Version 1.

1
April 2020

Publication ERSC-1020

ConveyLinx module firmware and functionality is protected by U.S. and international patents. For complete
patent information visit www.pulseroller.com/patents
Symbol Conventions 3

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

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

Publication ERSC-1020 Rev 1.1 – April 2020

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

Because of the variety of uses for the products described in this publication, those
responsible for the application and use of this control equipment must satisfy themselves
that all necessary steps have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws, regulations, codes,
and standards

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Important User Information 5

The illustrations, charts, sample programs and layout examples shown in this guide are
intended solely for purposes of example. Since there are many variables and requirements
associated with any particular installation, Insight Automation Inc. does not assume
responsibility or liability (to include intellectual property liability) for actual use based on
the examples shown in this publication

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

permission of Insight Automation Inc. is prohibited.

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Summary of Changes 7

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

Revision Date Change / Update

1.0 April 2016 Initial Release
1.1 April 2020 Updated Publication Number

GLOBAL CONTACT INFORMATION

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8 ConveyMerge Guide

TABLE OF CONTENTS
Symbol Conventions................................................................................................................................................... 3
Important User Information ........................................................................................................................................ 4
Summary of Changes ................................................................................................................................................. 7
Global Contact Information ........................................................................................................................................ 7
Table of Contents ........................................................................................................................................................ 8
Introduction to ConveyMerge .................................................................................................................................... 9
ConveyMerge Components .................................................................................................................................. 9
ConveyMerge Prerequisites and Requiements ............................................................................................... 10
Setting up Your Conveyor........................................................................................................................................ 11
Network Architecture ............................................................................................................................................ 11
Architecture Summary .....................................................................................................................................11
Sensor Placement ................................................................................................................................................ 12
Standard Merge Sensor Placement ..............................................................................................................12
90˚ Merge Sensor Placement .........................................................................................................................13
Module Logical Connections for Main Line ....................................................................................................... 13
Merging Zone on Upstream Zone ..................................................................................................................13
Merging Zone on Downstream Zone .............................................................................................................14
Single Zone ERSC ...........................................................................................................................................14
Merging Lines ................................................................................................................................................... 15
Merging Functionality ............................................................................................................................................... 17
Merge Types ......................................................................................................................................................... 17
Merge Priority ........................................................................................................................................................ 17
90˚ Merge Setting (T-Merge) .............................................................................................................................. 18
Accept Timeout ................................................................................................................................................. 18
Send Timeout....................................................................................................................................................19
Configuring Dynamic Priority (Merge Line Full) ............................................................................................... 20
Dynamic Priority Example ...............................................................................................................................20
Using EasyRoll with ConveyMerge ........................................................................................................................ 22
ConveyMerge Configuration Screen ................................................................................................................. 23
Standard Merge Example .................................................................................................................................... 25
T-Merge Example ................................................................................................................................................. 27
Merge with Merge Line Full Example ................................................................................................................ 29
Notes: ......................................................................................................................................................................... 31

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Introduction to ConveyMerge 9

INTRODUCTION TO CONVEYMERGE
ConveyMerge is an optional functionality layer built on top of ConveyLinx’s ZPA logic. Users can enable and configure
it using EasyRoll software. ConveyMerge behaves the same as ZPA logic, but allows the engineer to define a special
Merging Zone that can have up to three upstream zones connecting to it where ZPA logic only supports a single
upstream zone. ConveyMerge also has a simple priority schemes for the multiple upstream zones as well as the
ability to dynamically change those priorities on-the-fly by utilizing the Merge Line Full option. It also takes care of
passing tracking information properly and has Jam condition detection.

CONVEYMERGE COMPONENTS
ConveyMerge can accommodate product merge control from one or two conveyor paths onto a single take-away
conveyor path as shown in Figure 1.

FIGURE 1 – TYPICAL CONVEYMERGE COMPONENTS

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The following table identifies and defines these typical components.

Component Description
Powered conveyor section that accepts an item from any one of the 3 possible
Merging Zone upstream sources

Term to describe the 3 in-line conveyor sections - Center Line, Merging Zone and
Main Line Discharge Zone

Part of Main Line that is one of three possible sources of items that can flow into the
Center Line Merging Zone. This term is used in the configuration screen of EasyRoll to designate
the network that serves as the trunk line that contains the Merging Zone.
Part of the Main Line that is downstream of the Merging Zone. This conveyor section
Discharge Zone accepts the item from the Merging Zone.
One of the three possible conveyor sections that can discharge items into the
Left Line Merging Zone.
One of the three possible conveyor sections that can discharge items into the
Right Line Merging Zone.

