Version 4.

4
May 2014

Publication ERSC-1000
Glossary of Terms 3

GLOSSARY OF TERMS
Conveyor controls architecture based upon modular distributed devices connected via
ConveyLinx
Ethernet network.
Dynamic Host Configuration Protocol A protocol for assigning IP addresses to devices on
DHCP 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
ERSC
ConveyLinx family. Each ERSC can accommodate up to 2 MDRconveyor zones
Special sensor embedded within the brushless DC motor of an MDR used to provide
Hall Effect Sensor
motor rotor position feedback to the motor controller
This is the name of a particular connector manufacturer that produces a specific
JST plug/socket arrangement for MDR connection to control cards. This 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 ERSC to
LED
provide visual indication of module status
Term used to describe how the signaling output circuit of a photo-sensor is configured
Light / Dark Energized when it detects its reflected light. A photo-sensor that is light energized will activate its
output circuit when it detects its reflected light. A dark energized photo-sensor will
activate its output circuit when it does not detect its reflected light.

Load A separate (usually wrapped or boxed) object to be transported by the conveyor. The
terms tray, tote, or carton may also be used interchangeably in this document.
Motorized Drive Roller or Motor Driven Roller - Brushless DC motor and gearbox
MDR
assembly integrated into a single conveyor roller.
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
Normally Open / sensor would have its output circuit energized when it detected its reflected light and its
Normally Closed output circuit would be 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
NPN / PNP output for controllers. NPN devices will provide a common or ground 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 of a load on
Photo-sensor
the zone
Programmable Logic Controller – A wide variety of industrial computing devices that
PLC
control automatic equipment

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

Publication ERSC-1000 Rev 4.4 – May 2014

4 ConveyLinx User’s Guide

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.
Retro-reflective /
Reflex Reflex (or sometimes known as proximity) type photo-sensors emit light to 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
RJ-11 / RJ-12 connections. The typical standard connection for 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 pin
RJ-45
connections. The typical standard for computer network cable connections
Designed to “break-out” the RJ11 connection for easy installation. The module has an
amplifier to the output giving it up to 100mA output capabilities. Configurable diodes for
ERSC-SE4
the inputs to minimize leakage current to and from the ERSC. Module also allows for
external power source connection for auxiliary devices.
Conveyor control method for zoned controlled conveyor that dictates that when a zone
Singulation Release is discharging its load, the upstream load waiting to enter must wait until the discharged
load 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 slave rollers make up a physical zone. All of the slave rollers in a 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 Ethernet network. TCP
TCP/IP 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 when a zone is
Train Release
discharging, the upstream zone’s load can move in unison with the discharging load.

Zone A basic (linear or curved) cell of the conveyor consisting of a set of slave rollers driven by
one or more MDR’s and a single photo-sensor.
Zero Pressure Accumulation – Term that describes the conveyor controls and mechanical
ZPA scheme that will cause loads to queue on a conveyor in discrete zones such that loads do
not touch each other

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

Publication ERSC-1000 Rev 4.4 – May 2014

Glossary of Terms 5

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

Publication ERSC-1000 Rev 4.4 – May 2014

6 ConveyLinx User’s Guide

IMPORTANT USER INFORMATION

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

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

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

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

permission of Insight Automation Inc. is prohibited.

Publication ERSC-1000 Rev 4.4 – May 2014

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

Major revision to Easy Roll software section, added descriptions for new
3.0 August 31 2009
functionality
Updates to Hardware Interface and to EasyRoll software functionality,
3.1 July 2010
general updates
General revision, updated SE3 section, added new appendix for real world
4.0 September 2012
applications, updated many graphics in the document.
Update to Sensor & Control Port to include fusing information and current
4.1 November 2013 limitation, updated SE section to include ERSC-SE4 module and external
power connection capability.
4.2 January 2014 Added Global Contact Information
4.3 April 2014 Updated Global Contact Information
4.4 May 2014 Minor format revision

GLOBAL CONTACT INFORMATION

Publication ERSC-1000 Rev 4.4 – May 2014

8 User’s Guide

SUMMARY OF HARDWARE CHANGES

The following table summarizes the changes and updates made to this document since the last hardware revision.

Hardware Revisions

Revision Date Change / Update

February 2009
1.0 Initial Release
Serial # 87716
• Advanced Ethernet switch additions includes, improved switching
engine, enhanced diagnostics, and better support for
straight/crossover cables.
July 2010
2.0 • The RJ45 Ethernet connections werephysically rotated 180degrees
Serial # 102311
for ease of installation.
• Activity LED was removed from the front of the card.

• Thicker traces and enhanced solder points in a few critical areas of

the printed circuit board (PCB).
• The PCB traces allowed for an increase in the hardware protection
limit. Previous revisions were 19A peak, but the latest revision 3.0
has a peak of 21.5A.
April 2013 • Power-supply changed to be much more efficient which now uses
3.0
Serial # 137101 less energy and creates less overall heat.
• Changed pull-up resistors for Hall Effect inputs on the motor
connector. This greatly improved operations with extension cables.
• Power supply for the Hall Effect sensors was increased from 6.5V to
9V to support a wider range of motor rollers.

Publication ERSC-1000 Rev 4.4 – May 2014

Table of Contents 9

TABLE OF CONTENTS
Glossary of Terms....................................................................................................................................................... 3
Symbol Conventions .............................................................................................................................................. 4
Important User Information ........................................................................................................................................ 6
Summary of Changes ................................................................................................................................................. 7
Global Contact Information ........................................................................................................................................ 7
Summary of Hardware Changes .............................................................................................................................. 8
Table of Contents ........................................................................................................................................................ 9
Preface ....................................................................................................................................................................... 13
Who Should Use This Manual? .......................................................................................................................... 13
Purpose of This Manual ....................................................................................................................................... 13
Not Included in This Manual ............................................................................................................................... 13
Introduction to ConveyLinx® ................................................................................................................................... 14
ConveyLinx® Concept ......................................................................................................................................... 14
ConveyLinx® System Components ...............................................................................................................15
ConveyLinx® ERSC Module Features .............................................................................................................. 15
ConveyLinx® Control System Features ............................................................................................................ 16
ERSC Module Hardware Overview ........................................................................................................................ 17
Hardware Connections ............................................................................................................................................. 19
Motor Left and Motor Right Ports ....................................................................................................................... 19
Sensor Left and Sensor Right Ports .................................................................................................................. 20
Left and Right Control Ports................................................................................................................................ 21
Sensor and Control Port Fusing .....................................................................................................................21
Ethernet Left and Ethernet Right Ports ............................................................................................................. 23
Connections for Linear Conveyor ........................................................................................................................... 24
Example 1 –Two Zone Controller....................................................................................................................... 25
Example 2 – Single Zone Controller .................................................................................................................. 26
Example 3 – Dual MDR Single Zone Controller............................................................................................... 26
Invalid Configuration Examples .......................................................................................................................... 26
Motor Direction Definition .................................................................................................................................... 28
Network and Power Connections ....................................................................................................................... 29
Status Indicators ....................................................................................................................................................... 31
Communications ................................................................................................................................................... 31
Network & Module Function ................................................................................................................................ 31
Motors 32
Sensors .................................................................................................................................................................. 32
Auto-Configuration of Linear Conveyor ................................................................................................................. 33
Linear Conveyor Definition .................................................................................................................................. 33
Auto-Configuration Procedure ............................................................................................................................ 34
Auto-Configuration Examples ............................................................................................................................. 35
Auto Detection of Opposite Side Module Location......................................................................................36
Auto Configuration Results ................................................................................................................................. 36
Normal Results .................................................................................................................................................36
Trouble-shooting Failed Auto-Configuration ................................................................................................36
Default Configuration ........................................................................................................................................... 38
Default Singulation Release ZPA Mode .......................................................................................................39
Default Flex Zone Recognition Feature ........................................................................................................40
Jam Condition ....................................................................................................................................................... 40

Publication ERSC-1000 Rev 4.4 – May 2014

10 User’s Guide

Sensor Jam .......................................................................................................................................................40

No Arrival Jam ..................................................................................................................................................41
Network Fault ........................................................................................................................................................ 41
Low Voltage Fault ................................................................................................................................................. 41
Automatic Module Replacement ........................................................................................................................ 43
ERSC Replacement Procedure .......................................................................................................................... 44
Hardware Interface with Control Ports ................................................................................................................... 45
Local Zone Accumulation Control ...................................................................................................................... 45
Control Port Interlock Definition .......................................................................................................................... 47
Hardware Interface Cable ................................................................................................................................... 48
Single Zone ERSC Configuration....................................................................................................................... 50
Using Sensors in Control Ports .......................................................................................................................... 51
Sensor in Control Port for Downstream Interlock ........................................................................................51
Upstream Sensor in Control Port ...................................................................................................................52
Using Control Ports with PLC I/O ....................................................................................................................... 53
Upstream Interlock ...........................................................................................................................................53
Upstream Interlock Timing Chart ...............................................................................................................55
Downstream Interlock ......................................................................................................................................56
Downstream Interlock Timing Chart ..........................................................................................................57
Electrical Connections for PLC Controls.......................................................................................................59
Connections for ERSC Output to PLC Input ............................................................................................59
Connections for PLC Output to ERSC Input ............................................................................................61
Utilizing Solid State PLC Output Modules ................................................................................................63
Using ERSC-SE4 Terminal Breakout Module .........................................................................................66
EasyRoll Software Configuration Tool ................................................................................................................... 71
Introduction ............................................................................................................................................................ 71
Basic Features ..................................................................................................................................................71
Advanced Features ..........................................................................................................................................71
Installing EasyRoll tool on your PC .................................................................................................................... 72
ConveyLinx Ethernet Definition .......................................................................................................................... 72
Connecting Your PC to ConveyLinx Network .................................................................................................. 74
Options for Configuring Your PC’s IP Address ................................................................................................ 74
Method 1 - Using DHCP Service for PC I.P. Address ................................................................................75
Manual I.P. Address Configuration Methods ...............................................................................................75
Using EasyRoll to Locate Auto-Configuration Master ................................................................................76
Starting EasyRoll Application .....................................................................................................................76
Using the UDP Discover Utility ..................................................................................................................76
Method 2 - Change PC to Match Auto-Config Master ............................................................................78
Method 3 - Change Auto-Config Master I.P. Address ............................................................................78
EasyRoll Main Screen.......................................................................................................................................... 80
Connecting to ConveyLinx .................................................................................................................................. 81
Node Navigation ...............................................................................................................................................81
Node Identification ...........................................................................................................................................82
Upstream / Downstream Zone Configuration...............................................................................................82
ZPA Mode Selections ......................................................................................................................................83
Train Release Mode ....................................................................................................................................84
GAP Train Release Mode ...........................................................................................................................84
T-Bone Configuration ..................................................................................................................................85
Ignore Jam Settings.....................................................................................................................................86

Publication ERSC-1000 Rev 4.4 – May 2014

Table of Contents 11

MDR Settings ....................................................................................................................................................87

Motor Type ....................................................................................................................................................87
Brake Method ...............................................................................................................................................89
Speed ............................................................................................................................................................90
Closed Loop..................................................................................................................................................90
Motor Direction .............................................................................................................................................91
Acceleration / Deceleration ........................................................................................................................92
ConveyLinx Advanced Dialog ............................................................................................................................. 93
Invoking the ConveyLinx Advanced Dialog ..................................................................................................93
Look Ahead & Timing ..................................................................................................................................93
Upgrade .........................................................................................................................................................97
Connections ................................................................................................................................................100
Network Services .......................................................................................................................................105
Special Services.........................................................................................................................................105
Control Ports Configuration ......................................................................................................................105
Flex Zone ....................................................................................................................................................109
Sensors .......................................................................................................................................................109
Extensions ..................................................................................................................................................109
Network Lock Feature ...............................................................................................................................110
Appendix A – Dimensions and Mounting Information ....................................................................................... 113
ConveyLinx Module Dimensions ...................................................................................................................... 113
Conveyor Frame Fabrication Detail ................................................................................................................. 113
Appendix B–Configuring PC for Ethernet Subnets ............................................................................................ 115
ConveyLinx, IP Addresses, and Subnets........................................................................................................ 115
Configuration Example ...................................................................................................................................... 116
Change PC’s IP Address Procedure ...........................................................................................................117
Appendix C – ConveyLinx Accessories ............................................................................................................... 119
Notes on SE-Module Revisions ........................................................................................................................ 121
ERSC-SE2 ......................................................................................................................................................121
ERSC-SE3 ......................................................................................................................................................121
ERSC-SE4 ......................................................................................................................................................121
Appendix D – Application Examples .................................................................................................................... 123
Using Extensions for a Lift Gate ....................................................................................................................... 123
Notes: ....................................................................................................................................................................... 127

Publication ERSC-1000 Rev 4.4 – May 2014

Preface 13

PREFACE

WHO SHOULD USE THIS MANUAL?

This manual is intended for users who need basic product information and simple application procedures to
implement ConveyLinx ERSC 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.

For users and integrators interested in PLC based control integration with ConveyLinxERSC modules should refer to
Insight Automation publication ConveyLinx Developer’s Guide (publication ERSC-1500)

Insight Automation offers training classes on how to best apply ConveyLinx MDR controls in your applications. Get
a head start on engineering, commissioning, programming and various installation methods for ConveyLinx.
Contact our office more details and scheduling.

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.

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.

Publication ERSC-1000 Rev 4.4 – May 2014

14 User’s Guide

INTRODUCTION TO CONVEYLINX®

CONVEYLINX® CONCEPT
ConveyLinx control system as applied to conveyor control is a series of individual ConveyLinx ERSC modules
interconnected via standard shielded Ethernet cabling to form an integrated solution for MDR (Motorized Drive
Roller) conveyor functionality. Each ConveyLinx ERSC module can accommodate up to 2 MDR’s and 2 photo-
sensors to provide control for up to 2 conveyor zones. Each ERSC also includes convenient connectivity ports for
upstream and downstream Ethernet network cabling as well as connectivity ports for discrete I/O signals with non-
networked controls for local interlock interface functions.

FIGURE 1 - CONVEYLINX® CONCEPT WITH ERSC MODULES

ConveyLinx ERSC modules can be easily automatically configured to operate multiple zones of linear conveyor
“right out of the box” with the push of a button without any special tools or PC software required. However, with
the ConveyLinx Easy Roll software tool and a PC; each ERSC module’s default configuration can be modified to
customize functionality for specific applications.

Publication ERSC-1000 Rev 4.4 – May 2014

Introduction to ConveyLinx® 15

CONVEYLINX® SYSTEM COMPONENTS

The following are the typical components required for a ConveyLinx controlled conveyor installation:

 ERSC modules
 MDRs – one or two per
ERSC
 Photo-sensors – one or
two per ERSC
 24VDC Power Supplies

CONVEYLINX® ERSC MODULE FEATURES

Each individual ConveyLinx ERSC module has the following features:

 Built-in Ethernet switch

 Modular RJ style connection ports for photo-sensors and interfacing signals
 Modular JST style connectors for MDR
 Single 24VDC power connection for motor and control
 Context-sensitive multi-color LED indicators
 Thermal and over-current protection for MDR
 Automatic light/dark operate detection for photo-sensor inputs
 Automatic PNP/NPN detection for photo-sensor and hardware inputs
 Control Port Output default is PNP. To use NPN interlocking a SE Module is required.
 Proportional / Integral (PI) MDR speed regulation option
 Four MDR braking method options
 Adjustable acceleration and deceleration time and distance capability
 MDR mechanical brake control option
 Multiple MDR manufacturer capability

Publication ERSC-1000 Rev 4.4 – May 2014

16 User’s Guide

CONVEYLINX® CONTROL SYSTEM FEATURES

When one or more ERSC modules are installed and configured, there are several operational and configurable
features of the ConveyLinx control system that are accessible by the EasyRoll software package. Some of these
features are:

 Single zone to zone zero pressure accumulation (ZPA) control as default mode.

