Pulseroller ConveyLinx-Ai2 User manual

Version 1.4
October 2017
Publication ERSC-1006
ConveyLinx module firmware and functionality is protected by U.S. and international patents.
For complete patent information visit www.pulseroller.com/patents

3
Glossary of Terms
Publication ERSC-1006 Rev 1.4 – October 2017
GLOSSARYOFTERMS
ConveyLinx
Conveyor controls architecture based upon modular distributed devices connected via
Ethernet network.
ConveyLinx-Ai /
ConveyLinx-Ai2
Conveyor control module that is part of the ConveyLinx family. Each module can
accommodate up to 2 MDR conveyor zones. The modules allow connection for Senergy-
Ai platform motor rollers and gear drives.
DHCP
Dynamic Host Configuration Protocol A protocol for assigning IP addresses to devices on
anetworkfromapoolofavailableIP’s. A dynamic IP address changes each time the
device connects to the network
Hall Effect Sensor
Special sensor embedded within the brushless DC motor of an MDR used to provide
motor rotor position feedback to the motor controller
M8
Thisisthetypeofaparticularconnector , which has four connector pins and is used on
the ConveyLinx Ai2 modules for both sensor connectors and MDR connectors
LED
Light Emitting Diode – In the context of this document, LED’s are used on the
ConveyLinx-Ai2 to provide visual indication of module status
Light / Dark Energized
Term used to describe how the signaling output circuit of a photo-sensor is configured
whenitdetectsitsreflectedlight. Aphoto-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.
MDR
Motorized Drive Roller or Motor Driven Roller - Brushless DC motor and gearbox
assembly integrated into a single conveyor roller.
Normally Open /
Normally Closed
Control logicterminologytodefinethestateoftheoutputofaBoolean“on”or“off”
device. The term specifically describes the state of the output circuit when the device’s
sensing circuit is un-energized. In the context of photo-sensors; a normally open wired
sensor would have its output circuit energized when it detected its reflected light and its
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.
NPN / PNP
Electronicstermthatindicatesthetypeoftransistorcircuitusedforalogicalinputor
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.
Photo-sensor
A device, mounted near the end of the conveyor zone to sense the presence of a load on
the zone
PLC
Programmable Logic Controller – A wide variety of industrial computing devices that
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 ConveyLinx-Ai2 controller to
MDR.

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ConveyLinx-Ai2 User’s Guide
Publication ERSC-1006 Rev 1.4 – October 2017
Retro-reflective /
Reflex
Termusedtodescribethetwobasictypesofphoto-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.
Reflex (or sometimes known as proximity) type photo-sensors emitlighttobereflected
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.
IP54
The IP Code (International Protection Marking) specifies the device’s degree of
resistance to intrusions, dust and water. IP54 certified device must be fully protected
from splashed water , dust particles and completely protected from contact
RJ-45
Registered Jack Style 45 – Standard connector / receptacle format utilizing 8 pin
connections. The typical standard for computer network cable connections
Singulation Release
Conveyor control method for zoned controlled conveyor that dictates that when a zone
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
Senergy-Ai
PulseRoller brand proprietary motor control platform that provides electronic
intelligence inside the motor that can be read by ConveyLinx-Ai and ConveyLinx-Ai2
controlmodules.Theconnectionfromthemotortothecontrollerisvia4-Pin M8 style
connector.
Slave Rollers
Asetofnon-motorized conveyor rollers mechanically linked to an MDR.TheMDR and
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
TCP/IP
Transport Control Protocol / Internet Protocol - IP istheprotocolwhichoverseesthe
transmission of information packets from device to device on an Ethernet network. TCP
makes sure the packets have arrived and that the message is complete. These two
protocolsarethebasiclanguageoftheInternetandare often referred to together as
TCP/IP.
Train Release
Conveyor control method for zone configured conveyor that dictates that when a zone i s
discharging, the upstream zone’s load can move in unison with the discharging load.
Zone
Abasic(linearorcurved)celloftheconveyorconsistingofasetofslaverollersdrivenby
one or more MDR’s and a single photo-sensor.
ZPA
Zero Pressure Accumulation – Term that describes the conveyor controls and mechanical
scheme that will cause loads to queue on a conveyor in discrete zones such that loads do
not touch each other

5
Important User Information
Publication ERSC-1006 Rev 1.4 – October 2017
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.
IMPORTANTUSERINFORMATION
ConveyLinx-Ai2 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.

