• Service Code 16 – Write Multiple Registers (up to 45 registers per instruction)
• Service Code 23 – Read/Write Multiple Registers (up to 45 registers per instruction)

Properly A
Addr
ddressing
essing Assembly R
Registers
egisters
In the ConveyLinx Module, the Assembly Registers are “virtual” in that they are not “physical”
Module Register Addresses and as such are not directly addressable. The ConveyLinx Module
firmware intercepts the request and builds the assembly data in order to transmit it to the
requesting device. Because of this, you must always address an Assembly by using the first
address in the assembly in order for the ConveyLinx Module to return any data.

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! When using Input and Output Assemblies with Modbus TCP PLC, it is important to
always use the first address shown in the assembly group as the beginning
register to read or write regardless of which register in the assembly is needed
by the PLC. Trying to access Input or Output Assemblies starting with any
register in the assembly other than the first register will cause the ConveyLinx
Module to return an error

For example, for ZPA Mode Assembly Inputs, if you only need to read register 4:1504; your I/O
connection set-up in your PLC must use the starting address of 4:1500 and a sufficient length
of registers to read (in this example at least 5 registers) in order to get to the desired register.
If you set up your PLC to start reading at 4:1504, the ConveyLinx Module will return an error

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11.2.2. Ether
Ethernet
net I/P Assembly Instance
Structur
Structuree
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 them in terms of

them connected as Generic Ethernet I/O devices. For details on how to use EDS
files and Add On Instructions (AOIs), you can go to Connecting to Rockwell PLCs
section

Part of this procedure in the PLC is to instruct the Generic device as to which data configuration
or instance of Ethernet I/P the Generic device is to use to report and respond to data to and
from the PLC. From this point forward, it is assumed the reader is familiar with Allen-Bradley
Logix platform addressing notation:

:O
:O.Data[Inde
.Data[Index].Bit
x].Bit
:I.Data[Inde
:I.Data[Index].Bit
x].Bit

Where:
• ModuleName is the user-defined name of the device
• “O.Data” indicates data written by the PLC to the device
• “I.Data” indicates data read by the PLC from the device
• “[Index].Bit” indicates the word and bit within the image. If the bit notation is absent the
notation refers to the entire word data type

These Assembly Instances group the appropriate Module R Register

egister A
Addr
ddress
ess registers into
contiguous Input and Output array images that fit into the Allen-Bradley Logix 5000 controller
tags

Learn more about connecting to Rockwell PLCs

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11.2.3. Profinet IO Assembly Instance

Structrur
Structruree
Prior to connecting any modules to a Profinet IO capable (Siemens) PLC, a GSDXML
configuration file needs to be installed in your PLC programming software (i.e. STEP 7 or TIA
Portal). The GSDXML file contains, among other things, the definition of memory size required
when connecting a module to a Siemens PLC with Profinet IO. When assigning an individual
module to a PLC, you decide what memory address to use. The GSDXML file stipulates that
each module requires 64 bytes of input data from the module to the PLC and 64 bytes of output
data from the PLC to the module. When assigning an individual module to a PLC, you decide
what physical PLC memory address to use as the beginning of these 64-byte blocks.
In all of the charts showing module data registers and their assigned function, for Profinet IO
these are indicated as “Byte 0, Byte 1,…Byte 32”, etc. These are offsets from the starting
address in the Siemens PLC memory assigned by the Siemens programming software when the
module was installed into the network. For example, if a module’s inputs are installed
beginning at %IB256, then from our charts, the data for “Byte 6 and Byte 7” would be at
addresses %IB262 and %IB263 respectively.

Learn more about connecting to Siemens PLCs

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11.2.4. Assembly R
Register
egister Chart L
Legend
egend
All of the Assemblies are organized in charts that show:

• The Name of the register and its Module Address

• The Assembled Address for Modbus TCP, Ethernet IP, and Profinet
• Description of the register’s usage

The Assembled Addresses are shown in specific notation familiar to the specific protocol per
the following examples:

M: 4:1500 Indicates Modbus TCP addr

addressing
essing notation for Holding R
Registers
egisters

E: I.Data [0] Indicates Ether

Ethernet
net IP addr
addressing
essing notation for R
Rockwell
ockwell RSL
RSLogix
ogix T
Tags
ags

Indicates P
Prrofinet I/O addr
addressing
essing notation for P
Prrofinet IO memory
P: Byte 0 (Hi) Byte 1 (L
(Lo)
o)
location offset

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11.3. ZP
ZPA
A Mode Contr
Control
ol
When an ERSC is in its default ZPA mode, an external networked PLC or PC controller can
connect to the ERSC and perform the following:

• Instruct either or both the upstream and downstream zone to accumulate the next Carton
that arrives
• Receive indication that a new Carton has arrived at either zone
• Receive indication that a Carton has departed from either zone
• Read tracking data associated with Carton at accumulated zone
• Update tracking data associated with Carton at accumulated zone
• Instruct accumulated zone to release Carton and accumulate on next Carton arrival
• Change the MDR speed for either zone
• Remove accumulation control and return zone to normal operation
• Read fault and error status of either zone or motor
• Optionally take over control of either or both Control Ports

Notes about Assemblies in ZP

ZPA
A Mode
When an ERSC is in ZPA Mode, its primary task is to operate its local conveyor zones and
respond to its immediate upstream and downstream conditions. External PLC controller
interaction with an ERSC in ZPA mode is intended to be for decision point monitoring and
general status data gathering. Upstream and Downstream zones work exactly the same for
zone control, only the register addresses are different depending on which zone (or both) that
need to be controlled

* In general, when utilizing ZPA Mode registers; “upstream” and “downstream”

registers are logically determined by conveyor flow after the system has been
Auto-Configured and will not necessarily be associated with the ERSC’s physical
“left” or “right” side’s connections. For motor and port specific I/O items,
register’s description will explicitly indicate “left” or “right”.

* For ERSC modules that are auto-configured as single zone, regardless of whether
the left or right side is physically used as the single zone; external controller
must use the “Upstream” control registers to interface with the single zone

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11.3.1. PLC Inputs for ZP

ZPA
A Mode
This Assembly contains the output from the ERSC in ZPA Mode that is provided as input to the
PLC.

Register
Assembled
Name /
Addr
ddress
ess for Links
Module
PLC
Addr
ddress
ess

M: 4:1500
Local Status E: I.Data[0]
Upstream P: Byte 0
Local Zone Status
Zone (Hi)
4:0116 Byte 1
(L
(Lo)
o)

M: 4:1501
Local Status E: I.Data[1]
Downstream P: Byte 2
Local Zone Status
Zone (Hi)
4:0196 Byte 3
(L
(Lo)
o)

M: 4:1502
Arrival Count
E: I.Data[2]
Local
P: Byte 4 Ar
Arrival/Departur
rival/Departure
e
Upstream
(Hi) Counts
Zone
Byte 5
4:0106
(L
(Lo)
o)

M: 4:1503
Departure
E: I.Data[3]
Count Local
P: Byte 6 Ar
Arrival/Departur
rival/Departure
e
Upstream
(Hi) Counts
Zone
Byte 7
4:0107
(L
(Lo)
o)

M: 4:1504
Arrival Count
E: I.Data[4]
Local
P: Byte 8 Ar
Arrival/Departur
rival/Departure
e
Downstream
(Hi) Counts
Zone
Byte 9
4:0186
(L
(Lo)
o)

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M: 4:1505
Departure
E: I.Data[5]
Count Local
P: Byte 10 Ar
Arrival/Departur
rival/Departure
e
Downstream
(Hi) Counts
Zone
Byte 11
4:0187
(L
(Lo)
o)

M: 4:1506
Module E: I.Data[6]
Status Word P: Byte 12
Module Status
1 (Hi)
4:0088 Byte 13
(L
(Lo)
o)

M: 4:1507
Module E: I.Data[7]
Status Word P: Byte 14
Module Status
2 (Hi)
4:0089 Byte 15
(L
(Lo)
o)

Current M: 4:1508
Upstream E: I.Data[8]
Zone P: Byte 16 Tracking and
Tracking (Hi) Release Counts
Word 1 Byte 17
4:0119 (L
(Lo)
o)

Current M: 4:1509
Upstream E: I.Data[9]
Zone P: Byte 18 Tracking and
Tracking (Hi) Release Counts
Word 2 Byte 19
4:0120 (L
(Lo)
o)

Current M: 4:1510
Downstream E: I.Data[10]
Zone P: Byte 20 Tracking and
Tracking (Hi) Release Counts
Word 1 Byte 21
4:0199 (L
(Lo)
o)

Current M: 4:1511
Downstream E: I.Data[11] Tracking and
Zone P: Byte 22 Release Counts
Tracking (Hi)

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Word 2 Byte 23
4:0200 (L
(Lo)
o)

Current M: 4:1512
Release E: I.Data[12]
Count for P: Byte 24 Tracking and
Upstream (Hi) Release Counts
Zone Byte 25
4:0105 (L
(Lo)
o)

Current M: 4:1513
Release E: I.Data[13]
Count for P: Byte 26 Tracking and
Downstream (Hi) Release Counts
Zone Byte 27
4:0185 (L
(Lo)
o)

M: 4:1514
Get Tracking
E: I.Data[14]
Forward
P: Byte 28 Forwar
orwardd and
Direction
(Hi) Reverse T
Tracking
racking
Word 1
Byte 29
4:0201
(L
(Lo)
o)

M: 4:1515
Get Tracking
E: I.Data[15]
Forward
P: Byte 30 Forwar
orwardd and
Direction
(Hi) Reverse T
Tracking
racking
Word 2
Byte 31
4:0202
(L
(Lo)
o)

M: 4:1516
Get Tracking
E: I.Data[16]
Reverse
P: Byte 32 Forwar
orwardd and
Direction
(Hi) Reverse T
Tracking
racking
Word 1
Byte 33
4:0121
(L
(Lo)
o)

M: 4:1517
Get Tracking
E: I.Data[17]
Reverse
P: Byte 34 Forwar
orwardd and
Direction
(Hi) Reverse T
Tracking
racking
Word 2
Byte 35
4:0122
(L
(Lo)
o)

Sensor & M: 4:1518 Port Inputs and

Control Port E: I.Data[18] ConveyStop

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P: Byte 36
Inputs (Hi)
Status
4:0035 Byte 37
(L
(Lo)
o)

M: 4:1519
E: I.Data[19]
Reserved P: Byte 38
N/A (Hi)
Byte 39
(L
(Lo)
o)

M: 4:1520
E: I.Data[20]
ConveyStop Port Inputs and
P: Byte 40
Status ConveyStop
(Hi)
4:0019 Status
Byte 41
(L
(Lo)
o)

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11.3.1.1. Local Zone Status

Register Name / Assembled A
Addr
ddress
ess for
Description
Module AAddr
ddress
ess PLC

Local Status
M: 4:1500 (L(Lo
o Byte)
Upstream Zone
E: I.Data [0] (L
(Loo Byte)
Forward Direction
P: Byte 1
4:0116 Unsigned Value of Byte:

Local Status 0×01 = Zone sensor clear and motor stopped

M: 4:1500 (Hi Byte)
Upstream Zone
E: I.Data [0] (Hi Byte)
Reverse Direction 0×02 = Zone sensor clear, motor running,
P: Byte 0
4:0116 accepting from upstream zone
Local Status
Downstream M: 4:1501 (L(Lo
o Byte) 0×04 = Zone sensor blocked, motor running,
Zone Forward E: I.Data [1] (L
(Loo Byte) discharging to downstream zone
Direction P: Byte 3
4:0196 0×05 = Zone sensor blocked and motor stopped

Local Status 0×06 = Busy (state during ConveyStop active

Downstream M: 4:1501 (Hi Byte) mode)
Zone Reverse E: I.Data [1] (Hi Byte)
Direction P: Byte 2
4:0196

The values 0xXX01 thru 0xXX06 are shown because these are the possible logical values used
for inter-module communication. External networked devices (PLC or PC) monitoring these
registers may; depending on their scan rate, not actually see each of these values change in
sequence as a Carton is conveyed from zone to zone, even though the inter-module
communications and ZPA is functioning normally.

* IMPORTANT NOTE: Status register values utilize both the HIGH BYTE and the LOW
BYTE of the 16-Bit integer value. The HIGH BYTE is used for zone status for
reversing conveyor applications and MAY CONTAIN DATA. PLC/PC programmers
working with single direction conveyor applications who also are working with
the entire 16-bit register data MUST MASK THE HIGH BYTE or otherwise ignore
the high byte in processing status data from these registers.

* For PLC/PC programming purposes, you can only depend on seeing values
0xXX01 and 0xXX05 in program logic for determining zone status. The values
0xXX02 and 0xXX04 may not always be visible to PLC/PC from inter-module

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communication depending upon speed of the conveyor, length of the zone, and/
or location of the zone sensors.

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11.3.1.2. Ar
Arrival/Departur
rival/Departure
e Counts
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Arrival Count M: 4:1502

Local Upstream E: I.Data [2]
Zone P: Byte 4 (Hi) Unsigned Integer Value:
4:0106 Byte 5 (L
(Lo)
o)

Arrival Count • Increments by 1 each time a Carton ararrives

rives in the
M: 4:1504 zone
Local
E: I.Data [4] • Value rolls over from 65,535 back to 0
Downstream
P: Byte 8 (Hi)
Zone
Byte 9 (L
(Lo)
o)
4:0186

Departure Count M: 4:1503

Local Upstream E: I.Data [3]
Zone P: Byte 6 (Hi)
4:0107 Byte 7 (L
(Lo)
o) Unsigned Integer Value:

Departure Count • Increments by 1 each time a Carton departs the zone

M: 4:1505
Local • Value rolls over from 65,535 back to 0
E: I.Data [5]
Downstream
P: Byte 10 (Hi)
Zone
Byte 11 (L
(Lo)
o)
4:0187

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11.3.1.3. Module Status

Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Bitwise Value – Read Only

bit 0 = Module Reset Flag – 1 when module resets, 0
when PLC connected
bit 1 = Upstream Zone Flow Direction – 0 = Configured
Dir, 1 = Opposite of Configured Dir
bit 2 = Over-Voltage – Input Power > 30V
bit 3 = Left Motor Error – bit is set if any of the
following bits are set: 7,8,10 thru 14
bit 4 = Ethernet Connections NOT OK
bit 5 = Upstream Jam Error
M: 4:1506 bit 6 = Left Sensor Error
Module Status
E: I.Data [6] bit 7 = Low Voltage Error – Input Power < 18V
Word 1
P: Byte 12 (Hi) bit 8 = Left Motor Over-heated – Calculated
4:0088
Byte 13 (L
(Lo)
o) temperature over 120°C
bit 9 = Left Motor Over-current – Over limit for selected
MDR
bit 10 = Left Motor Short Circuit
bit 11 = Left Motor Not Connected
bit 12 = Left Motor Overload –Motor has been stalled
for more than 20 seconds
bit 13 = Left Motor Stalled – MDR slower than 10% of
selected speed
bit 14 = Left Motor Hall Sensor Error
bit 15 = Left Motor Not Used

Bitwise Value – Read Only

bit 0 = Reserved
bit 1 = Downstream Zone Flow Direction – 0 =
Configured Dir, 1 = Opposite of Configured Dir
bit 2 = Over-Voltage – Input Power > 30V
M: 4:1507 bit 3 = Right Motor Error – bit is set if any of the
Module Status
E: I.Data [7] following bits are set: 7,8,10 thru 14
Word 2
P: Byte 14 (Hi) bit 4 = Reserved
4:0089
Byte 15 (L
(Lo)
o) bit 5 = Downstream Jam Error
bit 6 = Right Sensor Error
bit 7 = Low Voltage Error – Input Power < 18V
bit 8 = Right Motor Over-heated – Calculated
temperature over 120°C
bit 9 = Right Motor Over-current – Over limit for

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selected MDR
bit 10 = Right Motor Short Circuit
bit 11 = Right Motor Not Connected
bit 12 = Right Motor Overload – Motor has been stalled
for more than 20 seconds
bit 13 = Right Motor Stalled – MDR slower than 10% of
selected speed
bit 14 = Right Motor Hall Sensor Error
bit 15 = Right Motor Not Used

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11.3.1.4. Tracking and R

Release
elease Counts
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Current Upstream M: 4:1508 When Carton is accumulated in UPSTREAM zone:

Zone Tracking E: I.Data [8] Value = Tracking data word #1 (16-bit integer) for the
Word 1 P: Byte 16 (Hi) Carton currently accumulated and stopped in the
4:0119 Byte 17 (L
(Lo)
o) module’s Upstream zone

Current Upstream M: 4:1509 When Carton is accumulated in UPSTREAM zone:

Zone Tracking E: I.Data [9] Value = Tracking data word #2 (16-bit integer) for the
Word 2 P: Byte 18 (Hi) Carton currently accumulated and stopped in the
4:0120 Byte 19 (L
(Lo)
o) module’s Upstream zone

Current When Carton is accumulated in DOWNSTREAM zone:

M: 4:1510
Downstream
E: I.Data [10] Value = Tracking data word #1 (16-bit integer) for the
Zone Tracking
P: Byte 20 (Hi) Carton currently accumulated and stopped in the
Word 1
Byte 21 (L
(Lo)
o) module’s Downstream zone
4:0199

Current When Carton is accumulated in DOWNSTREAM zone:

M: 4:1511
Downstream
E: I.Data [11] Value = Tracking data word #2 (16-bit integer) for the
Zone Tracking
P: Byte 22 (Hi) Carton currently accumulated and stopped in the
Word 2
Byte 23 (L
(Lo)
o) module’s Downstream zone
4:0200

Current Release M: 4:1512 Copy of the current value in the Release Upstream output
Count for E: I.Data [12] register which can be used by PLC logic to confirm
Upstream Zone P: Byte 24 (Hi) release count prior to writing new data to the Release
4:0105 Byte 25 (L
(Lo)
o) Upstream output register

Current Release
M: 4:1513 Copy of the current value in the Release Downstream
Count for
E: I.Data [13] output register which can be used by PLC logic to confirm
Downstream
P: Byte 26 (Hi) release count prior to writing new data to the Release
Zone
Byte 27 (L
(Lo)
o) Downstream output register
4:0185

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11.3.1.5. Forwar
orwardd and R
Reverse
everse T
Tracking
racking
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

When ERSC is discharging to Non-ConveyLinx controlled

Get Tracking M: 4:1514 conveyor:
Forward Direction E: I.Data [14] Value = Tracking data word #1 (16-bit integer) for the
Word 1 P: Byte 28 (Hi) Carton that has just discharged from the local
4:0201 Byte 29 (L
(Lo)
o) downstream zone when local conveyor is operating in
default or “forward” direction

When ERSC is discharging to Non-ConveyLinx controlled

Get Tracking M: 4:1515 conveyor:
Forward Direction E: I.Data [15] Value = Tracking data word #2 (16-bit integer) for the
Word 2 P: Byte 30 (Hi) Carton that has just discharged from the local
4:0202 Byte 31 (L
(Lo)
o) downstream zone when local conveyor is operating in
default or “forward” direction

When ERSC is discharging to Non-ConveyLinx controlled

Get Tracking M: 4:1516 conveyor:
Reverse Direction E: I.Data [16] Value = Tracking data word #1 (16-bit integer) for the
Word 1 P: Byte 32 (Hi) Carton that has just discharged from the local
4:0121 Byte 33 (L
(Lo)
o) downstream zone when local conveyor is operating in
opposite of default or “reverse” direction

When ERSC is discharging to Non-ConveyLinx controlled

Get Tracking M: 4:1517 conveyor:
Reverse Direction E: I.Data [17] Value = Tracking data word #2 (16-bit integer) for the
Word 2 P: Byte 34 (Hi) Carton that has just discharged from the local
4:0122 Byte 35 (L
(Lo)
o) downstream zone when local conveyor is operating in
opposite of default or “reverse” direction

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11.3.1.6. Port Inputs and ConveyStop

Status
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Bitwise Value – Read Only:

bit 0 = Left Sensor Port – Pin 3
bit 1 = Left Control Port – Pin 3
bit 2 = Right Sensor Port – Pin 3
M: 4:1518
Sensor & Control bit 3 = Right Control Port – Pin 3
E: I.Data [18]
Port Inputs bit 4 = Left Sensor Port – Pin 4
P: Byte 36 (Hi)
4:0035 bit 5 = Left Control Port – Pin 4
Byte 37 (L
(Lo)
o)
bit 6 = Right Sensor Port – Pin 4
bit 7 = Right Control Port – Pin 4
bit 8 – 14 Reserved
bit 15 = 2 sec on / 2 sec off heatbeat

M: 4:1519
E: I.Data [19]
Reserved
P: Byte 38 (Hi)
Byte 39 (L
(Lo)
o)

Bitwise Value – Read Only:

bit 0 – 4 Reserved
bit 5 = Stop active on another module in Stop Group
M: 4:1520 bit 6 = Stop active due to lost communication
ConveyStop
E: I.Data [20] connection
Status
P: Byte 40 (Hi) bit 7 = Stop active due to lost PLC connection
4:0019
Byte 41 (L
(Lo)
o) bit 8 = Stop active on local module’s Left Control Port
bit 9 = Stop active on local module’s Right Control Port
bit 10 = Stop active due to Stop Command from PLC
bit 11 – 15 Reserved

* The values for the signals on the Sensor ports (bit 0, bit 2, bit 4, and bit 6) are
determined by the module’s initial Auto-Configuration results and the bit values
are set to a 1 when sensor is blocked and 0 when sensor is clear regardless of
the sensor type used. For example, each Sensor port Pin 4 signal is for the
sensor’s output. If the sensor is light energized, N.O. then the electrical signal on
Pin 4 is ON when the sensor is clear and OFF when the sensor is blocked.
However, when reading bit 4 or bit 6 in this register, the bit will be a 1 when the
sensor is blocked and 0 when the sensor is clear

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11.3.2. PLC Outputs for ZP

ZPA
A Mode
This Assembly contains the output from the PLC that is provided as input to the ERSC when in
ZPA Mode.

Register
Assembled
Name /
Addr
ddress
ess for Links
Module
PLC
Addr
ddress
ess

Set Local M: 4:1600

Upstream E: O
O.Data[0]
.Data[0]
Zone P: Byte 0 Set L
Local
ocal
Tracking (Hi) Tracking
Word 1 Byte 1
4:0132 (L
(Lo)
o)

Set Local M: 4:1601

Upstream E: OO.Data[1]
.Data[1]
Zone P: Byte 2 Set L
Local
ocal
Tracking (Hi) Tracking
Word 2 Byte 3
4:0133 (L
(Lo)
o)

Set Local M: 4:1602

Downstream E: OO.Data[2]
.Data[2]
Zone P: Byte 4 Set L
Local
ocal
Tracking (Hi) Tracking
Word 1 Byte 5
4:0212 (L
(Lo)
o)

Set Local M: 4:1603

Downstream E: OO.Data[3]
.Data[3]
Zone P: Byte 6 Set L
Local
ocal
Tracking (Hi) Tracking
Word 2 Byte 7
4:0213 (L
(Lo)
o)

Accumulation M: 4:1604
Control for E: OO.Data[4]
.Data[4]
Local P: Byte 8 Accumulation
Upstream (Hi) Contr
Control
ol
Zone Byte 9
4:0104 (L
(Lo)
o)

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Accumulation M: 4:1605
Control for E: O
O.Data[5]
.Data[5]
Local P: Byte 10 Accumulation
Downstream (Hi) Contr
Control
ol
Zone Byte 11
4:0184 (L
(Lo)
o)

M: 4:1606
E: O
O.Data[6]
.Data[6]
Set Left MDR
P: Byte 12
Speed Speed Contr
Control
ol
(Hi)
4:0040
Byte 13
(L
(Lo)
o)

M: 4:1607
E: O
O.Data[7]
.Data[7]
Set Right
P: Byte 14
MDR Speed Speed Contr
Control
ol
(Hi)
4:0064
Byte 15
(L
(Lo)
o)

Release and
Accumulate M: 4:1608
on Next E: O
O.Data[8]
.Data[8]
Arrival for P: Byte 16 Release and
Local (Hi) Status
Upstream Byte 17
Zone (L
(Lo)
o)
4:0105

Release and
Accumulate M: 4:1609
on Next E: OO.Data[9]
.Data[9]
Arrival for P: Byte 18 Release and
Local (Hi) Status
Downstream Byte 19
Zone (L
(Lo)
o)
4:0185

M: 4:1610
E:
Set Status for
O.Data[10]
Upstream Release and
P: Byte 20
Induct Status
(Hi)
4:0134
Byte 21
(L
(Lo)
o)

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M: 4:1611
E:
Set Status for
O.Data[11]
Downstream Release and
P: Byte 22
Discharge Status
(Hi)
4:0232
Byte 23
(L
(Lo)
o)

M: 4:1612
Set Induct
E:
Tracking
O.Data[12] Induct T
Tracking
racking
Forward
P: Byte 24 Forwar
orwardd and
Direction
(Hi) Reverse
Word 1
Byte 25
4:0139
(L
(Lo)
o)

M: 4:1613
Set Induct
E:
Tracking
O.Data[13] Induct T
Tracking
racking
Forward
P: Byte 26 Forwar
orwardd and
Direction
(Hi) Reverse
Word 2
Byte 27
4:0140
(L
(Lo)
o)

M: 4:1614
Set Induct
E:
Tracking
O.Data[14] Induct T
Tracking
racking
Reverse
P: Byte 28 Forwar
orwardd and
Direction
(Hi) Reverse
Word 1
Byte 29
4:0237
(L
(Lo)
o)

M: 4:1615
Set Induct
E:
Tracking
O.Data[15] Induct T
Tracking
racking
Forward
P: Byte 30 Forwar
orwardd and
Direction
(Hi) Reverse
Word 2
Byte 31
4:0238
(L
(Lo)
o)

M: 4:1616
E:
Clear Motor
O.Data[16] Set Outputs and
Error
P: Byte 32 Motor Clear
4:0022
(Hi)
Byte 33

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(L
(Lo)
o)

M: 4:1617
E:
Set Control O.Data[17]
Set Outputs and
Port Outputs P: Byte 34
Motor Clear
4:0063 (Hi)
Byte 35
(L
(Lo)
o)

M: 4:1618
E:
O.Data[18]
Reserved
P: Byte 36
N/A
(Hi)
Byte 37
(L
(Lo)
o)

M: 4:1619
E:
ConveyStop O.Data[19]
ConveyStop and
Command P: Byte 38
Clear Jams
4:0020 (Hi)
Byte 39
(L
(Lo)
o)

Clear Sensor M: 4:1620

Jam E:
Command for O.Data[20]
ConveyStop and
Local P: Byte 40
Clear Jams
Upstream (Hi)
Zone Byte 41
4:0109 (L
(Lo)
o)

Clear Sensor M: 4:1621

Jam E:
Command for O.Data[21]
ConveyStop and
Local P: Byte 42
Clear Jams
Downstream (Hi)
Zone Byte 43
4:0189 (L
(Lo)
o)

Direction & M: 4:1622

Dir
Direction
ection and
Accumulation E:
Accumulation
Mode Control O.Data[22]
Mode
for Local P: Byte 44

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Upstream (Hi)
Zone Byte 45
4:0365 (L
(Lo)
o)

Direction & M: 4:1623

Accumulation E:
Mode Control O.Data[23] Dir
Direction
ection and
for Local P: Byte 46 Accumulation
Downstream (Hi) Mode
Zone Byte 47
4:0375 (L
(Lo)
o)

M: 4:1624
E:
ConveyMerge O.Data[24]
ConveyMer
ConveyMerge
ge
Interface P: Byte 48
Interface
4:0387 (Hi)
Byte 49
(L
(Lo)
o)

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11.3.2.1. Set L
Local
ocal T
Tracking
racking
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Set Local M: 4:1600

Upstream Zone E: O
O.Data
.Data [0] Write value for 16-bit integer tracking data word #1 for
Tracking Word 1 P: Byte 0 (Hi) the Carton accumulated in the Upstream Zone
4:0132 Byte 1 (L
(Lo)
o)

Set Local M: 4:1601

Upstream Zone E: O
O.Data
.Data [1] Write value for 16-bit integer tracking data word #2 for
Tracking Word 2 P: Byte 2 (Hi) the Carton accumulated in the Upstream Zone
4:0133 Byte 3 (L
(Lo)
o)

Set Local
M: 4:1602
Downstream
E: O
O.Data
.Data [2] Write value for 16-bit integer tracking data word #1 for
Zone Tracking
P: Byte 4 (Hi) the Carton accumulated in the Downstream Zone
Word 1
Byte 5 (L
(Lo)
o)
4:0212

Set Local
M: 4:1603
Downstream
E: O
O.Data
.Data [3] Write value for 16-bit integer tracking data word #2 for
Zone Tracking
P: Byte 6 (Hi) the Carton accumulated in the Downstream Zone
Word 2
Byte 7 (L
(Lo)
o)
4:0213

Writing T
Tracking
racking Details
Because the ERSC is connected as I/O, the PLC inherently is always trying to update the Output
image on (at least) RPI intervals. In order to prevent the PLC from inadvertently overwriting the
“real” tracking data registers; the Assembly Output implementation utilizes the holding register
locations shown and automatically updates the “real” tracking registers with this new data only
upon release of the Carton from the zone. Included in this automatic functionality are two
special reserved values that can be used for convenience:

• Set both tracking rregisters

egisters shown to 0: This will instruct the ERSC to not modify the
existing “real” tracking data and allow it to continue downstream “as-is” when the Carton
is released.

• Set both tracking rregisters

egisters shown to 0xFFFF
0xFFFF:: This will instruct the ERSC to clear the “real”
tracking data and when the Carton is released, the “real” tracking data will be “0” in both
registers.

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! Both word 1 and word 2 of the tracking data in question must have 0xFFFF
written to it in order to signal the ERSC to clear the tracking data. If only one
word has 0xFFFF written to it and the other does not, the value of 0xFFFF will be
the new tracking data for that word.

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11.3.2.2. Accumulation Contr

Control
ol
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Accumulation M: 4:1604 Bitwise Values:

Control for Local E: O
O.Data
.Data [4] bit 0 = Set/Clear Accumulation Mode for Local Zone
Upstream Zone P: Byte 8 (Hi) bit 8 = Accumulate adjacent upstream zone
4:0104 Byte 9 (L
(Lo)
o) bit 9 = Set Arrival Confirmation for Local zone
Accumulation bit 10 = Jog zone in default direction
M: 4:1605 bit 11 = Jog zone in opposite of default direction
Control for Local
E: O
O.Data
.Data [5] bit 12 = Wake up Local Zone
Downstream
P: Byte 10 (Hi) bit 13 = Enable Maintenance Mode
Zone
Byte 11 (L
(Lo)
o) All other bits reserved
4:0184

Notes for A
Accumulation
ccumulation Contr
Control
ol Bits

* Beginning with ConveyLinx firmware 3.45 and later; the function of this register
has been expanded to include separate bit-wise functionality. Previous to
firmware 3.45, only bit 0 function was available

Bit 8 – A
Accumulate
ccumulate A
Adjacent
djacent Upstr
Upstream
eam Zone

Setting this bit will cause the next upstream zone of the local module to accumulate. This next
upstream zone can be either on the local module or the downstream zone of the adjacent
upstream module.

Bit 9 – Set Ar
Arrival
rival Confir
Confirmation
mation for Downstr
Downstream
eam Zone

By default, for ZPA operation, ConveyLinx requires a confirmation from the downstream zone
when a Carton is discharged. Without this confirmation, the releasing zone will detect a jam
condition. This bit is used in applications where the Carton is removed from the conveyor
(either manually or say by a PLC controlled external mechanism such as a pusher or diverter)
and the PLC needs to “confirm” the removal of the Carton in order to satisfy the ZPA
confirmation logic.

Bits 10 & 11 – Jog Contr

Controls
ols

These bits can be used by the PLC to jog the local zone for specialized applications when local
movement of the Carton on a zone is required. An example would be once a Carton has arrived
in the local zone, the PLC determines that the Carton needs to be re-positioned or perhaps

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squared up against a PLC controlled pop-up stop.

! Jog control bits over

over-ride
-ride ZP
ZPA
A logic control and should be used with caution!
Improper usage of jog controls can produce unexpected results and/or damage to
product and equipment

Bit 12 – W
Wak
ake
e Up L
Local
ocal Zone

Setting this bit will cause the local zone to “wake up” and run to accept a carton the same as if
it’s upstream ERSC had written a status value of “4”. This function would be useful for a merge
onto a main line of ZPA conveyor.

* Wake up Local Zone functionality available in ERSC firmware versions 4.1 and
higher

Bit 13 – Enable Maintenance Mode

Setting this bit will place the local zone in maintenance mode. In this mode the motor will not
run regardless of zone conditions. The zone upstream of this local zone will receive a “busy”
status to inhibit release of any item into this local zone. While in this state, the SEN and Motor
LEDs will flash on and off in green color.