 Optional configuration for Train Release and Gap Train Release modes.

 Automatic Flexible Zone Recognition logic to detect and handle load sizes exceeding the length of one
physical zone.

 Optional configuration for Look Ahead Slow Down mode for higher speed applications.

 Ability to bridge separate Ethernet sub-networks for seamless operation.

 Ability to designate an ERSC to be an “Extension” to another ERSC such that it operates as simple motor
controller.

The first sections of this manual will describe in detail the hardware and connectivity requirements for ERSC
modules and the “one button” configuration procedures for simple linear conveyor installation.

The latter sections of this manual will describe a brief overview of the EasyRoll software package to gain access to
the various optional configuration parameters and utilities. For more details, the EasyRoll Software package now
has “Pop-Up” dialogue boxes for each function within EasyRoll.

Publication ERSC-1000 Rev 4.4 – May 2014

ERSC Module Hardware Overview 17

ERSC MODULE HARDWARE OVERVIEW

ConveyLinx ERSC modules are designed to be installed and integrated into the conveyor’s mechanical side frame
assembly. Please refer to Appendix A – Dimensions and Mounting Informationon page 113for module dimensions
and mounting details.

The ConveyLinx ERSC module is a controller for up to 2 Motorized Drive Roller (MDR) conveyor zones. Each ERSC
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.

FIGURE 2 - ERSC MODULE HARDWARE FEATURES IDENTIFICATION

Item Description
1 24VDC Power Connector
2 Install Button – Used for Auto Configuration and module reset functions
3&4 Motor Left and Motor Right - 9-pin JST style header for MDR connection
5&6 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
7&8
modules
Left Control Port and Right Control Port – RJ-12 style ports for discreet hard-wired signal
9 & 10
connections for non-networked interface interlocks and zone control
11 & 12 Motor Left LED & Motor Right LED – Motor status indicators

Publication ERSC-1000 Rev 4.4 – May 2014

18 User’s Guide

Item Description
13 Module Status LED Indicator
14 Module Network Status LED Indicator
15 & 16 Left Link & Right Link Status LED Indicators
17 & 18 Left Sensor & Right Sensor Status LED Indicators
19 & 20 Hardware Left & Hardware Right Status LED Indicators

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

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Connections 19

HARDWARE CONNECTIONS

MOTOR LEFT AND MOTOR RIGHT PORTS

Both of these ports utilize a 9-pin JST brand female receptacle. Each receptacle is mechanically keyed to assure
proper orientation upon plugging in.

FIGURE 3–JST DIAGRAM

FIGURE 4 - MOTOR PLUG-IN EXAMPLE

Pin Description
1 GND – Motor & Sensor Ground
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 Brake Control

Publication ERSC-1000 Rev 4.4 – May 2014

20 User’s Guide

SENSOR LEFT AND SENSOR RIGHT PORTS

Each sensor port is a standard RJ-11 style jack with the following pin-out:

FIGURE 5–CONVEYLINX SENSOR PORT DIAGRAM FIGURE 6 - ERSC WITH SENSOR PLUGGED IN

The signals are defined by the following chart:

Pin Signal Description

1 Not Used
2 GND Module DC Common
3 Sensor Error Logical Input for Sensor’s error output – Auto detect for NPN or PNP
4 Sensor Logical Input for Sensor’s state output – Auto detect for NPN or PNP
5 Vcc Module 24VDC Supply
6 Not Used

Shorting Pins 2 & 5 (Vcc and Gnd) will 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.

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Connections 21

LEFT AND RIGHT CONTROL PORTS

Each of these ports is identical in logical input and output pin-out as each Sensor port. The signals are defined as in
the following chart:

Pin Signal Description

1 Output E Interlock with Upstream/Downstream Module, SE Module recommended
2 GND Module DC Common
3 PNP/NPN Optional Zone Accumulate Control
4 PNP/NPN Interlock with Upstream/Downstream Module
5 Vcc Module 24VDC Supply
6 Output C Interlock with Upstream/Downstream Module, SE Module recommended

SENSOR AND CONTROL PORT FUSING

Because the ERSC utilizes a single external power connection for both control power and MDR power; the module
includes internal resettable 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 150 mA fuses. Figure 7 shows the basic schematic for the
ERSC control power.

FIGURE 7 - ERSC CONTROL POWER FUSING

If the 300 mA fuse trips, then the module will reset and perform a reboot. However, if either of the 150 mA fuses
trips, there is no direct indication of this state, because the LED’s associated with the Sensor and Control Ports are
part of the 300 mA fuse’s circuit.

Publication ERSC-1000 Rev 4.4 – May 2014

22 User’s Guide

User’s must take care in the types of sensors and devices that need to connect to a given
ERSC and assure that the current draw on any Sensor/Control port pair does not exceed
the fuse ratings.

If any of the 150 mA fuses shown 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 there are power concerns for devices connected to Sensor or Control Ports, see section
Using ERSC-SE4 Terminal Breakout Module on page 66 on how to use an external ERSC-
SE4 module to connect an external power source for Sensor / Control ports.

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Connections 23

ETHERNET LEFT AND ETHERNET RIGHT PORTS

Both of these ports are standard RJ-45 jacks conforming to standard Ethernet connection pin-out.

FIGURE 8 - ERSC WITH LEFT & RIGHT ETHERNET CABLES

FIGURE 9 - STANDARD RJ-45 PIN-OUT

FIGURE 10 - ETHERNET CROSSOVER CABLE DIAGRAM FOR REVISION 1

All Hardware Revision 1 ConveyLinx Modules 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.

Publication ERSC-1000 Rev 4.4 – May 2014

24 User’s Guide

CONNECTIONS FOR LINEAR CONVEYOR

For linear conveyor operation, ERSC modules are designed to perform an Auto-Configuration Procedure (as
described in detail in section

Publication ERSC-1000 Rev 4.4 – May 2014

Connections for Linear Conveyor 25

Auto-Configuration Procedure on page 34).

Further description and application examples of Ethernet networked solutions are included
in separate Insight Automation publication ConveyLinx Developer’s Guide (publication ERSC-
1500).

Before the Auto-Configuration Procedure can be performed; each individual ERSC module needs to have its
associated MDR’s and photo-sensors connected in the proper way for expected operational results.

In general, each ERSC module detects which Sensor ports have a device connected and will use this to determine
its specific configuration once it has been instructed to self-configure by the Auto-Configuration Procedure.

Before starting to configure your system to operate, each MDR and photo-sensor needs to be properly connected
to the ERSC modules mounted on the conveyor. ERSC modules will determine how to operate based upon how the
photo-sensors and MDR’s are connected.

A single ERSC module can operate as a:

• 2 zone controller with 2 MDR’s and 2 photo-sensors

• 1 zone controller with 1 MDR and 1 photo-sensor
• 1 zone controller with 2 MDR’s and 1 photo-sensor

The following examples illustrate these connections.

EXAMPLE 1 –TWO ZONE CONTROLLER

In this example an MDR and photo-sensor is connected to both the Left and Right group of ports. The module will
control the 2 MDRs as independent logical conveyor zones.

Publication ERSC-1000 Rev 4.4 – May 2014

26 User’s Guide

EXAMPLE 2 – SINGLE ZONE CONTROLLER

OR

In this example, a single MDR and photo-sensor is connected to either the Left or Right group of ports. The
module controls the MDR as a single independent logical conveyor zone.

EXAMPLE 3 – DUAL MDR SINGLE ZONE CONTROLLER

OR

In this case the ERSC module will control 2 MDR’s in tandem and operate as a single zone with a single photo-
sensor connected to either the Left or Right port. This configuration is typical for belted zones used particularly on
inclined conveyors which require the added torque of a second MDR to accommodate the conveying load.

INVALID CONFIGURATION EXAMPLES

Because the ERSC module determines its self-configuration intention by how photo-sensors are connected; it is
possible to connect photo-sensors and MDR’s in invalid ways that will result in unexpected results.

OR

In these cases the module will try to act as a Single zone conveyor control, but the MDR’s are not plugged into
same Left/Right port group as the photo-sensors.

Publication ERSC-1000 Rev 4.4 – May 2014

Connections for Linear Conveyor 27

OR

In these cases the ERSC will try to act as a two-zone conveyor control but only one MDR is connected.

These invalid configurations will not cause the Auto-Configuration function to fail. The
user will only experience incorrect operation and/or unexpected results.

Publication ERSC-1000 Rev 4.4 – May 2014

28 User’s Guide

MOTOR DIRECTION DEFINITION

The ERSC module uses a Clock-Wise (CW) and Counter Clock-Wise (CCW) motor rotation definition. The reference
for this distinction is based upon viewing the MDR from the cable exit end of the roller as depicted below in Figure
11.

FIGURE 11 - MOTOR ROTATION DIRECTION CONVENTION

This rotation definition convention applies to all Pulse Roller brand MDRs. Selection of
CW and CCW for certain models of other manufacturer’s MDRs may not result in actual
clock-wise or counter clock-wise rotation. Installations utilizing other manufacturers
MDR’s may require configuration using the EasyRoll software tool to both select the
equivalent MDR and to set the desired operational direction.
By default Pulse Roller brand MDRs will operate in the CW direction. Use the EasyRoll
software tool to change rotation if needed.
By default EasyRoll sets the MDR type to Pulse “28 Watt Roller”. Use the EasyRoll
software tool to select the correct MDR type installed.

Publication ERSC-1000 Rev 4.4 – May 2014

Connections for Linear Conveyor 29

NETWORK AND POWER 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 ERSC 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 a24VDC power connection. The Power Plug connection is the power
source for all logic, photo-sensors, and MDR’s.

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.

The Ethernet interconnections between ERSC modules on a linear conveyor must be

continuous with no other Ethernet devices (Ethernet switch for example) physically
connected between any module in the network chain. The Auto-Configuration Procedure
described below will fail if it encounters any non-ConveyLinx module device on its subnet.

Publication ERSC-1000 Rev 4.4 – May 2014

Status Indicators 31

STATUS INDICATORS
ERSC module status is indicated by several LED’s. All LED’s with the exception of the Ethernet Link and Activity
LEDs are multi-coloured and context sensitive. The following chart indicates the various meanings of all ERSC LED
indicators. Please refer to Error! Reference source not found. on page Error! Bookmark not defined. for the item
number locations on the module. By definition Blinking is approximately ½ second on/off cycle and Flashing is
approximately ¼ second on/off cycle.

COMMUNICATIONS
Indicator Item LED State Description
OFF No connection established
Ethernet Left Link 16 Solid Green Connection is established
Blinking Green When data transmission activity is occurring
OFF No connection established
Ethernet Right Link 15 Solid Green Connection is established
Blinking Green When data transmission activity is occurring

NETWORK & MODULE FUNCTION

Indicator Item LED State Description
Solid Red ERSC is booting up
Blinking Red ERSC is starting task processes
Blinking Green ERSC is ready
Flashing Green &
Module Status 13 Blinking Red Failsafe Mode

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 Status 14 Blinking Red Establishing inter-module connections
Blinking Green Inter-module communications established

Publication ERSC-1000 Rev 4.4 – May 2014

32 User’s Guide

MOTORS
Indicator Item LED State Description

OFF Motor is not running and no faults detected

Solid Green Connection is established
• If Motor is running, indicates current limit
Solid Red • If Motor is stopped, indicates motor is not
Motor Left & Motor Right 11 & 12 connected properly or is overheated
Motor is overloaded and ERSC is limiting current to
Blinking Red
reduce temperature
Motor short circuit detected between at least two of
Flashing Red
the phase windings

SENSORS
Indicator Item LED State Description
Solid Green Sensor (Pin 4) Input energized
Sensor Left & Right 17 & 18 Solid Red Sensor (Pin 3) Error Input energized
Blinking Red Zone Jam or missing sensor
Solid Green Pin 4 Input energized
Hardware Control Left &
19 & 20 Solid Red Pin 3 Input energized
Right
Flashing Red ERSC configuration error
All Sensor & Hardware 17 & 18
Flashing Red Network E-Stop Condition
Indicators 19 & 20

Publication ERSC-1000 Rev 4.4 – May 2014

Auto-Configuration of Linear Conveyor 33

AUTO-CONFIGURATION OF LINEAR CONVEYOR

The purpose of Auto-Configuration for networked ConveyLinx controls is to provide a simple and easy procedure
for linear conveyor system commissioning that does not require a PC or PC based software to implement. The
Auto-Configuration of Linear Conveyor feature of ConveyLinx requires only the proper interconnection of each
module and the press of a button on the most upstream module to complete.

LINEAR CONVEYOR DEFINITION

Auto-Configuration is only applicable to a Linear Conveyor arrangement. 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.

FIGURE 12 - SIMPLE LINEAR CONVEYOR EXAMPLE

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. Please refer to the Pop-up self-
help within the EasyRoll for details on PC based configuration.

Publication ERSC-1000 Rev 4.4 – May 2014

34 User’s Guide

AUTO-CONFIGURATION PROCEDURE
The direction of flow of the conveyor dictates how to begin the Auto-Configuration procedure. The ERSC module
located at the most upstream or in-feed end of the conveyor is defined as the Auto-Configuration Master.
The Auto-Configuration procedure is initiated from the Auto-Configuration Master. Because of its physical location
on the conveyor path and physical location in the Ethernet connection chain; the Auto-Configuration Master will
automatically connect to all downstream modules and set their I.P. address for communication. Then the routine
automatically sets the direction of flow. The following is the procedure to follow:

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 module will be initiated
as the Auto-Configuration Master and the Auto-Configuration routine will begin.

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.

Publication ERSC-1000 Rev 4.4 – May 2014

Auto-Configuration of Linear Conveyor 35

AUTO-CONFIGURATION EXAMPLES
The ConveyLinx Auto-Configuration routine will detect which photo-sensors and MDR’s are connected in order to
configure a given 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. The following figures illustrate the pressing of the
INSTALL button and the expected result of the Auto-Configuration routine. Please note that the red lines in the
figure depict the crossover Ethernet cable connections.

FIGURE 13 – SIMPLE AUTO CONFIGURATION EXAMPLE

Without changing any physical connections or cables; simply performing the same procedure at the opposite end
of the conveyor path will re-configure all modules to operate in the reverse direction. This illustrates how the
Auto-Configuration Master is easily changed by the Auto-Configuration procedure.

FIGURE 14 - SIMPLE AUTO CONFIGURATION EXAMPLE IN OPPOSITE DIRECTION

Please note that number of ERSC modules on a single Subnet is limited to 220.