CONVEYMERGE PREREQUISITES AND REQUIEMENTS

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

 EasyRoll version 4.3 or greater

 ConveyLinx Firmware version 4.25 or greater
 Only (1) one Merging Zone is allowed for any given single ERSC module
 Merging Zone cannot have any Extension (slaved) zone
 All ERSC modules controlling Merging Zone, Left Line Discharge, Right Line Discharge, and Center Line
discharge must be in ZPA mode
 Left, Right, and Center Lines discharges cannot also be included in another instance of ConveyMerge.

Please refer to Insight Automation publication ConveyLinx User’s Guide for ConveyLinx
ERSC module hardware details and basic function. The remaining sections of this
document assumes reader if familiar with ConveyLinx ERSC module and EasyRoll
software operation.

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Setting up Your Conveyor 11

SETTING UP YOUR CONVEYOR

NETWORK ARCHITECTURE
All lines (Main, Left, and Right) must be on separate subnets of modules, as shown in Figure 2. Each subnet should
be Auto-Configured 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- Configuration Procedure. 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).

FIGURE 2 - TYPICAL SUBNET ARRANGEMENT

For example, using the default mask of 255.255.128.0 you may setup the Main Line to be in the 192.168.1.XXX
subnet, the Left Line in the 192.168.2.XXX subnet, and the Right Line in the 192.168.3.XXX subnet.

ARCHITECTURE SUMMARY
 The Main Line is a separate subnet of modules that have been Auto-Configured. The Merging Zone and the
Discharge Zone are part of this subnet. The Main Line can consist of any number of ERSC modules and the
actual position of the Merging Zone can be on any ERSC within the subnet.
 The Discharge Zone has to be the zone immediately downstream of the Merging Zone. However, the
Discharge Zone can be on either the same ERSC as the Merging Zone or on the adjacent downstream ERSC
from the Merging Zone’s ERSC.

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 The Left Line is a separate subnet of ERSC modules and its most downstream zone has to physically
discharge on to the Merging Zone.
 The Right Line is a separate subnet of ERSC modules and its most downstream zone has to physically
discharge on to the Merging Zone.
 All three subnets must be connected to a common Ethernet switch only after each subnet has been Auto-
Configured.

SENSOR PLACEMENT

It is very important for the internal ConveyMerge logic, that the product
is seen by only one photo-eye at a time.

STANDARD MERGE SENSOR PLACEMENT

Figure 3 shows a suggested sensor arrangement for Standard Left Line and Right Line arrangement to flow into the
Merging Zone.

FIGURE 3 - SENSOR PLACEMENT FOR STANDARD MERGE

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Setting up Your Conveyor 13

90˚ MERGE SENSOR PLACEMENT

Figure 4 shows a suggested sensor arrangement for a 90˚ Merge (also called “T-Merge”) for both a Left Line and a
Right Line merge to the Merging Zone.

FIGURE 4 - 90˚ MERGE SENSOR PLACEMENT

MODULE LOGICAL CONNECTIONS FOR MAIN LINE

Depending on the physical arrangement of actual zones on the Main Line, the Merging Zone can be assigned to
either the Upstream or Downstream zone of its particular ERSC. This section illustrates some examples.

MERGING ZONE ON UPSTREAM ZONE

FIGURE 5 - MERGE ZONE ON UPSTREAM ZONE OF LOCAL ERSC

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MERGING ZONE ON DOWNSTREAM ZONE

FIGURE 6 - MERGE ZONE ON DOWNSTREAM ZONE OF LOCAL ERSC

SINGLE ZONE ERSC

Whenever an ERSC has been Auto-Configured as a single zone; regardless of whether the single zone is connected
to the right side or left side of the ERSC, the logical designation for the zone on the ERSC is always the Upstream
Zone. Figure 7 and Figure 8 each show an example of a single zone ERSC using the left and right sides of the module
respectively.

FIGURE 7 – SINGLE ZONE ERSC ON LEFT SIDE OF MODULE

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Setting up Your Conveyor 15

FIGURE 8 – SINGLE ZONE ERSC ON RIGHT SIDE OF MODULE

MERGING LINES
The Left Line and Right Line are set up in a similar fashion. Each of these lines are in their own separate subnet that
is both different form each other and different from the Main Line. Regardless of whether these merging lines are
an Standard arrangement or a 90˚ arrangement; the conveyor zone that discharges product onto the Merging Zone
must be the most downstream zone if its particular subnet. Figure 9 and Figure 10 illustrate this for an Standard Left
Line and a 90˚ Left Line respectively. The same would apply if these were Right Line examples as well.