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11.3.2.3. Speed Contr

Control
ol
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

M: 4:1606
Set Left Motor
E: O
O.Data
.Data [6]
Speed
P: Byte 12 (Hi) Value in % PWM:
4:0040
Byte 13 (L
(Lo)
o) Range: 0 to 1000
M: 4:1607 Example: 400 = 40%
Set Right Motor 0 = Remain at last non-zero value entered
E: O
O.Data
.Data [7]
Speed
P: Byte 14 (Hi)
4:0064
Byte 15 (L
(Lo)
o)

* Leaving these registers at “0” will instruct the module to use its configured
speed. Any non-zero value will instruct the nodule to use this non zero value as
the speed reference. The speed will stay at this reference until this register is
changed to a new non zero value or set to “0”. When this register is set to “0”,
the module will continue to use the last non zero value it was given. Setting this
value to “0” will not cause the motor to run at “0” speed

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11.3.2.4. Release and Status

Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Release and When bit 0 of Accumulation Control for Local Upstream

Accumulate on M: 4:1608 Zone is set:
Next Arrival for E: O
O.Data
.Data [8] Changing the value in this register will cause the
Local Upstream P: Byte 16 (Hi) Carton accumulated in this zone to release and the
Zone Byte 17 (L
(Lo)
o) zone will be armed to automatically accumulate the
4:0105 next Carton that arrives

Release and When bit 0 of Accumulation Control for Local Downstream

Accumulate on Zone is set:
M: 4:1609
Next Arrival for
E: O
O.Data
.Data [9] Changing the value in this register will cause the
Local
P: Byte 18 (Hi) Carton accumulated in this zone to release and the
Downstream
Byte 19 (L
(Lo)
o) zone will be armed to automatically accumulate the
Zone
4:0185 next Carton that arrives

Only used when local module is accepting loads from

Non-ConveyLinx controlled conveyor:
M: 4:1610
Set Status for Set value to 4 to cause the local upstream zone to run
E: O
O.Data
.Data [10]
Upstream Induct to accept the Carton being delivered by the non-
P: Byte 20 (Hi)
4:0134 ConveyLinx controlled conveyor. Set value to 1 to
Byte 21 (L
(Lo)
o)
cause the local upstream zone to accept the tracking
data written in Set Induct Tracking Word 1 / Word 2

Only used when local module is discharging loads to Non-

ConveyLinx controlled conveyor:
Set Status for M: 4:1611
Downstream E: O
O.Data
.Data [11] • Set value to 5 to cause the local downstream zone
Discharge P: Byte 22 (Hi) to accumulate and hold any Carton that arrives
4:0232 Byte 23 (L
(Lo)
o)
• Set value to 1 to allow the local downstream zone to
release the Carton

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11.3.2.5. Induct T
Tracking
racking F
Forwar
orwardd and
Reverse
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Only used when local module is accepting loads from

Non-ConveyLinx controlled conveyor:
Set Induct M: 4:1612
Tracking Forward E: O
O.Data
.Data [12]
Set value for 16-bit integer tracking word #1 for
Direction Word 1 P: Byte 24 (Hi)
Carton leaving non-ConveyLinx controlled conveyor that
4:0139 Byte 25 (L
(Lo)
o)
is in transit to arrive on the local upstream zone when
conveyor is running in default or “forward” direction

Only used when local module is accepting loads from

Non-ConveyLinx controlled conveyor:
Set Induct M: 4:1613
Tracking Forward E: O
O.Data
.Data [13]
Set value for 16-bit integer tracking word #2 for
Direction Word 2 P: Byte 26 (Hi)
Carton leaving non-ConveyLinx controlled conveyor that
4:0140 Byte 27 (L
(Lo)
o)
is in transit to arrive on the local upstream zone when
conveyor is running in default or “forward” direction

Only used when local module is accepting loads from

Non-ConveyLinx controlled conveyor:
Set Induct M: 4:1614
Tracking Reverse E: O
O.Data
.Data [14] Set value for 16-bit integer tracking word #1 for
Direction Word 1 P: Byte 28 (Hi) Carton leaving non-ConveyLinx controlled conveyor that
4:0237 Byte 29 (L
(Lo)
o) is in transit to arrive on the local upstream zone when
conveyor is running in opposite of default or “reverse”
direction

Only used when local module is accepting loads from

Non-ConveyLinx controlled conveyor:
Set Induct M: 4:1615
Tracking Reverse E: O
O.Data
.Data [15] Set value for 16-bit integer tracking word #2 for
Direction Word 2 P: Byte 30 (Hi) Carton leaving non-ConveyLinx controlled conveyor that
4:0238 Byte 31 (L
(Lo)
o) is in transit to arrive on the local upstream zone when
conveyor is running in opposite of default or “reverse”
direction

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11.3.2.6. Set Outputs and Motor Clear

Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

M: 4:1616
Logical 1 or 0:
Clear Motor Error E: O
O.Data
.Data [16]
1 = send reset command
4:0022 P: Byte 32 (Hi)
0 = clear reset command
Byte 33 (L
(Lo)
o)

M: 4:1617
Set Control Port Bitwise Value: 1 energizes Output
E: O
O.Data
.Data [17]
Outputs bit 1 = Left Control Port
P: Byte 34 (Hi)
4:0063 bit 3 = Right Control Port
Byte 35 (L
(Lo)
o)

M: 4:1618
E: O
O.Data
.Data [18]
Reserved
P: Byte 36 (Hi)
Byte 37 (L
(Lo)
o)

Clear Motor Er
Errror

Errors deemed “fatal” for the ERSC (motor short circuit and Hall Effect sensor fault) require
either removal of power to reset or remote reset by PLC. Setting bit 0 of this register to 1 will
initiate this remote error reset from the PLC to the local ERSC. Setting this bit will reset a fatal
error on either (or both) the left or right MDR.

! PLC must continuously set bit 0 = 1 in the Clear Motor Error register for at least
500 msec for the ERSC to recognize the reset command

Contr
Control
ol P
Port
ort Outputs

By default, in ZPA mode, the PLC does not have control of the local connected module’s Control
Port output signals. The default function of the Control Port output signals is to be energized
when the Control Port’s corresponding zone is occupied. In certain applications, it may be
desired to have the PLC actuate a device along the conveyor (i.e. illuminate a light or energize
a solenoid coil, etc.). With the ConveyLinx network this can be done without installing a
separate PLC I/O system to do this. Using EasyRoll software, one or both Control Ports can have
their function switched from internal ZPA logic control to be controlled by the PLC. See EasyRoll
software Advanced Screen|Control Ports| Checkboxes for Enable PLC Controls

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* Please note that the checkboxes in EasyRoll for selecting PLC control of Control
Ports is based upon upstream or downstream configuration of the ERSC
determined during Auto-Configuration and NOT by “left” or “right” Control Port
designation

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11.3.2.7. ConveyStop and Clear Jams

Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Integer Value:
M: 4:1619 0 = No Command
ConveyStop
E: O
O.Data
.Data [19] 1 = Command local module’s Stop Group to
Command Word
P: Byte 38 (Hi) go to Stopped State
4:0020
Byte 39 (L
(Lo)
o) 2 = Command Local Module’s Stop Group to
Clear Stopped State

Clear Sensor Jam M: 4:1620 Use when PLC detects a local Upstream jam in Module
for Local E: O
O.Data
.Data [20] Status Word #1 Bit 5:
Upstream Zone P: Byte 40 (Hi) PLC creates transition from 0 to 1 to send command to
4:0109 Byte 41 (L
(Lo)
o) local upstream zone to clear the jam condition

Clear Sensor Jam

M: 4:1621 Use when PLC detects a local Downstream jam in Module
for Local
E: O
O.Data
.Data [21] Status Word #2 Bit 5:
Downstream
P: Byte 42 (Hi) PLC creates transition from 0 to 1 to send command to
Zone
Byte 43 (L
(Lo)
o) local downstream zone to clear the jam condition
4:0189

* Refer to Pulseroller publication ERSC-1800 ConveyStop User’s Guide for details

on using ConveyStop

Sensor Jam Clear Commands

These registers are applicable only to a Sensor Jam condition. By default, in ZPA mode, the
ERSC will attempt 3 times to automatically clear a sensor jam and if the sensor is still blocked,
the ERSC will stop the zone. To reset this condition the Carton must be manually removed after
the 3rd attempt and the sensor cleared before the zone will return to normal operation.
These registers allow the PLC to remotely attempt another auto-clear cycle in an attempt to
clear the jam condition. Please note that this function requires the PLC to make a transition
from 0 to 1 in the register to initiate another auto-clear cycle. Holding the value to 1 will not
cause the retry to continue indefinitely. Each attempt requires a new transition from 0 to 1

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11.3.2.8. Dir
Direction
ection and A
Accumulation
ccumulation Mode
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Used to change direction of flow or accumulation mode

for a contiguous group of zones beginning with the local
upstream / downstream zone

Direction & Value for Low Byte of Register:

Accumulation M: 4:1622
0 = Normal Function
Mode Control for E: O
O.Data
.Data [22]
Local Upstream P: Byte 44 (Hi) 1 = Accumulate Zones
Zone Byte 45 (L
(Lo)
o)
2 = Accumulate Zones
4:0365
3 = Change Accumulation Release Mode

4 = Return Release Mode to Configured Default

5 = Run All FWD Direction

6 = Run All REV Direction

7 = Place All in Maintenance Mode

10 = Set Direction to Configured Default (Forward)

Direction &
Accumulation 11 = Set Direction to opposite of Configured default
M: 4:1623
Mode Control for (Reverse)
E: O
O.Data
.Data [23]
Local
P: Byte 46 (Hi)
Downstream
Byte 47 (L
(Lo)
o) Value for High Byte of Register:
Zone
4:0375 Number of ZONES beginning with the local Upstream /
Downstream Zone for which the Low Byte value is
applied – from 1 to 220. If ALL ZONES in the subnet
need to be controlled then leave the High Byte = “0”

Notes on A
Accumulate
ccumulate Zones F
Functionality
unctionality
The Accumulate Zones function (Low Byte values 1 or 2) expects all zones to be empty or in
the process of releasing downstream when the function is initiated. Once the Accumulate
Zones function has been initiated, the logic is expecting to see the zone status change from
clear to blocked before the zone accumulates.

This can produce une

unexpected esults if the Accumulate Zones function is initiated on a line
xpected rresults
where some or all zones are already occupied and accumulated.

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Let’s say that we

have a conveyor
line wher
where e all
cartons arare
e
stopped and
accumulated. If
the Accumulate
Zones function is
initiated; nothing
will happen and
it will appear
that all zones
ar
aree being
commanded to
accumulate.

However, each
zone needs to
see a transition
fr
from
om empty to
full again for the
function to be
initiated. So in
this case, if
someone
removes a
carton frfrom
om a
zone, the carton
upstr
upstream
eam will
still convey to fill
the empty zone,
as well as any
other upstr
upstream
eam
cartons. If a
given zone was
alr
already
eady empty
when the
function was
initiated; the
ne
nextxt carton that
ar
arrives
rives will
accumulate.

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11.3.2.9. ConveyMer
ConveyMerge
ge Interface
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

ONL
ONLY
Y AVAIL
AILABLE
ABLE for FIRMW
FIRMWARE
ARE 4.25 and HIGHER

Used to dynamically modify a ConveyMerge configuration

already established with EasyRoll

Bitwise Values:

Bit 15: Set to enable PLC control of ConveyMerge

Bit 4: Set to disable release from Center line

M: 4:1624 Bit 5: Set to disable release from Left line

ConveyMerge
E: O
O.Data
.Data [24]
Interface Bit 6: Set to disable release from Right line
P: Byte 48 (Hi)
4:0387
Byte 49 (L
(Lo)
o) Bits 0 thru 3 are interpreted as a numerical value to
change the release priority:

Value:

0 = First come, first served release

1 = Center Line has priority

2 = Left Line has priority

3 = Right Line has priority

* Please refer to publication ERSC-1005 User’s Guide Supplement for ConveyMerge

for details on configuring merging sections with EasyRoll software

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11.3.3. ZP
ZPA
A Examples

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11.3.3.1. Basic A
Accumulate
ccumulate and R
Release
elease
with T
Tracking
racking 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 write
tracking data, and finally how to release the Carton. For this example, the PLC must establish
ZPA Mode Assembly Input/Output connections to Module B as shown

Upstr
Upstream
eam Zone Example

First, let’s assume we want to accumulate any Carton that arrives on the upstream zone of
Module B. With the PLC:
1. Set bit 0 in Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to instruct this
zone to accumulate any Carton that arrives.
2. Monitor Ar Arrival
rival Count L
Local
ocal Upstr
Upstream
eam Zone and Departur
Departure
e Count LLocal
ocal Upstr
Upstream
eam
Zone registers. On the leading edge when these two values become not equal, the
PLC knows there is a new arrival. Note that as long as a Carton is physically
occupying the upstream zone, these two values will not be equal.

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3. Upon a successful arrival of a Carton in the upstream zone, then tracking data in
Cur
Currrent Upstr
Upstream
eam Zone T Tracking
racking W
Wor
ord
d 1 and Cur
Currrent Upstr
Upstream
eam Zone T Tracking
racking W Wor
ord
d2
will be valid for the newly arrived Carton.
4. The PLC may then decide that this tracking data is to be updated. The PLC can then
write new tracking data to registers Set LLocal
ocal Upstr
Upstream
eam Zone T Tracking
racking W Wor
ord
d 1 and Set
Local Upstr
Upstream
eam Zone T Tracking
racking W
Wor
ord
d2
5. When the PLC is ready to release the Carton in the upstream zone, it should read the
value in the Cur
Currrent R
Release
elease Count for Upstr
Upstream
eam Zone register, add 1 to this value,
and then write this new value to Release and A Accumulate
ccumulate on NeNext
xt Ar
Arrival
rival for L
Local
ocal
Upstr
Upstream
eam Zone register. When Module B sees this new value in this register, it will
release the Carton in the upstream zone and automatically accumulate the next new
Carton that arrives. Please note that if the downstream conditions from Module B are
full when this new value is written, Module B will remember that it was instructed to
release and will release the Carton when downstream conditions become clear
without any further signal from the PLC.
6. The PLC can detect when the Carton has departed the sensor on Module B upstream
zone by examining the values in Ar
Arrival
rival Count L
Local
ocal Upstr
Upstream
eam Zone and Departur
Departuree
Count L
Local
ocal Upstr
Upstream
eam Zone registers. On the leading edge of when these two values
are equal, the PLC will know that the Carton has departed the zone sensor in Module
B upstream zone.

If the PLC wants to cancel the accumulation control for Module B upstream zone:
PLC can reset bit 0 in Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register. This will
signal Module B to release any Carton accumulated and not accumulate the next Carton
that arrives at Module B upstream zone.

* Please note that if any new tracking data has been written to Set L
Upstr
Upstream
Wor
ord
eam Zone TTracking
racking W
Wor
ord
d 1 and/or Set LLocal
ocal Upstr
Upstream
eam Zone T
Local
ocal
Tracking
racking
d 2 and accumulation control is then canceled by resetting bit 0, this
data will NOT be assigned to the Carton when it is released. The ONL
ONLY Y way to
pass tracking data to a Carton is by following Step 5 above

Downstr
Downstream
eam Zone Example

First, let’s assume we want to accumulate any Carton that arrives on the upstream zone of
Module B. With the PLC:
1. Set bit 0 in Accumulation Contr
Control
ol for L
Local
ocal Downstr
Downstream
eam Zone register to instruct this
zone to accumulate any Carton that arrives.
2. Monitor Ar Arrival
rival Count L
Local
ocal Downstr
Downstream
eam Zone and Departur
Departure
e Count LLocal
ocal
Downstr
Downstream
eam Zone registers. On the leading edge when these two values become not
equal, the PLC knows there is a new arrival. Note that as long as a Carton is
physically occupying the downstream zone, these two values will not be equal.
3. Upon a successful arrival of a Carton in the downstream zone, then tracking data in

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Cur
Currrent Downstr
Downstream
eam Zone T Tracking
racking W
Wor
ord
d 1 and Cur
Currrent Downstr
Downstream
eam Zone T Tracking
racking
Worord
d 2 will be valid for the newly arrived Carton.
4. The PLC may then decide that this tracking data is to be updated. The PLC can then
write new tracking data to registers Set L Local
ocal Downstr
Downstream
eam Zone T Tracking
racking WWor
ordd 1 and
Set LLocal
ocal Downstr
Downstream
eam Zone T Tracking
racking W
Wor
ord
d 2.
5. When the PLC is ready to release the Carton in the downstream zone, it should read
the value in the Cur
Currrent RRelease
elease Count for Downstr
Downstream
eam Zone register, add 1 to this
value, and then write this new value to Release and A Accumulate
ccumulate on Ne
Next
xt Ar
Arrival
rival for
Local Downstr
Downstream
eam Zone register. When Module B sees this new value in this register,
it will release the Carton in the upstream zone and automatically accumulate the next
new Carton that arrives. Please note that if the downstream conditions from Module B
are full when this new value is written, Module B will remember that it was instructed
to release and will release the Carton when downstream conditions become clear
without any further signal from the PLC.
6. The PLC can detect when the Carton has departed the sensor on Module B
downstream zone by examining the values in Ar Arrival
rival Count L
Local
ocal Downstr
Downstream
eam Zone
and Departur
Departure e Count L Local
ocal Downstr
Downstream
eam Zone registers. On the leading edge of when
these two values are equal, the PLC will know that the Carton has departed the zone
sensor in Module B downstream zone.

If the PLC wants to cancel the accumulation control for Module B downstream zone:
PLC can reset bit 0 in Accumulation Contr
Control
ol for L
Local
ocal Downstr
Downstream
eam Zone register. This will
signal Module B to release any Carton accumulated and not accumulate the next Carton
that arrives at Module B downstream zone.

* Please note that if any new tracking data has been written to Set L
Downstr
Downstream
eam Zone T
Tracking WWor
ord
Tracking
racking W
Wor
ordd 1 and/or Set L
Local
ocal Downstr
Downstream
Local
ocal
eam Zone
d 2 and accumulation control is then canceled by resetting bit 0,
this data will NOT be assigned to the Carton when it is released. The ONL
ONLYY
way to pass tracking data to a Carton is by following Step 5 above

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11.3.3.2. Conveyor Setup for Simple Bar

Code RReader
eader
This example shows how to set up the conveyor control to easily singulate cartons through a
bar code scanning region

In this example, Module B must be logically configured as a single zone. This can be either a
single long zone with one MDR and one sensor, or a single long zone with 2 MDRs and one
sensor.

For this example to work properly; the discharging zone of Module A and the single zone of
Module B must be in the default singluation release mode (not Train mode). Module A must also
not have its Arrival Jam disabled
disabled.

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Because of built-in ZPA functionality, when a Carton leaves Module A discharge zone, Module A
waits until it receives confirmation from Module B that the Carton arrived. If a new Carton
arrives at Module A, it will accumulate until this arrival confirmation occurs. Because Module B
is a single long zone, the space for what would have been the upstream zone for Module B (if it
was configured as two zones) will now essentially be left clear when a Carton is accumulated
on Module B. This is the area where the bar code scanner is located. In this configuration, any
new arrival at Module B will be assured to be the Carton associated with the last scan from the
bar code reader. For this example, the PLC must establish a connection with Module B and then
simply follow the zone control as described for basic accumulate and release

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11.3.3.3. Upstr
Upstream
eam A
Accept
ccept 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
A. When PLC is ready to
transfer a Carton from the PLC controlled conveyor to the Upstream Zone of the MDR Conveyor,
the PLC logic must:

1. Write a “4” into Set Status for Upstr

Upstream
eam Induct register. This will cause the upstream zone
of Module A to run to accept Carton.
PE-1, write tracking data to Set Induct T
2. When Carton clears PE-1 Tracking
racking F
Forwar
orwardd Dir
Direction
ection
Wor
ord
d 1 and Set Induct TTracking
racking FForwar
orwardd Dir
Direction
ection W
Wor
ordd2
PE-1, write a “1” to Set Status for Upstr
3. When Carton clears PE-1 Upstream
eam Induct register. When
Module A sees this register change to “1”, it knows that the tracking data written to Set
Induct T
Tracking
racking FForwar
orwarddWWor
ordd 1 and Set Induct T Tracking
racking F
Forwar
orwarddWWor
ord
d 2 is valid and when
the Carton reaches the sensor in its upstream zone, the tracking data will be correctly
inducted

* Module A must see the Set Status for Upstr

Wor
ord
Upstream
eam Induct register change from 4 to
1 in order to recognize the tracking data written to Set Induct T Tracking
racking FForwar
orward
d registers. If using the clearing of PE-1 to initiate the write of “1” the Set
d

Status for Upstr

Upstream
eam Induct register in the PLC logic; the physical length of the
Carton must be less that the distance between PE-1 and Module A’s upstream
zone sensor because Module A inducts the tracking data upon the Carton arriving
at its upstream sensor and if Set Status for Upstr
Upstream
eam Induct has not changed
from 4 to 1, the tracking data will not be valid.

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! If a value of “4” is in the Set Status for Upstr

Upstream
eam Induct register at the same
time the Carton reaches the local upstream zone’s sensor; the local upstream
zone will assume the Carton is physically longer than one zone and will invoke
it’s on board Fle
Flex
x Zone logic and behave accordingly. Please refer to the
ConveyLinx User’s Guide for description of Flex Zone operation. To reliably
transfer tracking data and ensure single Carton induction to the local upstream
zone, the PLC programmer must ensure proper use of the Set Status for
Upstr
Upstream
eam Induct register

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11.3.3.4. Downstr
Downstream
eam Dischar
Discharge
ge 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
connection with Module XX.

1. To hold any Carton that arrives at Module X downstream zone, the PLC writes a “5” to Set
Status for Downstr
Downstream
eam Dischar
Discharge
ge register. This tells Module X that downstream conditions
are “full and stopped” so it will not try to release any loads downstream.
2. When the PLC controlled conveyor is ready to accept a Carton from the MDR downstream
zone, it writes a “1” to Set Status for Downstr
Downstream
eam Dischar
Discharge
ge register. This tells Module X
that downstream conditions are clear and if it has a Carton on its downstream zone, it will
run to release it downstream.
3. When the Carton clears the local sensor in Module X Downstream Zone, the tracking data
for that Carton will be populated in Get T Tracking
racking FForwar
orwardd Dir
Direction
ection W
Wor
ordd 1 and Get
Tracking FForwar
orwardd Dir
Direction
ection W
Wor
ordd 2 registers.
4. When Carton arrives at PE-2, the PLC writes a “5” to Set Status for Downstr
Downstream
eam Dischar
Discharge
ge
register. This tells Module X that the Carton successfully transferred. If this is not done,
then Module X will produce an ArArrival
rival Jam condition.

Optional Step:
If the application is such that the PLC would like to inhibit a new Carton from entering Module X
downstream zone for whatever reason, there is a way to accumulate the next upstream zone to
the Module X downstream zone. The PLC can set bit 8 in the Accumulation Contr
Control
ol for L
Local
ocal
Downstr
Downstream
eam Zone and this will cause the adjacent upstream zone to accumulate (whether this
zone is on Module X or next adjacent upstream ConveyLinx Module). To return the accumulated
upstream zone to normal operation; the PLC simply resets bit 8 in this register

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* Please note that if Module X is configured as a single zone

8 in the Accumulation Contr
Control
ol for L
zone module only has an upstr
upstream
Local
ocal Upstr
Upstream
zone, then you must set bit
eam Zone register because a single
eam zone and no downstr
downstream
eam zone
zone.

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11.3.3.5. 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 a jam
condition when the Carton is moved from the ZPA zone to the divert lane. The PLC will be
connected to Module BB.

* This example assumes that the tracking data arriving from each new Carton
arrival at Module B Upstream Zone contains a value that will indicate to the PLC
that a Carton does or does not need to divert. However, it is not required that
the PLC use Carton tracking data be used to determine when to divert a Carton.
The PLC can use whatever criteria it needs to make a divert decision.

Prepare Module B Upstream Zone:

1. Set bit 0 in Accumulation Contr

Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to instruct this zone to
accumulate any Carton that arrives.
2. Monitor Ar
Arrival
rival Count L
Local
ocal Upstr
Upstream
eam Zone and Departur
Departure
e Count LLocal
ocal Upstr
Upstream
eam Zone
registers. On the leading edge when these two values become not equal, the PLC knows
there is a new arrival. Note that as long as a Carton is physically occupying the upstream
zone, these two values will not be equal.
3. Upon a successful arrival of a Carton in the upstream zone, then tracking data in Cur Currrent

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Upstr
Upstream
eam Zone TTracking
racking W
Wor
ordd 1 and Cur
Currrent Upstr
Upstream
eam Zone T
Tracking
racking W
Wor
ordd 2 will be valid
for the newly arrived Carton

If the PLC determines that the newly arrived carton needs to divert:

1. Set bit 8 of Accumulation Contr

Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register. This will keep Module
A from releasing a Carton to Module B while the divert operation is in progress.
2. PLC will then initiate it’s divert mechanism.
3. When carton reaches PE-1PE-1, the PLC will then set bit 9 of the Accumulation ContrControl
ol for
Local Upstr
Upstream
eam Zone register. This will tell Module B that the carton “successfully arrived
at its downstream position”.
4. Once carton has cleared PE-1PE-1, then the PLC should clear bit 9 of the Accumulation Contr Control
ol
for L
Local
ocal Upstr
Upstream
eam Zone register.
5. PLC then can clear bit 8 of the Accumulation Contr Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to
instruct Module A that it is OK to allow the next carton to enter Module B’s upstr upstream
eam
zone
zone.

If the PLC determines that the newly arrived carton does not need to divert:

The PLC can simply modify Carton’s tracking data if desired and release the Carton as
described in Basic A
Accumulate
ccumulate and R
Release
elease section

* Do not release the Carton by clearing bit 0 of Accumulation Contr

Upstr
Upstream
Control
ol for L
eam Zone in your PLC program. Follow the procedure in the “Basic
Accumulate and R Release
elease” example
Basic
Local
ocal

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11.3.3.6. Mer
Merge
ge onto ZP
ZPA
A 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 zone to
accept a carton from the merging curve section.

1. With no PLC intervention, as long as cartons arrive into Module A they will be conveyed to
Module C/B and onto Module D in normal ZPA fashion.
2. To verify that Module C (and by extension Module B
B) is ready to accept a carton from the
merge curve; the PLC needs to know that Module C C’s zone is clear and stopped by
examining Local Status Upstr
Upstream
eam Zone F Forwar
orwardd Dir
Direction
ection register (Low Byte). When the
low byte of this register equals 1, the zone is clear and stopped.
3. When the PLC needs to convey a carton from the merging curve, the PLC needs to set bit
8 in Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to accumulate the adjacent
upstream zone, in this example setting bit 8 will cause Module A downstrdownstream
eam zone to
accumulate any carton that arrives.
4. When the PLC is ready to release a carton from the PLC Contr Controlled
olled Conveyor spur, the PLC
sets bit 12 in the Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to wake up the
Module C zone (along with Module B’s zones because Module B is an extension of Module
C).
5. When the PLC sees the low byte of the Local Status Upstr
Upstream
eam Zone F
Forwar
orward
d Dir
Direction
ection
register change to a value of 4 or 5, the PLC knows that the carton made it to Module C’s
zone sensor and must then reset bit 12 in the Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam

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Zone register. Either of these values will indicate a successful arrival at Module C
6. Upon reset of bit 12 of the Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register, the
PLC can reset bit 8 of the same register to indicate to Module A that it is OK to continue
normal ZPA function

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11.3.4. Reduced Size ZP

ZPA
A 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 applications where the
full functionality of the Standard ZPA Mode Assemblies is not required. The Reduced Size
Assemblies provide basic accumulation and release control along with module diagnostic data
while removing the interfaces for reading/writing tracking data.

ZP
ZPA
A Mode Inputs to PLC
Assembled Assembled Assembled
Module
Register Name Modbus EIP Profinet
Addr
ddress
ess
Addr
ddress
ess Addr
ddress
ess Addr
ddress
ess

Byte 0 (Hi)
4:0116 Local Status Upstream Zone 4:2900 I.Data [0]
Byte 1 (L
(Lo)
o)

Byte 2 (Hi)
4:0196 Local Status Downstream Zone 4:2901 I.Data [1]
Byte 3 (L
(Lo)
o)

Byte 4 (Hi)
4:0106 Arrival Count Local Upstream Zone 4:2902 I.Data [2]
Byte 5 (L
(Lo)
o)

Byte 6 (Hi)
4:0107 Departure Count Local Upstream Zone 4:2903 I.Data [3]
Byte 7 (L
(Lo)
o)

Byte 8 (Hi)
4:0186 Arrival Count Local Downstream Zone 4:2904 I.Data [4]
Byte 9 (L
(Lo)
o)

Byte 10 (Hi)
4:0187 Departure Count Local Downstream Zone 4:2905 I.Data [5]
Byte 11 (L
(Lo)
o)

Byte 12 (Hi)
4:0088 Module Status Word 1 4:2906 I.Data [6]
Byte 13 (L
(Lo)
o)

Byte 14 (Hi)
4:0089 Module Status Word 2 4:2907 I.Data [7]
Byte 15 (L
(Lo)
o)

Byte 16 (Hi)
4:0105 Current Release Count for Upstream Zone 4:2908 I.Data [8]
Byte 17 (L
(Lo)
o)

Byte 18 (Hi)
4:0185 Current Release Count for Downstream Zone 4:2909 I.Data [9]
Byte 19 (L
(Lo)
o)

Byte 20 (Hi)
4:0035 Sensor & Control Port Inputs 4:2910 I.Data [10]
Byte 21 (L
(Lo)
o)

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Byte 22 (Hi)
Reserved 4:2911 I.Data [11]
Byte 23 (L
(Lo)
o)

ZP
ZPA
A Mode Outputs fr
from
om PLC
Assembled Assembled Assembled
Module
Register Name Modbus EIP Profinet
Addr
ddress
ess
Addr
ddress
ess Addr
ddress
ess Addr
ddress
ess

Byte 0 (Hi)
4:0104 Accumulation Control for Local Upstream Zone 4:3000 O.Data [0]
Byte 1 (L
(Lo)
o)

Accumulation Control for Local Downstream Byte 2 (Hi)

4:0184 4:3001 O.Data [1]
Zone Byte 3 (L
(Lo)
o)

Byte 4 (Hi)
4:0040 Set Left MDR Speed 4:3002 O.Data [2]
Byte 5 (L
(Lo)
o)

Byte 6 (Hi)
4:0064 Set Right MDR Speed 4:3003 O.Data [3]
Byte 7 (L
(Lo)
o)

Release and Accumulate on Next Arrival for Byte 8 (Hi)

4:0105 4:3004 O.Data [4]
Local Upstream Zone Byte 9 (L
(Lo)
o)

Release and Accumulate on Next Arrival for Byte 10 (Hi)

4:0185 4:3005 O.Data [5]
Local Downstream Zone Byte 11 (L
(Lo)
o)

Byte 12 (Hi)
4:0134 Set Status for Upstream Induct 4:3006 O.Data [6]
Byte 13 (L
(Lo)
o)

Byte 14 (Hi)
4:0232 Set Status for Downstream Discharge 4:3007 O.Data [7]
Byte 15 (L
(Lo)
o)

Byte 16 (Hi)
4:0022 Clear Motor Error 4:3008 O.Data [8]
Byte 17 (L
(Lo)
o)

Byte 18 (Hi)
4:0063 Set Control Port Outputs 4:3009 O.Data [9]
Byte 19 (L
(Lo)
o)

O.Data Byte 20 (Hi)

Reserved 4:3010
[10] Byte 21 (L
(Lo)
o)

Clear Sensor Jam Command for Local O.Data Byte 22 (Hi)

4:0109 4:3011
Upstream Zone [11] Byte 23 (L
(Lo)
o)

Clear Sensor Jam Command for Local O.Data Byte 24 (Hi)

4:0189 4:3012
Downstream Zone [12] Byte 25 (L
(Lo)
o)

4:0365 Direction & Accumulation Mode Control for 4:3013 O.Data Byte 26 (Hi)

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Local Upstream Zone [13] Byte 27 (L

(Lo)
o)

Direction & Accumulation Mode Control for O.Data Byte 28 (Hi)

4:0375 4:3014
Local Downstream Zone [14] Byte 29 (L
(Lo)
o)

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11.4. PLC I/O Mode Contr

Control
ol
When an ConveyLinx Module is in PLC I/O mode, all automatic functions of detecting loads and
running motors are suspended by the local ConveyLinx Module’s on-board logic and the
external controller must explicitly read inputs and write data output to cause motors to run.
The following items are available for external controller when the ConveyLinx Module is in PLC
I/O Mode:

• Status of all available digital inputs on Sensor and Control ports (8 total inputs)
• Module voltage reading
• Left and Right motor status of frequency, current, and calculated temperature
• Left and Right motor diagnostic error status word
• Control of Control Port digital outputs
• Ability to independently run both Left and Right motors
• Ability to set speed, acceleration, deceleration, PI Mode, and Braking method for Left and
Right motors
• Ability to configure one or both motor ports to digital output mode
• Ability to remotely clear fatal motor error condition
• Ability to instruct module to stop motor outputs
• Ability to interface with upstream and downstream ZPA modules for status and tracking

* When an ERSC is placed in PLC I/O mode; it suspends all of its internal ZPA logic
control. Any sensors or motors connected to the ERSC require explicit interaction
with an external controller. The external controller will have typical Ethernet-
based remote I/O performance from an ERSC when in PLC I/O mode

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11.4.1. Setting PLC I/O Mode in EasyR

EasyRoll
oll
Individual ERSC’s must be placed into PLC I/O Mode from the EasyR
EasyRoll
oll software tool. This is
done by invoking the Advanced Dialog and using the Connections tab

From the main screen, first enter the

correct Subnet into the “Network IP”
boxes and the correct Node you want
to connect. Invoke the ConveyLinx
Advanced Dialog and select the
Connections tab. Note that the Node
is being viewed is in the center and it
is greyed out. Select the “PLC I/O
Controlled” checkbox. With this
checked the “Clear Connections”
checkbox becomes enabled. Check or
Uncheck the ““Clear
Clear Connections”
checkbo
checkbox x depending upon your
application
application. Click “Apply” to initiate
the change. The ERSC will restart and
this may take several seconds to
complete

! IMPORTANT NOTE: Once a given ERSC has been placed in PLC I/O mode, the ONLY
way to return it to ZPA mode is to perform an Auto-Configuration procedure or
Restore from a backup file with EasyRoll. There is no “undo” or “reset” function
for this action

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11.4.2. Optional Clear Connections Choice

The decision to “Clear Connections” is based upon the application. When a string of ERSC
modules are Auto-Configured, each successive ERSC in the string establishes a logical
upstream / downstream connection with its neighbor ERSC’s. These connections provide the
basis for the logical flow of inter-module status data for ZPA functionality. However, if a single
ERSC node within a string of ZPA configured nodes needs to be utilized in PLC I/O mode, these
logical connections can remain in place and be used to PLC programmer’s advantage.

When You DO NOT Clear Connections

You

By NOT clearing the connections, the ERSC in PLC I/O will maintain its inter-module data
exchange. This could be advantageous for applications where you want to control a specialized
conveyor section such as a right angle transfer or merge conveyor with an ERSC in PLC I/O
mode. For example, if the PLC I/O mode ERSC is being either fed or feeds conveyors controlled
by ERSC’s in standard ZPA mode, these ERSC’s will populate PLC I/O configured module’s
registers with their respective status data. Likewise, the PLC can manipulate the PLC I/O
configured module’s zone status registers and these registers will automatically be written to
the adjacent ERSC’s by virtue of these already established connections without requiring the
PLC to explicitly perform the messaging.

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When You DO Clear Connections

You

If you choose the option to “Clear Connections”, this automatic data transfer of status is
inhibited. This means that for an ERSC module in PLC I/O mode whose connections have been
cleared; its status registers are not automatically written to its adjacent neighbors. Clearing the
connections could be advantageous when utilizing several ERSC’s in a row configured as PLC I/
O where having this additional inter-module communication is not required and would only add
to unnecessary communication bandwidth usage.

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11.4.3. Configuring A
Action
ction for L
Loss
oss of
Communication
When changing the mode of a given ConveyLinx Module to PLC I/O mode in EasyRoll, you are
given the option to select the behavior of the ConveyLinx Module’s outputs upon loss of
communications with the PLC.

Select “Don’t Change” if you want

module’s logical outputs and MDR’s to
remain in the state they were in at the
time of the communication loss

Select “All OFF” to instruct the

ConveyLinx Module to turn off all
logical outputs and stop all MDR’s at
the time of communication loss.

Upon re-establishing communications

with the PLC, the ConveyLinx Module
will automatically resume having its
outputs and MDR’s controlled by PLC
command

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11.4.4. Lock PLC Mode

By default, anytime the Auto
Auto-Configuration
-Configuration procedure is performed, each ERSC on the network
is placed in ZP
ZPA
A Mode regardless of what mode it was in prior to the procedure. In certain
situations, such commissioning a larger system, you may need to perform the Auto-
Configuration procedure multiple times as you perhaps add to or modify your network. For
example, let’s say you need to add some more modules to the beginning of a network you have
already configured and this network has several modules in PLC I/O mode. When you perform
the Auto-Configuration procedure, not only will the I.P. address change for all of the existing
modules, but the modules previously in PLC I/O mode will revert back to ZPA mode. In order to
keep from having to individually go back and place those module back into PLC I/O mode, the
Lock PLC Mode checkbox allow you to lock the module into PLC I/.O mode so that if a new Auto-
Configuration procedure is performed, the module will stay in PLC I/O mode, even if it position
in the network (I.P. address) needs to change.

When you check the PLC I/O Mode

checkbox, the Lock PLC Mode
checkbox will enable. Once you click
“Apply” and the module is placed into
PLC I/O mode, it will also be locked so
that it will not go back into ZPA mode
upon an Auto
Auto-Configuration
-Configuration
procedure.

* To allow a locked module to able to be placed into ZP

ZPA
A Mode upon an Auto
Configuration procedure; you either need to uncheck the Lock PLC Mode
Auto--

checkbox and click “Apply” or perform a Reset to Factory Default Settings.

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11.4.5. Load ConveyL

ConveyLogix
ogix P
Prrogram
As a convenience, EasyRoll provides an easy way to download an already compiled
ConveyLogix program to one or mode modules without having to use the ConveyLogix
application. If you need to load the same identical program into multiple module in a range,
you can set the range at the top of the Advanced Dialog.