Publication ERSC-1000 Rev 4.4 – May 2014

36 User’s Guide

AUTO DETECTION OF OPPOSITE SIDE MODULE LOCATION

The cross-over cable connections between Left and Right Ethernet ports can be used in situations where the ERSC
has to be mounted in the conveyor’s opposite side frame. If properly connected, the Auto-Configure routine will
detect this and configure the conveyor flow properly. This is illustrated in the following figure:

FIGURE 15 - OPPOSITE SIDE MODULE LOCATION EXAMPLE

AUTO CONFIGURATION RESULTS

NORMAL RESULTS
When the auto-configuration routine is complete, each ERSC will automatically reboot. When an ERSC has been
successfully configured and rebooted, its Module and Network Status LED’s (see Error! Reference source not
ound. items 13 and 14) will blink on and off green.

Please note that the time to complete the Auto-Configuration procedure is dependent on
the number of ERSC modules being configured. Larger networks will take more time than
smaller networks.

If all ERSC’s Module and/or Network Status LED’s are blinking green; then to fully verify configuration is to place a
single load onto the most upstream zone and see that it conveys to the discharge zone. If it does, then the Auto-
Configuration is successful. If it does not, then see section Trouble-shooting Failed Auto-Configuration below.

Please note that once a network has been configured; pressing and holding the Install
button on any ERSC that is not the Auto Configuration Master will not initiate a new Auto
Configuration procedure. The ERSC will detect that it is not the most upstream unit and
abort the procedure. However the ERSC will perform its local re-booting procedure. This
procedure will take a few seconds to complete.
TROUBLE-SHOOTING FAILED AUTO-CONFIGURATION
The following chart lists some typical failed condition indicators and actions to take for resolution.

Publication ERSC-1000 Rev 4.4 – May 2014

Auto-Configuration of Linear Conveyor 37

Failed Condition Action

• Check that all photo-sensors are operational and that all zones are clear and
perform procedure again.
Status LED’s OK with • Check all networks, MDR, Sensor, and power connections and perform
Unexpected Result procedure again.
• Verify that all connections are valid. Refer to sectionInvalid Configuration
Examples on page 26. Correct connections and perform procedure again.
• Verify that there are no Ethernet Switches or PC’s connected between ERSC’s.
The Auto Configuration procedure will abort if a non-ERSC device is detected
Either or both Status along the path before reaching the last node. Modules up to that point will be
LED’s blinking or solid configured, but the remaining modules will not.
red on one or more • When removing an ERSC from an existing network that is already operational;
modules be sure to wait at least 2 minutes to allow the Ethernet switches on the
remaining ERSC’s to reset before attempting a new Auto Configuration
procedure.

Publication ERSC-1000 Rev 4.4 – May 2014

38 User’s Guide

DEFAULT CONFIGURATION
After a successful Auto Configuration, each ERSC will have the following default settings:

Item Default Value or Setting

MDR Type Senergy ECO Roller
MDR Speed 100% of rated motor PWM
Brake Method Standard Dynamic
Acceleration Rate 0.050 seconds
Deceleration Rate 0 seconds
ZPA Mode Singulation
Closed Loop Disabled
T-Bone Accept Time 0 seconds
Jam Timeout 5 seconds
Run After Sensor Clear Timeout 0.4 seconds
DIRECTION CW
These setting can be modified per individual ERSC zone and/or network wide by utilizing the EasyRoll software
tool. Please refer to section EasyRoll Software Configuration Tool starting on page 71 for definitions of these
settings and procedures for their modification.

You should also reference the self-help pop-up dialogues within EasyRoll for complete up
to date definitions of pin-outs, functions and settings.

Publication ERSC-1000 Rev 4.4 – May 2014

Auto-Configuration of Linear Conveyor 39

DEFAULT SINGULATION RELEASE ZPA MODE

Loads will normally convey from upstream zone to downstream zone in singulation release fashion. With no
Hardware Control connection on most downstream zone; load reaching last zone photo-sensor will cause last zone
motor to continue to run to discharge load to next conveyor or position. To control whether loads stop at most
downstream zone, you must utilize one of the hardware interface methods described in section Hardware
Interface on starting on page 45.

In Singulation Release Mode, each zone waits until the zone in front of it is clear before it is allowed to run. This
mode assures at least a zone-length of gap between loads as they are being conveyed. When the first load needs
to stop and cause all those behind it to accumulate; the trailing loads stop in their respective zones when their
leading edge blocks the zone’s photo-sensor. Figure 16 shows a typical example of singulation release.

FIGURE 16 - SINGULATION RELEASE EXAMPLE

Publication ERSC-1000 Rev 4.4 – May 2014

40 User’s Guide

DEFAULT FLEX ZONE RECOGNITION FEATURE

ERSC 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 operates for both singulation and train release modes.

FIGURE 17 - TYPICAL FLEX ZONE MODE EXAMPLE

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 will
produce undesirable results such as excessive detected jam conditions and faults.

Please refer to the integrated help inside EasyRoll for definitions and usage of the other
available ZPA modes.

JAM CONDITION
There are two (2) types of Jam conditions detected by the ERSC:

• Sensor Jam
• No Arrival Jam

SENSOR JAM
If a load remains blocking the photo-sensor in an upstream zone after an attempt to move the load to its next
downstream zone, the ERSC will detect a Sensor Jam. This will be indicated as shown on chart in section Sensors
on page 32. In this case, if the load is cleared from the photo-sensor, the ERSC will automatically clear the Sensor
Jam condition after the default 5 second Reset Timer expires.

Publication ERSC-1000 Rev 4.4 – May 2014

Auto-Configuration of Linear Conveyor 41

After the Sensor Jam occurs and the sensor remains blocked; the ERSC will attempt to self-clear the Sensor Jam
condition. First, the ERSC will run the affected zone’s motor in reverse for up to 1 second in order to clear the
blocked sensor. If the sensor is still blocked after this first reversing attempt, it will repeat this motion 2 more
times. If the sensor becomes clear after any of these three attempts, the zone will return to normal function and
the ERSC will attempt to convey the load downstream under normal ZPA control.

If the sensor remains blocked after three attempts of this motor reversing cycle; the zone will remain in Sensor
Jam state and the load must be removed manually to reset the zone.

The default timer and the condition itself may be changed via the EasyRoll. Please refer to Ignore Jam Settings on
page 86 or the integrated help inside EasyRoll.

NO ARRIVAL JAM
When a load leaves an upstream zone and is conveyed to its next downstream zone, this upstream zone expects
positive confirmation of load arrival from the downstream zone. This communication occurs automatically along
the ConveyLinx network. If a new load arrives at this upstream zone while this upstream zone is waiting for a
downstream arrival confirmation, the new load will accumulate on this upstream zone. If the upstream zone does
not receive this confirmation within the Jam Timer interval, the ERSC will produce a No Arrival Jam fault. Once a
No Arrival Jam occurs, the ERSC will automatically hold any new load at the upstream zone for a pre-determined
Reset Timer value and then resume normal ZPA function. By default, the Jam Timer and the Reset Timer values are
equal so that the maximum time a new load would remain accumulated in the upstream zone is 5 sec + 5 sec = 10
seconds.

The 5 second jam timer value is the default setting. Please refer to the integrated help
inside EasyRoll for instructions on changing this value.

Please refer to Ignore Jam Settings on page 86 or the integrated help inside EasyRoll for
help on changing the default logic to ignore a particular jam condition.

NETWORK FAULT
In instances where Ethernet network connection is interrupted between ERSC modules while in operation, loads
will continue to convey and accumulate to the farthest downstream zone prior to where the network is
interrupted. This farthest downstream zone will automatically accumulate the load and not allow it to convey
further downstream. Once network communications are re-established, the zone will return to normal operation.

LOW VOLTAGE FAULT

In instances when the ERSC module detects that its supply voltage has dipped below 18VDC; the ERSC will place its
configured zone or zones into accumulation mode. The ERSC will keep this state until it has detected that its input
voltage has risen to at least 21VDC.

Publication ERSC-1000 Rev 4.4 – May 2014

42 User’s Guide

Persistent unexplained momentary stopping or hesitations in normal zone to zone load

movement may be an indication of low voltage conditions. If this behaviour is consistently
observed; please verify voltage at farthest point from power supply and review power
supply sizing and wiring practices to insure proper voltage at all modules.

Publication ERSC-1000 Rev 4.4 – May 2014

Auto-Configuration of Linear Conveyor 43

AUTOMATIC MODULE REPLACEMENT

Once a linear conveyor has been commissioned by Auto-Configuration, the ERSC modules 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 ERSC firmware uses this
feature to allow for easy module replacement so that the entire linear conveyor does not have to be re-configured
in order to replace a single module.

For ERSCs with firmware version 1.xx: Automatic Module Replacement will only work to
replace an ERSC that is on a single Subnet network. For multiple Subnet installations that share
a single physical network; temporarily disconnecting all Subnets from the affected modules
Subnet will be required. Please refer to Appendix B–Configuring PC for Ethernet Subnets for a
more detailed explanation of Subnets
For ERSC’s with firmware version 2.xx and 3.xx and higher: Automatic Module Replacement
will work to replace an ERSC on multiple subnet installations without temporarily disconnecting
any network connections.

Publication ERSC-1000 Rev 4.4 – May 2014

44 User’s Guide

ERSC REPLACEMENT PROCEDURE

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 1second after applying power; the Module Status LED will start
blinking red. DO NOT RELEASETHE 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.
a. Observation 1: A good indication that the Auto Replace Procedure is going on is that all sensor
and control port LEDs will turn on solid red.
b. Observation 2: During the Auto Replace Procedure, you will also observe that 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.
5. 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 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.
6. Once at least 3 minutes have passed and the new module is finished with its multiple restarting cycles, the
new module should show that both its Module Status and Network LED’s are blinking green. When both
the Module Status and Network LED’s are blinking green you are good to go.

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 45

HARDWARE INTERFACE WITH CONTROL PORTS

Each ERSC module is equipped with a Left Control Port and a Right Control Port. Each of these is a 6 pin RJ-12 style
socket. Each of these ports contains electrical connections for 2 logical inputs into the ERSC and 1 logical output
controlled by the ERSC. The interpretation of the logical inputs by the ERSC on board logic and the meaning of the
logical outputs controlled by the ERSC on board logic are based upon the conditions detected by the ERSC after the
Auto-Configuration procedure.

Both Control Ports provide 2 overall functions for the ERSC:

• Local zone’s accumulation control

• Module’s upstream / downstream interlocking

The following sections describe the functionality of both ports and the Auto-Configuration conditions that dictate
each port’s interlocking configuration.

LOCAL ZONE ACCUMULATION CONTROL

Both the Left and Right Control Ports have an input available that is reserved to provide local accumulation control
for the given MDR zone. This input (Pin 3 on RJ-12 Hardware Control Ports) is PNP/NPN auto-sensing that will
accept a simple contact closure (relay, selector switch, foot switch, etc.). When the contact is closed, the zone will
accumulate any load that enters and occupies the zone and the load will not release regardless of the downstream
conditions. When the contact is open, the zone will return to its normal mode of operation as dictated by its
configuration. Figure 18 shows both ways to connect a contact signal to the accumulate input. Either connection
method is acceptable and is logically identical to the ERSC module.

Local Accumulate control connection is intended for use in all ERSC zones
except the most upstream or most downstream. Please use Upstream and
Downstream Interlocks for the most upstream and downstream zones.

Publication ERSC-1000 Rev 4.4 – May 2014

46 User’s Guide

FIGURE 18- ACCUMULATE CONTROL CONNECTION EXAMPLES

Please note that if the accumulation control connection becomes closed while a load is in
transit in a zone (MDR is running and load still blocking the photo-sensor); the ERSC will
immediately stop the MDR and begin accumulation.

The “open” and “closed” states for the ERSC Accumulate Input signal shown above in Figure
18 are the default states.
Please refer to section Control Ports Configuration on page 105for instructions on how to
invert the expected ERSC Accumulate Input signal for your specific application.

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 47

CONTROL PORT INTERLOCK DEFINITION

ConveyLinx modules provide built-in logical interlock signals to be able to automatically interface with another
ConveyLinx system or external hard-wired controls (such as push-buttons, relay contacts, or PLC’s) for basic
conveyor flow operation. This interlocking for the Left Control Port and Right Control Port can function in one of
two ways:

• Upstream Interlock
• Downstream Interlock

The Left Hardware Control and Right Hardware Control ports automatically configure themselves as either an
Upstream Interlock or Downstream Interlock based upon conveyor flow after the Auto-Configuration procedure.
The logical function of both the Upstream Interlock and Downstream Interlock is exactly the same whether the
hardwired connection to its respective Control Port is with a PLC or another ERSC module.

If the “Left” side of the ERSC module is controlling the most “upstream” zone with respect to conveyor flow, then
the Left Control Port provides the Upstream Interlock function. Similarly, if the “Left” side of the ERSC module is
controlling the “downstream” zone with respect to conveyor flow, then the Left Control Port provides the
Downstream Interlock function. This same description applies to the Right Control Port. Figure 19 and Figure 20
show the resulting Control Port functions based upon direction of conveyor flow after an Auto-Configuration
procedure.

FIGURE 19 - CONTROL PORT ASSIGNMENT BASED UPON FLOW EXAMPLE

Publication ERSC-1000 Rev 4.4 – May 2014

48 User’s Guide

FIGURE 20 - CONTROL PORT ASSIGNMENT EXAMPLE BASED UPON OPPOSITE FLOW DIRECTION

The logical function of the Upstream and Downstream Interlock is identical regardless of whether a
PLC is connected to the Control Ports or if another ERSC is connected to a Control Port. The ERSC
does not detect or otherwise determine if hardwired PLC or another hardwired ERSC is connected.

HARDWARE INTERFACE CABLE

Electrically, any Control Port on an ERSC module is designed to connect to any Control Port on another ERSC by
using a properly configured RJ-12 cable assembly. Various situations and conditions sometimes dictate that more
than one ConveyLinx network is required for a given application. One of these conditions, for example, is the
limitation of 220 ConveyLinx modules that can share the same network domain. In cases like these, one
ConveyLinx network can seamlessly connect to a second ConveyLinx network via simple Hardware Interface Cable
that allows the connected ERSC’s to exchange their respective Upstream and Downstream Interlock functions. The
discharge zone module’s Control Port from one network is simply connected to the in-feed zone module’s Control
Port on the second network (or vice-versa) via a properly configured Hardware Interface Cable. Figure 21 shows a
typical conveyor arrangement for connecting two separate ConveyLinx networks together with a Hardware
Interface Cable. The two ERSC’s shown will simply exchange digital interlock handshake signals to allow for
product to seamlessly convey from one network to the other.

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 49

FIGURE 21 - TYPICAL HARDWARE INTERFACE CABLE EXAMPLE

Figure 22 shows the cable assembly detail for a Hardware Interface Cable. Please note that either end of this cable
can be plugged into either ERSC Control Port.

FIGURE 22 - TYPICAL MODULE TO MODULE HARDWARE CONNECTION

Cable connection and cable assemblies are identical for upstream or downstream module-
to-module interlocks. ConveyLinx auto-detects functionality from internal configuration of
conveyor flow, etc.
Refer to Appendix C – ConveyLinx Accessories for Insight Automation’s line of available pre-
manufactured cable assemblies and accessories.