7
Summary of Changes
Publication ERSC-1006 Rev 1.4 – October 2017
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
June 2016
Intial Release
1.1
January 2017
Added Appendix E
1.2
February 2017
Added connection diagrams for Sensor Port Aux I/O
1.3
March 2017
Corrected Figure numbering, clarified Flex Zone and Train release modes
1.4
October 2017
Updated Appendix B – IOX-2 wiring diagrams and schematic
GLOBAL CONTACT INFORMATION

8
ConveyLinx-Ai2 User’s Guide
Publication ERSC-1006 Rev 1.4 – October 2017
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
1.0
June 2016
Initial Release

9
Table of Contents
Publication ERSC-1006 Rev 1.4 – October 2017
TABLE OF CONTENTS
Glossary of Terms.......................................................................................................................................................3
Symbol Conventions..............................................................................................................................................5
Important User Information........................................................................................................................................5
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®...................................................................................................................................15
ConveyLinx® Concept.........................................................................................................................................15
ConveyLinx® System Components...............................................................................................................15
ConveyLinx-Ai2 Module Features......................................................................................................................16
ConveyLinx® Control System Features............................................................................................................16
ConveyLinx-Ai2 Module Hardware Overview.......................................................................................................17
Hardware Connections.............................................................................................................................................18
Motor Left and Motor Right Ports.......................................................................................................................18
Sensor Left and Sensor Right Ports..................................................................................................................19
Electrical Connections for Sensor Port Aux I/O...........................................................................................19
Aux I/O Pin2 as Input ..................................................................................................................................19
Aux I/O Pin 2 as Output..............................................................................................................................20
Ethernet Left and Ethernet Right Ports.............................................................................................................21
Power Connections..............................................................................................................................................23
IP54 Installation................................................................................................................................................23
Logic and MDR Power.....................................................................................................................................23
Power Supply Common Grounding...............................................................................................................25
Connections for Linear Conveyor...........................................................................................................................27
Example 1 –Two Zone Controller.......................................................................................................................27
Example 2 – Single Zone Controller..................................................................................................................28
Example 3 – Dual MDR Single Zone Controller...............................................................................................28
Invalid Configuration Examples..........................................................................................................................29
Motor Direction Definition....................................................................................................................................30
Status Indicators .......................................................................................................................................................31
Communications...................................................................................................................................................31
Network & Module Function................................................................................................................................31
Motors ...................................................................................................................................................................31
Sensors..................................................................................................................................................................32
Power ...................................................................................................................................................................32
Auto-Configuration of Linear Conveyor .................................................................................................................33
Linear Conveyor Definition..................................................................................................................................33
Installing EasyRoll tool on your PC....................................................................................................................34
ConveyLinx Ethernet Definition..........................................................................................................................34
Connecting Your PC to ConveyLinx Network ..................................................................................................36
Auto-Configuration Procedure............................................................................................................................36
Auto Detection of Opposite Side Module Location......................................................................................41

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ConveyLinx-Ai2 User’s Guide
Publication ERSC-1006 Rev 1.4 – October 2017
Auto Configuration Results .................................................................................................................................41
Normal Results.................................................................................................................................................41
Trouble-Shooting Failed Auto-Configuration................................................................................................43
Default Singulation Release ZPA Mode .......................................................................................................44
Default Flex Zone Recognition Feature........................................................................................................45
Jam Conditions.....................................................................................................................................................46
Sensor Jam.......................................................................................................................................................46
No Arrival Jam..................................................................................................................................................46
Network Fault........................................................................................................................................................47
Low Voltage Fault.................................................................................................................................................47
Automatic Module Replacement ........................................................................................................................48
ConveyLinx-Ai2 Module Replacement Procedure Using EasyRoll ..........................................................48
Module Replacement Using Replacement Button ......................................................................................51
EasyRoll Software Configuration Tool...................................................................................................................53
Introduction............................................................................................................................................................53
Basic Features..................................................................................................................................................53
Advanced Features..........................................................................................................................................53
Options for Configuring Your PC’s IP Address ................................................................................................54
Method 1 - Using DHCP Service for PC I.P. Address................................................................................54
Manual I.P. Address Configuration Methods ...............................................................................................55
Using EasyRoll to Locate Auto-Configuration Master ................................................................................55
Starting EasyRoll Application.....................................................................................................................55
Using the Network Services Utility............................................................................................................56
Method 2 - Change PC to Match Auto-Config Master............................................................................57
Method 3 - Change Auto-Config Master I.P. Address............................................................................58
EasyRoll Main Screen..........................................................................................................................................59
Connecting to ConveyLinx ..................................................................................................................................60
Node Navigation...............................................................................................................................................61
Node Identification ...........................................................................................................................................61
Module Diagnostic Window ............................................................................................................................62
Upstream / Downstream Zone Configuration...............................................................................................64
ZPA Mode Selections......................................................................................................................................65
Train Release Mode....................................................................................................................................65
GAP Train Release Mode...........................................................................................................................65
T-Bone Configuration..................................................................................................................................66
Ignore Jam Settings.....................................................................................................................................68
MDR Settings....................................................................................................................................................69
Motor Type....................................................................................................................................................69
Brake Method...............................................................................................................................................69
Speed ............................................................................................................................................................71
Motor Direction.............................................................................................................................................72
Acceleration / Deceleration ........................................................................................................................72
ConveyLinx Advanced Dialog.............................................................................................................................72
Invoking the ConveyLinx Advanced Dialog..................................................................................................72
Look Ahead & Timing..................................................................................................................................72
Upgrade.........................................................................................................................................................77
Connections..................................................................................................................................................79
Network Services.........................................................................................................................................85
Special Services...........................................................................................................................................85