Clicking the button will open a file

selection dialog box. Select the
compiled ConveyLogix program file
(.bin). When you click “Apply”, the
compiled file will be downloaded to all
modules in the node range at the top
of the Advanced Dialog.

! Please note the ConveyLogix program file used in this dialog is the compiled
“.bin” file. It will not accept the ConveyLogix native “.clp” format source file.

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Clear ConveyL
ConveyLogix
ogix P
Prrogram and k
keep
eep PLC I/O Mode

With a module selected that currently

contains a ConveyLogix program,
check the “Delete PLC Program”
checkbox. When you click “Apply”, the
ConveyLogix program will be deleted
and the module will remain in PLC I/O
Mode

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11.4.6. 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
Assembled
Name /
Addr
ddress
ess for Links
Module
PLC
Addr
ddress
ess

M: 4:1700
E: I.Data[0]
ConveyStop
P: Byte 0 ConveyStop
Status Word
(Hi) Status
4:0019
Byte 1
(L
(Lo)
o)

M: 4:1701
Sensor & E: I.Data[1]
Control Port P: Byte 2 Sensor & Contr
Control
ol
Inputs (Hi) Ports
4:0035 Byte 3
(L
(Lo)
o)

M: 4:1702
E: I.Data[2]
Sensor
P: Byte 4 Sensor & Contr
Control
ol
Detect
(Hi) Ports
4:0036
Byte 5
(L
(Lo)
o)

M: 4:1703
E: I.Data[3]
Module
P: Byte 6 Sensor & Contr
Control
ol
Voltage
(Hi) Ports
4:0024
Byte 7
(L
(Lo)
o)

M: 4:1704
E: I.Data[4]
Left Motor
P: Byte 8
Current Lef
eftt Motor Status
(Hi)
4:0055
Byte 9
(L
(Lo)
o)

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M: 4:1705
E: I.Data[5]
Left Motor
P: Byte 10
Frequency Lef
eftt Motor Status
(Hi)
4:0056
Byte 11
(L
(Lo)
o)

M: 4:1706
E: I.Data[6]
Left Motor
P: Byte 12
Temperature Lef
eftt Motor Status
(Hi)
4:0057
Byte 13
(L
(Lo)
o)

M: 4:1707
E: I.Data[7]
Left Motor
P: Byte 14
Status Lef
eftt Motor Status
(Hi)
4:0058
Byte 15
(L
(Lo)
o)

M: 4:1708
E: I.Data[8]
Right Motor
P: Byte 16 Right Motor
Current
(Hi) Status
4:0079
Byte 17
(L
(Lo)
o)

M: 4:1709
E: I.Data[9]
Right Motor
P: Byte 18 Right Motor
Frequency
(Hi) Status
4:0080
Byte 19
(L
(Lo)
o)

M: 4:1710
E: I.Data[10]
Right Motor
P: Byte 20 Right Motor
Temperature
(Hi) Status
4:0081
Byte 21
(L
(Lo)
o)

M: 4:1711
Right Motor
E: I.Data[11] Right Motor
Status
P: Byte 22 Status
4:0082
(Hi)

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Byte 23
(L
(Lo)
o)

M: 4:1712
Left Motor E: I.Data[12]
Port Digital I/ P: Byte 24 Motor PPorts
orts
O Status (Hi) Digital Status
4:0060 Byte 25
(L
(Lo)
o)

M: 4:1713
Right Motor E: I.Data[13]
Port Digital I/ P: Byte 26 Motor PPorts
orts
O Status (Hi) Digital Status
4:0084 Byte 27
(L
(Lo)
o)

M: 4:1714
Upstream E: I.Data[14]
Upstr
Upstream
eam /
Module P: Byte 28
Downstr
Downstream
eam
Status (Hi)
Status & T
Tracking
racking
4:0134 Byte 29
(L
(Lo)
o)

M: 4:1715
Downstream E: I.Data[15]
Upstr
Upstream
eam /
Module P: Byte 30
Downstr
Downstream
eam
Status (Hi)
Status & T
Tracking
racking
4:0232 Byte 31
(L
(Lo)
o)

Current
M: 4:1716
Tracking
E: I.Data[16]
Word 1 for Upstr
Upstream
eam /
P: Byte 32
Adjacent Downstr
Downstream
eam
(Hi)
Upstream Status & T
Tracking
racking
Byte 33
Module
(L
(Lo)
o)
4:0139

Current
M: 4:1717
Tracking
E: I.Data[17]
Word 2 for Upstr
Upstream
eam /
P: Byte 34
Adjacent Downstr
Downstream
eam
(Hi)
Upstream Status & T
Tracking
racking
Byte 35
Module
(L
(Lo)
o)
4:0140

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M: 4:1718
Current
E: I.Data[18]
Module Upstr
Upstream
eam /
P: Byte 36
Reset Downstr
Downstream
eam
(Hi)
Counter Status & T
Tracking
racking
Byte 37
N/A
(L
(Lo)
o)

M: 4:1719
Left Motor E: I.Data[19]
Servo P: Byte 38 Servo Contr
Control
ol
Position (Hi) Status
4:0062 Byte 39
(L
(Lo)
o)

M: 4:1720
Right Motor E: I.Data[20]
Servo P: Byte 40 Servo Contr
Control
ol
Position (Hi) Status
4:0086 Byte 41
(L
(Lo)
o)

M: 4:1721
E: I.Data[21]
Left Motor
P: Byte 42 Servo Contr
Control
ol
Servo Status
(Hi) Status
4:0011
Byte 43
(L
(Lo)
o)

M: 4:1722
E: I.Data[22]
Right Motor
P: Byte 44 Servo Contr
Control
ol
Servo Status
(Hi) Status
4:0016
Byte 45
(L
(Lo)
o)

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11.4.6.1. ConveyStop Status

Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Bitwise Value – Read Only:

bit 0 – 4 Reserved
bit 5 = Stop active on another module in Stop Group
M: 4:1700 bit 6 = Stop active due to lost communication
ConveyStop
E: I.Data [0] connection
Status Word
P: Byte 0 (Hi) bit 7 = Stop active due to lost PLC connection
4:0019
Byte 1 (L
(Lo)
o) bit 8 = Stop active on local module’s Left Control Port
bit 9 = Stop active on local module’s Right Control Port
bit 10 = Stop active due to Stop Command from PLC
bit 11 – 15 Reserved

* Refer to Pulseroller publication ERSC-1800 ConveyStop User’s Guide for details

on using ConveyStop

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11.4.6.2. Sensor & Contr

Control
ol P
Ports
orts
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Bitwise Value – Read Only

bit 0 = Left Sensor Port – Pin 3
bit 1 = Left Control Port – Pin 3
bit 2 = Right Sensor Port – Pin 3
M: 4:1701
Sensor & Control bit 3 = Right Control Port – Pin 3
E: I.Data [1]
Port Inputs bit 4 = Left Sensor Port – Pin 4
P: Byte 2 (Hi)
4:0035 bit 5 = Left Control Port – Pin 4
Byte 3 (L
(Lo)
o)
bit 6 = Right Sensor Port – Pin 4
bit 7 = Right Control Port – Pin 4
bit bit 8 – 14 Reserved
bit 15 = 2 sec on / 2 sec off heartbeat

M: 4:1702
Bitwise Value – Read Only
Sensor Detect E: I.Data [2]
bit 0 = Device is connected to Right Sensor Port
4:0036 P: Byte 4 (Hi)
bit 1 = Device is connected to Left Sensor Port
Byte 5 (L
(Lo)
o)

M: 4:1703
Value in mV of Module Power Supply
Module Voltage E: I.Data [3]
Range: 0 to 35000
4:0024 P: Byte 6 (Hi)
Example: 23500 = 23.5 Volts
Byte 7 (L
(Lo)
o)

* The electrical logic state of the signal on the Sensor/Control Port pins are bit-wise
exclusive OR (XOR) with the bits set in the Sensor & Contr
Control
ol P
Port
ort Input Signal
Condition Mask register to arrive at the bit values seen in the Sensor & Contr Control
ol
Port Inputs register. This allows the PLC programmer to control whether an
electrically energized condition results in a logical 1 or a logical 0 in the Sensor &
Contr
Control
ol P
Port
ort Inputs register. This same relationship is also mirrored by the state
of the input’s corresponding LED indicator

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11.4.6.3. Lef
eftt Motor Status
Register Name /
Assembled A
Addr
ddress
ess for PLC Description
Module AAddr
ddress
ess

M: 4:1704
Left Motor Integer Value in mA for the current the motor is
E: I.Data [4]
Current drawing
P: Byte 8 (Hi)
4:0055 Example: 1900 = 1.9 Amps
Byte 9 (L
(Lo)
o)

M: 4:1705
Left Motor Integer value in Hz for the electrical frequency
E: I.Data [5]
Frequency the motor is running
P: Byte 10 (Hi)
4:0056 Example: 300 = 300 Hz
Byte 11 (L
(Lo)
o)

M: 4:1706 High Byte / Low Byte of temperatures in °C

Left Motor
E: I.Data [6] High Byte = Calculated motor temperature
Temperature
P: Byte 12 (Hi) Low Byte = Temperature reading from the on
4:0057
Byte 13 (L
(Lo)
o) board sensor

Bitwise Value – Read Only:

bit 0 = Motor Rotation Status
bit 1 = Motor Rotation Status
bit 2 = Port in Digital Mode
bit 3 = Reserved
bit 4 = Reserved
bit 5 = Board Overheat
M: 4:1707
bit 6 = Over-voltage
Left Motor Status E: I.Data [7]
bit 7 = Low Voltage
4:0058 P: Byte 14 (Hi)
bit 8 = Over-heated
Byte 15 (L
(Lo)
o)
bit 9 = Over-current
bit 10 = Short Circuit
bit 11 = Motor Not Connected
bit 12 = Overloaded
bit 13 = Stalled
bit 14 = Sensor Error
bit 15 = Motor Not Used

Motor R
Rotation
otation Status

Bits 0 and 1 are used in combination to provide 4 possible states. The following chart defines
the bit values for these states:

Bit 1 Bit 0 Description

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0 0 Motor not running, Normal or Servo Braking Mode applied

0 1 Motor running in CCW Direction

1 0 Motor running in CW Direction

1 1 Motor not running and Free Braking Mode applied

Motor F
Frrequency

This contains the current value of the electrical frequency of the motor if it is running. For
Senergy motors, electrical frequency divided by 5 = mechanical frequency. The mechanical
frequency is the number of motor rotations per second. You can use this value along with the
mechanical gear ratio of the gearbox to calculate the actual running motor RPM. Please consult
your Pulseroller catalog for the gear ratio value for the particular part number you are using.

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11.4.6.4. Right Motor Status

Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

M: 4:1708
Right Motor
E: I.Data [8] Integer Value in mA for the current the motor is drawing
Current
P: Byte 16 (Hi) Example: 1900 = 1.9 Amps
4:0079
Byte 17 (L
(Lo)
o)

M: 4:1709
Right Motor Integer value in Hz for the electrical frequency the motor
E: I.Data [9]
Frequency is running
P: Byte 18 (Hi)
4:0080 Example: 300 = 300 Hz
Byte 19 (L
(Lo)
o)

High Byte / Low Byte of temperatures in °C

M: 4:1710
Right Motor
E: I.Data [10]
Temperature High Byte = Calculated motor temperature
P: Byte 20 (Hi)
4:0081 Low Byte = Temperature reading from the on board
Byte 21 (L
(Lo)
o)
sensor

Bitwise Value – Read Only:

bit 0 = Motor Rotation Status
bit 1 = Motor Rotation Status
bit 2 = Port in Digital Mode
bit 3 = Reserved
bit 4 = Reserved
bit 5 = Board Overheat
M: 4:1711
Right Motor bit 6 = Over-voltage
E: I.Data [11]
Status bit 7 = Low Voltage
P: Byte 22 (Hi)
4:0082 bit 8 = Over-heated
Byte 23 (L
(Lo)
o)
bit 9 = Over-current
bit 10 = Short Circuit
bit 11 = Motor Not Connected
bit 12 = Overloaded
bit 13 = Stalled
bit 14 = Sensor Error
bit 15 = Motor Not Used

Motor R
Rotation
otation Status

Motor F
Frrequency

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11.4.6.5. Motor P
Ports
orts Digital Status
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

M: 4:1712
Left Motor Port
E: I.Data [12]
Digital I/O Status Bitwise Value – Read Only:
P: Byte 24 (Hi)
4:0060
Byte 25 (L
(Lo)
o)
bit 12 = Short Circuit Error on one or more outputs
M: 4:1713 bit 14 = Over Current – More than 1A detected on
Right Motor Port
E: I.Data [13] one or more outputs
Digital I/O Status
P: Byte 26 (Hi)
4:0084
Byte 27 (L
(Lo)
o)

How to wire Motor Port for Digital Output Control

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11.4.6.6. Upstr
Upstream
eam / Downstr
Downstream
eam Status &
Tracking
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

M: 4:1714 Interger Value of Low or High Byte:

Upstream Module
E: I.Data [14]
Status
P: Byte 28 (Hi) 0×01 = Zone sensor clear and motor stopped
4:0134
Byte 29 (L
(Lo)
o) 0×02 = Zone sensor clear, motor running, accepting
from upstream zone
M: 4:1715 0×04 = Zone sensor blocked, motor running,
Downstream discharging
E: I.Data [15]
Module Status to downstream zone
P: Byte 30 (Hi)
4:0232 0×05 = Zone sensor blocked and motor stopped
Byte 31 (L
(Lo)
o)
0×06 = Busy (state during ConveyStop active mode)

Current Tracking
M: 4:1716
Word 1 for Value = Tracking data word #1 (16-bit integer) for the
E: I.Data [16]
Adjacent Carton that has just discharged from the ERSC Adjacent
P: Byte 32 (Hi)
Upstream Module to this local ERSC module
Byte 33 (L
(Lo)
o)
4:0139

Current Tracking
M: 4:1717
Word 2 for Value = Tracking data word #2 (16-bit integer) for the
E: I.Data [17]
Adjacent Carton that has just discharged from the ERSC Adjacent
P: Byte 34 (Hi)
Upstream Module to this local ERSC module
Byte 35 (L
(Lo)
o)
4:0140

M: 4:1718
E: I.Data [18]
Reserved
P: Byte 36 (Hi)
Byte 37 (L
(Lo)
o)

Understanding A
Adjacent
djacent Modules

These registers only contain meaningful data if the ConveyLinx connections between upstream
and/or downstream ERSC’s are preserved when placing the local ERSC into PLC I/O mode from
within EasyRoll. If connections are cleared in EasyRoll, these registers will not contain any
pertinent data and will not be updated by adjacent ERSC’s. Learn about clearing connections.

Page 344 of 557

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11.4.6.7. Servo Contr

Control
ol Status
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

M: 4:1719
Left Motor Servo
E: I.Data [19] Signed integer value that indicates the current position of
Position
P: Byte 38 (Hi) the Left Motor in relation to its “0” position
4:0062
Byte 39 (L
(Lo)
o)

M: 4:1720
Right Motor Servo
E: I.Data [20] Signed integer value that indicates the current position of
Position
P: Byte 40 (Hi) the Right Motor in relation to its “0” position
4:0086
Byte 41 (L
(Lo)
o)

M: 4:1721 Bit 0: Servo Command Status

Left Motor Servo
E: I.Data [21] 1 = Last Servo Run Command Complete
Status
P: Byte 42 (Hi) 0 = Servo Command in Process
4:0011
Byte 43 (L
(Lo)
o)
Bit 1: Servo Reset Status
M: 4:1722 Echoes state of Motor Servo Command bit 0
Right Motor Servo
E: I.Data [22]
Status
P: Byte 44 (Hi) Bit 2: Servo Command Status
4:0016
Byte 45 (L
(Lo)
o) Echoes state of Motor Servo Command bit 1

See Servo Move example

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PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.4.7. 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
Assembled
Name /
Addr
ddress
ess for Links
Module
PLC
Addr
ddress
ess

M: 4:1800
E:
ConveyStop O.Data[0] ConveyStop
Command P: Byte 0 Command & Clear
4:0020 (Hi) Motor Er
Errror
Byte 1
(L
(Lo)
o)

M: 4:1801
E:
Set Left Motor
O.Data[1]
Port Digital Motor & Contr
Control
ol P
Port
ort
P: Byte 2
Control Digital Output
(Hi)
4:0060
Byte 3
(L
(Lo)
o)

M: 4:1802
E:
Set Right
O.Data[2]
Motor Port Motor & Contr
Control
ol P
Port
ort
P: Byte 4
Digital Control Digital Output
(Hi)
4:0084
Byte 5
(L
(Lo)
o)

M: 4:1803
E:
Control Port
O.Data[3]
Digital Output Motor & Contr
Control
ol P
Port
ort
P: Byte 6
Control Digital Output
(Hi)
4:0037
Byte 7
(L
(Lo)
o)

Left Motor M: 4:1804

Run / Reverse E: Lef
eftt Motor Contr
Control
ol
4:0260 O.Data[4]

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P: Byte 8
(Hi)
Byte 9
(L
(Lo)
o)

M: 4:1805
E:
Left Motor O.Data[5]
Brake Method P: Byte 10 Lef
eftt Motor Contr
Control
ol
4:0261 (Hi)
Byte 11
(L
(Lo)
o)

M: 4:1806
E:
Left Motor
O.Data[6]
Speed Control
P: Byte 12 Lef
eftt Motor Contr
Control
ol
Method
(Hi)
4:0262
Byte 13
(L
(Lo)
o)

M: 4:1807
E:
Right Motor O.Data[7]
Run / Reverse P: Byte 14 Right Motor Contr
Control
ol
4:0270 (Hi)
Byte 15
(L
(Lo)
o)

M: 4:1808
E:
Right Motor O.Data[8]
Brake Method P: Byte 16 Right Motor Contr
Control
ol
4:0271 (Hi)
Byte 17
(L
(Lo)
o)

M: 4:1809
E:
Right Motor
O.Data[9]
Speed Control
P: Byte 18 Right Motor Contr
Control
ol
Method
(Hi)
4:0272
Byte 19
(L
(Lo)
o)

Left Motor M: 4:1810 Lef

eftt Motor Contr
Control
ol

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PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

E:
O.Data[10]
Speed
P: Byte 20
Reference
(Hi)
4:0040
Byte 21
(L
(Lo)
o)

M: 4:1811
E:
Right Motor
O.Data[11]
Speed
P: Byte 22 Right Motor Contr
Control
ol
Reference
(Hi)
4:0064
Byte 23
(L
(Lo)
o)

M: 4:1812
E:
Left Motor
O.Data[12]
Acceleration
P: Byte 24 Lef
eftt Motor Contr
Control
ol
Ramp
(Hi)
4:0043
Byte 25
(L
(Lo)
o)

M: 4:1813
E:
Left Motor
O.Data[13]
Deceleration
P: Byte 26 Lef
eftt Motor Contr
Control
ol
Ramp
(Hi)
4:0044
Byte 27
(L
(Lo)
o)

M: 4:1814
E:
Right Motor
O.Data[14]
Acceleration
P: Byte 28 Right Motor Contr
Control
ol
Ramp
(Hi)
4:0067
Byte 29
(L
(Lo)
o)

M: 4:1815
E:
Right Motor
O.Data[15]
Deceleration
P: Byte 30 Right Motor Contr
Control
ol
Ramp
(Hi)
4:0068
Byte 31
(L
(Lo)
o)

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PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

M: 4:1816
E:
Clear Motor O.Data[16] ConveyStop
Error P: Byte 32 Command & Clear
4:0022 (Hi) Motor Er
Errror
Byte 33
(L
(Lo)
o)

M: 4:1817
E:
Set Status to
O.Data[17]
Downstream
P: Byte 34 Set Status & T
Tracking
racking
Module
(Hi)
4:0196
Byte 35
(L
(Lo)
o)

M: 4:1818
E:
Set Status to
O.Data[18]
Upstream
P: Byte 36 Set Status & T
Tracking
racking
Module
(Hi)
4:0116
Byte 37
(L
(Lo)
o)

M: 4:1819
Sensor Port E:
Input Signal O.Data[19]
Set Sensor & Contr
Control
ol
Condition P: Byte 38
Port Input Mask
Mask (Hi)
4:0034 Byte 39
(L
(Lo)
o)

M: 4:1820
E:
Set Discharge
O.Data[20]
Tracking Word
P: Byte 40 Set Status & T
Tracking
racking
1
(Hi)
4:0201
Byte 41
(L
(Lo)
o)

M: 4:1821
Set Discharge E:
Tracking Word O.Data[21]
Set Status & T
Tracking
racking
2 P: Byte 42
4:0202 (Hi)
Byte 43

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PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

(L
(Lo)
o)

M: 4:1822
E:
Set Module O.Data[22]
Reset Count P: Byte 44
N/A (Hi)
Byte 45
(L
(Lo)
o)

M: 4:1823
Left Motor E:
Servo O.Data[23]
Command P: Byte 46 Servo Contr
Control
ol
Pulses (Hi)
4:0008 Byte 47
(L
(Lo)
o)

M: 4:1824
Left Motor E:
Servo O.Data[24]
Command P: Byte 48 Servo Contr
Control
ol
Word (Hi)
4:0009 Byte 49
(L
(Lo)
o)

M: 4:1825
Right Motor E:
Servo O.Data[25]
Command P: Byte 50 Servo Contr
Control
ol
Pulses (Hi)
4:0013 Byte 51
(L
(Lo)
o)

M: 4:1826
Right Motor E:
Servo O.Data[26]
Command P: Byte 52 Servo Contr
Control
ol
Word (Hi)
4:0014 Byte 53
(L
(Lo)
o)

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PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.4.7.1. ConveyStop Command & Clear

Motor Er
Errror
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Integer Value
M: 4:1800 0= No Command
ConveyStop
E: O
O.Data
.Data [0] 1 = Command local module’s Stop Group to go to
Command Word
P: Byte 0 (Hi) Stopped State
4:0020
Byte 1 (L
(Lo)
o) 2 = Command local module’s Stop Group to Clear
Stopped State

M: 4:1816
Logical 1 or 0:
Clear Motor Error E: O
O.Data
.Data [16]
1 = send reset command
4:0022 P: Byte 32 (Hi)
0 = clear reset command
Byte 33 (L
(Lo)
o)

* Refer to Pulseroller publication ERSC-1800 ConveyStop User’s Guide for details

on using ConveyStop

Learn more about Clear Motor Error

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11.4.7.2. Motor & Contr

Control
ol P
Port
ort Digital
Output
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Set Left Motor M: 4:1801 Bitwise value – “1” Energizes Output:

Port Digital E: O
O.Data
.Data [1] bit 0 = Motor Port Pin 3
Control P: Byte 2 (Hi) bit 1 = Motor Port Pin 4
4:0060 Byte 3 (L
(Lo)
o) bit 2 = Motor Port Pin 5
bit 3 thru bit 5 = Reserved
bit 6 = Brake Output Pin 9
bit 7 = Enable Brake Pin 9 when Motor Port is NOT in
Set Right Motor M: 4:1802 Digital mode
Port Digital E: O
O.Data
.Data [2] bit 8 = Clear over-current error
Control P: Byte 4 (Hi) bit 9 thru 14 = Reserved
4:0048 Byte 5 (L
(Lo)
o) bit 15 = Digital Output Enable
0 = Use Port as Motor Control
1 = Use Port as Digital Outputs

Bitwise Value – “1” Energizes Output:

Control Port M: 4:1803 bit 0 = bit 0 = Reserved
Digital Output E: O
O.Data
.Data [3] bit 1 = Left Control Port
Control P: Byte 6 (Hi) bit 2 = Reserved
4:0037 Byte 7 (L
(Lo)
o) bit 3 = Right Control Port
All other bits reserved

Learn more about using Motor Ports for Digital Outputs

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11.4.7.3. Lef
eftt Motor Contr
Control
ol
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Bit 0:
M: 4:1804 1= Run Command
Left Motor Run /
E: O
O.Data
.Data [4] 0= Stop Command
Reverse
P: Byte 8 (Hi) Bit 8:
4:0260
Byte 9 (L
(Lo)
o) 0= Run in Configured Direction
1= Run opposite of Configured Direction

Integer Value:
M: 4:1805 1 = Use Standard Brake Method
Left Motor Brake
E: O
O.Data
.Data [5] 2 = Use Free Coast Brake Method
Method
P: Byte 10 (Hi) 3 = Use Servo 1 Brake Method
4:0261
Byte 11 (L
(Lo)
o) 4 = Use Servo 2 Brake Method
0 = Remain at last configured or last value entered

Low Byte Value:

0 = Remain at last configured or last value entered
1 = Use Open Loop
M: 4:1806 2 = Use Closed Loop
Left Motor Speed
E: O
O.Data
.Data [6] Hi Byte Value (requires FW 4.27/5.07 or later):
Control Method
P: Byte 12 (Hi) 0 = Ignore
4:0262
Byte 13 (L
(Lo)
o) 1 = Independent Control
2 = Slave Mode ON, Left motor mirrors Right motor
3 = Slave Mode ON, Left motor runs opposite direction
of Right motor

M: 4:1810 Value in % PWM:

Left Motor Speed
E: O
O.Data
.Data [10] Range: 0 to 1000
Reference
P: Byte 20 (Hi) Example: 400 = 40%
4:0040
Byte 21 (L
(Lo)
o) 0 = Remain at last non zero value entered

M: 4:1812 When Speed Control Method is in Open Loop:

Left Motor
E: O
O.Data
.Data [12] Value in milliseconds
Acceleration
P: Byte 24 (Hi) Range: 0 to 10000 (Deceleration)
4:0043
Byte 25 (L
(Lo)
o) Range: 30 to 10000 (Acceleration)
Example: 900 = 0.9 sec
M: 4:1813
Left Motor When Speed Control Method is in Closed Loop:
E: O
O.Data
.Data [13]
Deceleration Value in motor pulses
P: Byte 26 (Hi)
4:0044 Range: 0 to 10000 (Deceleration)
Byte 27 (L
(Lo)
o)
Range: 30 to 10000 (Acceleration)

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For Either Open or Closed Loop

0 = Remain at last non-zero value entered

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11.4.7.4. Right Motor Contr

Control
ol
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Bit 0:
M: 4:1807 1= Run Command
Right Motor Run /
E: O
O.Data
.Data [7] 0= Stop Command
Reverse
P: Byte 14 (Hi) Bit 8:
4:0270
Byte 15 (L
(Lo)
o) 0= Run in Configured Direction
1= Run opposite of Configured Direction

Integer Value:
M: 4:1808 1 = Use Standard Brake Method
Right Motor Brake
E: O
O.Data
.Data [8] 2 = Use Free Coast Brake Method
Method
P: Byte 16 (Hi) 3 = Use Servo 1 Brake Method
4:0271
Byte 17 (L
(Lo)
o) 4 = Use Servo 2 Brake Method
0 = Remain at last configured or last value entered

Low Byte Value:

0 = Remain at last configured or last value entered
1 = Use Open Loop
Right Motor M: 4:1809 2 = Use Closed Loop
Speed Control E: O
O.Data
.Data [9] Hi Byte Value (requires FW 4.27/5.07 or later):
Method P: Byte 18 (Hi) 0 = Ignore
4:0272 Byte 19 (L
(Lo)
o) 1 = Independent Control
2 = Slave Mode ON, Right motor mirrors Left motor
3 = Slave Mode ON, Right motor runs opposite
direction of Left motor

M: 4:1811 Value in % PWM:

Right Motor
E: O
O.Data
.Data [11] Range: 0 to 1000
Speed Reference
P: Byte 22 (Hi) Example: 400 = 40%
4:0064
Byte 23 (L
(Lo)
o) 0 = Remain at last non zero value entered

M: 4:1814 When Speed Control Method is in Open Loop:

Right Motor
E: O
O.Data
.Data [14] Value in milliseconds
Acceleration
P: Byte 28 (Hi) Range: 0 to 10000 (Deceleration)
4:0067
Byte 29 (L
(Lo)
o) Range: 30 to 10000 (Acceleration)
Example: 900 = 0.9 sec
M: 4:1815
Right Motor When Speed Control Method is in Closed Loop:
E: O
O.Data
.Data [15]
Deceleration Value in motor pulses
P: Byte 30 (Hi)
4:0068 Range: 0 to 10000 (Deceleration)
Byte 31 (L
(Lo)
o)
Range: 30 to 10000 (Acceleration)

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For Either Open or Closed Loop

0 = Remain at last non-zero value entered

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11.4.7.5. Set Status & T

Tracking
racking
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Used to write ConveyLinx Module ZPA Status to

Downstream ERSC:

Set Status to M: 4:1817 4 = Instruct Downstream ConveyLinx Module to

Downstream E: O
O.Data
.Data [17] “wake-up” and run its most upstream zone
Module P: Byte 34 (Hi)
4:0196 Byte 35 (L
(Lo)
o) 1 = Instructs Downstream ConveyLinx Module that
carton has exited local zone and to accept any
tracking data written in Set Discharge Tracking Word 1
/ Word 2 registers when carton arrives

Used to write ConveyLinx Module’s ZPA Status to

Upstream ConveyLinx Module:

M: 4:1818 5 = Instructs Upstream ConveyLinx Module’s

Set Status to
E: O
O.Data
.Data [18] discharge zone to accumulate and hold any carton
Upstream Module
P: Byte 36 (Hi) that arrives at its discharge zone.
4:0116
Byte 37 (L
(Lo)
o)
1 = Instructs Upstream ConveyLinx Module’s
discharge zone to release any carton that arrives at
its discharge zone

M: 4:1820
Set Discharge
E: O
O.Data
.Data [20]
Tracking Word 1
P: Byte 40 (Hi) Only used when local PLC I/O Mode ConveyLinx Module
4:0201
Byte 41 (L
(Lo)
o) needs to pass tracking data to a downstream connected
M: 4:1821 ConveyLinx Module. Used in conjunction with Set Status
Set Discharge to Downstream Module register
E: O
O.Data
.Data [21]
Tracking Word 2
P: Byte 42 (Hi)
4:0202
Byte 43 (L
(Lo)
o)

M: 4:1822
E: O
O.Data
.Data [22]
Reserved
P: Byte 44 (Hi)
Byte 45 (L
(Lo)
o)

* For registers involving status and tracking to upstream or downstream

ConveyLinx Module’s that are in ZPA mode, the connections must NOT be cleared
when placing this ConveyLinx Module into PLC I/O mode from within EasyRoll.

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Learn more about Clearing Connection Options

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11.4.7.6. Set Sensor & Contr

Control
ol P
Port
ort Input
Mask
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Bitwise Value:
bit 00 = Left Sensor Port – Pin 3
bit 01 = Left Control Port – Pin 3
Sensor Port Input M: 4:1819 bit 02 = Right Sensor Port – Pin 3
Signal Condition E: O
O.Data
.Data [19] bit 03 = Right Control Port – Pin 3
Mask P: Byte 38 (Hi) bit 04 = Left Sensor Port – Pin 4
4:0034 Byte 39 (L
(Lo)
o) bit 05 = Left Control Port – Pin 4
bit 06 = Right Sensor Port – Pin 4
bit 07 = Right Control Port – Pin 4
bit 08 thru bit 15 = Reserved

How Input signals ar

are
e conditioned in ZP
ZPA
A Mode

For an ConveyLinx Module in standard ZPA mode, the Auto-Configuration procedure sets values
in this register to allow the ConveyLinx Module to correctly display the Sensor and Control port
Input circuit LEDs to facilitate diagnostics. This is done, for example, to make visual LED
diagnostics the same for “zone blocked” regardless of the sensor type.
For example, suppose the zone photo sensors used are “Light Operate, Normally Open”. This
means that the sensor’s output is energizing the ConveyLinx Module’s sensor input pin 4 when
the zone is clear. The ConveyLinx Module’s Sensor port LED indicator for pin 4 (green) should
illuminate when the zone is blocked; so the Auto-Configuration procedure sets a bit in the
Sensor & Contr
Control
ol P
Port
ort Input Signal Condition Mask register to correspond to the pin 4 signal on
the appropriate sensor port. If the sensor is electrically opposite such that its output energizes
pin 4 of the sensor port when the zone is blocked, then the bit corresponding to pin 4 for this
sensor port is clear such that the sensor port’s LED illuminates green when pin 4 is energized.

How Input signals ar

are
e conditioned in PLC I/O Mode

When an ConveyLinx Module is placed in PLC I/O mode; the Sensor & Control Port Input Signal
Condition Mask register is cleared of the values set during the Auto-Configure procedure. The
Sensor & Control Port Input Signal Condition Mask register is made available for PLC I/O mode
Sensor and Control port inputs to give the PLC programmer the same flexibility for configuring
which electrical state (on or off) of the input will cause a logical 1 to appear in the Sensor &
Control Port Inputs register and illuminate the pin’s corresponding LED. By setting or clearing
the corresponding bit for a given port’s pin 3 or 4 signal, the PLC programmer can determine

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which physical state (on or off) of the input signal will cause its corresponding pin’s bit in the
Sensor & Control Port Inputs register to be set and its corresponding LED to illuminate. The
following are two examples that show the bit patterns and signals for one of the ConveyLinx
Module’s inputs. The same pattern applies to all 8 available ERSC inputs:

Example: Right Sensor P

Port
ort – P
Pin
in 4 Signal

Sensor & Contr

Controlol
Sensor & Contr
Control
ol P
Port
ort Input Signal
Electrical Signal Port Inputs LED State
Condition Mask Register bit 6
Register bit 6

OFF 0 0 Green = OFF

ON 0 1 Green = ON

OFF 1 1 Green = ON

ON 1 0 Green = OFF

Example: L
Lef
eftt Contr
Control
ol P
Port
ort – P
Pin
in 3 Signal

Sensor & Contr

Controlol
Sensor & Contr
Control
ol P
Port
ort Input Signal
Electrical Signal Port Inputs LED State
Condition Mask Register bit 1
Register bit 1

OFF 0 0 Red = OFF

ON 0 1 Red = ON

OFF 1 1 Red = ON

ON 1 0 Red = OFF

! Be careful when changing the Sensor & Control Port Input Signal Condition
Mask in your Ethernet I/P PLC program. The input bit values in the Sensor &
Control Port Inputs register can show unexpected or opposite values from
expected until the PLC has updated the Sensor & Control Port Input Signal
Condition Mask data. This update could take several program scans
depending upon the Ethernet IP RPI settings. Take care to be sure that the
Sensor & Control Port Input Signal Condition Mask data is written to the ERSC
Before acting on any input values in the Sensor & Control Port Inputs register

* Please note that the Sensor/Control Port LEDs are tri-colored. In applications
where both Pin 4 and Pin 3 are used on the same Sensor/Control Port; when
the green and red LEDs are illuminated at the same time, the color will be
amber

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11.4.7.7. Servo Contr

Control
ol
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

M: 4:1824
Left Motor Servo Bit 0: Reset Command
E: O
O.Data
.Data [24]
Command Word 1 = Set Current Pulse Count to “0”
P: Byte 48 (Hi)
4:0009
Byte 49 (L
(Lo)
o)
Bit 1: Servo Run Command
M: 4:1826 1 = Run in Motor from current pulse count to set
Right Motor Servo
E: O
O.Data
.Data [26] pulse count in Left Motor Servo Command
Command Word
P: Byte 52 (Hi) Pulses Register
4:0014
Byte 53 (L
(Lo)
o)

M: 4:1823
Left Motor Servo
E: O
O.Data
.Data [23]
Command Pulses
P: Byte 46 (Hi) Signed integer value in motor pulses of the position to
4:0008
Byte 47 (L
(Lo)
o) move to on the next Servo Run Command
M: 4:1825
Right Motor Servo Valid values are from -32767 to +32767
E: O
O.Data
.Data [25]
Command Pulses
P: Byte 50 (Hi)
4:0013
Byte 51 (L
(Lo)
o)

! Servo Motor Control requires ConveyLinx firmware 4.14 or later

! Servo Control functionality requires that the Closed Loop option be enabled for
the motor port in question. This can be done either by selecting the check box in
EasyRoll or using the PLC to write a value of “2” in the appropriate Motor Speed
Control register for the motor in question

* The Servo Motor Control function utilizes the existing motor speed, acceleration,
and deceleration registers. The existing starting, stopping, and direction control
registers are not used and these functions are incorporated into the Servo
Control registers

* Servo Control functionality utilizes motor pulses as generated by the BLDC

motor’s Hall Effect Sensors as the metric for movement and positioning. The
quantity of pulses per revolution of the BLDC motor is based upon the number of

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motor poles X 3. The actual number of pulses per revolution of the MDR tube is
based upon the gear reduction ratio of the gearbox in the MDR and the diameter
of the tube. Learn about Motor Pulse to Distance Calculation

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11.4.7.7.1. Servo Contr

Control
ol Example
For our example, we want to perform the following cycle using PLC control of the Left MDR on
an ConveyLinx Module:

• Establish a zero or home position by external input to PLC (sensor or operator button)
• Rotate in the CCW direction for 7000 pulses at a speed of 80% PWM with acceleration
ramp of 100 pulses and a deceleration ramp of 50 pulses
• Rotate the CW direction for 9000 pulses at a speed of 100% PWM with acceleration ramp
of 50 pulses and a deceleration ramp of 10 pulses.
• Rotate CCW back to the zero or home position at a speed of 80% PWM with acceleration
ramp of 50 pulses and a deceleration ramp of 10 pulses.
• Wait for a cycle dwell time of 4 seconds and then repeat the rotation cycles

! Rotation from 0 to a positive value always causes rotation in CCW direction and
rotation from 0 to a negative value always causes rotation in CW direction. Servo
Motor Control ignores the CW/CCW direction setting in EasyRoll and/or any
configured or default direction that may exist in the ConveyLinx Module’s
configuration

Define PLC Tags

Tag Name Data T

Type
ype Assembly R
Register
egister (/bit)

ZERO Boolean Left Servo Command Word – bit 0

ZERO_ACK Boolean Left Motor Servo Status – bit 1

RUN Boolean Left Servo Command Word – bit 1

READY Boolean Left Motor Servo Status – bit 0

POSITION Integer Left Servo Command Pulses

SPEED Integer Left Motor Speed Reference

ACCEL Integer Left Motor Acceleration Ramp

DECEL Integer Left Motor Deceleration Ramp

MODE Integer Left Motor Speed Control Method

Sequence of Operation

Step #1: Place Left Motor in Closed Loop Mode by writing a “2” to MODE

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Step #2: Upon external signal from sensor or button, set ZERO bit to establish zero or “home”
position. When PLC sees that the ZERO_ACK bit is set, then the PLC resets the ZERO bit.

