Interroll MultiControl Owner's manual

Supplementary Document
Interroll MultiControl
Operating and Programming

Operating and Programming I
Table of content
1About this document..........................................................................................................................................1
1.1 Information about this supplementary document......................................................................................1
1.2 Symbols.................................................................................................................................................................2
1.3 Data types............................................................................................................................................................2
2Description............................................................................................................................................................3
3Configuration options .......................................................................................................................................4
4Configure MultiControl.....................................................................................................................................5
4.1 The Magnetic Sensor.........................................................................................................................................5
Select function.....................................................................................................................................................5
LED displays when using the magnetic sensor...........................................................................................7
4.2 Service Data Objects (SDO)...........................................................................................................................9
Version information ...........................................................................................................................................9
Manufacturer information................................................................................................................................9
Diagnostic information...................................................................................................................................10
Error information.............................................................................................................................................11
Network online time .......................................................................................................................................11
Control program information ......................................................................................................................12
Bus parameter..................................................................................................................................................13
Motor settings...................................................................................................................................................15
Inputs and Outputs.........................................................................................................................................18
Application module.........................................................................................................................................19
Error handling ..................................................................................................................................................20
5Description of the control programs..........................................................................................................22
ZPA programs with stop function for straight sections and curves...................................................22
5.1 ZPA Single Release.........................................................................................................................................23
Timer...................................................................................................................................................................23
PLC references according to process image "Universal Full" (see process data) .........................24
5.2 ZPA Train Release...........................................................................................................................................26
Timer...................................................................................................................................................................26
PLC references according to process image "Universal Full" (see process data) .........................27

II Operating and Programming
Handover (Handshake Signals)...................................................................................................................29
5.3 ZPA Transfer In ................................................................................................................................................31
Timer...................................................................................................................................................................32
PLC references according to process image "Universal Full" (see process data) .........................32
Merge prioritization........................................................................................................................................34
Handover (Handshake-Signals)...................................................................................................................35
5.4 ZPA Transfer Out............................................................................................................................................37
Timer...................................................................................................................................................................38
PLC references according to process image "Universal Full" (see process data) .........................38
Merge prioritization........................................................................................................................................40
Handover (Handshake-Signals)...................................................................................................................41
5.5 ZPA Merge........................................................................................................................................................43
Timer...................................................................................................................................................................43
PLC references according to process image "Universal Full" (see process data) .........................44
Merge prioritization........................................................................................................................................45
Handover (Handshake-Signals)...................................................................................................................47
5.6 ZPA HPD (High Performance Divert) .........................................................................................................48
Timer...................................................................................................................................................................48
PLC references according to process image "Universal Full" (see process data) .........................49
Merge prioritization........................................................................................................................................51
Handover (Handshake-Signals)...................................................................................................................52
5.7 Semi-automatic programs ............................................................................................................................54
5.8 HPD Semi-Automatic......................................................................................................................................54
Timer...................................................................................................................................................................54
PLC references according to process image "Universal Full" (see process data) .........................55
5.9 Transfer Semi-Automatic...............................................................................................................................57
Timer...................................................................................................................................................................57
PLC references according to process image "Universal Full" (see process data) .........................58
5.10 I/O Device.........................................................................................................................................................60
5.11 Specific parameters (only Transfer and HPD) in the I/O device .......................................................61
Transfer..............................................................................................................................................................61

Operating and Programming III
PLC references according to process image "Universal Full" (see process data) .........................61
HPD .....................................................................................................................................................................62
PLC references according to process image "Universal Full" (see process data) .........................62
6Description of the service functions............................................................................................................64
6.1 Teach-in..............................................................................................................................................................64
Prerequisites......................................................................................................................................................65
Basic setting of the MultiControl.................................................................................................................65
Reading the motors.........................................................................................................................................65
Assign Slave RollerDrive................................................................................................................................66
Abort the Teach-in procedure.....................................................................................................................67
Configuring the sensors.................................................................................................................................67
6.2 Plug&Play...........................................................................................................................................................68
6.3 Plug&Play semi-automatic.............................................................................................................................69
7Examples of applications...............................................................................................................................70
7.1 Example 1: Conveyor with three MultiControl.......................................................................................70
7.2 Example 2: Conveyor and Transfer with five MultiControl ................................................................72
7.3 Example 3: Start sensor ................................................................................................................................74
7.4 Example 4: Stop of Zone 3..........................................................................................................................75
8Process data .....................................................................................................................................................76
8.1 Process image of the inputs..........................................................................................................................76
Sensors...............................................................................................................................................................76
Digital I/O .........................................................................................................................................................77
Motor State.......................................................................................................................................................78
System Status ...................................................................................................................................................79
Additional signals............................................................................................................................................79
8.2 Process image of the outputs.......................................................................................................................82
Digital outputs..................................................................................................................................................82
Motors................................................................................................................................................................82
8.3 Different process images...............................................................................................................................86
Comparison of the process images............................................................................................................86
PII, Process Image „Universal Full“ ..............................................................................................................88