Please note that a Hardware Interface Cable connection only exchanges discrete digital
handshaking signals between the two networks of ConveyLinx modules. Ethernet-based
information available from either network is not passed through this connection.

Publication ERSC-1000 Rev 4.4 – May 2014

50 User’s Guide

SINGLE ZONE ERSC CONFIGURATION

Determining the Upstream or Downstream Interlock functionality for a given Left Control Port or Right Control Port
is straight-forward when both the left and right zones of the ERSC are being utilized in a standard 2 zone
configuration.

However it is likely that some conveyor sections in a typical conveyor system will only utilize one of the two
available zones on an ERSC and that the other zone is not used at all (i.e. no MDR or Sensor plugged in). In these
cases, the Auto-Configuration procedure still defines the Upstream and Downstream Interlock functions for a single
zone ERSC. When an ERSC is configured as a single zone, the Left Control Port and the Right Control Port is affected
by whether the single zone’s one sensor is plugged into the Left Sensor Port or the Right Sensor Port.

For a single zone ERSC; the physical side of the ERSC that the sensor is plugged will be the
same side who’s Control Port will provide the Upstream Interlock function and the
opposite side’s Control Port will provide the Downstream Interlock function.

For example, if a single zone ERSC has its single zone sensor and MDR plugged into its Left Side; then the Left
Control Port will provide the Upstream Interlock function and the Right Control Port will provide the Downstream
Interlock function. Please note that this holds true regardless of which direction the conveyor is running. The ERSC
side with the sensor is always the “upstream zone”. An example configuration of a single zone ERSC with a
Hardware Interface Cable connection is shown in Figure 23.

FIGURE 23 - SINGLE ZONE HARDWARE INTERFACE EXAMPLE

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 51

USING SENSORS IN CONTROL PORTS

The Left Control Port and the Right Control Port are electrically very similar to the Left and Right Sensor Ports such
that the Control port will power a photo-sensor and the photo-sensor’s output connects to the ERSC’s interlocking
input. For certain basic applications, plugging a photo sensor into an ERSC Control Port can be used to stop
product flow for ERSC controlled discharge zones and can be used to start or “wake-up” ERSC controlled in feed
zones.

SENSOR IN CONTROL PORT FOR DOWNSTREAM INTERLOCK

FIGURE 24–SENSOR IN DOWNSTREAM INTERLOCK CONTROL PORT EXAMPLE

Figure 24 shows a typical example where the application calls for the ERSC controlled discharge zone to
accumulate a load when a downstream section (in this example a pitched gravity section) is occupied. In essence,
the photo sensor plugged into the Right Control Port provides the “downstream occupied” signal to the ERSC.
When the photo-sensor’s output is energized, the ERSC interprets this condition as “downstream zone is occupied”
and will thus accumulate any load that is conveyed into its discharge zone. If the photo-sensor’s output is de-
energized, then the ERSC will discharge the load from the last downstream zone.

Please note by pressing the F2 key within EasyRoll and clicking the “Control Ports” tab you
will see the “Lane Full Interface” on the right. Activating the lane full interface effectively
gives a block and clear time to the “Downstream occupied” signal to the ERSC which allows
for common applications such as running MDR onto gravity conveyor or “other” conveyor
types for a period of time.

Publication ERSC-1000 Rev 4.4 – May 2014

52 User’s Guide

UPSTREAM SENSOR IN CONTROL PORT

FIGURE 25–SENSOR IN UPSTREAM INTERLOCK CONTROL PORT EXAMPLE

Figure 25 shows a typical example where the application calls for the ERSC controlled in-feed zone to run to accept
a load if an upstream sensor is blocked. In essence, the photo sensor plugged into the Left Control Port provides
the “upstream is sending” signal to the ERSC. When the photo-sensor’s output is energized, the ERSC interprets
this condition as “upstream load is sending” and will thus begin to run its in-feed zone to accept the new load in
transit. If the photo-sensor’s output is de-energized, then the ERSC will not run its in-feed zone.

Photo-sensor outputs can be either “light energized” or “dark energized” as well as being either
“Normally Open” or “Normally Closed”. For both of the preceding examples of Sensors in
Hardware Control Port; the default configuration of ERSC’s Control Port inputs is for the
sensor’s output signal to be energized when the zone is occupied.
Please refer to section Control Ports Configuration on page 105 for instructions on how to invert
the signal of the photo-sensor to indicate zone is occupied when sensor output is de-energized.

Please note that single zone configuration definitions and considerations as to which Control
Ports are configured with the Upstream or Downstream Interlock functions still apply for photo-
sensor connections to Control Ports.

Some photo sensors (particularly models that already include an RJ-11 / RJ-12 connector) utilize a
separate “sensor health or light operate/dark operate” signal that resides on Pin 3 of the RJ
connection. If this type of sensor is used with an ERSC Control Port, the ERSC will interpret this
signal on Pin 3 as an “unconditional accumulate” command and will cause the zone to operate as
described in section Local Zone Accumulation Controlon page 45. If such a photo sensor
energizes its sensor health when sensor health is “OK” or light operate/dark operate signal when

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 53

clear, then this sensor cannot be used with an ERSC Control Port because simply plugging it into a
Control Port will cause its zone to unconditionally accumulate. If such a sensor only energizes its
sensor health signal upon a “Not OK” condition, then this photo sensor may be used with an
ERSC Control Port with the understanding that a “not OK” health condition will cause the ERSC to
unconditionally accumulate its Control Port’s zone.

USING CONTROL PORTS WITH PLC I/O

Based upon the definitions for Upstream Interlock and Downstream Interlock made in previous sections, the
following section will give description and logical timing chart examples that illustrate how the ERSC Control Ports
will respond to externally wired PLC I/O.

Once Auto-Configuration is complete; each ERSC Control Port will be logically configured to provide either an
Upstream Interlock or Downstream Interlock.

Regardless of a given Control Port’s logical interlock designation (Upstream or Downstream); the input signal to the
Control Port from external PLC Output is always connected to P4 of the Control Port’s RJ-12 connection jack.
Similarly, the output signal from a Control Port to external PLC input is connected between Pin 1 and Pin 6 of the
Control Port’s RJ-12 connection jack. An ERSC-SE4 Breakout Module simplifies this Interlock Connection by
providing Screw Terminals labelled “Out” for the Control Port Output and P4 for the Pin 4 Input.

Please refer to section Electrical Connections for PLC Controls beginning on page 59 for details
on physical connection options for various PLC I/O configurations.

UPSTREAM INTERLOCK
When a Control Port is acting as the Upstream Interlock, the ERSC interprets a signal on its input Pin 4 as a
command to begin running its upstream zone in order to accept product from an upstream source (conveyor or
other equipment). The ERSC output circuit on Pins 1 & 6 is energized when product is present on its upstream
zone. An ERSC-SE4 Breakout Module simplifies this Interlock Connection by providing Screw Terminals labelled
“Out” for the Control Port Output and P4 for the Pin 4 Input.

This scenario is used when a PLC controlled conveyor needs to discharge a load onto the In-feed zone of the most
upstream ERSC module of a ConveyLinx controlled conveyor as shown in Figure 26.

Publication ERSC-1000 Rev 4.4 – May 2014

54 User’s Guide

FIGURE 26 - TYPICAL UPSTREAM CONVEYOR INTERLOCK EXAMPLE

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 55

U PSTREAM I NTERLOCK T IMING C HART

Figure 27 depicts timing chart for a typical Upstream Interlock exchange of signals over time. Following Figure 27 is
a listing of descriptions of the events from the timing chart.

FIGURE 27 - TYPICAL UPSTREAM INTERLOCK TIMING EXAMPLE

Upstream Interlock Event Description

Start with ERSC In-feed zone clear and ready to accept a load from upstream PLC controlled zoned
 conveyor. PLC Input from ERSC Control Port output signal will be de-energized indicating that it is clear
and ready to accept load.
PLC controlled conveyor has a load ready to discharge onto ERSC in-feed zone. ERSC is signaled via PLC
 Output connected to ERSC Control Port input Pin 4. When this occurs, the ERSC will run its in-feed zone
conveyor
In-feed zone sensor becomes blocked, In-feed zone motor is stopped and the ERSC energizes its Control
 Port output signal to indicate to PLC input that the zone is now occupied.
Assume that zone downstream of ERSC in feed zone is ready to accept a load; ERSC in-feed zone motor
 runs to convey load to next downstream zone as in normal ZPA operation.
In-feed zone sensor becomes clear and Control Port output is de-energized to indicate to PLC Input that in
 feed zone is empty. Note that motor continues to run for a pre-configured run after sensor clear timer to
assure load is completely conveyed from the in-feed zone.
 Motor’s run after sensor clear timer has expired and in-feed zone’s motor is stopped

 Repeat of 

 Repeat of 

Publication ERSC-1000 Rev 4.4 – May 2014

56 User’s Guide

The logical “1” and “0” states for the ERSC Input and ERSC Output signals show above in
Figure 27 are the default states.
Please refer to section Control Ports Configuration on page 105 for instructions on how to
invert the expected ERSC Input and/or ERSC Output signals in order to customize
functionality for your specific hard-wired / PLC application.
DOWNSTREAM INTERLOCK
When a Control Port is acting as the Downstream Interlock, the ERSC interprets a signal on its input Pin 4 as
indication that downstream conditions do not allow for product flow. In this state, the ERSC will accumulate any
product that arrives in its downstream zone. The ERSC output circuit on Pins 1 & 6 is energized when product is
present on its upstream zone. A SE3 Module (Control/Sensor Port Breakout Module, Output Amplifier, Optional
Diodes Jumpers, and Timer) simplifies this Interlock Connection by providing Screw Terminals labelled “Out” for
the Control Port Output and P4 for the Pin 4 Input.

This scenario is used when a PLC controlled conveyor needs to accept a load in a singulating fashion from the
discharge zone of the most downstream ConveyLinx module as shown in Figure 28.

FIGURE 28 - TYPICAL DOWNSTREAM CONVEYOR INTERLOCK EXAMPLE

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 57

D OWNSTREAM I NTERLOCK T IMING C HART

Figure 29 depicts timing chart for a typical Upstream Interlock exchange of signals over time. Following Figure 29 is
a listing of descriptions of the events from the timing chart.

FIGURE 29 - TYPICAL DOWNSTREAM INTERLOCK TIMING EXAMPLE

Downstream Interlock Event Description

Start with ERSC Discharge zone and the PLC controlled accepting zone both occupied. ERSC Input Pin 4 is
 energized from PLC output indicating that PLC controlled accepting conveyor position is occupied.
PLC de-energizes output to ERSC Control Port Input pin 4 indicating to ERSC that downstream position is
 ready to accept load. ERSC starts to run its discharge zone motor to convey load to PLC controlled
conveyor.
Load clears the ERSC discharge zone’s sensor and ERSC Control Port output de-energizes indicating sensor
 is clear. ERSC continues to run the discharge zone motor for the pre-determined Run After time to assure
load has completely conveyed from the zone.
 ERSC discharge zone’s Run After time has expired and the zone motor is stopped.
PLC energizes output to ERSC Control Port Pin 4 to indicate successful arrival on PLC controlled conveyor.
 PLC keeps this energized as long as PLC controlled conveyor is not ready to accept a new load.
Assume that ERSC needs to convey a load into its discharge zone. ERSC’s discharge zone motor runs to
 accept load from its upstream zone under normal ZPA control.
Load conveying from ERSC’s upstream zone arrives at its discharge zone sensor and the discharge zone
 motor is stopped. ERSC also energizes its Control Port output indicating that the discharge zone is now
occupied.
 Repeat of 

 Repeat of 

 Repeat of 

 Repeat of 

Publication ERSC-1000 Rev 4.4 – May 2014

58 User’s Guide

Under normal operation, the time duration between steps  and  must not be greater
than the ERSC’s configured Jam Timer setting. If this time duration is greater than the
configured Jam Time setting, the ERSC discharge zone will produce a No Arrival Jam fault.
The ERSC discharge zone will also produce a No Arrival Jam fault if the PLC does not
energize ERSC Control Port Pin 4 within the same Jam Time interval.
Please refer to section Jam Condition on page 40 for full description of the No Arrival Jam
condition.
Please refer to section Jam, Auto Clear,& Run After Timerson page 95 for instruction on
changing the default Jam Timer setting for the discharge zone.
The logical “1” and “0” states for the ERSC Input and ERSC Output signals show above in
Figure 29 are the default states.
Please refer to section Control Ports Configuration on page 105 for instructions on how to
invert the expected ERSC Input and/or ERSC Output signals in order to customize
functionality for your specific hard-wired / PLC application.
Discharge hardware interlock only functions in Singulation Release Mode. Train Release
Mode is not enabled for a discharge interlock. Please refer to section

Default Singulation Release ZPA Mode on page 39 for description of this mode of operation.

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 59

ELECTRICAL CONNECTIONS FOR PLC CONTROLS

Both Upstream and Downstream electrical connections are the identical. Logically, the ERSC module is expecting a
single logical Input from a PLC Output and provides a single logical Output to a PLC Input. The ERSC module
automatically configures the logical meaning of each logical signal depending on whether the interlock is Upstream
or Downstream.

C ONNECTIONS FOR ERSC O UTPUT TO PLC I NPUT

These connection configurations are the same for both Upstream and Downstream scenarios for either the Left or
Right Hardware Control Port.

S INKING PLC I NPUT

Figure 30 shows a typical connection between a ConveyLinx ERSC module’s Control Port and a 24VDC sinking type
PLC Input card.

FIGURE 30–SINKING PLC INPUT FROM ERSC CONTROL PORT OUTPUT

Please refer to section

Using ERSC-SE4 Terminal Breakout Module on page 66 for details on utilizing ERSC-SE breakout
terminal board for applications requiring a higher current ERSC output.

Publication ERSC-1000 Rev 4.4 – May 2014

60 User’s Guide

S OURCING PLC I NPUT

Figure 31 shows a typical connection between a ConveyLinx ERSC module’s Control Port and a 24VDC sourcing type
PLC Input card.

FIGURE 31 - SOURCING PLC INPUT FROM ERSC CONTROL PORT OUTPUT

ERSC output circuit is VERY LOW POWER and provides only approximately 2mA current for
either sinking or sourcing connections. PLC input module must accommodate lower power
requirement.

Please refer to section

Using ERSC-SE4 Terminal Breakout Module on page 66 for details on utilizing ERSC-SE4
breakout terminal board for applications requiring a higher current ERSC output.

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 61

C ONNECTIONS FOR PLC O UTPUT TO ERSC I NPUT

These connection configurations are the same for both Upstream and Downstream scenarios for either the Left or
Right Hardware Control Port.

Note that Figure 32, Figure 33, Figure 34, and Figure 35 show both the Local
Accumulate and Interlock Inputs being connected to the same control port to
PLC I/O. This is shown for clarity to illustrate that both signal are connected to
a PLC in a similar way to an external PLC and that typically only one or the
other would actually connect for any given ERSC.

In normal applications, the Interlock Input is only used on the most upstream
or downstream zones and the Local Accumulate Input is only used for
intermediate zones. You may get unexpected results by failing to follow this
convention.