Step #3: To make the first rotation, we need write the speed, ramp values, and distance to
rotate to the appropriate registers:

• Write 800 to SPEED

• Write 100 to ACCEL
• Write 50 to DECEL
• Write 7000 to POSITION

Step #4: If READY is reset, then the PLC can set the RUN bit to begin the rotation. When the
rotation is complete, the ERSC sets the READY bit. This will be the signal to the PLC to reset the
RUN bit. Once the ERSC sees that the RUN bit has been reset, it will reset the READY bit.

Step #5: For the second rotation, we need to write the speed and ramp values to the
appropriate registers:

• Write 1000 to SPEED

• Write 50 to ACCEL
• Write 10 to DECEL

Because we want to rotate in the opposite direction, we need to determine the new location
based upon the zero or “home” position. In this case, we know we went 700 pulses “forward”
and we want to move 900 pulses “backward”. The position we want to end up is 7000-9000 =
-2000.

• Write -2000 to POSITION

Step #6: Repeat Step #4

Step #7: For the 3rd rotation, we keep the ramp values from the 2nd rotation, but we need to
set the speed and the position to rotate. In this case we want to go to the zero or “home
position.

• Write 800 to SPEED

• Write 0 to POSITION

Step #8: Repeat Step #4

PLC Ladder Diagram

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11.4.8. 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 applications where the
full functionality of the PLC I/O Mode Assemblies is not required. The Reduced Size Assemblies
provide basic I/O and motor control while removing the interfaces for servo moves, upstream/
downstream data, tracking data, etc.

PLC I/O Mode Inputs to PLC

Assembled Assembled Assembled
Module
Register Name Modbus EIP Profinet
Addr
ddress
ess
Addr
ddress
ess Addr
ddress
ess Addr
ddress
ess

Byte 0 (Hi)
4:0035 Sensor & Control Port Inputs 4:2700 I.Data [0]
Byte 1 (L
(Lo)
o)

Byte 2 (Hi)
4:0036 Sensor Detect 4:2701 I.Data [1]
Byte 3 (L
(Lo)
o)

Byte 4 (Hi)
4:0057 Left Motor Temperature 4:2702 I.Data [2]
Byte 5 (L
(Lo)
o)

Byte 6 (Hi)
4:0058 Left Motor Status 4:2703 I.Data [3]
Byte 7 (L
(Lo)
o)

Byte 8 (Hi)
4:0081 Right Motor Temperature 4:2704 I.Data [4]
Byte 9 (L
(Lo)
o)

Byte 10 (Hi)
4:0082 Right Motor Status 4:2705 I.Data [5]
Byte 11 (L
(Lo)
o)

Byte 12 (Hi)
4:0060 Left Motor Port Digital I/O Status 4:2706 I.Data [6]
Byte 13 (L
(Lo)
o)

Byte 14 (Hi)
4:0084 Right Motor Port Digital I/O Status 4:2707 I.Data [7]
Byte 15 (L
(Lo)
o)

Byte 16 (Hi)
Reserved 4:2708 I.Data [8]
Byte 17 (L
(Lo)
o)

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PLC I/O Mode Outputs fr

from
om PLC
Assembled Assembled Assembled
Module
Register Name Modbus EIP Profinet
Addr
ddress
ess
Addr
ddress
ess Addr
ddress
ess Addr
ddress
ess

Byte 0 (Hi)
4:0060 Set Left Motor Port Digital Control 4:2800 O.Data [0]
Byte 1 (L
(Lo)
o)

Byte 2 (Hi)
4:0084 Set Right Motor Port Digital Control 4:2801 O.Data [1]
Byte 3 (L
(Lo)
o)

Byte 4 (Hi)
4:0037 Control Port Digital Output Control 4:2802 O.Data [2]
Byte 5 (L
(Lo)
o)

Byte 6 (Hi)
4:0260 Left Motor Run / Reverse 4:2803 O.Data [3]
Byte 7 (L
(Lo)
o)

Byte 8 (Hi)
4:0270 Right Motor Run / Reverse 4:2804 O.Data [4]
Byte 9 (L
(Lo)
o)

Byte 10 (Hi)
4:0040 Left Motor Speed Reference 4:2805 O.Data [5]
Byte 11 (L
(Lo)
o)

Byte 12 (Hi)
4:0064 Right Motor Speed Reference 4:2806 O.Data [6]
Byte 13 (L
(Lo)
o)

Byte 14 (Hi)
4:0022 Clear Motor Error 4:2807 O.Data [7]
Byte 15 (L
(Lo)
o)

Byte 16 (Hi)
Reserved 4:2808 O.Data [8]
Byte 17 (L
(Lo)
o)

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11.5. ConveyL
ConveyLogix
ogix Interface
ConveyLinx Modules in PLC I/O mode allow for download of a user program generated with the
ConveyLogix programming tool. There may be instances when you would like for an external
PLC to be able to interface with an ConveyLinx Module that is running a ConveyLogix program.

* With ConveyLogix, because a custom user generated program is running in the

ConveyLinx Module, the previously defined existing Assemblies for ZPA and PLO
I/O modes are no longer valid and if used, could produce unexpected results

When using ConveyLogix programming software version 2.2 and later, the environment
provides predefined controlled input and output register tags that can be used by the
programmer to interface with an external PLC. The Assemblies described in this section are
those that the external PLC would connect and use to access the data in the ConveyLogix
program.

* Refer to Pulseroller publication ERSC-1200 ConveyLogix Programmer’s Guide for

details on how to create and download a program to your ConveyLinx Module

This data is divided into 16 Integer Input words and 16 Integer output words. It is left to the
ConveyLogix programmer and the PLC programmer to utilize as much or as little of these data
blocks as needed for their particular application.

! These assemblies are only available for ConveyLinx Module firmware 4.25 and
later and ConveyLogix version 2.02 or later is required to create programs that
can access these assemblies

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11.5.1. ConveyL
ConveyLogix
ogix Assembly Inputs to
PLC
ConveyL
ConveyLogix
ogix Modbus PLC
Ether
Ethernet
net I/P T
Tag
ag Profinet I/O Byte Offset
Contr
Controller
oller T
Tag
ag Holding R
Register
egister

ToPLCAr
oPLCArray
ray [0] E: I.Data [0] M: 4:13100 P: Byte 0 (Hi) Byte 1 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [1] E: I.Data [1] M: 4:13101 P: Byte 2 (Hi) Byte 3 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [2] E: I.Data [2] M: 4:13102 P: Byte 4 (Hi) Byte 5 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [3] E: I.Data [3] M: 4:13103 P: Byte 6 (Hi) Byte 7 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [4] E: I.Data [4] M: 4:13104 P: Byte 8 (Hi) Byte 9 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [5] E: I.Data [5] M: 4:13105 P: Byte 10 (Hi) Byte 11 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [6] E: I.Data [6] M: 4:13106 P: Byte 12 (Hi) Byte 13 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [7] E: I.Data [7] M: 4:13107 P: Byte 14 (Hi) Byte 15 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [8] E: I.Data [8] M: 4:13108 P: Byte 16 (Hi) Byte 17 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [9] E: I.Data [9] M: 4:13109 P: Byte 18 (Hi) Byte 19 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [10] E: I.Data [10] M: 4:13110 P: Byte 20 (Hi) Byte 21 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [11] E: I.Data [11] M: 4:13111 P: Byte 22 (Hi) Byte 23 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [12] E: I.Data [12] M: 4:13112 P: Byte 24 (Hi) Byte 25 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [13] E: I.Data [13] M: 4:13113 P: Byte 26 (Hi) Byte 27 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [14] E: I.Data [14] M: 4:13114 P: Byte 28 (Hi) Byte 29 (L
(Lo)
o)

ToPLCAr
oPLCArray
ray [15] E: I.Data [15] M: 4:13115 P: Byte 30 (Hi) Byte 31 (L
(Lo)
o)

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11.5.2. ConveyL
ConveyLogix
ogix Assembly Outputs
fr
from
om PLC
ConveyL
ConveyLogix
ogix Modbus PLC
Ether
Ethernet
net I/P T
Tag
ag Profinet I/O Byte Offset
Contr
Controller
oller T
Tag
ag Holding R
Register
egister

FromPLCAr
omPLCArray
ray [0] E: O
O.Data
.Data [0] M: 4:13200 P: Byte 0 (Hi) Byte 1 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray [1] E: O
O.Data
.Data [1] M: 4:13201 P: Byte 2 (Hi) Byte 3 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray [2] E: O
O.Data
.Data [2] M: 4:13202 P: Byte 4 (Hi) Byte 5 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray [3] E: O
O.Data
.Data [3] M: 4:13203 P: Byte 6 (Hi) Byte 7 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray [4] E: O
O.Data
.Data [4] M: 4:13204 P: Byte 8 (Hi) Byte 9 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray [5] E: O
O.Data
.Data [5] M: 4:13205 P: Byte 10 (Hi) Byte 11 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray [6] E: O
O.Data
.Data [6] M: 4:13206 P: Byte 12 (Hi) Byte 13 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray [7] E: O
O.Data
.Data [7] M: 4:13207 P: Byte 14 (Hi) Byte 15 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray [8] E: O
O.Data
.Data [8] M: 4:13208 P: Byte 16 (Hi) Byte 17 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray [9] E: O
O.Data
.Data [9] M: 4:13209 P: Byte 18 (Hi) Byte 19 (L
(Lo)
o)

FromPLCAr
omPLCArray
ray
E: O
O.Data
.Data [10] M: 4:13210 P: Byte 20 (Hi) Byte 21 (L
(Lo)
o)
[10]

FromPLCAr
omPLCArray
ray
E: O
O.Data
.Data [11] M: 4:13211 P: Byte 22 (Hi) Byte 23 (L
(Lo)
o)
[11]

FromPLCAr
omPLCArray
ray
E: O
O.Data
.Data [12] M: 4:13212 P: Byte 24 (Hi) Byte 25 (L
(Lo)
o)
[12]

FromPLCAr
omPLCArray
ray
E: O
O.Data
.Data [13] M: 4:13213 P: Byte 26 (Hi) Byte 27 (L
(Lo)
o)
[13]

FromPLCAr
omPLCArray
ray
E: O
O.Data
.Data [14] M: 4:13214 P: Byte 28 (Hi) Byte 29 (L
(Lo)
o)
[14]

FromPLCAr
omPLCArray
ray
E: O
O.Data
.Data [15] M: 4:13215 P: Byte 30 (Hi) Byte 31 (L
(Lo)
o)
[15]

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11.6. Assemblies with R

Reset
eset P
Prrotection
For control system applications where the Ethernet I/P PLC needs to take specific action to
recover from a loss of communications due to an ERSC module that has had its power cycled
off and on; there is an additional set of instances implemented that provides 2 new registers
that allows the PLC to manipulate the function of the ERSC module for recovery.

When an ERSC in ZPA Mode has lost power and then is powered back up, due to perhaps a
system E-stop that disconnects control power, some of the ERSC’s working register values are
reset to 0. Among these are the arrival counters, departure counters, and the accumulate
commands for each configured zone(s) on the ERSC. Upon power cycle to the ERSC, if the PLC
can establish its full Ethernet I/P connection prior to the ZPA task becoming fully functional, the
preceding PLC programming examples would still function as expected. However, because PLC
Ethernet I/P connection time is variable and not fixed; a robust control system design cannot
count on the PLC establishing Ethernet I/P connection prior to the ERSC’s ZPA task commanding
the module as if no PLC was connected. A consequence of this in the previous programming
example is that if a load happens to be accumulated in a PLC controlled zone at the time of
power loss, upon powering back up, the load can release without the PLC commanding it to do
so. This release could be caused by the PLC logic detecting a change in arrival count and thus
incrementing the release or it could be caused by the fact that the accumulate command is
cleared in the ERSC due to power cycle and because the PLC has not established
communications to set the accumulate command bit, the ERSC releases the zone because
there is no command present to accumulate.

For ERSC’s in PLC I/O mode, Reset Protection may not be as much a concern as for a module in
ZPA mode, however reset protection assemblies are available for PLC I/O mode. Some items
such as current servo position, etc. are reset upon restoration of power and thus the PLC
programmer may want to detect this condition and act accordingly.

* Reset Protection assemblies are used for applications where the ERSC remains in
a “hold” state until the PLC has established communications. Otherwise, the
register mappings for these assemblies are the same as their non-protected
counterparts.

! Please note that the Modbus TCP starting addresses for each assembly with reset
protection is different from their non-protected counterparts.

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11.6.1. ZP
ZPAA Mode Assembly Inputs with
Reset P
Prrotection
Modbus PLC
Module
Register Name Ether
Ethernet
net I/P T
Tag
ag Holding
Addr
ddress
ess
Register

4:0116 Local Status Upstream Zone E: I.Data [0] M: 4:3500

4:0196 Local Status Downstream Zone E: I.Data [1] M: 4:3501

4:0106 Arrival Count Local Upstream Zone E: I.Data [2] M: 4:3502

4:0107 Departure Count Local Upstream Zone E: I.Data [3] M: 4:3503

4:0186 Arrival Count Local Downstream Zone E: I.Data [4] M: 4:3504

4:0187 Departure Count Local Downstream Zone E: I.Data [5] M: 4:3505

4:0088 Module Status Word 1 E: I.Data [6] M: 4:3506

4:0089 Module Status Word 2 E: I.Data [7] M: 4:3507

4:0119 Current Upstream Zone Tracking Word 1 E: I.Data [8] M: 4:3508

4:0120 Current Upstream Zone Tracking Word 2 E: I.Data [9] M: 4:3509

4:0199 Current Downstream Zone Tracking Word 1 E: I.Data [10] M: 4:3510

4:0200 Current Downstream Zone Tracking Word 2 E: I.Data [11] M: 4:3511

4:0105 Current Release Count for Upstream Zone E: I.Data [12] M: 4:3512

4:0185 Current Release Count for Downstream Zone E: I.Data [13] M: 4:3513

4:0201 Get Tracking Forward Direction Word 1 E: I.Data [14] M: 4:3514

4:0202 Get Tracking Forward Direction Word 2 E: I.Data [15] M: 4:3515

4:0237 Get Tracking Reverse Direction Word 1 E: I.Data [16] M: 4:3516

4:0238 Get Tracking Reverse Direction Word 2 E: I.Data [17] M: 4:3517

4:0035 Sensor & Control Port Inputs E: I.Data [18] M: 4:3518

N/A Cur
Currrent Module R
Reset
eset Count E: I.Data [19] M: 4:3519

4:0019 ConveyStop Status E: I.Data [20] M: 4:3520

Page 374 of 557

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11.6.2. ZP
ZPAA Mode Assembly Outputs with
Reset P
Prrotection
Modbus PLC
Module Ether
Ethernet
net I/P
Register Name Holding
Addr
ddress
ess Tag
Register

4:0132 Set Local Upstream Zone Tracking Word 1 E: I.Data [0] M: 4:3600

4:0133 Set Local Upstream Zone Tracking Word 2 E: I.Data [1] M: 4:3601

4:0212 Set Local Downstream Zone Tracking Word 1 E: I.Data [2] M: 4:3602

4:0213 Set Local Downstream Zone Tracking Word 2 E: I.Data [3] M: 4:3603

4:0104 Accumulation Control for Local Upstream Zone E: I.Data [4] M: 4:3604

4:0184 Accumulation Control for Local Downstream Zone E: I.Data [5] M: 4:3605

4:0040 Set Left MDR Speed E: I.Data [6] M: 4:3606

4:0064 Set Right MDR Speed E: I.Data [7] M: 4:3607

Release and Accumulate on Next Arrival for Local

4:0105 E: I.Data [8] M: 4:3608
Upstream Zone

Release and Accumulate on Next Arrival for Local

4:0185 E: I.Data [9] M: 4:3609
Upstream Zone

E: I.Data
4:0134 Set Status for Upstream Induct M: 4:3610
[10]

E: I.Data
4:0232 Set Status for Downstream Discharge M: 4:3611
[11]

E: I.Data
4:0139 Set Induct Tracking Forward Direction Word 1 M: 4:3612
[12]

E: I.Data
4:0140 Set Induct Tracking Forward Direction Word 2 M: 4:3613
[13]

E: I.Data
4:0237 Set Induct Tracking Reverse Direction Word 1 M: 4:3614
[14]

E: I.Data
4:0238 Set Induct Tracking Reverse Direction Word 2 M: 4:3615
[15]

E: I.Data
4:0022 Clear Motor Error M: 4:3616
[16]

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E: I.Data
4:0063 Set Control Port Outputs M: 4:3617
[17]

E: I.Data
N/A Set Module R
Reset
eset Count M: 4:3618
[18]

E: I.Data
4:0020 ConveyStop Command M: 4:3619
[19]

E: I.Data
4:0109 Clear Sensor Jam Command for Local Upstream Zone M: 4:3620
[20]

E: I.Data
4:0189 Clear Sensor Jam Command for Local Downstream Zone M: 4:3621
[21]

Direction & Accumulation Mode Control for Local E: I.Data

4:0365 M: 4:3622
Upstream Zone [22]

Direction & Accumulation Mode Control for Local E: I.Data

4:0375 M: 4:3623
Downstream Zone [23]

E: I.Data
4:0387 ConveyMerge Interface M: 4:3624
[24]

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11.6.3. Reduced Size ZPZPA

A Mode Assemblies
with R
Reset
eset P
Prrotection
Inputs to PLC

Modbus PLC
Module Ether
Ethernet
net I/P
Register Name Holding
Addr
ddress
ess Tag
Register

4:0116 Local Status Upstream Zone E: I.Data [0] M: 4:4900

4:0196 Local Status Downstream Zone E: I.Data [1] M: 4:4901

4:0106 Arrival Count Local Upstream Zone E: I.Data [2] M: 4:4902

4:0107 Departure Count Local Upstream Zone E: I.Data [3] M: 4:4903

4:0186 Arrival Count Local Downstream Zone E: I.Data [4] M: 4:4904

4:0187 Departure Count Local Downstream Zone E: I.Data [5] M: 4:4905

4:0088 Module Status Word 1 E: I.Data [6] M: 4:4906

4:0089 Module Status Word 2 E: I.Data [7] M: 4:4907

4:0105 Current Release Count for Upstream Zone E: I.Data [8] M: 4:4908

4:0185 Current Release Count for Downstream Zone E: I.Data [9] M: 4:4909

4:0035 Sensor & Control Port Inputs E: I.Data [10] M: 4:4010

N/A Cur
Currrent Module R
Reset
eset Count E: I.Data [11] M: 4:4911

Outputs fr
from
om PLC

Modbus PLC
Module Ether
Ethernet
net I/P
Register Name Holding
Addr
ddress
ess Tag
Register

4:0104 Accumulation Control for Local Upstream Zone E: O.Data [0] M: 4:5000

4:0184 Accumulation Control for Local Downstream Zone E: O.Data [0] M: 4:5001

4:0040 Set Left MDR Speed E: O.Data [2] M: 4:5002

4:0064 Set Right MDR Speed E: O.Data [3] M: 4:5003

Release and Accumulate on Next Arrival for Local

4:0105 E: O.Data [4] M: 4:5004
Upstream Zone

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Release and Accumulate on Next Arrival for Local

4:0185 E: O.Data [5] M: 4:5005
Upstream Zone

4:0134 Set Status for Upstream Induct E: O.Data [6] M: 4:5006

4:0232 Set Status for Downstream Discharge E: O.Data [7] M: 4:5007

4:0022 Clear Motor Error E: O.Data [8] M: 4:5008

4:0063 Set Control Port Outputs E: O.Data [9] M: 4:5009

N/A Set Module R

Reset
eset Count E: O
O.Data
.Data [10] M: 4:5010

4:0109 Clear Sensor Jam Command for Local Upstream Zone E: O.Data [11] M: 4:5011

Clear Sensor Jam Command for Local Downstream

4:0189 E: O.Data [12] M: 4:5012
Zone

Direction & Accumulation Mode Control for Local

4:0365 E: O.Data [13] M: 4:5013
Upstream Zone

Direction & Accumulation Mode Control for Local

4:0375 E: O.Data [14] M: 4:5014
Downstream Zone

Page 378 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.6.4. PLC I/O Mode Assembly Inputs with

Reset P
Prrotection
Modbus PLC
Module
Register Name Ether
Ethernet
net I/P T
Tag
ag Holding
Addr
ddress
ess
Register

4:0019 ConveyStop Status E: I.Data [0] M: 4:3700

4:0035 Sensor & Control Port Inputs E: I.Data [1] M: 4:3701

4:0036 Sensor Detect E: I.Data [2] M: 4:3702

4:0024 Module Voltage E: I.Data [3] M: 4:3703

4:0055 Left Motor Current E: I.Data [4] M: 4:3704

4:0056 Left Motor Frequency E: I.Data [5] M: 4:3705

4:0057 Left Motor Temperature E: I.Data [6] M: 4:3706

4:0058 Left Motor Status E: I.Data [7] M: 4:3707

4:0079 Right Motor Current E: I.Data [8] M: 4:3708

4:0080 Right Motor Frequency E: I.Data [9] M: 4:3709

4:0081 Right Motor Temperature E: I.Data [10] M: 4:3710

4:0082 Right Motor Status E: I.Data [11] M: 4:3711

4:0060 Left Motor Port Digital I/O Status E: I.Data [12] M: 4:3712

4:0084 Right Motor Port Digital I/O Status E: I.Data [13] M: 4:3713

4:0134 Upstream Module Status E: I.Data [14] M: 4:3714

4:0232 Downstream Module Status E: I.Data [15] M: 4:3715

Current Tracking Word 1 for Adjacent

4:0139 E: I.Data [16] M: 4:3716
Upstream Module

Current Tracking Word 2 for Adjacent

4:0140 E: I.Data [17] M: 4:3717
Upstream Module

N/A Cur
Currrent Module R
Reset
eset Counter E: I.Data [18] M: 4:3718

4:0062 Left Motor Servo Position E: I.Data [19] M: 4:3719

4:0086 Right Motor Servo Position E: I.Data [20] M: 4:3720

4:0011 Left Motor Servo Status E: I.Data [21] M: 4:3721

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4:0016 Right Motor Servo Status E: I.Data [22] M: 4:3722

Page 380 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.6.5. PLC I/O Mode Assembly Outputs

with R
Reset
eset P
Prrotection
Modbus PLC
Module
Register Name Ether
Ethernet
net I/P T
Tag
ag Holding
Addr
ddress
ess
Register

4:0020 ConveyStop Command E: O.Data [0] M: 4:3800

4:0060 Set Left Motor Port Digital Control E: O.Data [1] M: 4:3801

4:0084 Set Right Motor Port Digital Control E: O.Data [2] M: 4:3802

4:0037 Control Port Digital Output Control E: O.Data [3] M: 4:3803

4:0260 Left Motor Run / Reverse E: O.Data [4] M: 4:3804

4:0261 Left Motor Brake Method E: O.Data [5] M: 4:3805

4:0262 Left Motor Speed Control Method E: O.Data [6] M: 4:3806

4:0270 Right Motor Run / Reverse E: O.Data [7] M: 4:3807

4:0271 Right Motor Brake Method E: O.Data [8] M: 4:3808

4:0272 Right Motor Speed Control Method E: O.Data [9] M: 4:3809

4:0040 Left Motor Speed Reference E: O.Data [10] M: 4:3810

4:0064 Right Motor Speed Reference E: O.Data [11] M: 4:3811

4:0043 Left Motor Acceleration Ramp E: O.Data [12] M: 4:3812

4:0044 Left Motor Deceleration Ramp E: O.Data [13] M: 4:3813

4:0067 Right Motor Acceleration Ramp E: O.Data [14] M: 4:3814

4:0068 Right Motor Deceleration Ramp E: O.Data [15] M: 4:3815

4:0022 Clear Motor Error E: O.Data [16] M: 4:3816

4:0196 Set Status to Downstream Module E: O.Data [17] M: 4:3817

4:0116 Set Status to Upstream Module E: O.Data [18] M: 4:3818

4:0034 Sensor Port Input Signal Condition Mask E: O.Data [19] M: 4:3819

4:0201 Set Discharge Tracking Word 1 E: O.Data [20] M: 4:3820

4:0202 Set Discharge Tracking Word 2 E: O.Data [21] M: 4:3821

N/A Set Module R

Reset
eset Count E: O
O.Data
.Data [22] M: 4:3822

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4:0008 Left Motor Servo Command Pulses E: O.Data [23] M: 4:3823

4:0009 Left Motor Servo Command Word E: O.Data [24] M: 4:3824

4:0013 Right Motor Servo Command Pulses E: O.Data [25] M: 4:3825

4:0014 Right Motor Servo Command Word E: O.Data [26] M: 4:3826

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PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.6.6. Reduced Size PLC I/O Mode

Assemblies with R
Reset
eset P
Prrotection
Inputs to PLC

Modbus PLC
Module Ether
Ethernet
net I/P
Register Name Holding
Addr
ddress
ess Tag
Register

4:0035 Sensor & Control Port Inputs E: I.Data [0] M: 4:4700

4:0036 Sensor Detect E: I.Data [1] M: 4:4701

4:0057 Left Motor Temperature E: I.Data [2] M: 4:4702

4:0058 Left Motor Status E: I.Data [3] M: 4:4703

4:0081 Right Motor Temperature E: I.Data [4] M: 4:4704

4:0082 Right Motor Status E: I.Data [5] M: 4:4705

4:0060 Left Motor Port Digital I/O Status E: I.Data [6] M: 4:4706

4:0084 Right Motor Port Digital I/O Status E: I.Data [7] M: 4:4707

N/A Cur
Currrent Module R
Reset
eset Count E: I.Data [8] M: 4:4708

Outputs fr
from
om PLC

Modbus PLC
Module Ether
Ethernet
net I/P
Register Name Holding
Addr
ddress
ess Tag
Register

4:0060 Set Left Motor Port Digital Control E: O.Data [0] M: 4:4800

4:0084 Set Right Motor Port Digital Control E: O.Data [1] M: 4:4801

4:0037 Control Port Digital Output Control E: O.Data [2] M: 4:4802

4:0260 Left Motor Run / Reverse E: O.Data [3] M: 4:4803

4:0270 Right Motor Run / Reverse E: O.Data [4] M: 4:4804

4:0040 Left Motor Speed Reference E: O.Data [5] M: 4:4805

4:0064 Right Motor Speed Reference E: O.Data [6] M: 4:4806

4:0022 Clear Motor Error E: O.Data [7] M: 4:4807

N/A Set Module R

Reset
eset Count E: O
O.Data
.Data [8] M: 4:4808

Page 383 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.6.7. How to use Assemblies with R

Reset
eset
Protection
When the PLC determines that it has a valid connection to the ConveyLinx Module in question
and is ready for it to respond to output data being written by the PLC:

• Your PLC program needs to move the value in the Cur

Currrent Module R
Reset
eset Counter register
into the Set Module R
Reset
eset Counter register

• When the ConveyLinx Module detects that the value in Set Module R Reset
eset Counter register
is equal to the value in the Cur
Currrent Module R
Reset
eset Counter register; the ConveyLinx Module
will respond to data being written by the PLC to the remaining output assembly registers.

* Please note that when the value in Cur

Currrent Module R
equal to the value in the Set Module R
Reset
Reset
eset Counter register is not
eset Counter register; the values in the
Input registers will updated by the ConveyLinx Module and will be valid in your
PLC program. In this state, even though the PLC may be writing data to Output
registers, the ConveyLinx Module will ignor
ignoree it

* To make sure a given ZPA zone accumulates upon power up, use EasyRoll
configuration tool software to set the zone to “Accumulate”. When set from
EasyRoll, this setting will be retained in the flash memory of the ConveyLinx
Module so that the zone will initially accumulate if a load happens to be in the
zone at the time of power up. Learn about Accumulate function in EasyRoll

* When a ZPA zone is commanded to accumulate with a PLC and you happen to
connect to that ConveyLinx Module with EasyRoll; the “Accumulate” switch icon
on the main screen will visibly indicate that the zone is accumulated. This visible
icon will look the same as if it was clicked ON from EasyRoll.
Keep in mind that a PLC command to accumulate IS NOT retained upon power
loss to the ConveyLinx Module
Module. Only if the “Accumulate” switch is toggled “ON”
with the EasyRoll is the accumulate condition for the zone retained in flash
memory for use upon power-up

Page 384 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.7. Motor P
Port
ort as Digital I/O

! Motor port as digital I/O is only applicable for an ERSC in PLC I/O Mode

External controller must first set bit 15 = 1 in the Set LLef

eft/Right
t/Right Motor PPort
ort Digital Contr
Control
ol
register for the motor port (Left or Right) that is to be used as digital output. If bit 15 = 0, then
the ERSC ignores the bit 0 thru bit 2 commands and will not provide meaningful status on bits
12 and 14 in the corresponding Lef eft/Right
t/Right Motor P
Port
ort Digital I/O Status register for the port in
question. Bit 0, bit 1, and bit 2 can be independently set and reset by the PLC and all 3 digital
outputs can be energized simultaneously.

Motor Phases as Digital Outputs

* Please note that the ERSC switches to GND to complete the circuit

! Short Circuit Error on bit 12 is classified as a “fatal” error that will require either
a cycle of power on the ERSC or an explicit Motor Fault Reset command from
external controller the same as if the port was being used as a motor port.
External controller must continuously write “1” to the Motor Fault Reset register
for at least 500 msec for reset to occur

Page 385 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

Using the Brak

Brake
e Output P
Pin
in on the Motor P
Port
ort

You can also utilize the Brake Output (Pin 9 on the JST connector) as a +24V output signal
controlled from your PLC program when the ERSC is in PLC I/O mode. This signal sources +24V
and is limited to 0.5A load.

* Unlike the motor phases (Pins 3, 4, and 5), the Brake Output is available when
the motor port is not in digital mode and is actually running a motor.