IV Operating and Programming
PIO, Process Image „Universal Full“............................................................................................................92
PII, Process Image „Universal Compact“ ...................................................................................................95
PIO, Process Image „Universal Compact“.................................................................................................99
PII, Process Image „I/O Mode“................................................................................................................. 103
PIO, Process Image „I/O Mode“.............................................................................................................. 105
PII, Process Image „Control Mode“.......................................................................................................... 106
PIO, Process Image „Control Mode“....................................................................................................... 110
PII, Process Image „I/O Mode Tiny“........................................................................................................ 114
PIO, Process Image „I/O Mode Tiny“..................................................................................................... 116
PIO, Process Image „Position Mode“....................................................................................................... 117
9I/O configuration ......................................................................................................................................... 118
10 Interface Box for VDC Motors.................................................................................................................. 120
DIP switch of the Interface Box................................................................................................................. 121
11 Signal flow...................................................................................................................................................... 122

About this document
Operating and Programming 1
1 About this document
1.1 Information about this supplementary document
The supplementary document describes the operation, the integrated programs and the
interfaces of the Interroll MultiControl.
In the further course, the term "control" is used alternatively.
The latest version of this document is available on the Internet at:
www.interroll.com/support/
All information and instructions in this document have been compiled taking into account the
applicable standards and regulations as well as the state of the art.
➢For trouble-free and safe operation and the fulfilment of any warranty claims, first read
the user manual and follow the instructions.
The manufacturer assumes no liability for damage and malfunctions resulting from
non-compliance with this document.
If you still have questions after reading this document, contact Interroll Customer
Service. Contact persons in your area can be found on the internet at
www.interroll.com/contact/

2 Operating and Programming
1.2 Symbols
This symbol indicates useful and important information.
✓This symbol indicates a prerequisite that must be met before installation or maintenance
work.
This symbol represents general safety-related information.
➢This symbol marks the steps to be carried out.
•This symbol stands for enumerations.
1.3 Data types
The following data types are used for cyclic and acyclic communication with the MultiControl:
Shortcut
Data type
Description
BOOL
Boolean
Truth value (true / false)
BYTE
Byte
Bit sequence with 8 bits
SINT
Short Integer
Integer variable with 8 bits
USINT
Unsigned Short Integer
Positive integer variable with 8 bits
INT
Integer
Integer variable with 16 bits
UINT
Unsigned Integer
Positive integer variable with 16 bits
DINT
Double Integer
Integer variable with 32 bits
UDINT
Unsigned Double Integer
Positive integer variable with 32 bits
LINT
Long Integer
Integer variable with 64 bits
STRING
String
Character string with a maximum of 31
characters

Description
Operating and Programming 3
2 Description
The MultiControl can be operated in different operating modes:
•as I/O device (fully PLC controlled)
•semi-automatic (partly PLC-controlled)
•fully automatic (without PLC)
A MultiControl can control up to four RollerDrive with different speeds, accelerations and
decelerations. In addition to the four sensor inputs, four inputs or outputs can be freely
configured.
Depending on the selected ZPA program (Zero Pressure Accumulation), the delivery process can
be influenced by a PLC. In operation as an I/O device, a PLC controls the motors without any
program influence.
Each MultiControl controls up to four zones. One zone corresponds to a conveyor section
consisting of RollerDrive, rotating rollers and the corresponding sensors and switches. Depending
on the selected ZPA program, up to three Slave-RollerDrive can be assigned.
The combination of a MultiControl with the associated zones, RollerDrive and sensors is called a
"module".
To configure larger conveying systems, multiple modules can be linked together. For this purpose,
different IP addresses are assigned to the MultiControls. The connection to additional conveying
systems is realized, for example, by configurable inputs/outputs. Data is exchanged with a
master control system (PLC) via the fieldbus systems "PROFINET", "EtherNet/IP" or "EtherCAT".
EtherCAT is only applicable as an I/O device.

Configuration options
4 Operating and Programming
3 Configuration options
To commission the MultiControl, it must first be configured. This can be done in different ways:
•All settings can be configured via a web-based user interface on a computer connected to
the MultiControl (see "Interroll MultiControl Instruction Manual")
•Using the magnetic sensor, the sensors, the bus type and the LED displays can be
configured directly on the MultiControl, as well as the MultiControl can be tested,
automatically configured or reset to the factory settings (see "The Magnetic Sensor", page
5)
•Service Data Objects (SDO) written by a higher-level controller can be used to configure
all settings except the bus type (see "Service Data Objects (SDO)", page 9)
•The station name, IP configuration and connection settings can be changed via a PLC
development environment

Configure MultiControl
Operating and Programming 5
4 Configure MultiControl
4.1 The Magnetic Sensor
An optional magnet (see Interroll MultiControl Instruction Manual / Appendix / Accessories)
activates the built-in magnetic sensor.
The magnetic sensor is located on the top side of the MultiControl, between the two "R" of the
"INTERROLL" lettering just before the base plate (see Interroll MultiControl Instruction Manual /
Product Information / Structure).
The magnetic sensor can be used to perform the following functions:
•Select sensors
•Select bus type
•Perform teach-in procedure
•Turn on/off the LED indicators of the sensors / I/O
•Reset MultiControl to factory settings
Select function
➢Hold magnet to the magnetic sensor.
When the magnetic sensor detects the magnet, the "Fault" LED lights up permanently. After
one second, a running light starts in the LED bar on the left side of the MultiControl.
Each LED is assigned a function:
No.
LED
Function
1
Sensor 1
Cancel
2
I/O 1
Select sensors
3
RD 1
Select bus type
4
RD 2
Perform teach-in procedure
5
Sensor 2
Turn on/off the LED indicators of the sensors / I/O
6
I/O 2
Reset MultiControl to factory settings