FIGURE 9 - STANDARD LEFT MERGE LINE DOWNSTREAM MODULE

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FIGURE 10 - 90˚ LEFT MERGE LINE DOWNSTREAM MODULE

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Merging Functionality 17

MERGING FUNCTIONALITY
Previous sections have shown arrangements and connections assuming a “full function” merge from both the left
and right sides of the Main Line. However, ConveyMerge allows for many options in arrangement and configuration,
all of which are configurable in EasyRoll.

MERGE TYPES
With EasyRoll, the basic selections for configuring ConveyMerge are:

 Identify the Merging Zone

 Select whether to use a Left Line Only, Right Line Only, or Both
 Identify the discharge module(s) address and zone (upstream or downstream)
 Optionally choose an upstream module and zone on any or all of the three lines as a trigger zone to
dynamically change release priority

MERGE PRIORITY
EasyRoll provides the ability to adjust which of the merging lines receives priority. The following chart outlines these
choices:

EasyRoll Priority Selection Description

The logic monitors the arrival status in each of the zones that discharge in to the
Merge Zone. The first product that arrives at any of these lines will be allowed
First Come First Served to convey into the Merge Zone. When the Merge Zone is clear, the next line
that has had a product arrive will be allowed to convey into the Merge Zone.
The Center Line will be allowed to release as long as product arrives at the
center line zone sensor prior to the previously released product having not
cleared the Merge Zone. When the Merging Zone is clear and if there is no
Center Line Priority product sensed on the center line zone; then the Left and/or Right Lines will be
allowed to release if product has arrived at their respective sensors. As long as
no product is arriving on the Center Line, if Left and Right Lines are enabled,
these will operate as First Come First Served between them.
The Left Line will be allowed to release as long as product arrives at the Left
Line’s most downstream sensor prior to the previously released product having
not cleared the Merge Zone. When the Merging Zone is clear and if there is no
product sensed on the Left Line’s most downstream sensor; then the Center
Left Line Priority and/or Right Lines will be allowed to release if product has arrived at their
respective sensors. As long as no product is arriving on the Left Line, if the Right
Line is enabled, the Center and Right will operate as First Come First Served
between them.

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EasyRoll Priority Selection Description

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 Merge Zone. When the Merging Zone is clear and if there is no
product sensed on the Right Line’s most downstream sensor; then the Center
Right Line Priority and/or Left Lines 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 Left
Line is enabled, the Center and Left will operate as First Come First Served
between them.

90˚ MERGE SETTING (T-MERGE)

For a T-Merge, the discharging conveyor is arranged perpendicular to the Merge 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 Merge Zone’s rollers stopped until the discharging conveyor has
completely finished “throwing” the product ontp the Merge Zone. In order to accommodate various conveyor
speeds and material handling situations; EasyRoll provides some timer adjustments to facilitate proper T-Merge
functionality.

ACCEPT TIMEOUT
This timer specifies how much time the Merge 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 Merge Zone also dictate if the motor is allowed to run. Figure 11 illustrates how the
Accept Timeout operates.

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Merging Functionality 19

FIGURE 11 - ACCEPT TIMEOUT EXAMPLE

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

FIGURE 12 - SEND TIMEOUT EXAMPLE

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CONFIGURING DYNAMIC PRIORITY (MERGE LINE FULL)

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

EasyRoll 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 Merge Zone. This
Block Timeout 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 Timeout once the priority release has begun. When this time value expires, the priority
setting will return to its original EasyRoll configured setting.

If multiple lines are configured for Dynamic Priority and each of their respective Block
Timers have expired; ConveyMerge logic will revert to the First Come First Serve release
mode until one or more of the releasing lines’ Clear Timer has expired.

DYNAMIC PRIORITY EXAMPLE

Please refer to Figure 13 for this example. In EasyRoll, Node 2 upstream zone of the Central Line has been selected
as the Merge Zone and the merge type is Up Left. The EasyRoll setting for priority is Center Line Priority. Also in
EasyRoll, the Merge Line Full function has been enabled as assigned to Node 3 downstream zone of the Left Line.