When using the Brake Output when the port is actually running a motor, you must set bit 7
in the appropriate left or right “Set Motor Port Digital Control” output word in order to
enable the Brake Output functionality. Once you do this, then bit 6 in the same word
controls the on/off state of the digital signal. If you have enabled the motor port for digital
control by setting bit 15, you do not have to also set bit 7 to enable the Brake Output. It is
already enabled when you set bit 15

Brake Output Pin as Digital Output

Page 386 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8. OD
ODVVA Compliant Cr
Cross-R
oss-Refer
eference
ence
Firmware 5.2 was developed to be 100% compliant with the ODVA specification for Ethernet I/P.
In generating this firmware, we found that the numbering system we used to identify our
Ethernet I/P assembly instances encroached on reserved values in the ODVA specification. In
order for Firmware 5.2 to be ODVA compliant requires that our previous assembly instance
identification numbers be reassigned. In so doing, this also had an effect on our Modbus
addressing for the contiguous blocks of registers used for accessing assembled data over
Modbus TCP

Page 387 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.1. ZP
ZPA
A Mode Assembly Inputs
Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0116 Local Status Upstream Zone 4:11500 4:1500

4:0196 Local Status Downstream Zone 4:11501 4:1501

4:0106 Arrival Count Local Upstream Zone 4:11502 4:1502

4:0107 Departure Count Local Upstream Zone 4:11503 4:1503

4:0186 Arrival Count Local Downstream Zone 4:11504 4:1504

4:0187 Departure Count Local Downstream Zone 4:11505 4:1505

4:0088 Module Status Word 1 4:11506 4:1506

4:0089 Module Status Word 2 4:11507 4:1507

4:0119 Current Upstream Zone Tracking Word 1 4:11508 4:1508

4:0120 Current Upstream Zone Tracking Word 2 4:11509 4:1509

4:0199 Current Downstream Zone Tracking Word 1 4:11510 4:1510

4:0200 Current Downstream Zone Tracking Word 2 4:11511 4:1511

4:0105 Current Release Count for Upstream Zone 4:11512 4:1512

4:0185 Current Release Count for Downstream Zone 4:11513 4:1513

4:0201 Get Tracking Forward Direction Word 1 4:11514 4:1514

4:0202 Get Tracking Forward Direction Word 2 4:11515 4:1515

4:0237 Get Tracking Reverse Direction Word 1 4:11516 4:1516

4:0238 Get Tracking Reverse Direction Word 2 4:11517 4:1517

4:0035 Sensor & Control Port Inputs 4:11518 4:1518

N/A Reserved 4:11519 4:1519

4:0019 ConveyStop Status 4:11520 4:1520

Page 388 of 557

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11.8.2. ZP
ZPA
A Mode Assembly Outputs
Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0132 Set Local Upstream Zone Tracking Word 1 4:11600 4:1600

4:0133 Set Local Upstream Zone Tracking Word 2 4:11601 4:1601

4:0212 Set Local Downstream Zone Tracking Word 1 4:11602 4:1602

4:0213 Set Local Downstream Zone Tracking Word 2 4:11603 4:1603

4:0104 Accumulation Control for Local Upstream Zone 4:11604 4:1604

Accumulation Control for Local Downstream

4:0184 4:11605 4:1605
Zone

4:0040 Set Left MDR Speed 4:11606 4:1606

4:0064 Set Right MDR Speed 4:11607 4:1607

Release and Accumulate on Next Arrival for

4:0105 4:11608 4:1608
Local Upstream Zone

Release and Accumulate on Next Arrival for

4:0185 4:11609 4:1609
Local Downstream Zone

4:0134 Set Status for Upstream Induct 4:11610 4:1610

4:0232 Set Status for Downstream Discharge 4:11611 4:1611

4:0139 Set Induct Tracking Forward Direction Word 1 4:11612 4:1612

4:0140 Set Induct Tracking Forward Direction Word 2 4:11613 4:1613

4:0237 Set Induct Tracking Reverse Direction Word 1 4:11614 4:1614

4:0238 Set Induct Tracking Forward Direction Word 2 4:11615 4:1615

4:0022 Clear Motor Error 4:11616 4:1616

4:0063 Set Control Port Outputs 4:11617 4:1617

N/A Reserved 4:11618 4:1618

4:0020 ConveyStop Command 4:11619 4:1619

Clear Sensor Jam Command for Local

4:0109 4:11620 4:1620
Upstream Zone

Page 389 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

Clear Sensor Jam Command for Local

4:0189 4:11621 4:1621
Downstream Zone

Direction & Accumulation Mode Control for

4:0365 4:11622 4:1622
Local Upstream Zone

Direction & Accumulation Mode Control for

4:0375 4:11623 4:1623
Local Downstream Zone

4:0387 ConveyMerge Interface 4:11624 4:1624

Page 390 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.3. ZP
ZPA
A Mode R
Reduced
educed Size
ZP
ZPA
A Mode Inputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0116 Local Status Upstream Zone 4:12900 4:2900

4:0196 Local Status Downstream Zone 4:12901 4:2901

4:0106 Arrival Count Local Upstream Zone 4:12902 4:2902

4:0107 Departure Count Local Upstream Zone 4:12903 4:2903

4:0186 Arrival Count Local Downstream Zone 4:12904 4:2904

4:0187 Departure Count Local Downstream Zone 4:12905 4:2905

4:0088 Module Status Word 1 4:12906 4:2906

4:0089 Module Status Word 2 4:12907 4:2907

4:0105 Current Release Count for Upstream Zone 4:12908 4:2908

4:0185 Current Release Count for Downstream Zone 4:12909 4:2909

4:0035 Sensor & Control Port Inputs 4:12910 4:2910

N/A Reserved 4:12911 4:2911

ZP
ZPA
A Mode Outputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0104 Accumulation Control for Local Upstream Zone 4:13000 4:3000

Accumulation Control for Local Downstream

4:0184 4:13001 4:3001
Zone

4:0040 Set Left MDR Speed 4:13002 4:3002

4:0064 Set Right MDR Speed 4:13003 4:3003

Release and Accumulate on Next Arrival for

4:0105 4:13004 4:3004
Local Upstream Zone

Page 391 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

Release and Accumulate on Next Arrival for

4:0185 4:13005 4:3005
Local Downstream Zone

4:0134 Set Status for Upstream Induct 4:13006 4:3006

4:0232 Set Status for Downstream Discharge 4:13007 4:3007

4:0022 Clear Motor Error 4:13008 4:3008

4:0063 Set Control Port Outputs 4:13009 4:3009

N/A Reserved 4:13010 4:3010

Clear Sensor Jam Command for Local

4:0109 4:13011 4:3011
Upstream Zone

Clear Sensor Jam Command for Local

4:0189 4:13012 4:3012
Downstream Zone

Direction & Accumulation Mode Control for

4:0365 4:13013 4:3013
Local Upstream Zone

Direction & Accumulation Mode Control for

4:0375 4:13014 4:3014
Local Upstream Zone

Page 392 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.4. PLC I/O Mode Assembly Inputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0019 ConveyStop Status 4:11700 4:1700

4:0035 Sensor & Control Port Inputs 4:11701 4:1701

4:0036 Sensor Detect 4:11702 4:1702

4:0024 Module Voltage 4:11703 4:1703

4:0055 Left Motor Current 4:11704 4:1704

4:0056 Left Motor Frequency 4:11705 4:1705

4:0057 Left Motor Temperature 4:11706 4:1706

4:0058 Left Motor Status 4:11707 4:1707

4:0079 Right Motor Current 4:11708 4:1708

4:0080 Right Motor Frequency 4:11709 4:1709

4:0081 Right Motor Temperature 4:11710 4:1710

4:0082 Right Motor Status 4:11711 4:1711

4:0060 Left Motor Port Digital I/O Status 4:11712 4:1712

4:0084 Right Motor Port Digital I/O Status 4:11713 4:1713

4:0134 Upstream Module Status 4:11714 4:1714

4:0232 Downstream Module Status 4:11715 4:1715

Current Tracking Word 1 for Adjacent

4:0139 4:11716 4:1716
Upstream Module

Current Tracking Word 2 for Adjacent

4:0140 4:11717 4:1717
Upstream Module

N/A Reserved 4:11718 4:1718

4:0062 Left Motor Servo Position 4:11719 4:1719

4:0086 Right Motor Servo Position 4:11720 4:1720

4:0011 Left Motor Servo Status 4:11721 4:1721

4:0016 Right Motor Servo Status 4:11722 4:1722

Page 393 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.5. PLC I/O Mode Assembly Outputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0020 ConveyStop Command 4:11800 4:1800

4:0060 Set Left Motor Port Digital Control 4:11801 4:1801

4:0084 Set Right Motor Port Digital Control 4:11802 4:1802

4:0037 Control Port Digital Output Control 4:11803 4:1803

4:0260 Left Motor Run / Reverse 4:11804 4:1804

4:0261 Left Motor Brake Method 4:11805 4:1805

4:0262 Left Motor Speed Control Method 4:11806 4:1806

4:0270 Right Motor Run / Reverse 4:11807 4:1807

4:0271 Right Motor Brake Method 4:11808 4:1808

4:0272 Right Motor Speed Control Method 4:11809 4:1809

4:0040 Left Motor Speed Reference 4:11810 4:1810

4:0064 Right Motor Speed Reference 4:11811 4:1811

4:0043 Left Motor Acceleration Ramp 4:11812 4:1812

4:0044 Left Motor Deceleration Ramp 4:11813 4:1813

4:0067 Right Motor Acceleration Ramp 4:11814 4:1814

4:0068 Right Motor Deceleration Ramp 4:11815 4:1815

4:0022 Clear Motor Error 4:11816 4:1816

4:0196 Set Status to Downstream Module 4:11817 4:1817

4:0116 Set Status to Upstream Module 4:11818 4:1818

4:0034 Sensor Port Input Signal Condition Mask 4:11819 4:1819

4:0201 Set Discharge Tracking Word 1 4:11820 4:1820

4:0202 Set Discharge Tracking Word 2 4:11821 4:1821

N/A Reserved 4:11822 4:1822

4:0008 Left Motor Servo Command Pulses 4:11823 4:1823

Page 394 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

4:0009 Left Motor Servo Command Word 4:11824 4:1824

4:0013 Right Motor Servo Command Pulses 4:11825 4:1825

4:0014 Right Motor Servo Command Word 4:11826 4:1826

Page 395 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.6. PLC I/O Mode R

Reduced
educed Size
PLC I/O Mode Inputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0035 Sensor & Control Port Inputs 4:12700 4:2700

4:0036 Sensor Detect 4:12701 4:2701

4:0057 Left Motor Temperature 4:12702 4:2702

4:0058 Left Motor Status 4:12703 4:2703

4:0081 Right Motor Temperature 4:12704 4:2704

4:0082 Right Motor Status 4:12705 4:2705

4:0060 Left Motor Port Digital I/O Status 4:12706 4:2706

4:0084 Right Motor Port Digital I/O Status 4:12707 4:2707

N/A Reserved 4:12708 4:2708

PLC I/O Mode Outputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0060 Set Left Motor Port Digital Control 4:12800 4:2800

4:0084 Set Right Motor Port Digital Control 4:12801 4:2801

4:0037 Control Port Digital Output Control 4:12802 4:2802

4:0260 Left Motor Run / Reverse 4:12803 4:2803

4:0270 Right Motor Run / Reverse 4:12804 4:2804

4:0040 Left Motor Speed Reference 4:12805 4:2805

4:0064 Right Motor Speed Reference 4:12806 4:2806

4:0022 Clear Motor Error 4:12807 4:2807

N/A Reserved 4:12808 4:2808

Page 396 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.7. Reset P
Prrotection for ZP
ZPA
A Mode
Assembly Inputs
Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0116 Local Status Upstream Zone 4:31500 4:3500

4:0196 Local Status Downstream Zone 4:31501 4:3501

4:0106 Arrival Count Local Upstream Zone 4:31502 4:3502

4:0107 Departure Count Local Upstream Zone 4:31503 4:3503

4:0186 Arrival Count Local Downstream Zone 4:31504 4:3504

4:0187 Departure Count Local Downstream Zone 4:31505 4:3505

4:0088 Module Status Word 1 4:31506 4:3506

4:0089 Module Status Word 2 4:31507 4:3507

4:0119 Current Upstream Zone Tracking Word 1 4:31508 4:3508

4:0120 Current Upstream Zone Tracking Word 2 4:31509 4:3509

4:0199 Current Downstream Zone Tracking Word 1 4:31510 4:3510

4:0200 Current Downstream Zone Tracking Word 2 4:31511 4:3511

4:0105 Current Release Count for Upstream Zone 4:31512 4:3512

4:0185 Current Release Count for Downstream Zone 4:31513 4:3513

4:0201 Get Tracking Forward Direction Word 1 4:31514 4:3514

4:0202 Get Tracking Forward Direction Word 2 4:31515 4:3515

4:0237 Get Tracking Reverse Direction Word 1 4:31516 4:3516

4:0238 Get Tracking Reverse Direction Word 2 4:31517 4:3517

4:0035 Sensor & Control Port Inputs 4:31518 4:3518

N/A Current Module Reset Count 4:31519 4:3519

4:0019 ConveyStop Status 4:31520 4:3520

Page 397 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.8. Reset P
Prrotection for ZP
ZPA
A Mode
Assembly Outputs
Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0132 Set Local Upstream Zone Tracking Word 1 4:31600 4:3600

4:0133 Set Local Upstream Zone Tracking Word 2 4:31601 4:3601

4:0212 Set Local Downstream Zone Tracking Word 1 4:31602 4:3602

4:0213 Set Local Downstream Zone Tracking Word 2 4:31603 4:3603

4:0104 Accumulation Control for Local Upstream Zone 4:31604 4:3604

Accumulation Control for Local Downstream

4:0184 4:31605 4:3605
Zone

4:0040 Set Left MDR Speed 4:31606 4:3606

4:0064 Set Right MDR Speed 4:31607 4:3607

Release and Accumulate on Next Arrival for

4:0105 4:31608 4:3608
Local Upstream Zone

Release and Accumulate on Next Arrival for

4:0185 4:31609 4:3609
Local Downstream Zone

4:0134 Set Status for Upstream Induct 4:31610 4:3610

4:0232 Set Status for Downstream Discharge 4:31611 4:3611

4:0139 Set Induct Tracking Forward Direction Word 1 4:31612 4:3612

4:0140 Set Induct Tracking Forward Direction Word 2 4:31613 4:3613

4:0237 Set Induct Tracking Reverse Direction Word 1 4:31614 4:3614

4:0238 Set Induct Tracking Forward Direction Word 2 4:31615 4:3615

4:0022 Clear Motor Error 4:31616 4:3616

4:0063 Set Control Port Outputs 4:31617 4:3617

N/A Set Module Reset Counter 4:31618 4:3618

4:0020 ConveyStop Command 4:31619 4:3619

4:0109 Clear Sensor Jam Command for Local 4:31620 4:3620

Page 398 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

Upstream Zone

Clear Sensor Jam Command for Local

4:0189 4:31621 4:3621
Downstream Zone

Direction & Accumulation Mode Control for

4:0365 4:31622 4:3622
Local Upstream Zone

Direction & Accumulation Mode Control for

4:0375 4:31623 4:3623
Local Downstream Zone

4:0387 ConveyMerge Interface 4:31624 4:3624

Page 399 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.9. Reset P
Prrotection for R
Reduced
educed Size
ZP
ZPA
A Assemblies
ZP
ZPA
A Mode Inputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0116 Local Status Upstream Zone Forward Direction 4:32900 4:4900

Local Status Downstream Zone Forward

4:0196 4:32901 4:4901
Direction

4:0106 Arrival Count Local Upstream Zone 4:32902 4:4902

4:0107 Departure Count Local Upstream Zone 4:32903 4:4903

4:0186 Arrival Count Local Downstream Zone 4:32904 4:4904

4:0187 Departure Count Local Downstream Zone 4:32905 4:4905

4:0088 Module Status Word 1 4:32906 4:4906

4:0089 Module Status Word 2 4:32907 4:4907

4:0105 Current Release Count for Upstream Zone 4:32908 4:4908

4:0185 Current Release Count for Downstream Zone 4:32909 4:4909

4:0035 Sensor & Control Port Inputs 4:32910 4:4910

N/A Current Module Reset Count 4:32911 4:4911

ZP
ZPA
A Mode Outputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0104 Accumulation Control for Local Upstream Zone 4:33000 4:5000

Accumulation Control for Local Downstream

4:0184 4:33001 4:5001
Zone

4:0040 Set Left MDR Speed 4:33002 4:5002

4:0064 Set Right MDR Speed 4:33003 4:5003

Page 400 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

Release and Accumulate on Next Arrival for

4:0105 4:33004 4:5004
Local Upstream Zone

Release and Accumulate on Next Arrival for

4:0185 4:33005 4:5005
Local Downstream Zone

4:0134 Set Status for Upstream Induct 4:33006 4:5006

4:0232 Set Status for Downstream Discharge 4:33007 4:5007

4:0022 Clear Motor Error 4:33008 4:5008

4:0063 Set Control Port Outputs 4:33009 4:5009

N/A Set Module Reset Counter 4:33010 4:5010

Clear Sensor Jam Command for Local

4:0109 4:33011 4:5011
Upstream Zone

Clear Sensor Jam Command for Local

4:0189 4:33012 4:5012
Downstream Zone

Direction & Accumulation Mode Control for

4:0365 4:33013 4:5013
Local Upstream Zone

Direction & Accumulation Mode Control for

4:0375 4:33014 4:5014
Local Upstream Zone

Page 401 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.10. Reset P
Prrotection for PLC I/O Mode
Assembly Inputs
Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0019 ConveyStop Status 4:31700 4:3700

4:0035 Sensor & Control Port Inputs 4:31701 4:3701

4:0036 Sensor Detect 4:31702 4:3702

4:0024 Module Voltage 4:31703 4:3703

4:0055 Left Motor Current 4:31704 4:3704

4:0056 Left Motor Frequency 4:31705 4:3705

4:0057 Left Motor Temperature 4:31706 4:3706

4:0058 Left Motor Status 4:31707 4:3707

4:0079 Right Motor Current 4:31708 4:3708

4:0080 Right Motor Frequency 4:31709 4:3709

4:0081 Right Motor Temperature 4:31710 4:3710

4:0082 Right Motor Status 4:31711 4:3711

4:0060 Left Motor Port Digital I/O Status 4:31712 4:3712

4:0084 Right Motor Port Digital I/O Status 4:31713 4:3713

4:0134 Upstream Module Status 4:31714 4:3714

4:0232 Downstream Module Status 4:31715 4:3715

Current Tracking Word 1 for Adjacent

4:0139 4:31716 4:3716
Upstream Module

Current Tracking Word 2 for Adjacent

4:0140 4:31717 4:3717
Upstream Module

N/A Current Module Reset Counter 4:31718 4:3718

4:0062 Left Motor Servo Position 4:31719 4:3719

4:0086 Right Motor Servo Position 4:31720 4:3720

4:0011 Left Motor Servo Status 4:31721 4:3721

Page 402 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

4:0016 Right Motor Servo Status 4:31722 4:3722

Page 403 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.11. Reset P
Prrotection for PLC I/O Mode
Assembly Outputs
Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0020 ConveyStop Command 4:31800 4:3800

4:0060 Set Left Motor Port Digital Control 4:31801 4:3801

4:0084 Set Right Motor Port Digital Control 4:31802 4:3802

4:0037 Control Port Digital Output Control 4:31803 4:3803

4:0260 Left Motor Run / Reverse 4:31804 4:3804

4:0261 Left Motor Brake Method 4:31805 4:3805

4:0262 Left Motor Speed Control Method 4:31806 4:3806

4:0270 Right Motor Run / Reverse 4:31807 4:3807

4:0271 Right Motor Brake Method 4:31808 4:3808

4:0272 Right Motor Speed Control Method 4:31809 4:3809

4:0040 Left Motor Speed Reference 4:31810 4:3810

4:0064 Right Motor Speed Reference 4:31811 4:3811

4:0043 Left Motor Acceleration Ramp 4:31812 4:3812

4:0044 Left Motor Deceleration Ramp 4:31813 4:3813

4:0067 Right Motor Acceleration Ramp 4:31814 4:3814

4:0068 Right Motor Deceleration Ramp 4:31815 4:3815

4:0022 Clear Motor Error 4:31816 4:3816

4:0196 Set Status to Downstream Module 4:31817 4:3817

4:0116 Set Status to Upstream Module 4:31818 4:3818

4:0034 Sensor Port Input Signal Condition Mask 4:31819 4:3819

4:0201 Set Discharge Tracking Word 1 4:31820 4:3820

4:0202 Set Discharge Tracking Word 2 4:31821 4:3821

N/A Set Module Reset Count 4:31822 4:3822

Page 404 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

4:0008 Left Motor Servo Command Pulses 4:31823 4:3823

4:0009 Left Motor Servo Command Word 4:31824 4:3824

4:0013 Right Motor Servo Command Pulses 4:31825 4:3825

4:0014 Right Motor Servo Command Word 4:31826 4:3826

Page 405 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

11.8.12. Reset P
Prrotection for PLC I/O Mode
Reduced Size
PLC I/O Mode Inputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0035 Sensor & Control Port Inputs 4:32700 4:4700

4:0036 Sensor Detect 4:32701 4:4701

4:0057 Left Motor Temperature 4:32702 4:4702

4:0058 Left Motor Status 4:32703 4:4703

4:0081 Right Motor Temperature 4:32704 4:4704

4:0082 Right Motor Status 4:32705 4:4705

4:0060 Left Motor Port Digital I/O Status 4:32706 4:4706

4:0084 Right Motor Port Digital I/O Status 4:32707 4:4707

N/A Current Module Reset Count 4:32708 4:4708

PLC I/O Mode Outputs

Assembled Assembled
Module
Register Name Addr
ddress
ess for FW Addr
ddress
ess for FW
Addr
ddress
ess
5.2 4.25 and earlier

4:0060 Set Left Motor Port Digital Control 4:32800 4:4800

4:0084 Set Right Motor Port Digital Control 4:32801 4:4801

4:0037 Control Port Digital Output Control 4:32802 4:4802

4:0260 Left Motor Run / Reverse 4:32803 4:4803

4:0270 Right Motor Run / Reverse 4:32804 4:4804

4:0040 Left Motor Speed Reference 4:32805 4:4805

4:0064 Right Motor Speed Reference 4:32806 4:4806

4:0022 Clear Motor Error 4:32807 4:4807

N/A Set Module Reset Count 4:32808 4:4808

Page 406 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

12. Setting Up Dual Motor Zones

! 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

This section describes how to set up conveyor zones with two motor rollers in scenarios
involving ZPA Mode, PLC I/O Mode, and ConveyLogix program control. The details of the set up
are also governed by the mechanical construction of the conveyor zone.

Solution Matrix for ConveyLinx-

ConveyLinx-ERSC
ERSC Family Modules
Zone T
Type
ype Operational Mode Solution

ZPA Requires set-up in EasyRoll

Requires program code to set up proper PLC Output

PLC I/O
2 MDRs – Coupled Assembly values

Requires program code to set up proper internal register

ConveyLogix
values

ZPA Not required to be set-up in Easy-Roll, but can be

No special adjustments required – Use program code to

2 MDRs – Non- PLC I/O
run independently or together as desired
Coupled
No special adjustments required – Use program code to
ConveyLogix
run independently or together as desired

ZPA Requires set-up in EasyRoll

Requires program code to set up proper PLC Output

2 Motors in 1 PLC I/O
Assembly values
MDR Tube
Requires program code to set up proper internal register
ConveyLogix
values

Page 407 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

12.1. 2 MDRs Mechanically Coupled

! 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

This scenario is perhaps the most common in that this would be the case for a two-motor roller
belted zone used in an incline or decline application as shown. Please note that mechanically
the two motor rollers can be coupled with just O-bands, Poly-V belts, etc. The concept is that
the upstream motor roller is there to assist the downstream motor roller.

Page 408 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

12.1.1. ZP
ZPA
A Mode
In general, when you perform an Auto
Auto-Configur
-Configure
e procedure, ConveyLinx Modules will configure
in ZP
ZPA
A 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 motors at the
same time. If the modules are at factory default, both motors will be at factory default settings.
Otherwise, the motor settings will be the ones last set by EasyRoll.

! Auto-Configuration of a two motor roller logical zone with an ERSC does not
automatically cause both motors to adopt the same motor settings.

For F
Fir
irmwar
mware
e 4.25 or OD
ODVVA Fir
irmwar
mware
e 5.02 and EasyR
EasyRoll
oll version 4.19

For F
Fir
irmwar
mware
e 4.27 and later or OD
ODVVA Fir
irmwar
mware
e 5.07 and later and EasyR
EasyRoll
oll
version 4.21

Page 409 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

12.1.1.1. For F
Fir
irmwar
mware
e 4.25/5.02
Open L
Loop
oop
If open loop speed control is desired; then set both motors to the same settings in EasyRoll

Closed L
Loop
oop
When using closed loop control, it is important to never place both motors into closed loop
control because they will “fight” each other particularly when accelerating and decelerating.
Perform the following basic steps in EasyRoll for the selected ERSC module:

Place
discharge
end motor
in closed
loop and
infeed end
motor in
open loop

Force Run
and both
motors
should run

Enter
desired
speed for
the zone
for the
closed loop
motor

Enter slow
speed in
open loop
motor

Verify that
the open
loop motor

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current is
non zero
and that
closed loop
current is
in the
range of
the rated
current

Adjust the
open loop
motor’s speed
until the
closed loop
motor’s
current is
approximately
500 to 800
mA

Please Note
that the
speed values
shown are
examples
only. The
actual speed
and current
values you
see may be
different

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It is
important to
not set the
Open Loop
motor’s
speed so
high as to
make the
Closed Loop
motor’s
current draw
be 0 mA

In our
example,
previously
our setting of
65% speed
on the Open
Loop motor
resulted in
@500 mA
draw on the
Closed Loop
motor. But
an
adjustment
to 70%
speed on the
Open Loop
motor results
in 0 mA
current draw
on the
Closed Loop
motor. This
will
eventually
cause an
overheat
error on the

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Closed Loop
motor.

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12.1.1.2. For F
Fir
irmwar
mware
e 4.27/5.07 and
EasyR
EasyRoll
oll 4.21
This is automatically handled when you utilize the Slave F
Function
unction in EasyRoll

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12.1.2. 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 your logic
or utilize some specific specialized programming to couple the motors together so that the on-
board firmware manages the master/slave control of the motors.

For F
Fir
irmwar
mware
e 4.25 or OD
ODVVA Fir
irmwar
mware
e 5.02

For F
Fir
irmwar
mware
e 4.27 and later or OD
ODVVA Fir
irmwar
mware
e 5.07 and later and EasyR
EasyRoll
oll
4.21 and later

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12.1.2.1. For F
Fir
irmwar
mware
e 4.25/5.02
Open L
Loop
oop
If open loop control is acceptable for your application, simply set both motors to open loop and
use the same settings in EasyRoll and write your PLC logic to run both motors at the same time
and in the same direction.

Closed L
Loop
oop
You have two choices if you wish to used closed loop speed control: Independent and Master/
Slave.

Independent

With this method you set up closed loop as described above for ZP
ZPA
A mode. In your PLC logic,
you must run both motors at the same time and in the same direction.

Master / Slave

The ConveyLinx Module firmware has the capability when in PLC I/O mode to operate both
motors at the same time by setting one motor as a master and its settings will be used for both
motors. With this method, your PLC logic first configures the functionality and then only
logically controls the master motor.

Unfortunately, the register to configure this functionality (4:0015) is not included in any of the
PLC I/O mode assemblies. Your PLC code must utilize a MSG instruction to write to this
configuration register.

The data is to be written to Register 4:0015 based on the following:

• Bit 0: Set for Left motor to be Master

• Bit 1: Set to make Right motor rotate opposite direction when Left is Master
• Bit 2: Set Right motor to be Master
• Bit 3: Set to make Left motor rotate opposite direction when Right is Master
• Bit 4: Always set to enable the functionality

* Programming Tip: You can set up your MSG instruction to continually write to
Register 15, even though the ConveyLinx Module only needs to get written to
once. If continually sending a MSG instruction is of concern for conservation of
PLC resources; you can monitor the module’s Reset Counter register or AOI
Module Enable bit to trigger the MSG write to register 15 only when you detect

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the module has power cycled or re-booted

You should use these bits as pairs. Either use bits 0 and 1 or use bits 2 and 3. Setting both bits
0 and 2 will not work
work.
For example, if you set bit 0, then your program logic only needs to control the Left motor in
the PLC I/O instance assembly and the Right motor will have its settings internally controlled by
the module.

! Please note when using Master/Slave motor control, the ConveyLinx Module
ignores the EasyRoll settings for the slave motor

! In 2 motor coupled conveyor application, always remember to never set bits 1 or

3

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12.1.2.2. For F
Fir
irmwar
mware
e 4.27/5.07 and
EasyR
EasyRoll
oll 4.21
Functionality is provided within the defined PLC I/O Assembly. See the Lef
eftt Motor Contr
Control
ol topic
to configure the Left Motor as a slave and see the Right Motor Contr
Control
ol topic to configure the
Right Motor as a slave.

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12.1.3. ConveyL
ConveyLogix
ogix P
Prrogram
You follow the same procedure as described for PLC I/O mode. You use the FirstLadderEx
irstLadderExec
ec
controller tag Boolean in a rung that executes a WR
WRCC block that writes the desired data to
Register 4:0015. By using the FirstLadderExec in this rung, it makes sure the data is written
upon any power up or re-boot of the ConveyLinx Module and that it is not continuously writing
the data every program scan and using up unnecessary module resources.

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12.2. Two Motors in One R

Roller
oller T
Tube
ube

! 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 shown.

! Regardless of which mode you will use, prior to performing the Auto
Configuration P
Prrocedur
ocedure
Auto--
e, unplug the motor cable opposite the ConveyLinx
Module

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During the Auto

Auto-Configur
-Configure
e
Procedur
ocedure e, all zones
become ZPZPA A mode and
motors will run. The
ConveyLinx Module does
not know the opposite
motor is in the same tube
and will try to rotate the
motors in the same
direction and they will be
in a mechanical bind.
Unplugging the opposite
motor will keep this from
happening

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12.2.1. ZP
ZPA
A Mode
Once Auto
Auto-Configur
-Configuree is complete with the opposite motor cable unplugged, you can reconnect
this motor cable.

For F
Fir
irmwar
mware
e 4.25 or OD
ODVVA Fir
irmwar
mware
e 5.02
You follow the same procedures as described for ZPA Mode in section Mechanically Coupled 2
Motor Roller – ZPA Mode for both Open Loop and Closed Loop control.

! Be sure to change the rotation direction in EasyRoll for the opposite motor

For F
Fir
irmwar
mware
e 4.27 and later or OD
ODVVA Fir
irmwar
mware
e 5.07 and
later and EasyR
EasyRoll
oll 4.21
This is handled by the Motor Slave F
Function
unction in EasyRoll

! Be sure to select the appropriate “opposite dir.” selection from the Motor Slave
drop down selector

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12.2.2. PLC I/O Mode

After Auto
Auto-Configuration
-Configuration is complete, you can reconnect the opposite motor cable and place
the ConveyLinx Module into PLC I/O mode with EasyR
EasyRoll
oll.

For F
Fir
irmwar
mware
e 4.25 or OD
ODVVA Fir
irmwar
mware
e 5.02
You have the same options as described in section Mechanically Coupled 2 Motor Roller – PLC I/
O Mode. For Open Loop control and Closed Loop – Independent control, remember to change
the direction of the opposite motor in EasyR
EasyRoll
oll. For Master/Slave control, be sure to remember
to set either bit 1 or bit 3 in Register 4:0015 to change the direction of the slave motor.

! Be sure to change the opposite motor’s direction either in EasyRoll or Register 15

depending on the method you choose

For F
Fir
irmwar
mware
e 4.27 and later or OD
ODVVA Fir
irmwar
mware
e 5.07 and
later and EasyR
EasyRoll
oll 4.21
Functionality is provided within the defined PLC I/O Assembly. See the Lef
eftt Motor Contr
Control
ol topic
to configure the Left Motor as a slave and see the Right Motor Contr
Control
ol topic to configure the
Right Motor as a slave.

! Be sure to use the appropriate “opposite direction” value for the Hi Byte in the
register

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12.2.3. ConveyL
ConveyLogix
ogix P
Prrogram
Follow the exact procedure as described in section Mechanically Coupled 2 Motor R
Roller
oller –
ConveyL
ConveyLogix
ogix P
Prrogram

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12.3. Two Motor R

Rollers
ollers in One L
Logical
ogical Zone
Not Coupled
In this mechanical scenario, the motor rollers are not coupled together as shown.

* Because the motors are not mechanically coupled, set the motor settings the
same in EasyR
EasyRoll
PLC I/O mode
oll and there are no other special things to do regardless of ZPA or

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13. Connecting to R
Rockwell
ockwell PLCs with
Ether
Ethernet
net I/P
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 Ether

Ethernet
net Device
• Import EDS and optionally import and use AOI
OIss
• 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.

Ether
Ethernet
net 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 ConveyLinx 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 ConveyLinx Connections as generic I/O modules utilizing any combination of
ZPA mode and PLC I/O Mode instances.
When a ConveyLinx module is attached as a “full-time generic I/O module” to the PLC, the
connection is continually maintained and data is exchanged at a minimum RPI value (referred
to as an implicit connection). If the PLC cannot communicate with the ConveyLinx module 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 ConveyLinx module it can physically reach over its Ethernet port without
the module being “full-time connected as a generic I/O module”. This is accomplished with a
Logix5000 MSG instruction (referred to as explicit connection).

* Reserve Ethernet I/P TCP connections for ConveyLinx modules in PLC I/O Mode

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and for key ZPA Mode modules where permanent accumulate/query/release

functionality is required

* Use MSG Instruction to gather less time-critical data for things such as status
and diagnostics

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13.1. Selecting Y
Your
our Connection Method
based upon Assembly
As described in our PLC Developer’s Guide, the data that you exchange with your PLC and a
given ConveyLinx 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 using the EDS file method or the Generic Ethernet Module
method.
All available assemblies can be connected utilizing the Generic Ethernet Module method and
only selected assemblies are available from the EDS file installation

Available as
Available
Generic
Assembly P
Pair
air fr
from
om EDS File
Ether
Ethernet
net
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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13.2. Using Generic Ether

Ethernet
net 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 Input and Output
Assemblies described in the PLC Developer’s Guide.

OD
ODVVA Compliant F
Fir
irmwar
mware
e 5.xx for ERSC
Pulseroller has been granted a Certificate of Conformity from ODVA for ConveyLinx ERSC
firmware version 5.02. The main difference between firmware 5.xx 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 4.25/4.27 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 or 4.27.
The following chart is a reference showing all the available assemblies and their respective
Instance Values used when connecting as a Generic Ethernet Device.

Recognized Instance V
Values
alues
Assembly
Pre 4.25 4.25/4.27 5.xx

ZPA Mode Assembly Inputs 5 5 & 105 105

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

39 39 & 319 319
Protection

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Reduced Size ZPA Mode Assembly Outputs with Reset

40 40 & 320 320
Protection

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

37 37 & 317 317
Protection

Reduced Size PLC I/O Mode Assembly Outputs with Reset

38 38 & 318 318
Protection

Not
ConveyLogix Assembly Inputs 121 121
Available

Not
ConveyLogix Assembly Outputs 122 122
Available

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13.3. Procedur
oceduree for Connecting using
Generic Ether
Ethernet
net 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.

https://www.youtube.com/embed/21vxtPUUWv8?rel=0

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13.3.1. 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 F
Fir
irmwar
mware
e 4.24 and Earlier

Assembly Type Instance V

Value
alue Size V
Value
alue

Input 5 21
ZP
ZPA
A Mode Assembly
Output 6 24

Input 25 21
ZP
ZPA
A Mode Assembly with R
Reset
eset P
Prrotection
Output 26 24

Input 7 23
PLC I/O Mode Assembly
Output 8 27

Input 27 23
PLC I/O Mode Assembly with R
Reset
eset P
Prrotection
Output 28 27

For F
Fir
irmwar
mware
e 4.25 and 4.27

Assembly Type Instance V

Value
alue Size V
Value
alue

Input 5 21
ZP
ZPA
A Mode Assembly
Output 6 25

Input 25 21
ZP
ZPA
A Mode Assembly with R
Reset
eset P
Prrotection
Output 26 25

Input 19 12
Reduced Size ZP
ZPA
A Mode Assembly
Output 20 15

Reduced Size ZP
ZPA
A Mode Assembly with R
Reset
eset Input 39 12
Protection Output 40 15

Input 7 23
PLC I/O Mode Assembly
Output 8 27

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Input 27 23
PLC I/O Mode Assembly with R
Reset
eset P
Prrotection
Output 28 27

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Input 17 9
Reduced Size PLC I/O Mode Assembly
Output 18 9

Reduced Size PLC I/O Mode Assembly with Input 37 9

Reset P
Prrotection Output 38 9

Input 121 16
ConveyL
ConveyLogix
ogix Assembly
Output 122 16

For F
Fir
irmwar
mware
e 5.02 and Higher

Assembly Type Instance V

Value
alue Size V
Value
alue

Input 105 21
ZP
ZPA
A Mode Assembly
Output 106 25

Input 305 21
ZP
ZPA
A Mode Assembly with R
Reset
eset P
Prrotection
Output 306 25

Input 119 12
Reduced Size ZP
ZPA
A Mode Assembly
Output 120 15

Reduced Size ZP
ZPA
A Mode Assembly with R
Reset
eset Input 319 12
Protection Output 320 15

Input 107 23
PLC I/O Mode Assembly
Output 108 27

Input 307 23
PLC I/O Mode Assembly with R
Reset
eset P
Prrotection
Output 308 27

Input 117 9
Reduced Size PLC I/O Mode Assembly
Output 118 9

Reduced Size PLC I/O Mode Assembly with Input 317 9

Reset P
Prrotection Output 318 9

Input 121 16
ConveyL
ConveyLogix
ogix Assembly
Output 122 16

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13.4. Procedur
oceduree for using EDS Method
Selecting the P
Prroper EDS File

The first step is to select the proper EDS file based upon the firmware version of your
ConveyLinx ERSC modules. Our Pulseroller.com website contains all EDS files for download
including older versions. The following chart lists firmware version, operation mode, and EDS
file cross-reference information:

ERSC Fir
irmwar
mware
e ERSC Mode EDS File

4.24 and Earlier ZP

ZPA
A Mode Only ConveyLinx_ZP
ConveyLinx_ZPA_Instance_1.eds
A_Instance_1.eds

4.24 and Earlier PLC I/O Mode Only ConveyLinx_PLC_IO_Instance_1.eds

4.25 and 4.27 ZP

ZPA
A & PLC I/O Mode ConveyLinx_V5_6.eds

5.02 and Later ZP

ZPA
A & PLC I/O Mode ConveyLinx_V5_6.eds

! For best results, you should remove any previous ERSC EDS file(s) you may have
installed in your RSLogix 5000 environment before installing a version from this
list

! 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 Pulseroller 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 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.