S OURCING PLC O UTPUT TO ERSC I NPUT

Figure 32 shows a typical connection between a ConveyLinx ERSC module’s Control Port and a 24VDC sourcing type
PLC Output card.

FIGURE 32 - SOURCING PLC OUTPUT TO SINKING ERSC CONTROL PORT INPUT

Please note that PLC Output connection to Local Accumulate Input is optional and is shown for
reference only to point out that local accumulation control can easily be provided by a PLC
output.

Publication ERSC-1000 Rev 4.4 – May 2014

62 User’s Guide

Please refer to section

Using ERSC-SE4 Terminal Breakout Module on page 66 for details on ERSC-SE4 module
interface to Control Port for screw terminal connections to access the P3 and P4 pins of the
RJ12 Port

S INKING PLC O UTPUT TO ERSC I NPUT

Figure 33 shows a typical connection between a ConveyLinx ERSC module’s Control Port and a 24VDC sinking type
PLC Output card. See the examples of

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 63

Using ERSC-SE4 Terminal Breakout Module with ConveyLinx and other interfaces on page 66.

FIGURE 33 - SINKING PLC RELAY CONTACT OUTPUT TO SINKING ERSC CONTROL PORT INPUT

Please note that PLC Output connection to Local Accumulate Input is optional and is shown
for reference only to point out that local accumulation control can easily be provided by a
PLC output.

PLC output modules MUST BE RELAY OR CONTACT style regardless of sourcing or sinking
operation. Utilizing solid state PLC output modules may result in unexpected results under
conditions where the solid state PLC module can be powered off while it’s connected ERSC
remains powered.
Please refer to section Utilizing Solid State PLC Output Modules beginning on page 63 for
details on using solid state PLC output modules for connections to Control Ports.
Please refer to section
Using ERSC-SE4 Terminal Breakout Module on page 66 for details on ERSC-SE module
interface to Control Port for screw terminal connections to access the P3 and P4 pins of the
RJ12 Port.

U TILIZING S OLID S TATE PLC O UTPUT M ODULES

ERSC Control Port inputs utilize an auto-detecting PNP/NPN circuit. To make this auto-detecting feature operate,
there is a residual voltage always on the circuit. For certain solid state PLC Output modules, when power is
removed from the output module while the ERSC remain powered, the ERSC’s input circuit can find a reverse
current path through the solid state PLC output module such that the ERSC would interpret that its input is
energized. If substituting the solid state module with a relay or contact type PLC output module is not an option;

Publication ERSC-1000 Rev 4.4 – May 2014

64 User’s Guide

the solution is to insert a blocking diode in series into the circuit for each ERSC input so that this reverse current
does not have a circuit path.

There are two means of accomplishing this:

• Provide and install diodes as shown in below

• Utilize an SE2 or greater Module RJ-12 terminal breakout module with integrated diode circuit

The connection polarity of the diode is dependent upon whether the solid state PLC output module is a sourcing
type or sinking type. Figure 34 and Figure 35 show the connection polarity of the blocking diode for sinking and
sourcing solid state PLC output modules respectively.

FIGURE 34 - DIODE CONNECTION POLARITY FOR SOLID STATE SINKING OUTPUT MODULE

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 65

FIGURE 35 - DIODE CONNECTION POLARITY FOR SOLID STATE SOURCING OUTPUT MODULE

Publication ERSC-1000 Rev 4.4 – May 2014

66 User’s Guide

U SING ERSC-SE4 T ERMINAL B REAKOUT M ODULE

Please note that this section describes the latest version of the breakout module which is
the ERSC-SE4. Please refer to Appendix C – ConveyLinx Accessories for details on the
previous versions of the ERSC-SE series modules.

Insight Automation part number ERSC-SE4-Kit is a small module that provides a RJ-12 cable jack breakout to screw
style wiring terminal blocks. In addition to providing simple wiring connectivity to the ERSC’s RJ-12 pins, the ERSC-
SE4 also provides blocking diodes for both the Local Zone Accumulate input signal (Pin 3) and the Interlock input
signal (Pin 4). The SE4 modules diodes are equipped with user settable jumpers to allow configurations for both
sourcing and sinking solid state PLC output modules. The ERSC-SE4 also includes an amplifier for the ERSC output
circuit (Pin 1 and Pin 6) to allow up to 100mA of current load. This feature will allow the ERSC 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 (see section

Sensor and Control Port Fusing on page 21), you can optionally connect an external +24V power source to the
“+24V” terminal on the SE-4 to provide power to devices connected to the SE-4. Without this external power
source, the current limit is 100mA on devices powered from the 24V terminal. The SE-4 contains blocking diode on
this terminal to prevent external power source from connecting to the ERSC’s power bus. Figure 36 shows a
typical ERSC-SE4 cable connection.

FIGURE 36 - ERSC-SE EXAMPLE

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 67

T YPICAL O UTPUT C ONNECTION

Figure 37 shows the typical connection for a device to the ERSC’s Control Port output circuit. Please note that with
the SE-4 the OUT terminal only supplies a +24V signal when energized.

FIGURE 37 - TYPICAL ERSC OUTPUT CONNECTION EXAMPLE

Publication ERSC-1000 Rev 4.4 – May 2014

68 User’s Guide

I NPUT C IRCUIT B LOCKING D IODE J UMPERS

Figure 38 shows the diodes jumper configuration for the ERSC-SE4 modules. When both Jumpers are installed
then electrical current can move to and from the ERSC card. Removing jumper 2(bottom) for pin 3 or 4 results in
keeping an external device (“Sinking” PLC output or Sensor) from leaking current back into the ERSC’s input. This is
beneficial when a solid state output or sensor is leaking current into the ERSC’s input keeping it in an on state
regardless of the output or sensor actual state. See Figure 39 or Figure 40 for further details. Removing Jumpers 1
and 3 does the same thing as above except for a Solid State “Sourcing” output.

FIGURE 38 – JUMPER LAYOUT FOR SE MODULE

Figure 39 shows the jumper configuration and typical wiring diagram to connect a solid state sourcing type PLC
output card to ERSC Control Port inputs. This diagram produces the same diode polarity result as is depicted in
Figure 35.

FIGURE 39 - TYPICAL PLC SOURCING OUTPUT CONNECTION TO ERSC INPUTS

Publication ERSC-1000 Rev 4.4 – May 2014

Hardware Interface with Control Ports 69

Figure 40 shows the jumper configuration and typical wiring diagram to connect a solid state sinking type PLC
output card to ERSC Control Port inputs. This diagram produces the same diode polarity result as is depicted in
Figure 34.

FIGURE 40 - TYPICAL PLC SINKING OUTPUT CONNECTION TO ERSC INPUTS

ERSC output circuit from ERSC-SE4 provides a +24V PNP (source) connection only. When the
ERSC logically energizes the output; the “OUT” terminal provides +24VDC.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 71

EASYROLL SOFTWARE CONFIGURATION TOOL

INTRODUCTION
The EasyRoll Software Configuration Tool is a PC based application that provides an alternative means to configure
a ConveyLinx controlled conveyor system. EasyRoll also provides the ability to change ConveyLinx module default
parameters that are otherwise not accessible from the module’s built-in Auto-Configuration routine.

BASIC FEATURES
Some of the basic module parameters that can be modified by EasyRoll are:

• ZPA Mode Selection (singulation, train, etc.)

• MDR brand and type
• MDR rotation direction
• MDR speed, acceleration and deceleration time values
• Jam and Run After clear time values
• Look Ahead slow down and Lane Full Interface settings
• Blink &Wink function used to visually locate an ERSC on the conveyor
EasyRoll provides the ability change these parameters for a single module or a group of modules all at once.

EasyRoll has the ability to display the status information for any ConveyLinx module on the network’s subnet.

EasyRoll has the ability to display more in-depth status information by clicking on the graphic of the connected
module.

ADVANCED FEATURES
Some of the advanced features available with EasyRoll are:

• Firmware Upgrade utility for one or a group of ERSC’s.

• UDP Discover utility used to find all ERSC’s on a network and manually set their I.P. addresses.
• Module Connection mapping to logically link two or more separate ConveyLinx networks.
• Extensions to allow an ERSC to suspend its ZPA function and be logically connected to an adjacent ERSC
for motor run command.
• PLC mode selection allows an ERSC to suspend its ZPA function and be logically controlled from an
external PLC or PC.
• The ability to Back-Up and Restore the Network Configuration.
• The ability to restore a backup by IP or by Nodes. Restoring by IP’s is useful when you need to duplicate
part or all of a system.

Publication ERSC-1000 Rev 4.4 – May 2014

72 User’s Guide

INSTALLING EASYROLL TOOL ON YOUR PC

The files for EasyRoll can be download for free at www.pulseroller.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\".

CONVEYLINX ETHERNET DEFINITION

Please refer to Appendix B–Configuring PC for Ethernet Subnets for pre-requisite
information on understanding Ethernet network I.P. addresses and Subnet concepts.
Further description in this section assumes you have a general knowledge level of I.P.
addressing and subnets.
All ConveyLinx ERSC 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: AAA.BBB.CCC.DDD where AAA, BBB, CCC, and DDD are numerical values
between 0 and 255.

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

For example; if an ERSC has an I.P. address of “192.168.25.20” then its Subnet address is “192.168.25” and its Node
is “20”

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

When the Auto-Configuration Procedure 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 whichever ERSC is selected as the Auto Configuration Master. Even if all downstream
modules from the Auto Configuration Master have the same or different Subnet or Node values; these
downstream modules will have their Subnet changed to the existing Subnet of the Auto Configuration Master.
Furthermore, when the Auto Configuration Procedure occurs; the Auto Configuration Master will also have its
Node value changed to 20. All downstream ERSC modules will then have their Node values automatically set
beginning with 21.

In the example below; 4 ERSC’s are installed “out of the box” onto the conveyor. Once the Auto Configuration
Master is identified and the Auto-Configuration Procedure is performed; all 4 ERSC’s will have their I.P. address
configured as shown.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 73

The Auto-Configuration Procedure will assign Nodes up to and including Node 240. Therefore each Subnet is
limited to 220 ERSC Nodes.

Publication ERSC-1000 Rev 4.4 – May 2014

74 User’s Guide

CONNECTING YOUR PC TO CONVEYLINX NETWORK

Using a crossover Ethernet cable to connect to Revision 1 Hardware ERSC’s or a straight through cable for Revision
2 Hardware ERSC’s; connect your PC’s Ethernet port to the Auto-Configuration Master as shown below in Figure 41

FIGURE 41 - INITIAL PC CONNECTION TO CONVEYLINX SUBNET

It is highly recommended to connect the PC directly to the ConveyLinx network. Avoid

trying to connect via Ethernet switches or wireless router/switches. If a wireless switch is
not setup properly then the Discover Feature will not work. Also ensure that network
firewall is turned off for proper discovery.

OPTIONS FOR CONFIGURING YOUR PC’S IP ADDRESS

Once a ConveyLinx network or Subnet has been configured by the Auto-Configuration Procedure with the Subnet
value taken from the factory “out of the box” IP address of the Auto Configuration Master (similar to example
shown above); you will need to do one of the three following procedure in order to have your PC be able to
connect to the Subnet and use EasyRoll software:

Option Description
Method 1 Allow ConveyLinx’s built-in DHCP service automatically assign an I.P. address to your PC
Manually change the I.P. address and/or subnet mask of your PC to match the ConveyLinx
Method 2
Subnet
Manually change the I.P. address of the Auto-Configuration Master to a new Subnet that is
Method 3
accessible from the I.P. address already configured in your PC

Any of these choices is equally valid and totally dependent on user preference.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 75

METHOD 1 - USING DHCP SERVICE FOR PC I.P. ADDRESS

For installations where you are connecting to a single simple Subnet and your PC is already configured to have its
I.P. address assigned; it is recommended to allow the ConveyLinx network automatically assign an I.P. address to
your PC utilizing ConveyLinx’s built-in DHCP service. This is the easiest method particularly if your PC is already set-
up to have its I.P. addressed assigned.

If using the ConveyLinx DHCP service to assign your PC’s I.P. address; you do not need to even start EasyRoll to
accomplish this. By following the procedures described in section Change PC’s IP Address Procedure from
Appendix B–Configuring PC for Ethernet Subnets on page 117 you will see your PC’s TCP/IP Properties.

If your PC is already configured to obtain an IP address

automatically; then by simply connecting you PC as
shown in Figure 41 - Initial PC Connection to ConveyLinx
Subnet is all you have to do to have the PC’s I.P. address
configured so you can use EasyRoll

MANUAL I.P. ADDRESS CONFIGURATION METHODS

Manual configuration of your PC’s I.P. address may be your preference for larger system configurations with
multiple Subnets and/or installations where you want to keep a dedicated PC connected all the time.

For installations where there are multiple ConveyLinx Subnets that share the same physical Ethernet cabling (either
directly or through Ethernet switches); it is recommended that the Subnets be pre-determined and that each Auto-
Configuration Master have its Subnet set in advance of performing each of their respective Auto Configuration
Procedures. By pre-determining all Subnets required; your PC can have its I.P. address and subnet mask set to
appropriate values so that you can access all of your ConveyLinxSubnets from a single PC with EasyRoll.

Further description and application examples of multiple ConveyLinxSubnet solutions are

included in separate Insight Automation publication ConveyLinx Developer’s Guide
(publication ERSC-1500)

Regardless of which manual procedure you choose, with your PC and EasyRoll you can easily accomplish either.

Publication ERSC-1000 Rev 4.4 – May 2014

76 User’s Guide

USING EASYROLL TO LOCATE AUTO-CONFIGURATION MASTER

For either manual method of I.P. address configuration, you must access the I.P. address information of the Auto-
Configuration Master ERSC on your network by using EasyRoll.

S TARTING E ASY R OLL A PPLICATION

If you followed the default installation setting when you installed EasyRoll; the program should be selected from
“Start – All Programs – Industrial Software – EasyRoll”. If you selected a different location when you installed; go
to that location and run “EasyRoll.exe”.

When you first run

EasyRoll; you should see a
window similar to this
with greyed out status
values and blank
parameter boxes

Regardless of whether you need to change your PC’s I.P. address to match your already configured ConveyLinx
Subnet or change the ConveyLinx Subnet’s Auto-Configuration Master to match a subnet address you want to use;
you have to connect to the Auto-Configuration Master.

U SING THE UDP D ISCOVER U TILITY

One of the features of EasyRoll is that it has a utility called UDP Discover that allows your PC to go and find any
ERSC 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 ERSC modules.

To access the UDP Discover Utility; you need to invoke the ConveyLinx Advanced Dialog window. To do this, press
F2.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 77

When you press F2,EasyRoll will

try to first communicate with the
default Network IP shown on the
screen, then because the Node No.
fields are blank; you will see an
error message similar to that
shown here. This is normal and
you can simply click OK.

After clicking OK on the error

message above, EasyRoll will
display the ConveyLinx Advanced
Dialog screen. Click on the tab
Network Services.