As shown in Figure 13, assuming we did not enable the Merge Line Full function for the Left Line; if there is a steady
flow of product on the central line; the Left Line will never be able to release because the central line was set as the
default line for priority in EasyRoll. Now, with the Merge Line Full feature enabled on the Left Line; once Left Line
Node 3 downstream zone remains accumulated for the Block Timer’s timeout; priority will dynamically change to
the Left Line. This Left Line priority will remain in effect until the Clear Timer’s timeout has expired. When this
occurs, the priority will automatically revert to the EasyRoll configured priority (center line in this example). Figure
14 illustrates the Clear Timeout function.

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Merging Functionality 21

FIGURE 13 - MERGE LINE FULL PRIORITY EXAMPLE - BLOCK TIMER

FIGURE 14 - MERGE LINE FULL PRIORITY EXAMPLE - CLEAR TIMER

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USING EASYROLL WITH CONVEYMERGE

 Open EasyRoll
 Connect to the ERSC that will control the Merge Zone. See indicated area in Figure 15
 Press CTRL+SHIFT+M to open the ConveyMerge Configuration Screen

FIGURE 15 - EASYROLL MAIN SCREEN

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Using EasyRoll with ConveyMerge 23

CONVEYMERGE CONFIGURATION SCREEN

❶ ❶
❹ ⓫
❼ ❺ ❻

⓬ ⓬

❽ ❷ ❽
❾ ❸
❿
⓮
⓯

⓰
⓭ ⓱

FIGURE 16 - CONVEYMERGE CONFIGURATION SCREEN

Item Description
1 Browse Nodes

2 Drop down selector for Merge Type – from Left, Right, or Both

3 Drop down selector for Merge Priority

4 Display of IP Address for the ERSC selected for the Merge Zone

5 User button to click to apply changes made during configuration

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Item Description
6 User button to click to Cancel and exit the ConveyMerge Configuration Screen

7 IP Address of Left Line’s most downstream ERSC

8 User checkbox to enable the Merge Line Full function

IP Address of the ERSC that contains the zone being defined as the Monitor Zone for the Merge
9 Line Full function
Radio buttons to select whether the upstream or downstream zone of the ERSC identified in
10 Item 9 will be used as the Monitor Zone.
11 IP Address of Right Line’s most downstream ERSC

12 User checkbox to select T-Merge type

Graphical representation of the merge. Please note this will update and change as settings and
13 configuration is modified.
14 Merge Line Full Block Timer preset value

15 Merge Line Full Clear Timer preset value

16 T-Merge Accept Timer preset value

17 T-Merge Send Timer preset value

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Using EasyRoll with ConveyMerge 25

STANDARD MERGE EXAMPLE

Figure 17 depicts a standard Standard spur merge example with a single merge line on the left. In the example, we
wish to set the Merge Priority to First Come First Served.

FIGURE 17 - STANDARD MERGE EXAMPLE

The Merge Zone is the upstream zone of the module at 192.168.25.28 and the most downstream ERSC for the Left
Line is at 192.168.24.31. Figure 18 shows the ConveyMerge Configuration screen with these values entered.

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26 ConveyMerge Guide

FIGURE 18 - CONVEYMERGE SCREEN FOR STANDARD MERGE EXAMPLE

The last step for configuration is to click the “Apply” button.

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
of all of the affected zones may briefly run their motors.

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Using EasyRoll with ConveyMerge 27

T-MERGE EXAMPLE
Figure 19 depicts a T-Merge line on the right. In the example, we wish to set the Merge Priority to First Come First
Served.

FIGURE 19 - T-MERGE EXAMPLE

The Merge Zone is the upstream zone of the module at 192.168.24.28 and the most downstream ERSC for the Right
Line is at 192.168.26.58. Figure 20 shows the ConveyMerge Configuration screen with these values entered.

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FIGURE 20 - CONVEYMERGE SCREEN FOR T-MERGE EXAMPLE

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Using EasyRoll with ConveyMerge 29

MERGE WITH MERGE LINE FULL EXAMPLE

Figure 21 shows an example of a Left Line merge with the Merge Line Full function.

FIGURE 21 - MERGE LINE FULL EXAMPLE

The Merge Zone is the upstream zone of ERSC 192.168.26.33 and the merge line’s most downstream node is
192.168.24.31 and we want this line to have the Merge Line Full function enabled. On the merge line (Left Line), we
would like for the upstream zone of ERSC 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 Left Line
to release for 5 seconds and then return the priority to the Center Line. Figure 22 shows the ConveyMerge
Configuration Screen with the values entered for this example.

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FIGURE 22 - CONVEYMERGE CONFIGURATION SCREEN FOR MERGE LINE FULL EXAMPLE

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Notes: 31

NOTES:

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