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https://www.youtube.com/embed/z28iBdmeRyg?rel=0

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13.5. Using ERSC AAdd

dd On Instructions (A
(AOI)
OI)
with RSL
RSLogix
ogix 5000
Pulseroller 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; your 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 is pur

purely
ely optional
optional. However, you must install the
EDS file as previously described before you can use any AOI

Selecting the P
Prroper AOI Instruction

AOI are imported to your specific PLC program file and not into the RSLogix 5000 environment
like an EDS file. The following chart provides a cross-reference for selecting the proper AOI file
based upon the ERSC firmware version and mode of operation

ERSC Fir
irmwar
mware
e ERSC Mode EDS File AOI File

4.24 and Earlier ZP

ZPA
A Mode ConveyLinx_ZP
ConveyLinx_ZPA_Instance_1.eds
A_Instance_1.eds ERSC
ERSC_ZP
_ZPA_424.L5X
A_424.L5X

PLC I/O
4.24 and Earlier ConveyLinx_PLC_IO_Instance_1.eds ERSC
ERSC_PLCIO_424.L5X
_PLCIO_424.L5X
Mode

4.25 ZP
ZPA
A Mode ConveyLinx_V5_6.eds ERSC
ERSC_ZP
_ZPA_425_5xx.L5X
A_425_5xx.L5X

PLC I/O
4.25 ConveyLinx_V5_6.eds ERSC
ERSC_PLCIO_425_5xx.L5X
_PLCIO_425_5xx.L5X
Mode

5.02 ZP
ZPA
A Mode ConveyLinx_V5_6.eds ERSC
ERSC_ZP
_ZPA_425_5xx.L5X
A_425_5xx.L5X

PLC I/O
5.02 ConveyLinx_V5_6.eds ERSC
ERSC_PLCIO_425_5xx.L5X
_PLCIO_425_5xx.L5X
Mode

4.27/5.07 ZP
ZPA
A Mode ConveyLinx_V5_6.eds ERSC
ERSC_ZP
_ZPA_427_507.L5X
A_427_507.L5X

PLC I/O
4.27/5.07 ConveyLinx_V5_6.eds ERSC
ERSC_PLCIO_425_507.L5X
_PLCIO_425_507.L5X
Mode

* Please refer to the downloads section of Pulseroller.com for the latest updates to

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EDS and/or AOI files

https://www.youtube.com/embed/dvkgMVEocoI?rel=0

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13.5.1. AOI T
Tag
ag 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

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13.5.1.1. ZP
ZPA
A Mode Inputs

* These tags ar
aree for AOI file ERSC
ERSC_ZP
_ZPA_427_507.L5X
A_427_507.L5X

Data Module
Tag Name Bit Description
Type Register

Arrival at Local Upstream Zone –

AOI Only active if zone becomes
I_Ar
I_ArrivalUPZn
rivalUPZn BOOL 4:0116
Logic occupied and it has been set to
accumulate

Arrival at Local Downstream Zone

AOI – Only active if zone becomes
I_Ar
I_ArrivalDNZn
rivalDNZn BOOL 4:0196
Logic occupied and it has been set to
accumulate

I_Contr
I_ControlP
olPortP
ortPin3_L
in3_Lef
eftt BOOL 4:0035 1 Left Control Port Pin 3 Energized

I_Contr
I_ControlP
olPortP
ortPin3_Right
in3_Right BOOL 4:0035 3 Right Control Port Pin 3 Energized

I_Contr
I_ControlP
olPortP
ortPin4_L
in4_Lef
eftt BOOL 4:0035 5 Left Control Port Pin 4 Energized

I_Contr
I_ControlP
olPortP
ortPin4_Right
in4_Right BOOL 4:0035 7 Right Control Port Pin 4 Energized

ConveyStop Activated at Local Left

I_ConveyStopByL
I_ConveyStopByLef
eftContr
tControlP
olPort
ort BOOL 4:0020 8
Control Port

ConveyStop Activated because of

I_ConveyStopByL
I_ConveyStopByLostConnection
ostConnection BOOL 4:0020 6
Lost Connection

ConveyStop Activated because of

I_ConveyStopByPLCCmd BOOL 4:0020 7
PLC Command

ConveyStop Activated because of

I_ConveyStopByPLCDisconnect BOOL 4:0020 10
Lost PLC Connection

ConveyStop Activated by another

I_ConveyStopByR
I_ConveyStopByRemoteModule
emoteModule BOOL 4:0020 5
module in Stop Group

ConveyStop Activated at Local

I_ConveyStopByRightContr
I_ConveyStopByRightControlP
olPort
ort BOOL 4:0020 9
Right Control Port

4:0201
(MSW) Current Forward Tracking Value at
I_GetF
I_GetForwar
orwardT
dTracking
racking DINT -
4:0202 Induct to Local Upstream Zone
(LSW)

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I_Heartbeat BOOL 4:0035 15 Module Heartbeat

Sensor Jam at Local Upstream

I_JamA
I_JamAtUPZn
tUPZn BOOL 4:0088 5
Zone

Sensor Jam at Local Downstream

I_JamA
I_JamAtDNZn
tDNZn BOOL 4:0089 5
Zone

Local ERSC Module Output are

I_ModuleEnabled BOOL - -
Enabled

Module Fault Active (Logical OR of

4:0088 AOI
I_ModuleF
I_ModuleFault
ault BOOL bits 2,4,and 7 from 5-6 and bits 2
4:0089 Logic
and 7 from 5-7

4:0088
(MSW)
I_ModuleStatus DINT Modules Status Words 1 and 2
4:0089
(LSW)

I_MtrEr
I_MtrErrror_L
or_Lef
eftt BOOL 4:0088 3 Left Motor Error is Active

I_MtrEr
I_MtrErrror_Right BOOL 4:0089 3 Right Motor Error is Active

I_SensorP
I_SensorPortP
ortPin3_L
in3_Lef
eftt BOOL 4:0035 0 Left Sensor Port Pin 3 Energized

I_SensorP
I_SensorPortP
ortPin3_Right
in3_Right BOOL 4:0035 2 Right Sensor Port Pin 3 Energized

I_SensorP
I_SensorPortP
ortPin4_L
in4_Lef
eftt BOOL 4:0035 4 Left Sensor Port Pin 4 Energized

I_SensorP
I_SensorPortP
ortPin4_Right
in4_Right BOOL 4:0035 6 Right Sensor Port Pin 4 Energized

4:0199
(MSW) Current Tracking Value for Arrival
I_T
I_TrackingDNZn
rackingDNZn DINT -
4:0200 at Local Downstream Zone
(LSW)

4:0119
(MSW) Current Tracking Value for Arrival
I_T
I_TrackingUPZn
rackingUPZn DINT -
4:0120 at Local Upstream Zone
(LSW)

Zone Status Local Downstream

I_ZoneStatusDnZn SINT 4:0196 Lo Byte
Zone Forward Direction

Zone Status Local Uptream Zone

I_ZoneStatusUpZn SINT 4:0116 Lo Byte
Forward Direction

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13.5.1.2. ZP
ZPA
A Mode Outputs

* These tags ar
aree for AOI file ERSC
ERSC_ZP
_ZPA_427_507.L5X
A_427_507.L5X

Data Module
Tag Name Bit Description
Type Register

Set Local Downstream Zone to

O_A
O_AccF
ccForAr
orArrivalDNZn
rivalDNZn BOOL 4:0184 0
Accumulate

Set Local Upstream Zone to

O_A
O_AccF
ccForAr
orArrivalUPZn
rivalUPZn BOOL 4:0104 0
Accumulate

Accumulate Adjacent Upstream

O_A
O_AccumA
ccumAdjUpstr
djUpstreamT
eamToDNZn
oDNZn BOOL 4:0184 8
to Local Downstream Zone

Accumulate Adjacent Upstream

O_A
O_AccumA
ccumAdjUpstr
djUpstreamT
eamToUPZn
oUPZn BOOL 4:0104 8
to Local Upstream Zone

Clear Jam at Local Upstream

O_ClearJamDNZn BOOL 4:0189 0
Zone

Clear Jam at Local Downstream

O_ClearJamUPZn BOOL 4:0109 0
Zone

O_ClearMotorEr
O_ClearMotorErrror BOOL 4:0022 0 Clear Motor Error Left & Right

Confirm Downstream Arrival for

O_ConfAr
O_ConfArrivalA
rivalAdjDownstr
djDownstreamT
eamToDNZn
oDNZn BOOL 4:0184 9
Local Downstream Zone

Confirm Downstream Arrival for

O_ConfAr
O_ConfArrivalA
rivalAdjDownstr
djDownstreamT
eamToUPZn
oUPZn BOOL 4:0104 9
Local Upstream Zone

O_Contr
O_ControlP
olPortOutputL
ortOutputLef
eftt BOOL 4:0063 1 Set Left Control Port Output

O_Contr
O_ControlP
olPortOutputRight
ortOutputRight BOOL 4:0063 3 Set Right COntrol Port Output

O_ConveyMer
O_ConveyMerge_DisableCenter
ge_DisableCenter BOOL 4:0387 4 Set to disable center release

O_ConveyMer
O_ConveyMerge_DisableL
ge_DisableLef
eftt BOOL 4:0387 5 Set to disable left release

O_ConveyMer
O_ConveyMerge_DisableRight
ge_DisableRight BOOL 4:0387 6 Set to disable right release

Set to enable PLC over-ride of

O_ConveyMer
O_ConveyMerge_EnablePLCCtrl
ge_EnablePLCCtrl BOOL 4:0387 15
configured ConveyMerge

Numerical value to set merge

O_ConveyMer
O_ConveyMergeP
gePriority
riority SINT 4:0387 -
priority

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Set Local ConveyStop

O_ConveyStopCommand INT 4:0020 -
Command Word

Direction & Accumulation Mode

Lo
O_D
O_DAModeCmdDNZn
AModeCmdDNZn SINT 4:0375 Command Byte for Downstream
Byte
Zone

Direction & Accumulation Mode

Lo
O_D
O_DAModeCmdUPZn
AModeCmdUPZn SINT 4:0365 Command Byte for Upstream
Byte
Zone

Direction & Accumulation Mode

Hi
O_D
O_DAModeV
AModeValueDNZn
alueDNZn SINT 4:0375 Data Byte for Downstream
Byte
Zone

Hi Direction & Accumulation Mode

O_D
O_DAModeV
AModeValueUPZn
alueUPZn SINT 4:0365
Byte Data Byte for Upstream Zone

AOI
O_EnableModule BOOL - Enable Output to ERSC
Logic

Jog Forward for Local

O_JogFwdDNZn BOOL 4:0184 10
Downstream Zone

Jog Forward for Local Upstream

O_JogFwdUpZn BOOL 4:0104 10
Zone

Jog Reverse for Local

O_JogR
O_JogRevDNZn
evDNZn BOOL 4:0184 11
Downstream Zone

Jog Reverse for Local Upstream

O_JogR
O_JogRevUPZn
evUPZn BOOL 4:0104 11
Zone

Release and Accumulate on

AOI Next at Downstream Zone –
O_R
O_ReleaseDNZn
eleaseDNZn BOOL 4:0105
Logic Automatically increments
release counter

Release and Accumulate on

AOI Next at Upstream Zone –
O_R
O_ReleaseUPZn
eleaseUPZn BOOL 4:0185
Logic Automatically increments
release counter

O_SpeedL
O_SpeedLef
eftMtr
tMtr INT 4:0040 - Set Left Motor Speed Reference

Set Right Motor Speed

O_SpeedRightMtr INT 4:0064 -
Reference

Set Downstream Discharge

O_StatusDownstr
O_StatusDownstreamDischar
eamDischarge
ge INT 4:0232 -
Zone Status Value

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Set Upstream Induct Zone

O_StatusUpstr
O_StatusUpstreamInduct
eamInduct INT 4:0134 -
Status Value

4:0212
(MSW) Set Tracking Value for Local
O_T
O_TrackingDNZn
rackingDNZn DINT -
4:0213 Downstream Zone
(LSW)

4:0139
(MSW) Set Forward Induct Tracking
O_T
O_TrackingInductFwd
rackingInductFwd DINT -
4:0140 Value
(LSW)

4:0132
(MSW) Set Tracking Value for Local
O_T
O_TrackingUPZn
rackingUPZn DINT -
4:0133 Upstream Zone
(LSW)

Wakeup Local Downstream

O_W
O_Wak
akeUpDNZn
eUpDNZn BOOL 4:0184 12
Zone

O_W
O_Wak
akeUpUPZn
eUpUPZn BOOL 4:0104 12 Wakeup Local Upstream Zone

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13.5.1.3. PLC I/O Mode Inputs

* These tags ar
aree for AOI file ERSC
ERSC_PLCIO_427_507.L5X
_PLCIO_427_507.L5X

Data Module
Tag Name Bit Description
Type Register

I_Contr
I_ControlP
olPortP
ortPin3_L
in3_Lef
eftt BOOL 4:0019 1 Port Inputs

I_Contr
I_ControlP
olPortP
ortPin3_Right
in3_Right BOOL 4:0035 3 Port Inputs

I_Contr
I_ControlP
olPortP
ortPin4_L
in4_Lef
eftt BOOL 4:0035 5 Port Inputs

I_Contr
I_ControlP
olPortP
ortPin4_Right
in4_Right BOOL 4:0035 7 Port Inputs

I_ConveyStopByL
I_ConveyStopByLef
eftContr
tControlP
olPort
ort BOOL 4:0019 8 ConveyStop

I_ConveyStopByL
I_ConveyStopByLostConnection
ostConnection BOOL 4:0019 6 ConveyStop

I_ConveyStopByPLCDisconnect BOOL 4:0019 7 ConveyStop

I_ConveyStopByPLCCmd BOOL 4:0019 10 ConveyStop

I_ConveyStopByR
I_ConveyStopByRemoteModule
emoteModule BOOL 4:0019 5 ConveyStop

I_ConveyStopByRightContr
I_ConveyStopByRightControlP
olPort
ort BOOL 4:0019 9 ConveyStop

I_DigitalMtrOverCur
I_DigitalMtrOverCurrrent_L
ent_Lef
eftt BOOL 4:0060 14 Left Motor Port as Digital

I_DigitalMtrOverCur
I_DigitalMtrOverCurrrent_Right BOOL 4:0084 14 Right Motor Port as Digital

I_DigitalMtrShortCkt_L
I_DigitalMtrShortCkt_Lef
eftt BOOL 4:0060 12 Left Motor Port as Digital

I_DigitalMtrtShortCkt_Right BOOL 4:0084 12 Right Motor Port as Digital

I_Downstr
I_DownstreamModuleStatus
eamModuleStatus SINT 4:0232 Lo Byte Module Status

I_Heartbeat BOOL 4:0035 15 Port Inputs

I_ModuleEnabled BOOL - - Module Status

I_ModuleV
I_ModuleVoltage
oltage REAL 4:0024 - Module Status

I_MtrCur
I_MtrCurrrent_L
ent_Lef
eftt REAL 4:0055 - Left Motor Status

I_MtrCur
I_MtrCurrrent_Right REAL 4:0079 - Right Motor Status

I_MtrF
I_MtrFrreq_L
eq_Lef
eftt INT 4:0056 - Left Motor Status

I_MtrF
I_MtrFrreq_Right INT 4:0080 - Right Motor Status

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AOI
I_MtrR
I_MtrRunningCCW_L
unningCCW_Lef
eftt BOOL 4:0058 Left Motor Status
Logic

AOI
I_MtrR
I_MtrRunningCCW_Right
unningCCW_Right BOOL 4:0082 Right Motor Status
Logic

AOI
I_MtrR
I_MtrRunningCW_L
unningCW_Lef
eftt BOOL 4:0058 Left Motor Status
Logic

AOI
I_MtrR
I_MtrRunningCW_Right
unningCW_Right BOOL 4:0082 Right Motor Status
Logic

I_MtrStatus_L
I_MtrStatus_Lef
eftt INT 4:0058 - Left Motor Status

I_MtrStatus_Right INT 4:0082 - Right Motor Status

I_SensorDetectL
I_SensorDetectLef
eftP
tPort
ort BOOL 4:0036 1 Sensor Port Status

I_SensorDetectRightP
I_SensorDetectRightPort
ort BOOL 4:0036 0 Sensor Port Status

I_SensorP
I_SensorPortP
ortPin3_L
in3_Lef
eftt BOOL 4:0035 0 Port Inputs

I_SensorP
I_SensorPortP
ortPin3_Right
in3_Right BOOL 4:0035 2 Port Inputs

I_SensorP
I_SensorPortP
ortPin4_L
in4_Lef
eftt BOOL 4:0035 4 Port Inputs

I_SensorP
I_SensorPortP
ortPin4_Right
in4_Right BOOL 4:0035 6 Port Inputs

I_ServoCmdStatus_L
I_ServoCmdStatus_Lef
eftt BOOL 4:0011 2 Left Servo Function

I_ServoCmdStatus_Right BOOL 4:0016 2 Right Servo Function

I_ServoLastCmdComplete_L
I_ServoLastCmdComplete_Lef
eftt BOOL 4:0011 0 Left Servo Function

I_ServoLastCmdComplete_Right BOOL 4:0016 0 Right Servo Function

I_ServoP
I_ServoPosition_L
osition_Lef
eftt INT 4:0062 - Left Servo Function

I_ServoP
I_ServoPosition_Right
osition_Right INT 4:0086 - Right Servo Function

I_ServoR
I_ServoResetStatus_L
esetStatus_Lef
eftt BOOL 4:0011 1 Left Servo Function

I_ServoR
I_ServoResetStatus_Right
esetStatus_Right BOOL 4:0016 1 Right Servo Function

I_T
I_Temperatur
emperatureCalculated_L
eCalculated_Lef
eftt SINT 4:0057 Hi Byte Left Motor Status

I_T
I_Temperatur
emperatureCalculated_Right
eCalculated_Right SINT 4:0081 Hi Byte Right Motor Status

I_T
I_Temperatur
emperatureOnBoar
eOnBoard_L
d_Lef
eftt SINT 4:0057 Lo Byte Left Motor Status

I_T
I_Temperatur
emperatureOnBoar
eOnBoard_Right
d_Right SINT 4:0081 Lo Byte Right Motor Status

I_Upstr
I_UpstreamModuleStatus
eamModuleStatus SINT 4:0134 Lo Byte ZPA Status

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4:0139
(MSW)
I_Upstr
I_UpstreamT
eamTracking
racking DINT - ZPA Tracking
4:0140
(LSW)

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13.5.1.4. PLC I/O Mode Outputs

* These tags ar
aree for AOI file ERSC
ERSC_PLCIO_427_507.L5X
_PLCIO_427_507.L5X

Data Module
Tag Name Bit Description
Type Register

Lo
O_Brak
O_BrakeMethod_L
eMethod_Lef
eftt SINT 4:0261 Left Motor Control
Byte

Lo
O_Brak
O_BrakeMethod_Right
eMethod_Right SINT 4:0271 Right Motor Control
Byte

O_ClearMotorEr
O_ClearMotorErrror BOOL 4:0022 Motor Control

O_Contr
O_ControlP
olPortOutput_L
ortOutput_Lef
eftt BOOL 4:0037 1 Left Motor Control

O_Contr
O_ControlP
olPortOutput_Right
ortOutput_Right BOOL 4:0037 3 Right Motor Control

Sensor/Control Port
O_Contr
O_ControlP
olPortP
ortPin3Mask_L
in3Mask_Lef
eftt BOOL 4:0034 1
Configuration

Sensor/Control Port
O_Contr
O_ControlP
olPortP
ortPin3Mask_Right
in3Mask_Right BOOL 4:0034 3
Configuration

Sensor/Control Port
O_Contr
O_ControlP
olPortP
ortPin4Mask_L
in4Mask_Lef
eftt BOOL 4:0034 5
Configuration

Sensor/Control Port
O_Contr
O_ControlP
olPortP
ortPin4Mask_Right
in4Mask_Right BOOL 4:0034 7
Configuration

O_ConveyStopCommand INT 4:0020 ConveyStop

4:0201
(MSW)
O_Dischar
O_DischargeT
geTracking
racking DINT ZPA Tracking
4:0202
(LSW)

Lo
O_Downstr
O_DownstreamStatus
eamStatus SINT 4:0196 ZPA Status
Byte

O_EnableModule BOOL - - Module Control

O_L
O_Lef
eftMtrDigitalP
tMtrDigitalPin3
in3 BOOL 4:0060 0 Left Motor Port Digital Control

O_L
O_Lef
eftMtrDigitalP
tMtrDigitalPin4
in4 BOOL 4:0060 1 Left Motor Port Digital Control

O_L
O_Lef
eftMtrDigitalP
tMtrDigitalPin5
in5 BOOL 4:0060 2 Left Motor Port Digital Control

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O_MtrA
O_MtrAccel_L
ccel_Lef
eftt INT 4:0043 Left Motor Control

O_MtrA
O_MtrAccel_Right
ccel_Right INT 4:0067 Right Motor Control

O_MtrDecel_L
O_MtrDecel_Lef
eftt INT 4:0044 Left Motor Control

O_MtrDecel_Right INT 4:0068 Right Motor Control

Right Motor Port Digital

O_RightMtrDigitalP
O_RightMtrDigitalPin3
in3 BOOL 4:0084 0
Control

Right Motor Port Digital

O_RightMtrDigitalP
O_RightMtrDigitalPin4
in4 BOOL 4:0084 1
Control

Right Motor Port Digital

O_RightMtrDigitalP
O_RightMtrDigitalPin5
in5 BOOL 4:0084 2
Control

O_Mtr_R
O_Mtr_Run_L
un_Lef
eftt BOOL 4:0260 0 Left Motor Control

O_Mtr_R
O_Mtr_Run_Right
un_Right BOOL 4:0270 0 Right Motor Control

O_Mtr_Dir_L
O_Mtr_Dir_Lef
eftt BOOL 4:0260 8 Left Motor Control

O_Mtr_Dir_Right BOOL 4:0270 8 Right Motor Control

Hi
O_Mtr_Slave_Mode_L
O_Mtr_Slave_Mode_Lef
eftt SINT 4:0260 Left Motor Control
Byte

Hi
O_Mtr_Slave_Mode_Right SINT 4:0260 Right Motor Control
Byte

Sensor/Control Port
O_SensorP
O_SensorPortP
ortPin3Mask_L
in3Mask_Lef
eftt BOOL 4:0034 0
Configuration

Sensor/Control Port
O_SensorP
O_SensorPortP
ortPin3Mask_Right
in3Mask_Right BOOL 4:0034 2
Configuration

Sensor/Control Port
O_SensorP
O_SensorPortP
ortPin4Mask_L
in4Mask_Lef
eftt BOOL 4:0034 4
Configuration

Sensor/Control Port
O_SensorP
O_SensorPortP
ortPin4Mask_Right
in4Mask_Right BOOL 4:0034 6
Configuration

O_ServoCmdP
O_ServoCmdPulses_L
ulses_Lef
eftt INT 4:0008 Left Servo Function

O_ServoCmdP
O_ServoCmdPulses_Right
ulses_Right INT 4:0013 Right Servo Function

O_ServoGoCmd_L
O_ServoGoCmd_Lef
eftt BOOL 4:0009 1 Left Servo Function

O_ServoGoCmd_Right BOOL 4:0014 1 Right Servo Function

O_ServoZer
O_ServoZero_L
o_Lef
eftt BOOL 4:0009 0 Left Servo Function

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O_ServoZer
O_ServoZero_Right
o_Right BOOL 4:0014 0 Right Servo Function

O_L
O_Lef
eftMtrDigital_Enable
tMtrDigital_Enable BOOL 4:0060 15 Left Motor Port Digital Control

Right Motor Port Digital

O_RightMtrDigital_Enable BOOL 4:0084 15
Control

Lo
O_SpeedMethod_L
O_SpeedMethod_Lef
eftt SINT 4:0262 Left Motor Control
Byte

Lo
O_SpeedMethod_Right SINT 4:0272 Right Motor Control
Byte

O_SpeedR
O_SpeedRefer
eference_L
ence_Lef
eftt INT 4:0040 Left Motor Control

O_SpeedR
O_SpeedRefer
eference_Right
ence_Right INT 4:0064 Right Motor Control

Lo
O_Upstr
O_UpstreamStatus
eamStatus SINT 4:0116 ZPA Status
Byte

Enable the Left Motor Port

O_L
O_Lef
eftMtrDigital_Brak
tMtrDigital_BrakeP
ePinEnable_NoD
inEnable_NoD BOOL 4:0060 7
Brake pin digital output

Left Motor Brake Pin Digital

O_L
O_Lef
eftMtrDigital_Brak
tMtrDigital_BrakeP
ePin
in BOOL 4:0060 6
Control

Left Motor Digital Clear Over-

O_L
O_Lef
eftMtrDigital_ClearOC
tMtrDigital_ClearOC BOOL 4:0060 8
current Error

Enable the Right Motor Port

O_RightMtrDigital_Brak
O_RightMtrDigital_BrakeP
ePinEnable_NoD
inEnable_NoD BOOL 4:0084 7
Brake pin digital output

Right Motor Brake Pin Digital

O_RightMtrDigital_Brak
O_RightMtrDigital_BrakeP
ePin
in BOOL 4:0084 6
Control

Right Motor Digital Clear Over-

O_RightMtrDigital_ClearOC BOOL 4:0084 8
current Error

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PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

13.6. Using L
Logix
ogix 5000 MSG Instruction
Access to ConveyLinx ERSC modules is also available utilizing the Logix 5000 MSG instruction.
The MSG instruction utilizes CIP Explicit Messaging. This means that the connection is not
maintained as an implicit connection. Generic Ethernet Module and EDS connections are
implicit and thus must be maintained at all times or there will be a communication fault.
Explicit Messaging opens the connection, reads/writes data, and then closes the connection
thus freeing up communications resources for the PLC.

When to use MSG Instructions

Because the MSG instruction is executed asynchronous to program scan and is not subject to
implicit messaging RPI restrictions; the response time between requesting data and receiving
data is not deterministic and can vary between separate requests for the same data from the
ecommend that MSG instructions should not be used for dedicated
same device. Therefore, we rrecommend
“real time” contr
control equipment. For ConveyLinx ERSC modules, MSG instructions are intended
ol of equipment
to gather “low priority” status information and/or to send infrequent parameter changes.
Please note that this is only a recommendation. Your particular application’s specifics, PLC’s
capacity, available network bandwidth, etc. may allow you to get expected results with “real
time” control utilizing MSG instructions to interface with ERSC modules.

Module VS. Assembly A

Addr
ddresses
esses with MSG Instruction

Module Addresses are the 512 “actual” registers in the module and and Assemblies are
“virtual” registers grouped based upon function. There are certain restrictions on what you can
do with a MSG Instruction:

• You can us a single MSG instruction to read one and up to 30 consecutive Module
registers
• You can use a single MSG instruction to write to one (an only one) of the Module registers
• You can use a single MSG instruction to read any of the available Input Assembly registers
in their entirety
• You CANNOT use any MSG instruction to write to any Output Assembly registers.

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13.6.1. Read MSG Instruction

For this example, we have created an ERSC module in our Ethernet Tree and added a MSG
Instruction to a ladder rung. We named this MSG block “ReadStatus” and created the Controller
Tag for it. With this MSG Instruction we are going to read Module Address 4:0088 and 4:0089
which are Module Status Word 1 and 2. We also created a Controller Tag of data type DINT we
named “TempDiagStatus” to hold this data. Data from 4:0088 will be in the High Word of the
DINT and 4:0089 will be in the low word of the DINT.

From the Message Type drop down, select CIP Generic

From the Service Type drop down, select Get Attribute Single

For the Instance Field, enter “88”

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For the Class Field, enter “64”

For the Attribute Field, enter “2” because we want to read 4:0088 and 4:0089

For the Destination Element, use the Tag Browser drop down to select TempDiagStatus

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PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

13.6.2. Write MSG Instruction

For this example, we have created an ERSC module in our Ethernet Tree and added a MSG
Instruction to a ladder rung. We named this MSG block “WriteSpeed” and created the Controller
Tag for it. With this MSG Instruction we are going to write a value for the Left Motor Speed at
Module Address 4:0040. We also created a Controller Tag of data type INT we named
“NewSpeed” which will hold the speed value we want to write to the module when we execute
the MSG Instruction.

From the Message Type drop down, select CIP Generic

From the Service Type drop down, select Set Attribute Single

For the Instance Field, enter “40”

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For the Class Field, enter “64”

For the Attribute Field, enter “1”

For the Source Element, use the Tag Browser drop down to select NewSpeed

For the Source Length, enter “2” (2 bytes = 1 INT)

Page 455 of 557

PULSEROLLER ConveyLinx ERSC Complete Guide - 5.1_en

13.6.3. Reading ERSC Input Assembly with

MSG Instruction

! This functionality is only available in firmware versions 4.25 and higher

For this example, we have created an ERSC module in our Ethernet Tree and added a MSG
Instruction to a ladder rung. We named this MSG block “ReadZPA” and created the Controller
Tag for it. With this MSG Instruction we are going to read all 21 registers from PLC Inputs for
ZPA Mode. We also created a Controller Tag called “ZPA_Inputs” which is an INT array of 21
elements in order to hold the data.

* When reading any input Assembly with a MSG Instruction, be sure you create the
Destination Element Controller Tag an array of INT with the number of elements
that match the number of registers in the Assembly

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From the Message Type drop down, select CIP Generic

From the Service Type drop down, select Get Attribute Single

For the Instance Field, enter “105” which is the Assembly vale for the ZPA Mode inputs

For the Class Field, enter “4”

For the Attribute Field, enter “3”

For the Destination Element, use the Tag Browser drop down to select ZPA_Inputs and
expand to select the [0] element

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13.7. EDS Module Data T

Type
ype Cr
Cross
oss
Refer
eference
ence
When you create an instance of a device from an EDS file in your RSLogix 5000 environment;
the EDS file provides a Module Defined Data Type for the inputs and outputs of the device. This
Module Defined Data Type’s name is automatically generated by the EDS file creation’s
software and is based upon (among other things) a checksum of the items in the file. This often
creates a somewhat cryptic alpha-numeric string for the name.

In situations where you may inherit an existing program and your RSLogix 5000 environment is
missing the EDS file used for this program; you will need to determine which version of EDS file
was used and then go find it on our Pulseroller.com web site. Similarly, you may also have the
situation where you need to be able to match your AOI version to its correct EDS file. The
following chart cross references the most common EDS files, AOI files, and Module Data Types

EDS File AOI File Fir

irmwar
mware
e Module Data T
Type
ype

4.24 and _055C:ERSC_ZPA_84EED4D3:I:

ConveyLinx_ZPA_Instance_1.eds ERSC_ZPA_424.L5X
older _055C:ERSC_ZPA_FB496954:O

4.24 and _055C:ERSC_PLCIO_C92675D8:

ConveyLinx_PLC_IO_Instance_1.eds ERSC_PLCIO_424.L5X
older _055C:ERSC_PLCIO_7DDD1BFA:O

4.25 / _055C:ERSC_84EED4D3:I:0
ERSC_ZPA_5_2.L5X 5.02 and
newer _055C:ERSC_3015BAF1:O:0
ConveyLinx_V5_4.eds
4.25 / _055C:ERSC_C92675D8:I:0
ERSC_PLCIO_5_2.L5X 5.02 and
newer _055C:ERSC_7DDD1BFA:O:0

4.25 / _055C:ERSC_84EED4D3:I:0
ERSC_ZPA_425_5xx.L5X 5.02 and
newer _055C:ERSC_3015BAF1:O:0
ConveyLinx_V5_6.eds
4.25 / _055C:ERSC_C92675D8:I:0
ERSC_PLCIO_425_5xx.L5X 5.02 and
newer _055C:ERSC_7DDD1BFA:O:0

4.24 and _055C:ERSC_ZPA_84EED4D3:I:

ConveyLinx_ZPA_Instance.eds ERSC_ZPA_424.L5X
older _055C:ERSC_ZPA_FB496954:O

4.24 and
ConveyLinx_PLC_IO_Instance.eds ERSC_PLCIO_424.L5X _055C:ERSC_PLCIO_C92675D8:
older

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_055C:ERSC_PLCIO_7DDD1BFA:O

* For versions or Module Data Types not shown, please contact

[email protected]

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14. 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 examples, but the concepts are
applicable to all ConveyLinx modules

S7 PLCs from Siemens can use ConveyLinx modules because they support PROFINET IO
communication protocol and can act as PROFINET IO-devices with the S7 PLC acting as a
PROFINET IO controller. The PLC can connect in different ways to the same ConveyLinx module
based upon how you want to use it. Each of these different ways that the PLC can connect to a
given module is called a Device A Access
ccess PPoint
oint ((D AP)). For a given ConveyLinx module type or
DAP
family, your PLC programming environment needs a GSDML file installed so your environment
can display each of the DAP AP’s
’s available for that given module type or family. Each ConveyLinx
module family (ConveyLinx-ERSC, ConveyLinx-Ai, and ConveyLinx-ECO) has their own GSDML
file that contains all of its DAP information. Each DAP corresponds to a Mode of Operation of the
ConveyLinx module.

Preparing your P
Prrogramming Envir
Environment
onment
Understanding the ConveyLinx Module’s Modes of Operation

Device A
Access
ccess P
Points
oints ((D
DAP
AP))
The ProfiNet protocol allows for multiple access ways for a single physical device. This is called
a Device A
Access
ccess PPoint
oint or DAP. In essence each DAP allows the PLC to connect to the same
physical device in a different way from the other DAPs for that device. The number of DAPs a
device supports is vendor specific so every manufacturer decides how many access ways to
provide for their device.

After you install the appropriate GSDML file into your programming environment based upon
the ConveyLinx Family you are using, there will be two directories (or folders) of DAP
APss:

1. Contains the DAPs that are used when you want to use Separate ConveyLinx Auto
Auto--
Configuration by either Install Button (ConveyLinx-ERSC Family) or by EasyRoll
(ConveyLinx-Ai Family and ConveyLinx-ECO)
2. Contains DAPs that are used when you want to use Integrated Configuration Dir
Direct
ect fr
from
om
PLC Topology to detect the topology of your ConveyLinx network and configure all

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modules

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14.1. Preparing Y
Your
our P
Prrogramming
Envir
Environment
onment
In order to use ConveyLinx with your PLC, you need to install the proper configuration files into
your TIA Portal or STEP 7 programming environment. The files required will be included in a
downloadable .zip ararchive
chive fr
from
om our site and will include an xml with the filename structur
structuree
“GSDML
GSDML--V2.xx-IndustrialSof
V2.xx-IndustrialSoftwar
tware-ConveyLinx-yyyymmdd.xml”
e-ConveyLinx-yyyymmdd.xml” and at least 1 bitmap file ((.bmp)
with the graphic image of the particular module(s) for which the xml file specifies for your
Siemens programming environment.

There are also optional (but highly recommended) User Data T

Type
ype ((UDT
UDT)) files specific for each
module type and Mode of Operation you wish to use.

* The files you will need are dependent on the specific Conveylinx module and
module firmware version you are using.