After clicking the Network Services

tab, you will see the screen you
will use to both “discover” the
ERSC’s that can be found as well as
select a specific ERSC in which to
modify its I.P. address settings.
On this screen, click the “Discover”
button

Publication ERSC-1000 Rev 4.4 – May 2014

78 User’s Guide

After clicking the “Discover”

button, EasyRoll will query the
network and return a list of all
ERSC modules it finds and shows
each module’s I.P. address, serial
number and current Firmware.
We already know that the Auto-
Configuration Master is the ERSC
with the Node of 20.
In this example, 25ERSC’swere
found and the Auto-Configuration
Master is at 192.168.26.20, its
serial number is 71544 and has
Firmware x.xx

Please refer to section

ConveyLinx Advanced Dialog on page 93 for further descriptions for the remaining
ConveyLinx Advanced Dialog screen selection tabs.

M ETHOD 2 - C HANGE PC TO M ATCH A UTO -C ONFIG M ASTER

At this point, because you now know the Auto-Configuration Master’s I.P. address you can simply change your PC’s
IP address configuration so that is can have access to the Auto-Configuration Master’s Subnet. In the example
above, the Auto-Configuration Master’s I.P. address is 192.168.26.20 therefore the ConveyLinx Subnet is
192.168.26. Please refer to Appendix B–Configuring PC for Ethernet Subnets for details on how to set your PC’s IP
address and subnet mask to access the ConveyLinx Subnet you discovered.

M ETHOD 3 - C HANGE A UTO -C ONFIG M ASTER I.P. A DDRESS

In cases where you want to set the Auto-Configuration Master’s I.P. address to something other than the default it
used when the Auto Configuration Procedure was performed, you can do this from the same Network Services
screen.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 79

Single click the Auto-

Configuration Master in
the list. When you do
this, its I.P. address
information is filled in as
shown. Simply enter in
the new I.P. address
information you want to
use and then click the
“Set” button.

After clicking the “Set” button, you can click the “Discovering” button again and EasyRoll will refresh the list of
modules at the left. You can verify that the module has the new I.P. address settings.

At this point, this particular ConveyLinx Subnet will no longer operate because its Auto
Configuration Master’s I.P. address has been changed. You must perform the Auto
Configuration Procedure again so that all downstream ERSC’s will have their I.P. address
updated to match the Auto Configuration Master’s new Subnet.

Publication ERSC-1000 Rev 4.4 – May 2014

80 User’s Guide

EASYROLL MAIN SCREEN

Assuming you have either changed your PC’s configuration or changed the Auto Configuration Master’s
configuration as described above; you should now be able to use the EasyRoll main screen to view your system’s
status and change operational parameters. If you have followed the above example, simply closing the ConveyLinx
Advanced Dialog will show the main screen. The main screen is also shown when you first run EasyRoll. Figure 42
- EasyRoll Main Screen shows a typical main screen.

FIGURE 42 - EASYROLL MAIN SCREEN

The numbered items in Figure 42 - EasyRoll Main Screen show the basic functional areas and detailed descriptions
will follow for each.

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

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 81

2. 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.

3. Upstream Zone / Downstream Zone – These selections allow you to change the ZPA mode of the
particular zone as well as diagnostic controls to jog the zone (“Forced Run”) and command the zone to
Accumulate if a load arrives.

4. Left Zone / Right Zone Settings – These are the selections for changing MDR type, braking method, closed
loop regulation, speed, direction, and accel/decel time values. There are also “Set” and “Set All” buttons
used to write values to module(s).

5. Left / Right Status – Various indicators and values of the current ERSC’s status are shown.

6. Force Jog and Force Accumulate – These are on/off toggle controls used to jog the local zone’s motor and
to set the local zone to accumulation mode.

7. Configuration Indicator – This area will display a graphic image of the current module’s detected
configuration.

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.

CONNECTING TO CONVEYLINX
Once the Network IP boxes (1) have been entered with the correct Subnet, you then type in a range of Nodes (2)
you wish to connect; the “Refresh” button will become enabled. Click the “Refresh” button and data for the rest of
the main screen should fill in.

NODE NAVIGATION

Whatever Node is entered in the first box will be

the particular ERSC data shown in the
remainder of the main screen.

The Node value entered in the second box does

not have to be the actual “last” node of the
network. If you enter a Node value higher that
exists; an error message will display after you
click the “Refresh” button. For the example
shown; if there were only 10 Nodes installed
and you entered 12, you would receive 2 error
messages in succession after clicking the
“Refresh” button.

Publication ERSC-1000 Rev 4.4 – May 2014

82 User’s Guide

Clicking the “+” and “-“ buttons will increment /

decrement the Node value in the first box and
display the ERSC 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.

NODE IDENTIFICATION
EasyRollmain 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 first text box in

the “Node No.” area and its information is
displayed on the main screen; clicking the
“Blink&Wink” switch will signal the selected
ERSC to blink on and off all of its LED indicators.
Click the “Blink&Wink” switch again to turn this
off.

UPSTREAM / DOWNSTREAM ZONE CONFIGURATION

Once you have selected the particular Node you wish to view and/or modify, you can go to the particular settings.

Selecting the pull down box for “ZPA Mode” will

show the available selections. Singulation is the
default configuration. Please refer to section
ZPA Mode Selections for descriptions for Train
and GAP Train modes.

Clicking the “Forced Run” switch will cause the

zone’s MDR to jog in its default rotation direction.
Clicking the “Accumulate” switch will place the
zone in accumulation mode and the next load
that arrives at that zone will stop and remain until
you click the switch again to turn off the
accumulation mode.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 83

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” buttons.
Similarly, you can do the same operation in the
“Downstream Zone” portion of the main screen.

ZPA MODE SELECTIONS

Singulation mode is the default configuration for all zones upon the completion of the Auto Configuration
Procedure. Please refer to section

Publication ERSC-1000 Rev 4.4 – May 2014

84 User’s Guide

Default Singulation Release ZPA Mode on page 39 for description. The following sections describe the ZPA modes
available via EasyRoll.

T RAIN R ELEASE M ODE

For zones configured for Train Release Mode; when the downstream train zone releases, all subsequent upstream
zones begin to run simultaneously. This makes the MDR conveyor operate similar to a conventional single drive
roller conveyor in that all loads move at once. Figure 43 illustrates a typical Train Release example.

FIGURE 43 - TRAIN RELEASE EXAMPLE

Please note that singulation and train modes are configurable per zone and can be mixed
on the same network.

GAP T RAIN R ELEASE M ODE

Gap Train is a variant to Train release in that it incorporates a fixed time delay prior to allowing the loads to move.
The typical usage of Gap Train would be to apply this configuration to the discharge zone of a group of zones
already placed in Train mode. This configuration could be used to assure a specific minimum gap between cartons.

For example, let’s say the Gap Timer is set to 5 seconds on the discharge zone and we have 10 zones behind this
discharge zone all set to Train Mode and all zones are occupied and accumulated. We then release the carton in
the discharge zone. All cartons in all 10 zones move simultaneously because they are in Train mode. Once the
lead carton in the discharge zone has cleared its photo-sensor; the Gap Timer starts. The next carton arriving at
the discharge zone will stop at the discharge zone and remain stopped until the Gap Timer expires. When the Gap
Timer expires; the discharge zone will release and the train of cartons in all 10 upstream zones will again move
simultaneously forward.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 85

When you select “Gap Train” from the “ZPA

Mode” drop-down box; the “Gap Timer” data
entry box and “Set” button are enabled. Simply
enter the desired time value and click the “Set”
button to update the value in the selected Node

Gap Train mode is designed to be used at the discharge zone of a group of zones configured
for Train mode. 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. Depending on the
time value used, the result will appear to be Singulation mode.

T-B ONE C ONFIGURATION

In conveyor applications, transferring a load 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 load 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-Bone arrangement. ConveyLinx contains the logic to control a T-Bone
arrangement without requiring any external control interface or programming. Figure 44 shows the kind of T-Bone
arrangement that is available within ConveyLinx without any external control interface.

FIGURE 44 - TYPICAL T-ZONE CONFIGURATION

Material handling considerations such as discharge conveyor speed and load weight have
to be analysed prior to implementing a T-Bone configuration. Be sure to verify your
mechanical design and load characteristics before utilizing a T-Bone arrangement.

C ONNECTING ERSC FOR T-B ONE A RRANGEMENT

Publication ERSC-1000 Rev 4.4 – May 2014

86 User’s Guide

A T-Bone arrangement can be made operational in one of two ways:

1. Sending and Accepting zones can be on the same ERSC

2. Sending and Accepting zones can be on two different ERSC’s.

Figure 45 and Figure 46 depict two ways to connect the MDR’s and photo-sensors to ERSC modules to result in a
valid T-Bone configuration.

FIGURE 45 - SINGLE ERSC T-BONE EXAMPLE FIGURE 46 - TWO ERSC T-BONE EXAMPLE

To configure a T-Bone arrangement to operate properly, the “T-zone Accept Time” on the main screen must be set
to a non-zero value. This time value is the duration that the accepting zone’s rollers will delay in running so the
upstream sending zone can convey the load onto stopped rollers in the accepting zone. Once this time value has
expired, the accepting zone’s rollers will be enabled to run based upon normal downstream conditions. A value of
200 milliseconds is typical for nominal MDR system speeds.

Enter the value, for example 0.200 for 200

milliseconds and click the “Set” button. Whether to
change the Upstream Zone or Downstream Zone value
on the main screen is dependent upon which zone is
the accepting zone. The “T-zone accept time” is
always applied to the accepting zone.

I GNORE J AM S ETTINGS
Any individual zone or group of zones can be configured to ignore the auto reset time delay for either or both of
the detected jam conditions. These jam conditions are described in section Jam Condition on page 40. Selecting
either of these options will not eliminate the detection of the particular jam condition; it simply eliminates the
default time delay the logic utilizes before automatically clearing the condition. For example, assume the Jam
Timer setting is 5 seconds. If a particular zone sensor remains blocked while its zone is running for 5 seconds, the
zone will stop and there will be a sensor jam condition. Under default configuration, the sensor must be cleared
for 5 seconds (same value as Jam Timer setting) before the zone will return to automatic function. If the checkbox

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 87

for “Ignore Sensor Jam” is selected, this delay of 5 seconds after the sensor is clear is not used and the zone will
return to normal automatic operation immediately after the sensor is cleared.

Similarly for the Arrival Jam, if a load is in transit from upstream to downstream, the logic expects the load to
arrive downstream within the time dictated by the Jam Timer setting. If it does not arrive within this time window,
there is an Arrival Jam. After the Arrival Jam is detected, by default, it will automatically clear after the Jam Timer
value of time has expired again. By selecting the checkbox for “Ignore Arrival Jam”, the logic will not wait for the
additional delay time and the Arrival Jam will automatically reset immediately after being detected.

Clicking either or both checkboxes will cause the

zone’s logic to ignore the reset delay for the
particular jam condition.

MDR SETTINGS
The two largest areas of the main screen are for “Left Zone” and “Right Zone” and these areas display MDR
settings and overall status as well as the ability to change motor settings.

M OTOR T YPE

The “Motor Type” pull-down box lists all motor

brand and types whose profiles are available for
ERSC. Pulse Roller 28W is the default setting
upon completion of the Auto-Configuration
Procedure. The new settings are downloaded to
the selected Node upon selecting a new item
from the list. Clicking “Set All” will download the
selected setting to the Left Zones of all ERSC’s
entered in the range of Nodes at the top of the
main screen in the “Node No:” boxes. If for
example the “Node No.” boxes had the values of
5 and 12; changing the selection in the “Motor
Type” pull down will change Node 5 and clicking
“Set All” will change Nodes 6 thru 12 to the same
setting as Node 5.

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

Publication ERSC-1000 Rev 4.4 – May 2014

88 User’s Guide

Selecting Pulse Roller 35W will enable the mechanical brake control signal on Pin 9 of the
MDR connector. Refer to section Motor Left and Motor Right Portson page 19 for
connection details. Connecting a non-Pulse brand roller with the Pulse Roller 35W motor-
type setting can potentially damage the MDR.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 89

B RAKE M ETHOD
The “Brake Method” pull-down box lists all the
MDR braking methods available for ERSC. Brake
is the default setting upon completion of the
Auto-Configuration Procedure. The new settings
are downloaded to the selected Node upon
selecting a new item from the list. Clicking “Set
All” will download the selected setting to the Left
Zones of all ERSC’s entered in the range of Nodes
at the top of the main screen in the “Node No:”
boxes. If for example the “Node No.” boxes had
the values of 5 and 12; changing the selection in
the “Brake Method” pull down will change Node
5 and clicking “Set All” will change Nodes 6 thru
12 to the same setting as Node 5.
The following table defines the MDR Braking Methods available:

Method Description
Standard Dynamic braking - MDR power circuit in ERSC is internally connected
during motor stop sequence to provide backward energy to bring rotor to a stop.
Normal When ERSC has detected that the motor has stopped; all winding current is shut
off from the MDR. This is the MDR industry standard braking method and is the
default factory setting for all ERSC zones from the Auto-Configuration Procedure
MDR power circuit in ERSC is internally disconnected to allow rotor to “free spin”
Free
until its mechanical load brings it to a stop.
When a zone is commanded to stop; the ERSC utilizes the MDR’s Hall Effect
sensors to determine the position of the rotor and will inject current into the
Servo Brake 1
motor windings to maintain rotor position. Servo Brake 1 utilizes 2 of its power
transistors for current injection.
When a zone is commanded to stop; the ERSC utilizes the MDR’s Hall Effect
sensors to determine the position of the rotor and will inject current into the
Servo Brake 2
motor windings to maintain rotor position. Servo Brake 2 utilizes 3 of its power
transistors for current injection.

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.

Publication ERSC-1000 Rev 4.4 – May 2014

90 User’s Guide

S PEED
The Speed setting value is in % of the selected Motor Type’s rated Pulse Width Modulation (PWM) current. The
MDR’s speed is directly proportional to the PWM current being fed to it. The default setting is 80% which means
that the ERSC power circuit delivers 80% of the rated PWM current for whichever Motor Type is selected. This
rated PWM current value is part of the motor profile data associated with the Motor Type selected and is
determined for each MDR brand and model listed.

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. MDR’s with identical motors
may run at very different speeds and have very different torque characteristics depending
on the mechanical gearing used.

C LOSED L OOP
Closed Loop speed control utilizes a proportional – integral (PI) algorithm to regulate MDR speed. When enabled,
the ERSC motor control processor accepts the input from the MDR’s Hall Effect sensors to measure rotor speed
and will adjust motor current accordingly to more precisely regulate speed. The default setting is for Closed Loop
to be disabled.

Closed Loop speed regulation can be used for applications where you need maintaining constant speed with
varying load weights. Without Closed Loop enabled (default) the ERSC will provide the %PWM current specified by
the Speed setting and actual MDR speed can fluctuate depending on mechanical loading of the MDR.

