Pulseroller CONVEYLINX ConveyMerge User manual

Version 1.1
April 2020
Publication ERSC-1020
ConveyLinx module firmware and functionality is protected by U.S. and international patents. For complete
patent information visit www.pulseroller.com/patents

3
Symbol Conventions
Publication ERSC-1020 Rev 1.1 – April 2020
SYMBOL CONVENTIONS
This symbol indicates that special attention should be paid in order to ensure correct
use as well as to avoid danger, incorrect application of product, or potential for
unexpected results
This symbol indicates important directions, notes, or other useful information for the
proper use of the products and software described herein.

Publication ERSC-1020 Rev 1.1 – April 2020
IMPORTANT USER INFORMATION
ConveyLinx ERSC modules contain ESD (Electrostatic Discharge) sensitive parts and
components. Static control precautions are required when installing, testing, servicing or
replacing these modules. Component damage may result if ESD control procedures are
not followed. If you are not familiar with static control procedures, reference any
applicable ESD protection handbook. Basic guidelines are:
 Touch a grounded object to discharge potential static
 Wear an approved grounding wrist strap
 Do not touch connectors or pins on component boards
 Do not touch circuit components inside the equipment
 Use a static-safe workstation, if available
 Store the equipment in appropriate static-safe packaging when not in use
Because of the variety of uses for the products described in this publication, those
responsible for the application and use of this control equipment must satisfy themselves
that all necessary steps have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws, regulations, codes,
and standards

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Important User Information
Publication ERSC-1020 Rev 1.1 – April 2020
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-1020 Rev 1.1 – April 2020

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Summary of Changes
Publication ERSC-1020 Rev 1.1 – April 2020
SUMMARY OF CHANGES
The following table summarizes the changes and updates made to this document since the last revision
Revision Date Change / Update
1.0 April 2016 Initial Release
1.1 April 2020 Updated Publication Number
GLOBAL CONTACT INFORMATION

8 ConveyMerge Guide
Publication ERSC-1020 Rev 1.1 – April 2020
TABLE OF CONTENTS
Symbol Conventions ................................................................................................................................................... 3
Important User Information ........................................................................................................................................ 4
Summary of Changes ................................................................................................................................................. 7
Global Contact Information ........................................................................................................................................ 7
Table of Contents ........................................................................................................................................................ 8
Introduction to ConveyMerge .................................................................................................................................... 9
ConveyMerge Components .................................................................................................................................. 9
ConveyMerge Prerequisites and Requiements ............................................................................................... 10
Setting up Your Conveyor........................................................................................................................................ 11
Network Architecture ............................................................................................................................................ 11
Architecture Summary ..................................................................................................................................... 11
Sensor Placement ................................................................................................................................................ 12
Standard Merge Sensor Placement .............................................................................................................. 12
90˚ Merge Sensor Placement ......................................................................................................................... 13
Module Logical Connections for Main Line ....................................................................................................... 13
Merging Zone on Upstream Zone .................................................................................................................. 13
Merging Zone on Downstream Zone ............................................................................................................. 14
Single Zone ERSC ........................................................................................................................................... 14
Merging Lines ................................................................................................................................................... 15
Merging Functionality ............................................................................................................................................... 17
Merge Types ......................................................................................................................................................... 17
Merge Priority ........................................................................................................................................................ 17
90˚ Merge Setting (T-Merge) .............................................................................................................................. 18
Accept Timeout ................................................................................................................................................. 18
Send Timeout.................................................................................................................................................... 19
Configuring Dynamic Priority (Merge Line Full) ............................................................................................... 20
Dynamic Priority Example ............................................................................................................................... 20
Using EasyRoll with ConveyMerge ........................................................................................................................ 22
ConveyMerge Configuration Screen ................................................................................................................. 23
Standard Merge Example .................................................................................................................................... 25
T-Merge Example ................................................................................................................................................. 27
Merge with Merge Line Full Example ................................................................................................................ 29
Notes: ......................................................................................................................................................................... 31

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Introduction to ConveyMerge
Publication ERSC-1020 Rev 1.1 – April 2020
INTRODUCTION TO CONVEYMERGE
ConveyMerge is an optional functionality layer built on top of ConveyLinx’s ZPA logic. Users can enable and configure
it using EasyRoll software. ConveyMerge behaves the same as ZPA logic, but allows the engineer to define a special
Merging Zone that can have up to three upstream zones connecting to it where ZPA logic only supports a single
upstream zone. ConveyMerge also has a simple priority schemes for the multiple upstream zones as well as the
ability to dynamically change those priorities on-the-fly by utilizing the Merge Line Full option. It also takes care of
passing tracking information properly and has Jam condition detection.
CONVEYMERGE COMPONENTS
ConveyMerge can accommodate product merge control from one or two conveyor paths onto a single take-away
conveyor path as shown in Figure 1.
FIGURE 1 – TYPICAL CONVEYMERGE COMPONENTS

10 ConveyMerge Guide
Publication ERSC-1020 Rev 1.1 – April 2020
The following table identifies and defines these typical components.
Component Description
Merging Zone Powered conveyor section that accepts an item from any one of the 3 possible
upstream sources
Main Line Term to describe the 3 in-line conveyor sections - Center Line, Merging Zone and
Discharge Zone
Center Line Part of Main Line that is one of three possible sources of items that can flow into the
Merging Zone. This term is used in the configuration screen of EasyRoll to designate
the network that serves as the trunk line that contains the Merging Zone.
Discharge Zone Part of the Main Line that is downstream of the Merging Zone. This conveyor section
accepts the item from the Merging Zone.
Left Line One of the three possible conveyor sections that can discharge items into the
Merging Zone.
Right Line One of the three possible conveyor sections that can discharge items into the
Merging Zone.
CONVEYMERGE PREREQUISITES AND REQUIEMENTS
The following items are the prerequisites and constraints required to provide a fully functioning automatic conveyor
merge:
 EasyRoll version 4.3 or greater
 ConveyLinx Firmware version 4.25 or greater
 Only (1) one Merging Zone is allowed for any given single ERSC module
 Merging Zone cannot have any Extension (slaved) zone
 All ERSC modules controlling Merging Zone, Left Line Discharge, Right Line Discharge, and Center Line
discharge must be in ZPA mode
 Left, Right, and Center Lines discharges cannot also be included in another instance of ConveyMerge.
Please refer to Insight Automation publication ConveyLinx User’s Guide for ConveyLinx
ERSC module hardware details and basic function. The remaining sections of this
document assumes reader if familiar with ConveyLinx ERSC module and EasyRoll
software operation.