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14.2. Modes of Operation

When installed, ConveyLinx modules can be configured as one of the following 6 basic modes:

Full ZP
ZPA
A Mode
n this mode, ConveyLinx works as a one or two zone ZP
ZPAA contr
controller
oller. When communicating with
module in this mode, the S7-300 PLC can control mainly material handling properties such as
accumulation, release, wake-up/full stop, read/write tracking, MDR parameters (speed,
acceleration and deceleration), and ConveyStop. In this mode the PLC does not have access to
directly control start/stop of MDRs because internal ZPA logic is operating the module. When
communicating with ConveyLinx in ZPA mode, the PLC does not require fast reaction time as
would be expected for a remote I/O device. Typically, 32 ms to 256 ms is the range of response
time utilized between the PLC and a ConveyLinx module in ZPA mode. The data array instance
lengths for input and output data mode are 64 bytes.

Reduced ZP
ZPA
A Mode
In this mode, the ConveyLinx modules operates as a one or two zone ZP ZPAA contr
controller
oller just like the
Full ZPA Mode. However, the instance data presented to the S7-300 PLC is limited to basic
material handling properties such as accumulation, release, wake-up/full stop, and MDR speed.
In this mode, because the instances length is reduced to 30 bytes; the PLC may be able to
accommodate more modules especially in applications where all ZPA features (such as
tracking) are not required. Similarly to the Full ZPA Mode, the 32 ms to 256 ms response time is
typical for this mode.

Mer
Merger
ger Mode
In this mode, the module is running in ZP
ZPA
A mode and exchanging 64 bytes of data with the PLC.
In addition to the ZPA logic, the module now runs the Merger task on one of their zones.
Configuring the Merger zone, differs between the two configuration methods (see Configuration
methods chapter). Similarly to the Full ZPA Mode, the 32 ms to 256 ms response time is typical
for this mode. The exchanged data is the same as for the Full ZPA mode.

Full PLC Contr

Controlled
olled Mode
In this mode, the ConveyLinx module is placed into PLC I/O mode with the EasyRoll software
tool. When the module is in PLC I/O mode, all inter
internal
nal ZP
ZPA
A logic is suspended and the module
requires an external PLC to read port inputs and run/stop MDRs connected to the module. The
PLC contains any and all logic to process inputs from sensor/control ports, run stop MDRs, set
direction/speed/accel/decel of MDRs, and more. Also, in this mode the PLC has access to
registers in the PLC I/O module that can interface to neighboring ZPA modules for material

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handling control and tracking data support. A ConveyLinx module in PLC I/O mode is also
capable of Servo functions that are made available to the PLC. In this mode, the ConveyLinx
module responds as would be expected for a remote I/O device. ConveyLinx will connect to the
PLC with a 4 ms communication response time. The data array instance lengths for input and
output data in this mode are 64 bytes.

Reduced PLC Contr

Controlled
olled Mode
In this mode, the ConveyLinx module is configured and operates without ZP ZPA
A logic the same as
it does in Full PLC Controlled Mode. However in this mode, only port I/O and MDR run/stop/
speed functions are available to the PLC. In this mode, because the instances length is
reduced; the PLC may be able to accommodate more modules especially in applications where
all the features in Full PLC Controlled Mode are not required. ConveyLinx modules in this mode
communicate at the same 4 ms response time as the Full PLC Controlled Mode. The data array
instance lengths for input and output data in this mode are 16 bytes

PLC Contr
Controlled
olled Mode with ConveyL
ConveyLogix
ogix P
Prrogram
In this mode, the ConveyLinx module has been programmed with ConveyLogix and this
program is running inside. ConveyLogix allows you to write your own programs and download it
to the ConveyLinx module turning it into a small PLC. The ToPLCArray(WORD [16] ) and
FromPLCArray(WORD [16]) are exchanged with the PLC. What data is exchanged in those data
arrays, is programmed by the engineer in the ConveyLogix program and in the PLC. The
communication response time should be adjusted by the programmer, based on the size and
complexity of the ConveyLogix program. The bigger it is, the higher update speeds should be
selected.

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14.3. Understanding the T

Two
wo Configuration
Methods

! Before going further, you will need to decide which of these two methods you are
going to use!

In general, a network of ConveyLinx modules must be AutoAuto-Configur

-Configured
ed before they can work
together in ZPA mode or exchange any data with each other when in PLC I/O mode. The typical
method is to utilize the Install Button (on ERSC family modules) or EasyR
EasyRoll
oll (for ConveyLinx-Ai
Family and ConveyLinx-ECO). When you use Siemens S7 PLCs and TIA Portal or Step 7 Manager,
you can have the ConveyLinx modules automatically configur
configured
ed fr
from
om the PLC based upon the
topology you create at design time in your Siemens PLC programming environment.

Separate ConveyLinx Auto

Auto-Configuration
-Configuration
When using this method, the configuration of a module or group of modules is initiated with the
Install Button or EasyR
EasyRoll
oll software. All of the module parameters such as motor modes
(ECO/BOOST etc.), module mode (PLC/ZPA), inter-module connections, Merger zone, IP
addresses and all other general parameters are assigned during the Auto Auto-Configuration
-Configuration
procedure. The Profinet name is formed by the module during the Auto-Configuration procedure
as well. In order write your program in the PLC, you will need to know the e exact
xact P
Prrofinet name
of each module you wish to connect and you do not have the fle flexibility
xibility to change these names.

Advantages of Separate ConveyLinx Auto

Auto-Configuration
-Configuration

* Changing parameters like motor settings, ZPA functionality, etc. can be done
for multiple modules all at once with EasyRoll
* Your PLC only has to connect to modules it needs to interface with and not
every module in the network
* ZPA Extension function is able to be configured

Disadvantages to Separate ConveyLinx Auto

Auto-Configuraton:
-Configuraton:

* Profinet name of the module is set during Auto-Configuration and cannot be

modified
* Your PLC must use the exact syntax of the module’s Profinet name in order to
connect
* You have to know in advance your exact network topology and I.P. addressing
prior to programming your PLC

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Integrated Configuration Dir

Direct
ect fr
from
om PLC Topology

! This method is only available for ConveyLinx-ERSC Family for 4 series firmware
4.27 and higher and 5 series firmware 5.03 and higher

When using this method, you create your network topology within the Siemens PLC
programming environment (TIA Portal or STEP 7). All pertinent module parameters become
available within your environment and can be configured at design time. As long as your
physical installed network topology of control modules matches your designed topology in your
PLC programming environment; when you download your project to your PLC, the PLC takes
care of all of the ConveyLinx control module configuration.

Advantages of Configuration fr
from
om PLC Topology
opology::

* No module naming restrictions

* No need to use separate EasyRoll software
* Module replacement is true plug and play because PLC handles the procedure
* All module parameters are integrated into the Siemens PLC programming
environment

Disadvantages to Configuration fr
from
om PLC Topology
opology::

* You have to include all ConveyLinx modules in your topology regardless of

whether you need to interact with them with your PLC logic for your system
* No built in ability to change parameters for multiple modules at the same
time; you have to construct own PLC logic to do this
* ZPA Extension function is not available

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14.4. Separate ConveyLinx Auto

Auto--
Configuration

! This section applies ONLY when you use Separate ConveyLinx Auto-Configuration
(EasyRoll or ConveyLinx module Install button)

Adding ConveyLinx Modules to Y

Your
our P
Prroject
Once you have installed the GSDXML file into your environment, ConveyLinx devices are
available to be used in your project. You can find ConveyLinx devices in the Har
Hardwar
dware
e Catalog
window

Drill down the tree

structure to get to the
folder Conveyor Contr
Control
ol
with EasyR
EasyRoll
oll configuration
to see the available DAPs

* The Mode of Operation of a given ConveyLinx module will determine which of the
DAP
APss to drag and drop from the Har
Hardwar
dware
e Catalog window into your project

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14.4.1. Profinet Name

When ConveyLinx modules are Auto
Auto-Configur
-Configured
ed from either EasyR
EasyRoll
oll or by Install button , each
module automatically generates its own specific Profinet Names each with an exact syntax that
corresponds to the Mode of Operation (ZP
ZPAA or PLC I/O) determined during Auto-Configuration. If
you performed Auto-Configuration with an Install button, each module defaults to ZP ZPA
A Mode
and the ZP
ZPA
A Profinet Names will be automatically generated. If you use EasyR
EasyRoll
oll to change a
module from ZPA to PLC I/O Mode, the Profinet Names are automatically updated for PLC I/O
Mode

The following chart shows the exact syntax for Profinet Names:

Mode Syntax Remarks

Full ZPA conveylinxzpa-

Reduced ZPA xxx-yyy xxx = 3rd Octet
of I.P. Address
Full PLC
Controlled conveylinxplc- yyy = 4th Octet
xxx-yyy of I.P. Address
Reduced PLC
Controlled

! With ConveyLinx Auto-Configured modules, you cannot change the Profinet

Name in the module and you MUST use the EXACT Profinet Name in your
Siemens programming environment in order to communicate with a given
module.

* Please do not confuse the module’s General Name or Project Name that you
assign for a given device with its Profinet Name
Name. The Profinet Name is required to
be in the proper syntax or the module will not connect to the PLC. The module’s
Project Name is completely user’s choice to identify the module in the your
Siemens programming environment and is what is displayed in your project’s
Network View(s) and Project Tree.

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14.4.2. Examples of A
Adding
dding Modules
In this section we will provide an example that will add a single module of each Mode to a
project. This will require a combination of selecting the proper DAP from the Hardware catalog
coupled with using the correct Profinet Name to achieve our desired result. The following chart
lists the 6 modules we want to add to our project and the proper Device and Profinet Name
syntax needed.

DAP fr
from
om
Module
I.P
I.P.. A
Addr
ddress
ess Har
Hardwar
dware
e Profinet Name
Mode
Catalog

Full ZPA 192.168.0.20 ConveyLinx-Ai conveylinxzpa-0-20

Full PLC
192.168.101.21 ConveyLinx-Ai conveylinxplc-101-21
Controlled

ConveyLinx-Ai in
Reduced
192.168.101.22 reduced ZPA conveylinxzpa-101-22
ZPA
mode

Reduced ConveyLinx-Ai in
PLC 192.168.20.123 reduced PLC conveylinxplc-20-123
Controlled mode

Full ZPA with

192.168.0.21 ConveyLinx-Ai conveylinxzpa-0-21
Merger

ConveyLinx-Ai in
ConveyLogix
192.168.0.22 PLC mode with conveylogix-0-22
Interface
ConveyLogix

* The following sections will show the details of adding each of these items to you
TIA Portal environment

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14.4.2.1. Full ZP
ZPA
A
STEP 1: A
Add
dd the Module to the PLC Network

From the Catalog window,

drag and drop the
ConveyLinx-Ai DAP into
the Network V
View
iew window

To attach the module to

the PLC, click on the Not
Assigned link and select
the desired Profinet
Interface of the PLC

When attached, you will

see the green graphic
linking the PLC and the
module together

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STEP 2: Assign the EXA

EXACT
CT Profinet Name to the Module

In the Project T
Trree locate
your newly created
module under the
Ungr
Ungrouped
ouped devices folder.
Right Click on your module
to show a pop-up menu
and select Properties

A new window will open.

Select General from the
menu on the left. In the
Name field enter the
required name for the
device. In our example it is
conveylinxzpa-0-20 from
the Example Table

Type in the EXA CT Profinet

EXACT
Name and press enter to
make the change

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STEP 3: Enter the I.P

I.P.. A
Addr
ddress
ess

In the same properties

area that you changed the
Profinet Name, click on
Ether
Ethernet
net addr
addresses
esses and
enter the I.P. address. In
our example it is
192.168.0.20 from the
Example Table

STEP 4: Select Update T

Time
ime Interval
In the same properties
area that you changed the
Profinet Name, click on
Advanced options and
select a proper Update
Time. For a ConveyLinx
module in ZPA mode, the
recommended Update
time should be between
32ms and 512ms.

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14.4.2.2. Full PLC Contr

Controlled
olled
STEP 1: A
Add
dd the Module to the PLC Network

From the Catalog window,

drag and drop the
ConveyLinx-Ai DAP into
the Network V
View
iew window

To attach the module to

the PLC, click on the Not
Assigned link and select
the desired Profinet
Interface of the PLC

When attached, you will

see the green graphic
linking the PLC and the
module together

STEP 2: Assign the EXA

EXACT
CT Profinet Name to the Module
Follow the same STEP 2 as in Full ZPA Example. For this example the correct Profinet Name per
our Example Table is conveylinxplc-101-21

STEP 3: Enter the I.P

I.P.. A
Addr
ddress
ess
Follow the same STEP 3 as in Full ZPA Example. For this example the correct I.P. Address per
our Example Table is 192.168.101.21

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STEP 4: Select Update T

Time
ime Interval
Follow the same STEP 4 as in Full ZPA Example. Because this module’s I/O and motors are
under complete PLC control, the fastest Update time of 4ms is recommended.

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14.4.2.3. Reduced ZP
ZPA
A
STEP 1: A
Add
dd the Module to the PLC Network

From the Catalog window,

drag and drop the
ConveyLinx-Ai in rreduced
educed
ZP
ZPA
A mode DAP into the
Network V
View
iew window

To attach the module to

the PLC, click on the Not
Assigned link and select
the desired Profinet
Interface of the PLC

When attached, you will

see the green graphic
linking the PLC and the
module together

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STEP 2: Assign the EXA

EXACT
CT Profinet Name to the Module
Follow the same STEP 2 as in Full ZPA Example. For this example the correct Profinet Name per
our Example Table is conveylinxzpa-101-22

STEP 3: Enter the I.P

I.P.. A
Addr
ddress
ess
Follow the same STEP 3 as in Full ZPA Example. For this example the correct I.P. Address per
our Example Table is 192.168.101.22

STEP 4: Select Update T

Time
ime Interval
Follow the same STEP 4 as in Full ZPA Example. Because this module is in ZPA mode, the
recommended Update time to be between 32ms and 512ms.

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14.4.2.4. Reduced PLC

STEP 1: A
Add
dd the Module to the PLC Network

From the Catalog window,

drag and drop the
ConveyLinx-Ai in rreduced
educed
ZP
ZPA
A mode DAP into the
Network V
View
iew window

To attach the module to

the PLC, click on the Not
Assigned link and select
the desired Profinet
Interface of the PLC

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When attached, you will

see the green graphic
linking the PLC and the
module together

STEP 2: Assign the EXA

EXACT
CT Profinet Name to the Module
Follow the same STEP 2 as in Full ZPA Example. For this example the correct Profinet Name per
our Example Table is conveylinxplc-20-123

STEP 3: Enter the I.P

I.P.. A
Addr
ddress
ess
Follow the same STEP 3 as in Full ZPA Example. For this example the correct I.P. Address per
our Example Table is 192.168.20.123

STEP 4: Select Update T

Time
ime Interval
Follow the same STEP 4 as in Full ZPA Example. Because this module’s I/O and motors are
under complete PLC control, the fastest Update time of 4ms is recommended.

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14.4.2.5. Mer
Merger
ger Mode
The Mer
Merge
ge function is configured in EasyR
EasyRoll
oll. Follow the exact same steps as for a Full ZPA
module to add a module that will eventually be configured as merging zone in EasyR
EasyRoll
oll

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14.4.2.6. PLC Contr

Controlled
olled with ConveyL
ConveyLogix
ogix
Interface
STEP 1: A
Add
dd the Module to the PLC Network

From the Catalog window,

drag and drop the
ConveyLinx-Ai in PLC
mode with ConveyL
ConveyLogix
ogix
DAP into the Network V
View
iew
window

To attach the module to

the PLC, click on the Not
Assigned link and select
the desired Profinet
Interface of the PLC

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When attached, you will

see the green graphic
linking the PLC and the
module together

STEP 2: Assign the EXA

EXACT
CT Profinet Name to the Module
Follow the same STEP 2 as in Full ZPA Example. For this example the correct Profinet Name per
our Example Table is conveylogix-0-22

STEP 3: Enter the I.P

I.P.. A
Addr
ddress
ess
Follow the same STEP 3 as in Full ZPA Example. For this example the correct I.P. Address per
our Example Table is 192.168.0.22

STEP 4: Select Update T

Time
ime Interval
Follow the same STEP 4 as in Full ZPA Example. Because this module is running a ConveyLogix
program, the Update time interval is recommended to be set based upon the CPU usage the
ConveyLogix program is causing on the module.

* The CPU usage on a ConveyLinx module can be viewed when you go on-line with
the ConveyLogix programming software

CPU Usage and R

Recommended
ecommended Update T
Times
imes

The following table provides the recommended Update times based upon CPU usage of your
ConveyLogix program.

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Minimum
CPU Usage Recommended
Update T
Time
ime

< 50% 8ms

50% – 60% 16ms

60% – 70% 32ms

70% – 80% 64ms

80% – 90% 128ms

! Using a faster than recommended Update Time may produce unexpected results.

! It is recommended that you do not operate ConveyLinx modules with

ConveyLogix programs that utilize more that 90% CPU usage. ConveyLinx
module CPU usages above 90% can result in compromised module performance.

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14.5. Integrated PLC T

Topology
opology
Configuration

! This section applies ONLY when you use TIA Portal or STEP 7 Manager Topology to
configure your ConveyLinx modules

! ConveyLinx-ERSC Family of modules require firmware 5.07 or later for PLC

Topology configuration

Adding ConveyLinx Modules to Y

Your
our P
Prroject
Once you have installed the GSDXML file into your environment, ConveyLinx devices are
available to be used in your project. You can find ConveyLinx devices in the Har
Hardwar
dware
e Catalog
window

Drill down the tree

structure to get to the
folder Conveyor Contr
Control
ol
with topology and full PLC
Configuration to see the
available DAPs

* The Mode of Operation of a given ConveyLinx module will determine which of the
DAP
APss to drag and drop from the Har
Hardwar
dware
e Catalog window into your project

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14.5.1. Profinet Name

There are no module-specific name conventions when you use Integrated PLC Topology
Configuration from the PLC. The name of the device can be whatever you want. TIA Portal will
auto-correct if the name is outside of Profinet limitations.

* For users new to ConveyLinx and are familiar with the Siemens platform should
find the Integrated PLC Topology Configuration quicker and easier to implement.

! Please note that Step7 Manager will not auto-correct if you enter a non-
compliant name. A frequent mistake is using upper case letters which are not
allowed according to the Profinet standard. TIA Portal will autocorrect upper case,
but Step7 Manager will not auto-correct and will eventually result in program
error.

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14.5.2. 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 T
Time
ime
The DAPs for Integrated PLC Topology Configuration are already pre-configured with the lowest
recommended Update time for the given functionality. This means that you can skip STEP 4
when adding your modules.

The Update time will

default to the Calculate
update time automatically
setting. You can always
manually enter a longer
time if needed.

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14.5.3. Topology Example

An example of a conveyor layout is a great way to illustrate the Integrated PLC Topology
Configuration method.

DAP fr
from
om
Module Profinet
I.P
I.P.. A
Addr
ddress
ess Har
Hardwar
dware
e
Mode Name
Catalog

ConveyLinx-
Full ZPA 192.168.0.20 Ai in ZPA feeder
mode

Full ZPA with ConveyLinx-

192.168.0.21 merge
Merger Ai merger

ConveyLinx-
ConveyLogix Ai in PLC
192.168.0.22 divert
Interface mode with
ConveyLogix

Full PLC ConveyLinx-

192.168.0.23 workstation
Controlled Ai in PLC

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mode

ConveyLinx-
Reduced Ai in
192.168.10.20 spur
ZPA reduced ZPA
mode

ConveyLinx-
Reduced
Ai in
PLC 192.168.15.20 reject
reduced PLC
Controlled
mode

For this example, add these to your network in the same fashion as described earlier in the
Examples of Adding Modules section. Because our example is using a switch, you need to
select a Profinet switch from the Catalog. In our example we selected a SCLANCE XF204 four
port switch. Here is a view showing all the items added to our topology including the Profinet
switch and ConveyLinx modules.

Connecting PLC and Switch

To make a topology connection, click and drag from the small connection square on the PLC to
one of the ports on the switch.

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14.5.3.1. Connecting 1st Subnet of Modules

Click and drag from one of the Profinet switch ports to the divert ConveyLinx module’s left port.
Repeat the process to connect the divert module to the workstation module, and then the
workstation module to the reject module.

When you are done with the 1st subnet of modules, it should look like the following:

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14.5.3.2. Connecting 2nd Subnet of

Modules
Same as for the 1st Subnet, click and drag connection from switch to spur module and spur
module to the right port on the merge module. Connect the left port of the merge module to
the left port of the feeder module.

* Note which port on the merge module is connected to which specific port on its
neighbor modules.

When you are done with the 2nd subnet of modules, it should look like the following:

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14.5.4. Module Configuration

With Integrated PLC Topology Configuration , you do not need EasyR
EasyRoll
oll for initial module
configuration or changing ConveyLinx module parameters. The PLC programming environment
provides the ability to configure most all the parameters and settings you can access with
EasyRoll.

The following sections show the various parameters you have access to for each of the DAPs
along with links to the corresponding EasyRoll explanations of the particular parameter:

ZPA/Reduced ZPA Modes

PLC/Reduced PLC Modes
Merger Mode
ConveyLogix Mode

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14.5.4.1. ZP
ZPA/R
A/Reduced
educed ZP
ZPA
A Modes
General

There is no equivalent setting in EasyR

EasyRoll
oll
because these are determined by the Auto
Auto--
Configuration procedure

Set up for master/slave motor rollers in a

belted zone. There is no equivalent setting
in EasyR
EasyRoll
oll

Sensor Debounce setting

Enable/Disable FlexZone operation

Change Upstr
Upstream
eam ConveyLinx Connection.
If you want to perform the EasyR
EasyRoll
oll
equivalent of selecting “None” for the
connection, select the drop down option
“Connect the the module with the below IP
address” and enter “0” for each IP address
octet.

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Change Downstr
Downstream
eam ConveyLinx
Connection. If you want to perform the
EasyR
EasyRoll
oll equivalent of selecting “None” for
the connection, select the drop down
option “Connect the the module with the
below IP address” and enter “0” for each IP
address octet.

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14.5.4.1.1. Upstr
Upstream/Downstr
eam/Downstream
eam Zones

Timer
Change
value
the
Set zone’s when
logical
release mode using
polarity
of operation GAP
of the
Train
Sensor
Release

Configure
Sensor port to
accept Push
Pull type
sensor

Change
motor’s Default
Rotation
Direction

Enable/Disable
various zone
options

Set zone’s
Motor Type

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Enter desired
Motor Speed

Change
motor’s Brake
Method

Enter desired
motor Accel/
Decel values

* These settings are identical for the Downstream Zone

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14.5.4.1.2. Upstr
Upstream/Downstr
eam/Downstream
eam 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 Slowdown

feature operation

* These settings are identical for the Downstream Zone

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14.5.4.1.3. Connection to Mer

Merger
ger Module

These settings are only used if this given module is discharging onto another ConveyLinx
module that is configured as a Mer
Merger
ger. In EasyR
EasyRoll
oll this operation is performed when connected
to the Merger module’s Mer
Merge
ge Zone. The difference here is that you enter the I.P. address of
the Mer
Merger
ger module where the Mer
Mergege Zone is located. In the EasyR
EasyRoll
oll example you are
connected to the Mer
Merger
ger module’s Mer
Merge
ge Zone and you enter the I.P. address of the ZPA
module that is feeding the Mer
Merge
ge Zone. This function is depicted in an example in the
ConveyMer
ConveyMergege section.

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14.5.4.2. PLC/R
PLC/Reduced
educed PLC Mode
General

There is no equivalent setting in EasyR

EasyRoll
oll
because these are determined by the Auto
Auto--
Configuration procedure

Change Upstr
Upstream
eam ConveyLinx Connection.
If you want to perform the EasyR
EasyRoll
oll
equivalent of selecting “None” for the
connection, select the drop down option
“Connect the the module with the below IP
address” and enter “0” for each IP address
octet.

Change Downstr
Downstream
eam ConveyLinx
Connection. If you want to perform the
EasyR
EasyRoll
oll equivalent of selecting “None” for
the connection, select the drop down
option “Connect the the module with the
below IP address” and enter “0” for each IP
address octet.

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Lef
eftt / Right Side Configuration

For PLC mode, this function is not set in

EasyR
EasyRoll
oll but with populating data in the
Set Sensor Port Input Mask register from
the PLC. When you use Integrated PLC
Topology Configuration, you set this
function here and you do not need to write
data from your PLC logic

There is not an equivalent function in

EasyRoll

Change motor’s Default Rotation Direction

Set zone’s Motor Type

Enter desired Motor Speed

Change motor’s Brake Method

Enter desired motor Accel/Decel values

* These settings are identical for the Right side

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14.5.4.3. Mer
Merger
ger Mode
The Mer
Merger
ger DAP is essentially a Full ZP
ZPA
A mode module with an added parameter to configure
the mer
merger
ger. So the General, Upstream/Downstream Zones, and Upstream/Downstream Zone
Timing parameters are the same as previously described.

Mer
Merger
ger Configuration

An example of using these parameters in _*EasyRoll* is shown in section Conventional Spur

Merge from the ConveyMerge topic.

* For complete information about setting up and using ConveyMer

to the ConveyMerge section
ConveyMerge
ge, please refer

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14.5.4.4. ConveyL
ConveyLogix
ogix Mode
The ConveyL
ConveyLogix
ogix 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.

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14.6. Accessing Data fr

from
om ConveyLinx
Modules
There are 3 methods to access data from your modules:

1. R
Raw
aw Unmapped Dir
Direct
ect fr
from
om 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 communications using
GETIO/SETIO functions within your block. This method is typically only used by advanced
programmers or programmers who do not want to use tags or UDTs. This method is not
recommended for new users.

* This method is not recommended for new users or applications where multiple
programmers have to edit and understand the same program

2. Module Data Elements Mapped to T

Tags
ags

With this method, you create separate program tags for the particular word/integer array
element you want to read or write to on a given module. This method would maybe be
desirable if you know you only need to access a small number of items from a given module
and not all available data. This method also requires that you have detailed knowledge of the
structure of the given module’s Input/Output Assembly Instances and operational mode as
defined in the Developer’s Guide. Also, this method does not allow for simple access to sub-
element items such as Boolean bits within a Word element.

* 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 and it is not very sub-
element friendly.

3. Module Data Instances Mapped to User Defined T

Types
ypes ((UDT
UDTs)
s)

With this method, you import a UDT file provided by Pulseroller that has pre-defined tags and
structures that match up with each operational mode available for the module. You then use
these intuitively named tags directly in your PLC program. This method allows you to have
access to all of the data that is made available to/from the module based upon its assigned
DAP and operational mode.

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* Using the UDTs is the recommended method of data access with ConveyLinx
modules because these have been tested and verified by Pulseroller.

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14.6.1. Raw Unmapped Data Dir

Direct
ect fr
from
om
Module

* This method is not recommended for new users or applications where multiple
programmers have to edit and understand the same program

With this method of data access, you are copying data to/from the module’s I/O memory
directly to your function block’s local variables by using the GETIO/SETIO instructions. The I/O
memory addresses for you module were assigned when you added the module to your project.
The memory locations are dependent upon the order you added them to you project and the
amount of memory used as defined in the DAP.

Example
You are creating a function block called Block_1 and you want to read the input data from and
write output data to the ConveyLinx module we created called workstation from our Topology
Example. For your local static variables in your Block_1, you need to set the Data types for your
in and out variables to be Ar
Array[0..31]
ray[0..31] of W
Wor
ordd. To read data to the local in variable you need to
use the GETIO function and to write data to the local out variable you need to use the SETIO
function. Both the GETIO and SETIO functions require an ID parameter which corresponds to the
specific module’s input and output memory.

Create your Block_1 and

set the Data type for the in
and out variables. We
know the workstation
module is in Full PLC Mode
so it requires 64 Bytes (32
Words) of input and output
data

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We need to find the

Har
Hardwar
dware
e Identifier for the
inputs for the workstation
module. Go to Ungr
Ungrouped
ouped
devices in the project tree,
select the workstation
module, select virtual
input module, and select
Properties

From here you can see

that the Har
Hardwar
dwaree
identifier for the inputs for
the workstation module is
274. Note this value
because you will need it
later when you configure
your GETIO function.

Follow the same procedure

from the project tree to
select the virtual output
module. From here you
can see that the Har
Hardwar
dwaree
identifier for the outputs
for the workstation module
is 275. Note this value
because you will need it
later when you configure
your SETIO function.

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Here is the Block_1

program code showing the
GETIO function utilizing
the Har
Hardwar
dware e identifier
value of 274 and putting
the data to the in local
tag. There is also code
showing the SETIO
function utilizing the
Har
Hardwar
dwaree identifier value
of 275 and using the out
local tag.

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14.6.2. 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 meaningful names and map them
to a specific Wor
ord
d address within a given module. To use this method you will have to be very
familiar with the Instance Assembly structure for the ConveyLinx Module

Example
In this example we want to read the sensor port inputs and be able to send a clear jam
command to the upstream zone on the ConveyLinx module we named feeder in our Topology
Example. We also want to read the sensor port inputs and control the left motor on the
ConveyLinx module we named workstation in our Topology Example.

Cr
Create
eate Tags for our feeder Module
Tags

From Network V View

iew, locate
the module feeder, right
click and select Device
configuration and from
Device view expand the
window from the right to
display the Device
overview. This will show
you the I and Q address
byte locations in memory
that were assigned when
you added the module to
you project. As you can
see, the feeder module’s I
and Q are located in bytes
0 thru 63 respectively.

We want to read the Sensor P Port

ort Inputs register from the feeder module. As shown in the Port
Inputs and ConveyStop Status description from the PLC Developer’s Guide section, we can see
that the Sensor P
Port
ort Inputs data is at wor
wordd rregister
egister offset 01 within the ZPA Mode assembly
instance. To point our new tag to the correct starting byte, we take our word address x 2 to get

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the starting byte offset address. In our example, this means that the Sensor Port Inputs word
register data will be located at I address bytes 36 and 37. When we declare our tag with the W
syntax, it will know that the tag requires the 2 bytes beginning at I address 36.

From our Default tag table,

create a new tag and let’s
call it
feeder_SensorPortInputs.
Select Word as the Data
type and enter %IW36 for
the Addr
ddress
ess.

We want to write a command to the Clear Jam for L Local

ocal Upstr
Upstream
eam Zone register to the feeder
module. As shown in the ConveyStop and Clear Jams description from the PLC Developer’s
Guide section, we can see that the Clear Jam for L
Local
ocal Upstr
Upstream
eam Zone data is at wor
wordd rregister
egister
offset 20 within the ZPA Mode assembly instance. To point our new tag to the correct starting
byte, we take our word address x 2 to get the starting byte offset address. In our example, this
means that the Sensor Port Inputs word register data will be located at Q address bytes 40 and
41. When we declare our tag with the W syntax, it will know that the tag requires the 2 bytes
beginning at Q address 40.

From our Default tag table,

create a new tag and let’s call
it
feeder_ClearJamUpstreamZone.
Select Word as the Data type
and enter %QW40 for the
Addr
ddress
ess.

Cr
Create
eate Tags for our workstation Module
Tags

From Network V View

iew, locate
the module workstation,
right click and select
Device configuration and
from Device view expand
the window from the right
to display the Device
overview. This will show
you the I and Q address
byte locations in memory
that were assigned when

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you added the workstation

module to you project. As
you can see, the
workstation module’s I and
Q are located in bytes 64
thru 127 respectively.

We want to read the Sensor P Port

ort Inputs register from the workstation module. As shown in the
Sensor Ports description from the PLC Developer’s Guide section, we can see that the Sensor
Port Inputs data is at wor
wordd rregister
egister offset 1 within the PLC I/O Mode assembly instance. To point
our new tag to the correct starting byte, we take our word address x 2 to get the starting byte
offset address. In our example, this means that the Sensor Port Inputs word register data will
be located at I address bytes 2 and 3 within the workstation module. We also need to account
for where the workstation module is located within the entire I/O memory. We know that the
workstation module starts at %I64 / %Q64, so we need to add our offset of 2 to the starting
point of the workstation modules memory. This results in an offset of 66 (64 + 2). When we
declare our tag with the W syntax, it will know that the tag requires the 2 bytes beginning at I
address 66.

From our Default tag table,

create a new tag and let’s call
it
workstation_SensorPortInputs.
Select Word as the Data type
and enter %IW66 for the
Addr
ddress
ess.

We want to write a command to the Lef eftt Motor Contr

Controlol register to the workstation module. As
shown in the Left Motor Control description from the PLC Developer’s Guide section, we can see
that the Lef
eftt Motor R
Run
un / R
Reverse
everse data is at wor
wordd rregister
egister offset 4 within the PLC I/O Mode
assembly instance. To point our new tag to the correct starting byte, we take our word address
x 2 to get the starting byte offset address. In our example, this means that the Left Motor Run /
Reverse word register data will be located at Q address bytes 8 and 9 within the workstation
module. We also need to account for where the workstation module is located within the entire
I/O memory. We know that the workstation module starts at %I64 / %Q64, so we need to add
our offset of 2 to the starting point of the workstation modules memory. This results in an
offset of 72 (64 + 8). When we declare our tag with the W syntax, it will know that the tag
requires the 2 bytes beginning at Q address 72.

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From our Default tag table,

create a new tag and let’s
call it
workstation_LeftMotorControl.
Select Word as the Data type
and enter %QW72 for the
Addr
ddress
ess.

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14.6.3. Module Data Instances Mapped to

User Defined T
Types
ypes (UDT
(UDTs)
s)

* 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 (UDT

UDTss) are used to generate structured data type blocks within the PLC
programming environment for each DAP AP’s
’s inputs and outputs. When you create tags to use in
your program, you can then assign the appropriate data types for the given ConveyLinx
module’s inputs and outputs.

Each given DAP consumes some number of input memory bytes and output memory bytes.
When you use UDT
UDTss and create tags with the UDT data types; the PLC
PLC’s
’s I/O memory is properly
allocated and the memory boundaries between modules are easily established.

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14.6.3.1. Installing UDT

UDTss into P
Prrogramming
Envir
Environment
onment
In your Project trtree
ee,
expand Exter
External
nal sour
source
ce
files and select Add new
exter
xternal
nal file. Browse to the
location on your PC where
you saved the UDT file you
downloaded from
Pulseroller.com. In this
example we are using
ConveyLinx-Ai Family
modules so we select the
corresponding file.

Once you select the file, it

will appear as an item in
the Exter
External
nal sour
source
ce files
folder. Select the file, right
click, and select Generate
blocks fr
from
om sour
source
ce.

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Once the blocks have been

generated, you can go to
the PLC data types folder
in the Project tr
tree
ee and
expand the folder to see
the UDT
UDTss generated. In
this example, all of the
UDTs required for the
ConveyLinx-Ai Family have
been generated.

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14.6.3.2. Selecting the cor

corrrect UDT for the
Module’s Assigned D DAP
AP
The UDT’s are structured based upon the I/O memory being utilized by the ConveyLinx
module’s mode of operation. The DAP selected for you module is dependent upon what you
want to do with it and which of the two configuration methods you are going to use. These
sections indicate the combinations of functionality, the DAP to select, it memory requirements,
and the UDT to use.