The “Set All” buttons for both the Speed and

Closed Loop settings will apply these settings to
all Nodes in the range of Nodes selected at the
top of the main screen similarly to the Motor
Type and Brake Method “Set All” buttons

Closed Loop speed control will provide PWM current 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. Please consult your particular motor brand and model’s
documentation and review your particular mechanical application prior to implementing
Closed Loop speed control.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 91

**WARNING** Due to lower inductance of higher speed Senergy Motors, the chances of
Short Circuit Errors increase when using very low deceleration values.
SHORT CIRCUIT ERRORS may occur when using speeds over 75% along with deceleration
values less than 0.1 second with Servo Braking (1 or 2) and Closed Loop disabled. This error
may also occur when Closed Loop is enabled and using Servo 2 braking while in Senergy Eco
Mode. There are 3 ways to reset a Short Circuit Error:
1. Go to the Special Services Tab in the EasyRoll Utility and click Reset.
2. Cycle power to the ERSC.
3. Use programming Software such as ConveyLogix or RSLogix500.

M OTOR D IRECTION
This setting is either Clock-Wise (CW) or Counter-Clock Wise and is determined for each ERSC based upon the
Auto-Configuration Procedure results. Please refer to section

Publication ERSC-1000 Rev 4.4 – May 2014

92 User’s Guide

Motor Direction Definition on page 28 for definition of rotation direction.

This setting is available because some MDR brands and models do not rotate the MDR tube in the same direction
in relation to the motor rotor for all the particular model’s speed codes.

Please note that Motor Direction does not have a “Set All” button because motor direction is determined during
the Auto-Configuration Procedure.

A CCELERATION / D ECELERATION
The acceleration and deceleration control for a given MDR is configurable in value of time duration. The default
acceleration value is 0.050 seconds (50 milliseconds) and the default deceleration time is 0 seconds.

The limit for acceleration values is 0.05 to 10 seconds. The limit for deceleration values is 0 to 10 seconds.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 93

CONVEYLINX ADVANCED DIALOG

We introduced the ConveyLinx Advanced Dialog briefly in section Using the UDP Discover Utility on page 76. This
section will define the remaining tab selections from this screen.

INVOKING THE CONVEYLINX ADVANCED DIALOG

To invoke the ConveyLinx Advanced Dialog, simply press the F2 key or simultaneously press [Shift][Ctrl]U:

Whatever Node is entered in the first box when

you press [SHIFT][CTRL] U or F2 will be the
particular ERSCNode data in context for the
ConveyLinx Advanced Dialog tab selections
when the dialog screen pops up.

L OOK A HEAD & T IMING

The default screen tab of the ConveyLinx Advanced Dialog is the Look Ahead & Timing settings.

L OOK A HEAD F EATURE

The Look Ahead feature configures the ERSC logic to “look ahead” to its next downstream zone and if it is occupied
when a load is entering its zone, theERSC will dynamically adjust the MDR to the selected speed. This feature
would be used in higher speed applications were increased stopping distance is required to keep loads from over-
travelling their stop positions. This function can be applied per zone or system-wide.

FIGURE 47 - NORMAL RUNNING BEFORE LOOK AHEAD ENABLES

In Figure 47, conveyor runs at the speed configured for the ERSC per the Auto-Configuration Procedure or the value
entered if it was manually changed.

Publication ERSC-1000 Rev 4.4 – May 2014

94 User’s Guide

FIGURE 48 - LOOK AHEAD ENABLED

As shown in Figure 48, when a carton arrives at Zone C’s photo-sensor, Zone B’s ERSC will automatically adjust the
speed of Zone B to the configured Look 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
slowdown speed will be proportional
to 50% of 100% PWM current. If the
PWM speed on the main screen was
set to 80% PWM, then the slowdown
speed would be “50% of 80% PWM”.
(Refer to the Easyroll Tool Pop-Up
Dialogue for more detail information
regarding Slow Down and Fast
Release Time.)

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 95

Clicking “Set All” will enable the Look

Ahead feature at the % speed
entered for all Nodes in the range of
Nodes on the main screen. (Refer to
the Easyroll Tool Pop-Up Dialogue for
detailed information regarding Slow
Down and Fast Release Time
feature.)

J AM , A UTO C LEAR ,& R UN A FTER T IMERS

The Jam timers are used by the logic as the expected time it takes for a load to travel from one zone to the next. If
this timer expires before the load reaches the next zone, the ERSC will indicate a Jam condition. Jam condition at
any zone will automatically clear once its photo-sensor has been clear for the Jam timer value.

If a zone is in a Jam condition and its photo-sensor remains blocked; the photo-sensor must be cleared and remain
clear for the Jam time value. When a given zone is in a jammed condition, the logic inhibits any upstream loads
from entering that zone.

The default value for the Jam timer is 5 seconds and the valid range of values for any given Jam timer can be found
is from 1 seconds to 20 seconds.

The Auto Clear Timer is the amount of times that ConveyLinx waits before trying to clear a jam. After a Jam does
occur, it’s now possible to set a time to wait before attempting to clear the current jam and trying again.

The Run After time value is used by the logic for normal zone discharge. This is the amount of time the zone’s MDR
is to 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 to completely pass the photo-sensor and
fully enter the next zone. This timer value is adjustable to compensate for special conditions where a zone photo-
sensor is required to be placed farther upstream or downstream.

The default value for the Run After timer is 0.4 seconds, the ranges for the Auto Clear Timer is from 0 to 10, and
the valid range of values for any given Run After timer is from 0.1 seconds to 6 seconds.

Publication ERSC-1000 Rev 4.4 – May 2014

96 User’s Guide

Clicking any of the “Set”

buttons for either Jam or
Run After timers will
download the entered
setting to the respective
zone on the selected
Node.(Refer to the
EasyRoll Tool Pop-Up
Dialogue for detailed
information regarding the
Jam and Auto Clear Timer
settings and functions)

Clicking “Set All” for

either the Jam or Run
After timers will set the
entered values for all
Nodes in the range of
Nodes on the main
screen. (Refer to the
EasyRoll Tool Pop-Up
Dialogue for detailed
information regarding the
Jam and Auto Clear Timer
settings and functions)

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 97

U PGRADE
The Upgrade tab screen gives access to the ERSC 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 ERSC modules.

A firmware upgrade will be in the form of a data file sent to you or made available for download. The
Upgrade utility allows you to browse for this data file and then select a single Node or group of Nodes to
upload.

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.

Publication ERSC-1000 Rev 4.4 – May 2014

98 User’s Guide

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 12 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.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 99

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.

Publication ERSC-1000 Rev 4.4 – May 2014

100 User’s Guide

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

The Connections utility also gives you the ability to place one or both MDR zones on an ERSC into Slave mode
which logically attaches the MDR run and stop functions to another ERSC’s zone control. A common application of
Slave mode for an ERSCwould be for a conveyor lift gate.

C ONNECT T WO N ETWORKS T OGETHER

Figure 49 shows a typical boundary between two Subnets. The most downstream Node of the first Subnet has an
I.P. address of 192.168.27.25 and the most upstream Node of the second Subnet has an I.P. address of
192.168.25.20.

FIGURE 49 - SUBNET BOUNDARY EXAMPLE

By simply connecting a crossover Ethernet cable between these two boundary Nodes and then using EasyRoll
establish the “logical” connection between the two Subnets; you can achieve seamless flow between the two
networks. This is shown in Figure 50.

FIGURE 50 - SUBNET BOUNDARY EXAMPLE WITH CABLE

The procedure requires that you have to instruct Node at 192.168.27.25 to convey loads to Node at 192.168.25.20,
and likewise you have to instruct Node at 192.168.25.20 to accept loads from Node at 192.168.27.25.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 101

Configuring Node at 192.168.27.25

From the main screen, first enter the correct Subnet into the “Network IP” boxes and the correct Node you want to
connect. In this case we know that xxx.xxx.xxx.25 is Node 6 for this particular Subnet.
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. Also note that its Downstream designation
indicates “None”.

Publication ERSC-1000 Rev 4.4 – May 2014

102 User’s Guide

We want to change the Downstream flow to I.P. address 192.168.25.20 which is the next downstream Node.
Click the IP Address button and enter the correct I.P. address value and click the “Apply” button.
Please note that this will take approximately 20 seconds for the module to accept the change and restart.
At this point we are half-way complete in that we now have to instruct the downstream module to accept from
upstream.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 103

Configuring Node at 192.168.25.20

From the main screen, first enter the correct Subnet into the “Network IP” boxes and the correct Node you want to
connect. In this case we know that xxx.xxx.xxx.20 is Node 1 for this particular Subnet.
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. Also note that its Upstream designation
indicates “None”.

Publication ERSC-1000 Rev 4.4 – May 2014

104 User’s Guide

We want to tell this Node to accept loads from I.P. address 192.168.27.25 which is the next upstream Node.
Click the IP Address button and enter the correct I.P. address value and click the “Apply” button.
Please note that this will take approximately 20 seconds for the module to accept the change and restart.
Now we are complete and loads should flow from Node at 192.168.27.25 to Node at 192.168.25.20

The above example requires that your PC can access multiple Subnets. Please refer to
Appendix B–Configuring PC for Ethernet Subnets for further details.

Please Note: Each ERSC also has hard-wired functionality built-in to accomplish a simple network-to-network
connection to maintain product flow. This is shown in section Hardware Interface Cable on page 48. The
limitation of the hard-wired connection is that the release mode from upstream to downstream is always
singulation. With a full logical network to network connection established through EasyRoll as described, full
release mode capability is maintained. For example, you can seamlessly maintain Train or Gap Train modes
through the network boundary.

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 105

Further description and application examples of Ethernet networked solutions are included
in separate Insight Automation publication ConveyLinx Developer’s Guide(publication ERSC-
1500)

N ETWORK S ERVICES
The Network Services screen is used to both explore any networks reachable by the PC for any ERSC modules and it
is used to set the I.P. address of a selected ERSC. Refer to section Using the UDP Discover Utility on page 76 for
details. The Network services screen may also be used to backup and restore via node number or IP address for
later use. Please refer to the self-help pop-up dialog within the EasyRoll tool for more information regarding
backup/restore.

S PECIAL S ERVICES
Each ERSC maintains a running time meter for each MDR connected to it. This value is displayed as Operating Time
on the main screen (5). This screen on the ConveyLinx Advanced Dialog allows you to reset this meter in the event
you have to replace a given MDR.

The other function on the Special Services screen 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 ERSC be powered down and then powered back up or by clicking the “Reset”
button on this screen. This function is made available in EasyRoll as a convenience so you don’t have to cycle the
power on the ERSC.

C ONTROL P ORTS C ONFIGURATION

Each of the two Control ports on the ERSC has a default “out-of-the-box” configuration state of the meanings of
the expected inputs and provided output signals. This screen dialog will let you change or “invert” the logical on or
off state required for the particular signal.

Publication ERSC-1000 Rev 4.4 – May 2014

106 User’s Guide

By default, the ERSC interprets

the “Infeed/Discharge” input
signal (Interlock Pin 4 on RJ-12
Control Port or P4 on a SE3)
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 ERSCfor the Interlock Pin
4 Control Port signal. (Refer to
the Easyroll Tool Pop-Up
Dialogue for detailed
description of operation when
checking this option in Control
Ports.)

By default, the ERSC interprets

the “Accumulation” input signal
(Pin 3 on RJ-12 Control Port)
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
ERSCfor the Pin 3 Control Port
signal. (Refer to the Easyroll
Tool Pop-Up Dialogue for
detailed description of
operation when checking this
option in Control Ports.)

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 107

The default Control port output

configuration signal is “ON” or
logical “1” to indicate to
external controls that it’s
associated zone is occupied. By
clicking the associated “Zone
Invert” check box, the ERSC will
make the output “OFF” or
logical “0” when its associated
zone is occupied. (Refer to the
Easyroll Tool Pop-Up Dialogue
for detailed description of
operation when checking this
option in Control Ports.)

Please note that the left and right Control ports can be configured independently for maximum flexibility.

Any change of these signals from the default “out-of-the-box” settings will cause the
hardware module to module connection as described in section Hardware Interface Cable
on page 48 to no longer operate as expected. You must return both ERSC modules in this
scenario back to default Control port hardware settings for module to module connection
to operate properly.
Section Sensor in Control Port for Downstream Interlock on page 51 describes plugging a sensor into the ERSC
Control Port to provide a Downstream Interlock signal. The hardware Connections Configuration tab provides
selection and adjustment to this functionality to allow the plugged in sensor to provide “Lane Full Interface”
functionality that is typical in conveyor applications. With “Lane Full Interface” checkbox checked; the
“Downstream Interlock” will change its default functionality to essentially ignore the arrival signal from the
downstream controls and thus eliminate the logical “No 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 sensor for added flexibility.

Publication ERSC-1000 Rev 4.4 – May 2014

108 User’s Guide

When a sensor is plugged into

the downstream Control Port,
enabling the Lane Full Interface
causes the zone to ignore the
downstream arrival interlock.
Block and Clear timers are
provided to adjust the
behaviour of product flow
based upon the blocking and
clearing of the sensor. (Refer to
the Easyroll Tool Pop-Up
Dialogue for detailed
description of operation when
checking this option in Control
Ports.)

The default PLC Control for

Upstream/downstream is off.
By clicking the Enable PLC
Control of Upstream or
downstream allows a PLC to
control the input and outputs of
the respective port you enabled
while keeping ConveyLinx
standard ZPA faction intact.
(Refer to the EasyRoll Tool Pop-
Up Dialogue for detailed
description of operation when
checking this option in Control
Ports.)

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 109

F LEX Z ONE
ERSC 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 operates for both singulation and train release mode. This
tab allows you to either enable or disable the feature.

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 group of zones within the same
subnet.

S ENSORS
The sensors tab displays the status of how the sensor was configured during the initial “Auto Configuration” of the
system. For example, if all the sensors on the system are light energized normally open then the corresponding
zone’s sensor will show “off blocked”. Use this tab to change each modules default sensor configuration to match
what is existing. Please refer to the EasyRoll Tool’s self-help pop up dialog for more details regarding changing the
sensor’s or sensor’s error state after auto-configuration.

E XTENSIONS

Publication ERSC-1000 Rev 4.4 – May 2014

110 User’s Guide

The Extension tab allows you to extend or “slave” a single or multiple zones to one “master” zone. By going to the
upstream or downstream node of the module you’d like to extend you can select “This module (current node) is
an extension of the downstream or upstream (node that you’d like for the current node to extend to). One
example of extensions in use can be found in the appendix section Using Extensions for a Lift Gate on page 123.
You can also refer to the EasyRoll Tool Pop-Up dialog for detailed description of operation when checking this
option in Control Ports.)

N ETWORK L OCK F EATURE

The Lock Feature allows the User to “Lock” the Network. With Lock Enabled, there can be no changes to the
Network without connecting with EasyRoll. The “Install” Feature is disabled with Lock Enabled. The Lock Feature
has NO affect on the Replacement Procedure.

To Lock a Network(s) or part of a Network(s), first select Discovery. Next, select the desired Modules and press
“Lock Selected Network”. The “Locked” icon appears next to the selected Modules.

To Unlock a Network(s) or part of a Network(s), first select Discovery. Next, select the desired Modules and press
“Unlock Selected Network”. The “Unlocked” icon appears next to the selected Modules

Notice the “Padlock” icon next to the Discovered Modules in a Locked and Unlocked Network:

Publication ERSC-1000 Rev 4.4 – May 2014

EasyRoll Software Configuration Tool 111

L OCKED N ETWORK

Publication ERSC-1000 Rev 4.4 – May 2014

112 User’s Guide

U NLOCKED N ETWORK

Publication ERSC-1000 Rev 4.4 – May 2014

Appendix A – Dimensions and Mounting Information 113

APPENDIX A – DIMENSIONS AND MOUNTING INFORMATION

CONVEYLINX MODULE DIMENSIONS

Dimensions in mm

CONVEYOR FRAME FABRICATION DETAIL

FIGURE 51 - CONVEYOR SIDE FRAME ELEVATION VIEW OF PERFORATION

Publication ERSC-1000 Rev 4.4 – May 2014

114 User’s Guide

FIGURE 52 - PERFORATION PATTERN FOR CONVEYOR SIDE FRAME

FIGURE 53 - TYPICAL RAIL SECTION WITH ERSC MOUNTED

Publication ERSC-1000 Rev 4.4 – May 2014

Appendix B–Configuring PC for Ethernet Subnets 115

APPENDIX B–CONFIGURING PC FOR ETHERNET SUBNETS

CONVEYLINX, IP ADDRESSES, AND SUBNETS

In order to connect to a ConveyLinx network and/or utilize and manage a multiple subnet ConveyLinx conveyor
installation; a certain level of Ethernet I.P. addressing knowledge is required. This reference provides some
background information and a quick guide for setting up your PC to be able to take full advantage of ConveyLinx
and EasyRoll.

Your PC’s I.P. address is used by an Ethernet network to identify the PC on a network. An I.P. address is
constructed of 4 numbers or octets. Each of the numbers can be a value from 0 to 255. The format of an I.P.
address is:

AAA.BBB.CCC.DDD

Where AAA, BBB, CCC, and DDD can theoretically be any values from 0 to 255 each. For any given network, this I.P.
address is unique for each PC on the network. The AAA value identifies the Class of the network and is most
relevant to I.T. professionals and other entities such as internet providers, etc. For our purposes, we will use a
Class C type network which uses the value 192 for AAA. For the BBB value we will use 168. The 192.168 value for
the first 2 octets of our I.P. address is the most common for user configurable networks. The values AAA.BBB.CCC
together identify the Subnet that the PC will be connected. The Subnet can be thought of as a group of PC’s or
ConveyLinx modules that can all communicate directly with each other. For example, if a PC’s I.P. Subnet
(AAA.BBB.CCC) address is 192.168.0; then any other PC or device on the same network who’s Subnet is equal to
192.168.0 can communicate with each other. In this case, our network can have up to 256 devices because the
DDD octet has to be in the range of 0 to 255 and each complete I.P. address has to be unique. Any other PC’s or
ConveyLinx modules on our network who’s Subnet does not equal 192.168.0 will not be able to communicate with
each other.

In order to allow your PC to communicate with more than 256 possible address on its network; your PC’s I.P.
address configuration also uses another 4 octet value known as the Subnet Mask. This value allows your PC to see
other Subnets on the same network.

The following figure shows some typical values for Subnet Mask and the resulting number of Subnets that can be
addressed:

Publication ERSC-1000 Rev 4.4 – May 2014

116 User’s Guide

FIGURE 54 - AVAILABLE SUBNETS PER TYPICAL SUBNET MASK VALUES

As you can see, by simply manipulating the Subnet Mask values, you can configure your PC to see multiple
ConveyLinx networks.

CONFIGURATION EXAMPLE
Your PC’s I.P. address is used by an Ethernet network to identify the PC on a network. For most office networks,
the I.P. address is automatically assigned by your office network or in smaller networks (like a home network) the
IP address is assigned by a router device. In some cases, your I.T. department may assign your PC or laptop a fixed
I.P. address.

For our example we wish to be able to communicate with up to 4 separate ConveyLinx Subnets. With a properly
configured PC, we can use EasyRoll to view and set parameters for all modules on all 4 networks.

The following figure illustrates how we want our PC’s I.P. address settings to be configured:

Publication ERSC-1000 Rev 4.4 – May 2014

Appendix B–Configuring PC for Ethernet Subnets 117

FIGURE 55 - IP ADDRESS CONFIGURATION EXAMPLE

Please Note: The ConveyLinx IP address structure is designed such that all ERSC’s last octet (DDD) of their address
is greater than or equal to 20 and less than or equal to 240. This leaves 36 spare valid addresses (256 – 220 = 36)
on the same Subnet for other devices such as PC’s and PLC’s. In our example, the last Octet for the PC’s I.P.
address is arbitrarily set to 10. This value could be any value from 0 to 19 or 241 to 255. Network conventions are
such that on a given Subnet the last octet (DDD) values of 0 and 1 are usually reserved for the Default Gateway
which is often the address of an Ethernet router.

Also note that our example is utilizing all the possible Subnets for the Subnet Mask (255.255.252.0) shown. From
Figure 54 above; we could have selected any of the values for X on the chart that was listed above the 252 value.
In these cases there would simply be more Subnets available to address.

CHANGE PC’S IP ADDRESS PROCEDURE

To change your PC’s I.P. address, click Start – Control Panel – Network Connections – Local Area Network. This will
display your Local Area Connection Status window (1). From this window, click Properties (2) and it will display
your Local Area Connection Properties window (3). Scroll down the selection box and single click to select Internet
Protocol (TCP/IP) (4). Then click the Properties button (5):

2 4 5

When you click properties (5), the Internet Protocol (TCP/IP) Properties window appears. For this example, we are
assuming that your PC is being assigned its I.P. address by your office network. This is indicated by the text entry
boxes in this window being greyed out. Click on the selector button for Use the Following IP address (6) and the
text entry boxes will become active to allow entry.

Publication ERSC-1000 Rev 4.4 – May 2014

118 User’s Guide

6 7
5

Per our example, we need to enter the IP address, subnet mask and default gateway values (7) and click OK for the
settings to take place. Please note in (7) that we entered a value into the Default gateway field. This may or may
not be required depending on whether your network has a specific router device. In most cases, this value is the
same Subnet as the IP address field and its last octet (DDD value) is usually 0 or 1.

Please consult your I.T. department if you are unsure about modifying your PC’s IP
Address.

Upon reaching item 5; if your PC has a values entered for IP address, Subnet mask, and
Default gateway; be sure to record these values before you click the button in item 6.
Once you click the Use the following IP address button in item 6, these values will be lost!
Once you are done with communicating with your ConveyLinx network(s) and you need to
return you PC to its previous network settings; simply follow this procedure again and re-
enter the previous values you recorded.

Publication ERSC-1000 Rev 4.4 – May 2014

Appendix C – ConveyLinx Accessories 119

APPENDIX C – CONVEYLINX ACCESSORIES

Included in this manual are various details for you to assemble your own various cable assemblies, connection kits,
and power supplies to provide a successful installation. However, Insight Automation has made it easy for you to
purchase approved and proven ConveyLinx accessories. Please contact Insight Automation for pricing and delivery.

Accessory Part Number Description

CACRSC-EXT-050 Motor Extension Harness – 50 cm
CACRSC-EXT-100 Motor Extension Harness – 100 cm
CACRSC-EXT-150 Motor Extension Harness – 150 cm
Motor Extension
CACRSC-EXT-200 Motor Extension Harness – 200 cm
CACRSC-EXT-250 Motor Extension Harness – 250 cm
CACRSC-EXT-300 Motor Extension Harness – 300 cm
IN-STR-RJ12-015 8 Inch Patch Straight Cables with RJ12 Connectors. 6Pin |
6 Conductor.
IN-STR-RJ12-100 1Meter Patch Straight Cables with RJ12 Connectors. 6Pin
Module to Module | 6 Conductor.
Hardware Interlock IN-STR-RJ12-200 2 Meter Patch Straight Cables with RJ12 Connectors. 6Pin
| 6 Conductor.
IN-STR-RJ12-300 3 Meter Patch Straight Cables with RJ12 Connectors. 6Pin
| 6 Conductor.
IN-CAT5-1-100601BK Cat 5 - 1' Ethernet Shielded Patch Cable - Black Overmold
IN-CAT5-3-100603BK Cat 5 - 3' Ethernet Shielded Patch Cable - Black Overmold
IN-CAT5-5-100604BK Cat 5 - 5' Ethernet Shielded Patch Cable - Black Overmold
IN-CAT5-7-100605BK Cat 5 - 7' Ethernet Shielded Patch Cable - Black Overmold
Cat 5 - 10' Ethernet Shielded Patch Cable - Black
IN-CAT5-10-100606BK
Overmold
Shielded Ethernet Cat 5 - 15' Ethernet Shielded Patch Cable - Black
IN-CAT5-15-100607BK
Patch Cable Overmold
Cat 5 - 20' Ethernet Shielded Patch Cable - Black
IN-CAT5-20-100616BK
Overmold
Cat 5 - 25' Ethernet Shielded Patch Cable - Black
IN-CAT5-25-100608BK
Overmold
Cat 5 - 50' Ethernet Shielded Patch Cable - Black
IN-CAT5-50-100609BK
Overmold

Publication ERSC-1000 Rev 4.4 – May 2014

120 User’s Guide

Accessory Part Number Description

RJ-12 to Screw Terminal Breakout Module with Output
Amplifier and Bias Diodes and a short time to ensure
outputs do not initialize during the power up phase.
Breakout Module ERSC-SE4 Includes blocking diode circuit to allow external power to
be used. (By Adding “Kit” at the end of the part number
now includes the necessary 8” Cable that runs between
the SE and ConveyLinx module.
Private (Banner)Labeled Insight Photo-Eye 10-30VDC,
IN-PE-RJ11-1 NPN Light Operate w/ Health output RJ11 Cable 1Meter
Sensors (Kit: Sensor, reflector, and brackets)
(Offered in 1 and 2 Private (Banner) Labeled Insight Photo-Eye 10-30VDC,
IN-PPE-RJ11-1
PNP Light Operate w/ Health output RJ11 Cable 1Meters
Meters & PNP and
Private (Banner) Labeled Insight Photo-Eye 10-30VDC,
NPN)
NPN Light Operate WITHOUT Health output RJ-11 Cable 1
IN-PE-FL-1
Meter long
Used for Full-Lane or Wake-Up
MDR|Power 10amp@24VDC, 120VAC Input w/ Load
IN-P-DIS-PS-10-120
Switch,Transparent Poly Carbonate Enclosure
DC Power MDR|Power 20amp@24VDC, 120VAC Input w/ Load
IN-P-DIS-PS-20-120
Supplies(Omit “DIS” Switch, Transparent Poly Carbonate Enclosure
For No Load MDR|Power (2) - 20amp@24VDC, 120VAC Input w/ Load
IN-P-DIS-PS-40-120
Switch, Transparent Poly Carbonate Enclosure
Switch/Add “UL”
MDR|Power 20amp@24VDC, 480VAC Input w/ Load
after IN to make any IN-P-DIS-PS-20-480
Switch, Transparent Poly Carbonate Enclosure
Box UL Approved) MDR|Power 40amp@24VDC, 480VAC Input w/ Load
IN-P-DIS-PS-40-480 Switch, 2 20A-Circuit Breaker, Transparent Poly Carbonate
Enclosure

Publication ERSC-1000 Rev 4.4 – May 2014

Appendix C – ConveyLinx Accessories 121

NOTES ON SE-MODULE REVISIONS

As of August 2013, Insight Automation began shipping only ERSC-SE4 modules and no longer manufactures ERSC-
SE3, ERSC-SE2 modules. Due to the smallness and simplicity of these modules, they are not individually serialized
at manufacturing. Because there is an installed base of modules prior to ERSC-SE4; the following describes the
updates and warnings of usage for each of these part numbers.

ERSC-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.
ERSC-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.
ERSC-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.

Publication ERSC-1000 Rev 4.4 – May 2014

Appendix D – Application Examples 123

APPENDIX D – APPLICATION EXAMPLES

USING EXTENSIONS FOR A LIFT GATE

The most common use of the Extension mode configuration available from the Connections tab selection is for a
powered lift gate. Figure 56 shows a typical powered lift gate example. In this example the ERSC on the lifting or
gate portion of conveyor has 2 MDR’s and no photo-sensors. Normal operation when the gate is down is for the
MDR’s on the gate to run when its immediate downstream zone runs so as to create “one long logical zone”. This
means that if a load is accumulated on the upstream zone of Node 192.168.25.25; a load arriving at the
downstream zone of Node 192.168.25.23 will stop and accumulate and no loads will ever be logically accumulated
or stopped on the gate portion. In order accomplish this we need to first establish the logical flow from
192.168.25.23 to Node 192.168.25.25. Secondly, we will then instruct Node 192.168.25.24 to be anExtension to
the upstream zone of Node 192.168.25.25.

FIGURE 56 - TYPICAL LIFT GATE EXAMPLE

Publication ERSC-1000 Rev 4.4 – May 2014

124 User’s Guide

Configure Node 192.168.25.23

From the main screen, enter the correct Subnet and then select the proper Node within the Subnet. In this case it
is Node 4 of Subnet 192.168.25. Invoke the ConveyLinxAdvanced Dialog. Note that Node 4’s information is
displayed in the center and that it is greyed out.
From the Auto-Configuration Procedure, Node 4’s natural upstream Node is 3 and its natural downstream Node 5.
In this case we want to skip over Node 5 because it will be our Slave zone. We want Node 6 to be the Node that
accepts loads from Node 4. Select Node 6 from the pull down box and click apply.

Publication ERSC-1000 Rev 4.4 – May 2014

Appendix D – Application Examples 125

Configure Node 192.168.25.25

From the main screen, enter the correct Subnet and then select the proper Node within the Subnet. In this case it
is Node 6 of Subnet 192.168.25. Invoke the ConveyLinxAdvanced Dialog. Note that Node 6’s information is
displayed in the center and that it is greyed out.
From the Auto-Configuration Procedure, Node 6’s natural upstream Node is 5. In this case we want our upstream
zone to be fed from Node 4 instead of Node 5 because Node 5 will be our Slave zone. For the Upstream zone,
select Node 4 from the pull down box and click apply.
The Downstream can remain its default configuration for this application example.

Publication ERSC-1000 Rev 4.4 – May 2014

126 User’s Guide

Configure Node 192.168.25.24

0
0
0
0

From the main screen, enter the correct Subnet and then select the proper node within the subnet from the main
screen or the advanced dialog. In this case it is Node 5 of Subnet 192.168.25. Invoke the ConveyLinx Advanced
Dialog and select the extension Tab. Note that Node 5’s information is displayed in the center and that it is greyed
out.
Pull down the “This Module is an extension of the “ “ module and select downstream.
Click apply.

In Figure 56, there is an optional “Gate Down” sensor shown. This can be provided to hard-wire back to the
upstream zone ERSC (Node 192.168.25.23 in our example) to cause the upstream zone just prior to the gate to
immediately accumulate product. This sensor would connect as described in section Local Zone Accumulation
Control on page 45. For the lift gate example, the sensor would have to be selected and/or wired to give a signal
when the gate is lifted to tell the upstream ERSC to accumulate. When the gate is down, the sensor signal should
be removed from the ERSC to instruct its zone to convey as normal.

Publication ERSC-1000 Rev 4.4 – May 2014

NOTES:

Publication ERSC-1000 Rev 4.4 – May 2014

Publication ERSC-1000 Rev 4.4 – May 2014