Ai F
Family
amily DAP
APss when using Separate ConveyLinx Auto
Auto--
Configuration
Module Module Input Output
Input UDT Output UDT
Mode Mode Bytes Bytes

ConveyLinx
Full ZPA 64 CLXAiZPA_IN 64 CLXAiZPA_OUT
Ai

Full ZPA with ConveyLinx

64 CLXAiZPA_IN 64 CLXAiZPA_OUT
Merger Ai

ConveyLinx
Reduced Ai in
30 CLXAiZPAmini_IN 30 CLXAiZPAmini_OUT
ZPA reduced ZPA
mode

ConveyLinx
Full PLC 64 CLXAiPLC_IN 64 CLXAiPLC_OUT
Ai

ConveyLinx
Reduced Ai in
16 CLXAiPLCmini_IN 16 CLXAiPLCmini_OUT
PLC reduced PLC
mode

ConveyLinx
PLC with Ai in PLC
32 N/A 32 N/A
ConveyLogix mode with
ConveyLogix

Ai F
Family
amily DAP
APss when using T
Topology
opology Configuration
Module Module Input Output
Input UDT Output UDT
Mode Mode Bytes Bytes

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ConveyLinx
Full ZPA Ai in ZPA 64 CLXAiZPA_IN 64 CLXAiZPA_OUT
mode

Full ZPA with ConveyLinx

64 CLXAiZPA_IN 64 CLXAiZPA_OUT
Merger Ai Merger

ConveyLinx
Reduced Ai in
30 CLXAiZPAmini_IN 30 CLXAiZPAmini_OUT
ZPA reduced ZPA
mode

ConveyLinx
Full PLC Ai in PLC 64 CLXAiPLC_IN 64 CLXAiPLC_OUT
mode

ConveyLinx
Reduced Ai in
16 CLXAiPLCmini_IN 16 CLXAiPLCmini_OUT
PLC reduced PLC
mode

ConveyLinx
PLC with Ai in PLC
32 N/A 32 N/A
ConveyLogix mode with
ConveyLogix

ERSC Family DAP

APss when using Separate ConveyLinx Auto
Auto--
Configuration
Module Module Input Output
Input UDT Output UDT
Mode Mode Bytes Bytes

ConveyLinx
Full ZPA 64 CLXERSCZPA_IN 64 CLXERSCZPA_OUT
in ZPA mode

Full ZPA with ConveyLinx

64 CLXERSCZPA_IN 64 CLXERSCZPA_OUT
Merger in ZPA mode

ConveyLinx
Reduced
in reduced 30 CLXERSCZPAmini_IN 30 CLXERSCZPAmini_OUT
ZPA
ZPA mode

ConveyLinx
Full PLC 64 CLXERSCPLC_IN 64 CLXERSCPLC_OUT
in PLC mode

Reduced ConveyLinx 16 CLXERSCPLCmini_IN 16 CLXERSCPLCmini_OUT

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in reduced
PLC
PLC mode

ConveyLinx
PLC with in PLC mode
32 N/A 32 N/A
ConveyLogix with
ConveyLogix

ERSC Family DAP

APss when using T
Topology
opology Configuration
Module Module Input Output
Input UDT Output UDT
Mode Mode Bytes Bytes

ConveyLinx
Full ZPA 64 CLXERSCZPA_IN 64 CLXERSCZPA_OUT
in ZPA mode

Full ZPA with ConveyLinx

64 CLXERSCZPA_IN 64 CLXERSCZPA_OUT
Merger Merger

ConveyLinx
Reduced
in reduced 30 CLXERSCZPAmini_IN 30 CLXERSCZPAmini_OUT
ZPA
ZPA mode

ConveyLinx
Full PLC 64 CLXERSCPLC_IN 64 CLXERSCPLC_OUT
in PLC mode

ConveyLinx
Reduced
in reduced 16 CLXERSCPLCmini_IN 16 CLXERSCPLCmini_OUT
PLC
PLC mode

ConveyLinx
PLC with in PLC mode
32 N/A 32 N/A
ConveyLogix with
ConveyLogix

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14.6.3.3. 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 UDT
UDTss we
generated. So for the feeder module, we know from the previous section that its starting
address for both Inputs and outputs is byte 0. So, we are going to create a tag to store all of
the feeder module’s inputs and a tag to write to all of the feeder module’s outputs.

Example Modules and UDT Assignment

Using the modules we defined in the Topology Example section, we are going to assign each
module’s input and output data to the UDTs we generated in the previous section.

DAP fr
from
om
Profinet Module
Har
Hardwar
dware
e Input UDT Name Output UDT Name
Name Mode
Catalog

ConveyLinx-
feeder Full ZPA Ai in ZPA CLXAiZPA_IN CLXAiZPA_OUT
mode

Full ZPA with ConveyLinx-

merge CLXAiZPA_IN CLXAiZPA_OUT
Merger Ai merger

ConveyLinx-
ConveyLogix Ai in PLC
divert N/A N/A
Interface mode with
ConveyLogix

ConveyLinx-
Full PLC
workstation Ai in PLC CLXAiPLC_IN CLXAiPLC_OUT
Controlled
mode

ConveyLinx-
Reduced Ai in
spur CLXAiZPAmini_IN CLXAiZPAmini_OUT
ZPA reduced ZPA
mode

ConveyLinx-
Reduced
Ai in
reject PLC CLXAiPLCmini_IN CLXAiPLCmini_OUT
reduced PLC
Controlled
mode

Adding feeder Module

Adding workstation Module

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Adding R
Remaining
emaining Modules

What about ConveyL

ConveyLogix
ogix Interface?
There is no UDT required for the ConveyL
ConveyLogix
ogix interface because the input and output data have
no pre-defined meanings or operations. The I/O data for a module using ConveyL
ConveyLogix
ogix is a
“blank” block of 32 input and 32 output bytes (16 input and 16 output Words) that is available
for the programmer to use as needed based upon the application.

For this example, you can access the divert module by either the Raw Unmapped Data Direct
from Module or Module Data Elements Mapped to Tags method previously described.

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14.6.3.3.1. 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 offset 0, we know
what to enter for the
address.

From our Default tag table,

create a new tag for the
outputs and let’s call it
feeder_Inputs. Select
CLXAiZPA_OUT as the Data
type.

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Because we know from

Module Data Elements
Mapped to Tags section
example that the outputs
for the feeder module
starts at Output byte
offset 0, we know what to
enter for the address.

To continue and add the

workstation module, from
our Default tag table,
create a new tag and let’s
call it workstation_Inputs.
Select CLXAiPLC_IN as the
Data type.

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14.6.3.3.2. 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.

Because we know from

Module Data Elements
Mapped to Tags section
example that the
workstation module starts
at Input byte offset 64, we
know what to enter for the
address.

From our Default tag table,

create a new tag for the
outputs and let’s call it
workstation_Outputs.
Because we know that the
workstation module is in
Full PLC I/O mode, select
CLXAiPLC_OUT as the Data
type.

Page 521 of 557

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Because we know from

Module Data Elements
Mapped to Tags section
example that the outputs
for the workstation module
starts at Output byte
offset 64, we know what to
enter for the address.

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14.6.3.3.3. Add rremaining

emaining 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

we look at its Device view
we see that its starting
input and output byte
offset is 128
128. From the
chart in the UDT
Assignment Example
topic, we know that the
spur module is in Reduced
ZPA mode.

For the reject module,

when we look at its Device
view we see that its
starting input and output
byte offset is 158
158. From
the chart in the UDT
Assignment Example
topic, we know that the
spur module is in Reduced
PLC mode.

For the reject module,

when we look at its Device
view we see that its
starting input and output
byte offset is 174
174. From
the chart in the UDT
Assignment Example
topic, we know that the
spur module is in Reduced
PLC mode.

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With all starting byte

offsets known and
following the naming
convention we used for
the feeder and workstation
modules, we can complete
creating our tags mapped
to UDTs

Page 524 of 557

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14.7. User Data T

Types
ypes (UDT
(UDTs)
s)
User Data Types (UDT
UDTss) are used to generate structured data type blocks within the PLC
programming environment for each DAP AP’s
’s inputs and outputs. When you create tags to use in
your program, you can then assign the appropriate data types for the given ConveyLinx
module’s inputs and outputs.

Each given DAP consumes some number of input memory bytes and output memory bytes.
When you use UDT
UDTss and create tags with the UDT data types; the PLC
PLC’s
’s I/O memory is properly
allocated and the memory boundaries between modules are easily established.

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14.7.1. UDT
UDTss for ConveyLinx-ERSC F
Family
amily
Conveyor Contr
Control
ol DAP
APss for Separate ConveyLinx Auto
Auto--
Configuration
ConveyLinx Input Output
DAP fr
from
om Catalog
Mode Bytes Bytes

ConveyLinx in
Full ZPA 64 64
ZPA mode

ConveyLinx in
Full PLC 64 64
PLC mode

Full ZPA with ConveyLinx in

64 64
Merger ZPA mode

ConveyLinx in
PLC with
PLC mode with 32 32
ConveyLogix
ConveyLogix

ConveyLinx in
Reduced
reduced PLC 16 16
PLC
mode

ConveyLinx in
Reduced
reduced ZPA 30 30
ZPA
mode

Conveyor Contr
Control
ol DAP
APss for Integrated PLC Topology
Configuration
ConveyLinx Input Output
DAP fr
from
om Catalog
Mode Bytes Bytes

ConveyLinx in
Full PLC 64 64
PLC Mode

ConveyLinx in
PLC with
PLC mode with 32 32
ConveyLogix
ConveyLogix

Reduced ConveyLinx in
16 16
PLC reduced PLC

Page 526 of 557

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mode

ConveyLinx in
Reduced
reduced ZPA 30 30
ZPA
mode

ConveyLinx in
Full ZPA 64 64
ZPA mode

ZPA with ConveyLinx

64 64
Merge Merger

Page 527 of 557

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14.7.1.1. Full ZP
ZPA
A Mode Inputs
CLX
CLX_ERSC_ZP
_ERSC_ZPA_IN
A_IN
Element Name Sub Element Data T
Type
ype Link

LocalUpstr
ocalUpstreamZoneStatus_R
eamZoneStatus_Rev
ev Byte

LocalUpstr
ocalUpstreamZoneStatus_Fwd
eamZoneStatus_Fwd Byte More
LocalDownstr
ocalDownstreamZoneStatus_R
eamZoneStatus_Rev
ev Byte Info

LocalDownstr
ocalDownstreamZoneStatus_Fwd
eamZoneStatus_Fwd Byte

Ar
ArrivalCountUpstr
rivalCountUpstreamZone
eamZone Int

Departur
DepartureCountUpstr
eCountUpstreamZone
eamZone Int More
Ar
ArrivalCountDownstr
rivalCountDownstreamZone
eamZone Int Info

Departur
DepartureCountDownstr
eCountDownstreamZone
eamZone Int

Lef
eftMotorOver
tMotorOverheat
heat Bool

Lef
eftMotorMaxT
tMotorMaxTor
orque
que Bool

Lef
eftMotorShort
tMotorShort Bool

Lef
eftMotorNotConn
tMotorNotConn Bool

Lef
eftMotorOverload
tMotorOverload Bool

Lef
eftMotorStalled
tMotorStalled Bool

Lef
eftMotorBadHall
tMotorBadHall Bool

Lef
eftMotorNotUsed
tMotorNotUsed Bool More
Diagnostic
ModuleR
ModuleResetFlag
esetFlag Bool Info

Inde
Index06Bit01
x06Bit01 Bool

OverV
OverVoltage
oltage Bool

Lef
eftMotorAnyEr
tMotorAnyErrr Bool

ConnectionsNotOK Bool

Upstr
UpstreamJamEr
eamJamErrr Bool

Lef
eftSensL
tSensLowGain
owGain Bool

LowV
owVoltage
oltage Bool

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RightMotorOver
RightMotorOverheat
heat Bool

RightMotorMaxT
RightMotorMaxTor
orque
que Bool

RightMotorShort Bool

RightMotorNotConn Bool

RightMotorOverload Bool

RightMotorStalled Bool

RightMotorBadHall Bool

RightMotorNotUsed Bool

Inde
Index07Bit00
x07Bit00 Bool

Inde
Index07Bit01
x07Bit01 Bool

OverV
OverVoltage1
oltage1 Bool

RightMotorAnyEr
RightMotorAnyErrr Bool

Inde
Index07Bit04
x07Bit04 Bool

Downstr
DownstreamJamEr
eamJamErrr Bool

RightSensL
RightSensLowGain
owGain Bool

LowV
owVoltage1
oltage1 Bool

TrackingUpstr
rackingUpstreamZone
eamZone DWord More
TrackingDownstr
rackingDownstreamZone
eamZone DWord Info

ReleaseCounterUpstr
eleaseCounterUpstreamZone
eamZone Int More
ReleaseCounterDownstr
eleaseCounterDownstreamZone
eamZone Int Info

GetDischar
GetDischargeT
geTracking_Fwd
racking_Fwd DWord More
GetDischar
GetDischargeT
geTracking_R
racking_Rev
ev DWord Info

Bit08 Bool

Bit09 Bool

Bit10 Bool More

PortInputs
Bit11 Bool Info

Bit12 Bool

Bit13 Bool

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Bit14 Bool

Heartbeat Bool

Lef
eftSensorP
tSensorPin3
in3 Bool

Lef
eftContr
tControlP
olPin3
in3 Bool

RightSensorP
RightSensorPin3
in3 Bool

RightContr
RightControlP
olPin3
in3 Bool

Lef
eftSensorP
tSensorPin4
in4 Bool

Lef
eftContr
tControlP
olPin4
in4 Bool

RightSensorP
RightSensorPin4
in4 Bool

RightContr
RightControlP
olPin4
in4 Bool

Inde
Index19
x19 Word

StopOnL
StopOnLef
eftt Bool

StopOnRight Bool

StopA
StopActiveCommandPLC
ctiveCommandPLC Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool

Bit15 Bool More

ConveyStopStatus
Bit00 Bool Info

Bit01 Bool

Bit02 Bool

Bit03 Bool

Bit04 Bool

StopA
StopActiveOtherModule
ctiveOtherModule Bool

StopA
StopActiveL
ctiveLostConn
ostConn Bool

StopA
StopActiveL
ctiveLostPLC
ostPLC Bool

Futur
uture
e Array[21..31]

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of Word

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14.7.1.2. Full ZP
ZPA
A Mode Outputs
CLX
CLX_ERSC_ZP
_ERSC_ZPA_OUT
A_OUT
Element Name Sub Element Data T
Type
ype Link

InductT
InductTrackingOnUpstr
rackingOnUpstreamZone
eamZone DWord More
InductT
InductTrackingOnDownstr
rackingOnDownstreamZone
eamZone DWord Info

AccumUpstr
ccumUpstreamT
eamToThisZone
oThisZone Bool

SetAr
SetArrival
rival Bool

JogZoneFwd Bool

JogZoneR
JogZoneRev
ev Bool

Wak
akeUp
eUp Bool

MaintEnable Bool

Bit14 Bool

Bit15 Bool More

AccumulateContr
ccumulateControlUpstr
olUpstream
eam
Accumulate Bool Info

Bit01 Bool

Bit02 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

AccumUpstr
ccumUpstreamT
eamToThisZone
oThisZone Bool

SetAr
SetArrival
rival Bool

JogZoneFwd Bool More

AccumulateContr
ccumulateControlDownstr
olDownstream
eam
JogZoneR
JogZoneRev
ev Bool Info

Wak
akeUp
eUp Bool

MaintEnable Bool

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Bit14 Bool

Bit15 Bool

Accumulate Bool

Bit01 Bool

Bit02 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

SetSpeedL
SetSpeedLef
eftMotor
tMotor Int More
SetSpeedRightMotor Int Info

SetR
SetReleaseCountUpstr
eleaseCountUpstream
eam Int More
SetR
SetReleaseCountDownstr
eleaseCountDownstream
eam Int Info

SetInductStatus Word More

SetDishar
SetDishargeStatus
geStatus Word Info

SetInductT
SetInductTrackingFwd
rackingFwd DWord More
SetInductT
SetInductTrackingR
rackingRev
ev DWord Info

More
ClearMotorEr
ClearMotorErrror Word
Info

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool More

SetContr
SetControlP
olPortOutputs
ortOutputs
Bit12 Bool Info

Bit13 Bool

Bit14 Bool

Bit15 Bool

Page 533 of 557

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Bit00 Bool

Ener
EnergizeL
gizeLef
eftt Bool

Bit02 Bool

Ener
EnergizeRight
gizeRight Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

Inde
Index18
x18 Word

More
ConveyStopContr
ConveyStopControl
ol Word
Info

ClearJamUpstr
ClearJamUpstream
eam Word More
ClearJamDownstr
ClearJamDownstream
eam Word Info

SetDir
SetDirectionContr
ectionControlUpstr
olUpstream
eam Word More
SetDir
SetDirectionContr
ectionControlDownstr
olDownstream
eam Word Info

More
ConveyMer
ConveyMerge
ge Word
Info

Array[25..31]
Futur
uture
e
of Word

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14.7.1.3. Reduced ZP
ZPA
A Mode Inputs
CLX
CLX_ERSC_ZP
_ERSC_ZPA_R
A_Reduced_IN
educed_IN
Element Name Sub Element Data T
Type
ype Link

LocalUpstr
ocalUpstreamZoneStatus_R
eamZoneStatus_Rev
ev Byte

LocalUpstr
ocalUpstreamZoneStatus_Fwd
eamZoneStatus_Fwd Byte More
LocalDownstr
ocalDownstreamZoneStatus_R
eamZoneStatus_Rev
ev Byte Info

LocalDownstr
ocalDownstreamZoneStatus_Fwd
eamZoneStatus_Fwd Byte

Ar
ArrivalCountUpstr
rivalCountUpstreamZone
eamZone Int

Departur
DepartureCountUpstr
eCountUpstreamZone
eamZone Int More
Ar
ArrivalCountDownstr
rivalCountDownstreamZone
eamZone Int Info

Departur
DepartureCountDownstr
eCountDownstreamZone
eamZone Int

Lef
eftMotorOver
tMotorOverheat
heat Bool

Lef
eftMotorMaxT
tMotorMaxTor
orque
que Bool

Lef
eftMotorShort
tMotorShort Bool

Lef
eftMotorNotConn
tMotorNotConn Bool

Lef
eftMotorOverload
tMotorOverload Bool

Lef
eftMotorStalled
tMotorStalled Bool

Lef
eftMotorBadHall
tMotorBadHall Bool

Lef
eftMotorNotUsed
tMotorNotUsed Bool More
Diagnostic
ModuleR
ModuleResetFlag
esetFlag Bool Info

Inde
Index06Bit01
x06Bit01 Bool

OverV
OverVoltage
oltage Bool

Lef
eftMotorAnyEr
tMotorAnyErrr Bool

ConnectionsNotOK Bool

Upstr
UpstreamJamEr
eamJamErrr Bool

Lef
eftSensL
tSensLowGain
owGain Bool

LowV
owVoltage
oltage Bool

Page 535 of 557

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RightMotorOver
RightMotorOverheat
heat Bool

RightMotorMaxT
RightMotorMaxTor
orque
que Bool

RightMotorShort Bool

RightMotorNotConn Bool

RightMotorOverload Bool

RightMotorStalled Bool

RightMotorBadHall Bool

RightMotorNotUsed Bool

Inde
Index07Bit00
x07Bit00 Bool

Inde
Index07Bit01
x07Bit01 Bool

OverV
OverVoltage1
oltage1 Bool

RightMotorAnyEr
RightMotorAnyErrr Bool

Inde
Index07Bit04
x07Bit04 Bool

Downstr
DownstreamJamEr
eamJamErrr Bool

RightSensL
RightSensLowGain
owGain Bool

LowV
owVoltage1
oltage1 Bool

ReleaseCounterUpstr
eleaseCounterUpstreamZone
eamZone Int More
ReleaseCounterDownstr
eleaseCounterDownstreamZone
eamZone Int Info

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool More

PortInputs
Bit13 Bool Info

Bit14 Bool

Heartbeat Bool

Lef
eftSensorP
tSensorPin3
in3 Bool

Lef
eftContr
tControlP
olPin3
in3 Bool

Page 536 of 557

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RightSensorP
RightSensorPin3
in3 Bool

RightContr
RightControlP
olPin3
in3 Bool

Lef
eftSensorP
tSensorPin4
in4 Bool

Lef
eftContr
tControlP
olPin4
in4 Bool

RightSensorP
RightSensorPin4
in4 Bool

RightContr
RightControlP
olPin4
in4 Bool

Array[11..14]
Futur
uture
e
of Word

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14.7.1.4. Reduced ZP
ZPA
A Mode Outputs
CLX
CLX_ERSC_ZP
_ERSC_ZPA_R
A_Reduced_OUT
educed_OUT
Data
Element Name Sub Element Link
Type

AccumUpstr
ccumUpstreamT
eamToThisZone
oThisZone Bool

SetAr
SetArrival
rival Bool

JogZoneFwd Bool

JogZoneR
JogZoneRev
ev Bool

Wak
akeUp
eUp Bool

MaintEnable Bool

Bit14 Bool

Bit15 Bool More

AccumulateContr
ccumulateControlUpstr
olUpstream
eam
Accumulate Bool Info

Bit01 Bool

Bit02 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

AccumUpstr
ccumUpstreamT
eamToThisZone
oThisZone Bool

SetAr
SetArrival
rival Bool

JogZoneFwd Bool
More
AccumulateContr
ccumulateControlDownstr
olDownstream
eam JogZoneR
JogZoneRev
ev Bool
Info
Wak
akeUp
eUp Bool

MaintEnable Bool

Bit14 Bool

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Bit15 Bool

Accumulate Bool

Bit01 Bool

Bit02 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

SetSpeedL
SetSpeedLef
eftMotor
tMotor Int More
SetSpeedRightMotor Int Info

SetR
SetReleaseCountUpstr
eleaseCountUpstream
eam Int More
SetR
SetReleaseCountDownstr
eleaseCountDownstream
eam Int Info

SetInductStatus Word More

SetDishar
SetDishargeStatus
geStatus Word Info

More
ClearMotorEr
ClearMotorErrror Word
Info

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool
More
SetContr
SetControlP
olPortOutputs
ortOutputs Bit13 Bool
Info
Bit14 Bool

Bit15 Bool

Bit00 Bool

Ener
EnergizeL
gizeLef
eftt Bool

Bit02 Bool

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Ener
EnergizeRight
gizeRight Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

Inde
Index10
x10 Word

ClearJamUpstr
ClearJamUpstream
eam Word More

ClearJamDownstr
ClearJamDownstream
eam Word Info

SetDir
SetDirectionContr
ectionControlUpstr
olUpstream
eam Word More

SetDir
SetDirectionContr
ectionControlDownstr
olDownstream
eam Word Info

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14.7.1.5. Full PLC I/O Mode Inputs

CLX
CLX_ERSC_PLC_IN
_ERSC_PLC_IN
Element Name Sub Element Data T
Type
ype Link

StopOnL
StopOnLef
eftt Bool

StopOnRight Bool

StopA
StopActiveCommandPLC
ctiveCommandPLC Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool

Bit15 Bool More

ConveyStopStatus
Bit00 Bool Info

Bit01 Bool

Bit02 Bool

Bit03 Bool

Bit04 Bool

StopA
StopActiveOtherModule
ctiveOtherModule Bool

StopA
StopActiveL
ctiveLostConn
ostConn Bool

StopA
StopActiveL
ctiveLostPLC
ostPLC Bool

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool More

PortInputs
Bit12 Bool Info

Bit13 Bool

Bit14 Bool

Heartbeat Bool

Page 541 of 557

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Lef
eftSensorP
tSensorPin3
in3 Bool

Lef
eftContr
tControlP
olPin3
in3 Bool

RightSensorP
RightSensorPin3
in3 Bool

RightContr
RightControlP
olPin3
in3 Bool

Lef
eftSensorP
tSensorPin4
in4 Bool

Lef
eftContr
tControlP
olPin4
in4 Bool

RightSensorP
RightSensorPin4
in4 Bool

RightContr
RightControlP
olPin4
in4 Bool

Bits08_15 Byte

RightSensorDetect Bool

Lef
eftSensorDetect
tSensorDetect Bool

Bit02 Bool
More
SensorDetect Bit03 Bool
Info
Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

More
ModuleV
ModuleVoltage
oltage Int
Info

Lef
eftMotorCur
tMotorCurrrent Int

Lef
eftMotorF
tMotorFrreq Int More
Lef
eftMotorCalcT
tMotorCalcTemp
emp Byte Info

Lef
eftModuleT
tModuleTemp
emp Byte

Over
Overheat
heat Bool

MaxT
MaxTor
orque
que Bool
More
Lef
eftMotorDiagnostic
tMotorDiagnostic ShortCir
ShortCircuit
cuit Bool
Info
MotorNotConnected Bool

Overload Bool

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Stalled Bool

BadHall Bool

MotorNotUsed Bool

MotorStatus1 Bool

MotorStatus2 Bool

MotorP
MotorPortinDOmode
ortinDOmode Bool

Bit03 Bool

Bit04 Bool

Boar
BoardOver
dOverheat
heat Bool

OverV
OverVoltage
oltage Bool

LowV
owVoltage
oltage Bool

RightMotorCur
RightMotorCurrrent Int

RightMotorF
RightMotorFrreq Int More
RightMotorCalcT
RightMotorCalcTemp
emp Byte Info

RightModuleT
RightModuleTemp
emp Byte

Over
Overheat
heat Bool

MaxT
MaxTor
orque
que Bool

ShortCir
ShortCircuit
cuit Bool

MotorNotConnected Bool

Overload Bool

Stalled Bool
More
RightMotorDiagnostic BadHall Bool
Info
MotorNotUsed Bool

MotorStatus1 Bool

MotorStatus2 Bool

MotorP
MotorPortinDOmode
ortinDOmode Bool

Bit03 Bool

Bit04 Bool

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Bit05 Bool

OverV
OverVoltage
oltage Bool

LowV
owVoltage
oltage Bool

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool
More
Lef
eftMotorDIOstatus
tMotorDIOstatus ShortCir
ShortCircuit
cuit Bool
Info
Bit13 Bool

OverCur
OverCurrrent Bool

Bit15 Bool

Bits00_07 Byte

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool
More
RightMotorDIOstatus ShortCir
ShortCircuit
cuit Bool
Info
Bit13 Bool

OverCur
OverCurrrent Bool

Bit15 Bool

Bits00_07 Byte

Upstr
UpstreamModuleStatus
eamModuleStatus Word
More
Downstr
DownstreamModuleStatus
eamModuleStatus Word
Info
TrackingF
rackingFrromUpstr
omUpstream
eam DWord

Inde
Index18
x18 Word

ServoL
ServoLocationL
ocationLef
eftt Int
More
ServoL
ServoLocationRight
ocationRight Int
Info
ServoStatusL
ServoStatusLef
eftt Word

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ServoStatusRight Word

Array[23..31]
Futur
uture
e
of Word

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14.7.1.6. Full PLC I/O Mode Outputs

CLX
CLX_ERSC_PLC_OUT
_ERSC_PLC_OUT
Element Name Sub Element Data T
Type
ype Link

More
ConveyStopContr
ConveyStopControl
ol Word
Info

ClearP
ClearPortEr
ortErrror Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool

EnableDIO Bool More

Lef
eftMotorAsDIO
tMotorAsDIO
Ener
EnergizeJSTP
gizeJSTPin3
in3 Bool Info

Ener
EnergizeJSTP
gizeJSTPin4
in4 Bool

Ener
EnergizeJSTP
gizeJSTPin5
in5 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Ener
EnergizeJSTP
gizeJSTPin9
in9 Bool

EnableJSTP
EnableJSTPin9
in9 Bool

ClearP
ClearPortEr
ortErrror Bool

Bit09 Bool

Bit10 Bool More

RightMotorAsDIO
Bit11 Bool Info

Bit12 Bool

Bit13 Bool

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Bit14 Bool

EnableMotDIO Bool

Ener
EnergizeJSTP
gizeJSTPin3
in3 Bool

Ener
EnergizeJSTP
gizeJSTPin4
in4 Bool

Ener
EnergizeJSTP
gizeJSTPin5
in5 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Ener
EnergizeJSTP
gizeJSTPin9
in9 Bool

EnableJSTP
EnableJSTPin9
in9 Bool

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool

Bit15 Bool More

Contr
ControlP
olPortsDO
ortsDO
Bit00 Bool Info

Ener
EnergizeL
gizeLef
eftP
tPort
ort Bool

Bit02 Bool

Ener
EnergizeRightP
gizeRightPort
ort Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

Dir
Direction
ection Bool More
Lef
eftMotorContr
tMotorControl
ol
Bit09 Bool Info

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Bit10 Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool

Bit15 Bool

Run Bool

Bit01 Bool

Bit02 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

SetL
SetLef
eftMotorBrak
tMotorBrakeMode
eMode Word More
SetL
SetLef
eftMotorSpeedMode
tMotorSpeedMode Word Info

Dir
Direction
ection Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool More

RightMotorContr
RightMotorControl
ol
Bit14 Bool Info

Bit15 Bool

Run Bool

Bit01 Bool

Bit02 Bool

Bit03 Bool

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Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

SetRightMotorBrak
SetRightMotorBrakeMode
eMode Word More
SetRightMotorSpeedMode Word Info

More
SetSpeedL
SetSpeedLef
eftMotor
tMotor Int
Info

More
SetSpeedRightMotor Int
Info

SetL
SetLef
eftMotorA
tMotorAccel
ccel Int More
SetL
SetLef
eftMotorDeccel
tMotorDeccel Int Info

SetRightMotorA
SetRightMotorAccel
ccel Int More
SetRightMotorDeccel Int Info

More
ClearMotorEr
ClearMotorErrror Word
Info

SendStatusT
SendStatusToDownstr
oDownstream
eam Word More
SendStatusT
SendStatusToUpstr
oUpstream
eam Word Info

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool
More
SetSensorP
SetSensorPolarity
olarity Bit13 Bool
Info
Bit14 Bool

Bit15 Bool

Lef
eftSensorP
tSensorPin3
in3 Bool

Lef
eftContr
tControlP
olPin3
in3 Bool

RightSensorP
RightSensorPin3
in3 Bool

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RightContr
RightControlP
olPin3
in3 Bool

Lef
eftSensorP
tSensorPin4
in4 Bool

Lef
eftContr
tControlP
olPin4
in4 Bool

RightSensorP
RightSensorPin4
in4 Bool

RightContr
RightControlP
olPin4
in4 Bool

More
TrackingT
rackingToDownstr
oDownstream
eam DWord
Info

Inde
Index22
x22 Word

ServoContr
ServoControlDistanceL
olDistanceLef
eftt Int

ServoContr
ServoControlCommandL
olCommandLef
eftt Word More
ServoContr
ServoControlDistanceRight
olDistanceRight Int Info

ServoContr
ServoControlCommandRight
olCommandRight Word

Array[27..31]
Futur
uture
e
of Word

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14.7.1.7. Reduced PLC I/O Mode Inputs

CLX
CLX_ERSC_PLC_R
_ERSC_PLC_Reduced_IN
educed_IN
Data
Element Name Sub Element Link
Type

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool

Heartbeat Bool More

PortInputs
Lef
eftSensorP
tSensorPin3
in3 Bool Info

Lef
eftContr
tControlP
olPin3
in3 Bool

RightSensorP
RightSensorPin3
in3 Bool

RightContr
RightControlP
olPin3
in3 Bool

Lef
eftSensorP
tSensorPin4
in4 Bool

Lef
eftContr
tControlP
olPin4
in4 Bool

RightSensorP
RightSensorPin4
in4 Bool

RightContr
RightControlP
olPin4
in4 Bool

Bits08_15 Byte

RightSensorDetect Bool

Lef
eftSensorDetect
tSensorDetect Bool
More
SensorDetect Bit02 Bool
Info
Bit03 Bool

Bit04 Bool

Bit05 Bool

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Bit06 Bool

Bit07 Bool

Lef
eftMotorCalcT
tMotorCalcTemp
emp Byte More

Lef
eftModuleT
tModuleTemp
emp Byte Info

Over
Overheat
heat Bool

MaxT
MaxTor
orque
que Bool

ShortCir
ShortCircuit
cuit Bool

MotorNotConnected Bool

Overload Bool

Stalled Bool

BadHall Bool

MotorNotUsed Bool More

Lef
eftMotorDiagnostic
tMotorDiagnostic
MotorStatus1 Bool Info

MotorStatus2 Bool

MotorP
MotorPortinDOmode
ortinDOmode Bool

Bit03 Bool

Bit04 Bool

Boar
BoardOver
dOverheat
heat Bool

OverV
OverVoltage
oltage Bool

LowV
owVoltage
oltage Bool

RightMotorCalcT
RightMotorCalcTemp
emp Byte More

RightModuleT
RightModuleTemp
emp Byte Info

Over
Overheat
heat Bool

MaxT
MaxTor
orque
que Bool

ShortCir
ShortCircuit
cuit Bool More
RightMotorDiagnostic
MotorNotConnected Bool Info

Overload Bool

Stalled Bool

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BadHall Bool

MotorNotUsed Bool

MotorStatus1 Bool

MotorStatus2 Bool

MotorP
MotorPortinDOmode
ortinDOmode Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

OverV
OverVoltage
oltage Bool

LowV
owVoltage
oltage Bool

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool
More
Lef
eftMotorDIOstatus
tMotorDIOstatus ShortCir
ShortCircuit
cuit Bool
Info
Bit13 Bool

OverCur
OverCurrrent Bool

Bit15 Bool

Bits00_07 Byte

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool
More
RightMotorDIOstatus ShortCir
ShortCircuit
cuit Bool
Info
Bit13 Bool

OverCur
OverCurrrent Bool

Bit15 Bool

Bits00_07 Byte

Page 553 of 557

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14.7.1.8. Reduced PLC I/O Mode Outputs

CLX
CLX_ERSC_PLC_R
_ERSC_PLC_Reduced_OUT
educed_OUT
Data
Element Name Sub Element Link
Type

ClearP
ClearPortEr
ortErrror Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool

EnableDIO Bool More

Lef
eftMotorAsDIO
tMotorAsDIO
Ener
EnergizeJSTP
gizeJSTPin3
in3 Bool Info

Ener
EnergizeJSTP
gizeJSTPin4
in4 Bool

Ener
EnergizeJSTP
gizeJSTPin5
in5 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Ener
EnergizeJSTP
gizeJSTPin9
in9 Bool

EnableJSTP
EnableJSTPin9
in9 Bool

ClearP
ClearPortEr
ortErrror Bool

Bit09 Bool

Bit10 Bool
More
RightMotorAsDIO Bit11 Bool
Info
Bit12 Bool

Bit13 Bool

Bit14 Bool

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EnableMotDIO Bool

Ener
EnergizeJSTP
gizeJSTPin3
in3 Bool

Ener
EnergizeJSTP
gizeJSTPin4
in4 Bool

Ener
EnergizeJSTP
gizeJSTPin5
in5 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Ener
EnergizeJSTP
gizeJSTPin9
in9 Bool

EnableJSTP
EnableJSTPin9
in9 Bool

Bit08 Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool

Bit15 Bool More

Contr
ControlP
olPortsDO
ortsDO
Bit00 Bool Info

Ener
EnergizeL
gizeLef
eftP
tPort
ort Bool

Bit02 Bool

Ener
EnergizeRightP
gizeRightPort
ort Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

Dir
Direction
ection Bool
More
Lef
eftMotorContr
tMotorControl
ol Bit09 Bool
Info
Bit10 Bool

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Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool

Bit15 Bool

Run Bool

Bit01 Bool

Bit02 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

Bit07 Bool

Dir
Direction
ection Bool

Bit09 Bool

Bit10 Bool

Bit11 Bool

Bit12 Bool

Bit13 Bool

Bit14 Bool
More
RightMotorContr
RightMotorControl
ol Bit15 Bool
Info
Run Bool

Bit01 Bool

Bit02 Bool

Bit03 Bool

Bit04 Bool

Bit05 Bool

Bit06 Bool

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Bit07 Bool

More
SetSpeedL
SetSpeedLef
eftMotor
tMotor Int
Info

More
SetSpeedRightMotor Int
Info

More
ClearMotorEr
ClearMotorErrror Word
Info

Page 557 of 557