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

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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

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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

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Table of Contents
Publication ERSC-1006 Rev 1.4 – October 2017
Sensor Port Aux I/O Pin 2 Usage..............................................................................................................85
Flex Zone ......................................................................................................................................................94
Sensors .........................................................................................................................................................94
Extensions ....................................................................................................................................................94
Appendix A – Module Dimensions .........................................................................................................................97
Appendix B - IOX-2Breakout Module.....................................................................................................................99
Appendix C–Configuring PC for Ethernet Subnets............................................................................................105
ConveyLinx, IP Addresses, and Subnets........................................................................................................105
Configuration Example ......................................................................................................................................106
Appendix D – Application Examples....................................................................................................................109
Using Extensions for a Lift Gate.......................................................................................................................109
Appendix E – Power Supply Loading...................................................................................................................113
Notes: .......................................................................................................................................................................115

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Preface
Publication ERSC-1006 Rev 1.4 – October 2017
PREFACE
WHO SHOULD USE THISMANUAL?
This manual is intended for users who need basic product information and simple application procedures to
implement ConveyLinx-Ai2 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.
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.
NOTINCLUDED 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.

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Introduction to ConveyLinx®
Publication ERSC-1006 Rev 1.4 – October 2017
INTRODUCTIONTOCONVEYLINX®
CONVEYLINX®CONCEPT
ConveyLinx control system as applied to conveyor control is a series of individual ConveyLinx Ai2 modules
interconnected via standard Ethernet cabling to form an integrated solution for MDR (Motorized Drive Roller)
conveyor functionality. Each ConveyLinx Ai2 module can accommodate up to 2 Senergy Ai MDRs and 2 photo-
sensorstoprovidecontrolforupto2conveyorzones. EachConveyLinx Ai2 also includes convenient connectivity
ports for upstream and downstream Ethernet network cabling.
FIGURE 1 - C O N V E Y L I NX ® CONCEPT WITH CONVEYLINX-AI2 M O D U L E S
ConveyLinx Ai2 modulescanbeeasilysoftwareconfiguredtooperatemultiplezonesoflinearconveyorwiththe
EasyRoll software.Also,withtheConveyLinx Easy Roll software tool; each ConveyLinx Ai2 module’s default
configuration can be modified to customize functionality for specific applications.
CONVEYLINX®SYSTEMCOMPONENTS
The following are the typical components required for a ConveyLinx controlled conveyor installation:
ConveyLinx-Ai2 modules
MDRs – one or two per
ConveyLinx-Ai2
Photo-sensors – one or two
per ConveyLinx-Ai2
24VDC Power Supplies

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ConveyLinx-Ai2 User’s Guide
Publication ERSC-1006 Rev 1.4 – October 2017
CONVEYLINX-AI2MODULE FEATURES
Each individual ConveyLinx-Ai2 module has the following features:
Built-in Ethernet switch
Modular M8 (female) style connection ports for photo-sensors
Modular M8 (male) style connectors for MDR
24VDC power connection with separate power supplies for logic and motors
Context-sensitive multi-color LED indicators
Thermal and over-current protection for MDR
Automatic light/dark operate detection for photo-sensor inputs
Accommodates PNP or NPN type photo-sensor
Proportional / Integral (PI) MDR speed regulation
Three MDR braking method options
Adjustable acceleration and deceleration capability
IP54 compliant
CONVEYLINX®CONTROLSYSTEMFEATURES
When one or more ConveyLinx-Ai2 modules are installed and configured, there are several operational and
configurable features of the ConveyLinx control system that are accessible by the EasyRollsoftware package.
Some of these features are:
Single zone to zone zero pressure accumulation (ZPA) control once module is configured.
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 a ConveyLinx-Ai2 to be an “Extension” to another ConveyLinx-Ai2 such that it operates
as simple motor controller.
The first sections of this manual will describe in detail the hardware and connectivity requirements for ConveyLinx
Ai2 modules and the software configuration procedures for simple linear conveyor installation.
ThelattersectionsofthismanualwilldescribeindetailtheusageoftheEasyRoll software package to gain access
to the various optional configuration parameters and utilities.

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ConveyLinx-Ai2 Module Hardware Overview
Publication ERSC-1006 Rev 1.4 – October 2017
CONVEYLINX-AI2MODULE HARDWARE OVERVIEW
ConveyLinx-Ai2 modules are designed to be installed and integrated into the conveyor’s mechanical side frame
assembly. Please refer to Appendix A – Module Dimensions page 97 for module dimensions and mounting details.
The ConveyLinx-Ai2 module isacontrollerforupto2MotorizedDriveRoller(MDR)conveyorzones.Each
ConveyLinx-Ai2 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 – CONVEYLINX-AI2 MODULE HARDWARE FEATURES IDENTIFICATION
Item
Description
1
24VDC Power Terminals with separate connections for Logic and Motors
2 & 3
Motor Left LED & Motor Right LED – Motor status indicators
4 & 5
Left Sensor & Right Sensor Status LED Indicators
6
Module Status LED Indicator
7
Module Power LED Indicator
8 & 9
Motor Left and Motor Right - 4-pin M8 style connector for MDR connection
10 & 11
Sensor Left and Sensor Right – M8 style connector for zone photo-sensor connection
12
RemovableIP54 Power Compartment Cover
13
Module Replacement Button
14 & 15
Link Left and Link Right – RJ-45 style Ethernet network connection between modules
16
Removable IP54 Ethernet RJ-45 Port Compartment Cover – Left and Right
17*
IP54 Protection Shrouds for Ethernet cabling and power wiring
* Indicates items shipped unattached to the module but included in the module’s box

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ConveyLinx-Ai2 User’s Guide
Publication ERSC-1006 Rev 1.4 – October 2017
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”
HARDWARE CONNECTIONS
MOTORLEFT AND MOTORRIGHT PORTS
Bothoftheseportsutilizea4-pin M8 male receptacle. Each receptacle is mechanically keyed to assure proper
orientation upon plugging in.
FIGURE 3 - M8 MALE RECEPTACLE AND SENERGY-AI2 FEMALE CONNECTOR

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Hardware Connections
Publication ERSC-1006 Rev 1.4 – October 2017
SENSOR LEFT AND SENSOR RIGHT PORTS
Each sensor port is a standard M8 Female receptacle with the following pin-out:
FIGURE 4–CONVEYLINX S E N S O R P O R T D I A G R A M
FIGURE 5 – CONVEYLINX-AI2 F EM A L E S E N S O R P O R T A N D M A T I N G
SENSOR’S MALE CONNECTOR
The signals are defined by the following chart:
Pin
Signal
Description
1
24V DC
Module 24VDC Supply
2
Aux I/O
I/O Signal – Function configured with EasyRoll software
3
GND
Module DC Common
4
Sensor Signal
Logical Input for Sensor’s state output – Auto detect for NPN or PNP
ELECTRICALCONNECTIONSFOR SENSORPORTAUXI/O
When connecting to either Sensor port with an M8 connector to access Pin 2 signal; it depends on whether you are
using Pin 2 as an input or output that will determine the electrical connection.
See Sensor Port Aux I/O Pin 2 Usage beginning on page 85 for details on using
EasyRoll to configure the function of Sensor Port Pin2
AUXI/OPIN2ASINPUT
When the Aux I/O Pin 2 is configured as an input, the circuit is NPN/PNP auto-sensing. The signal can be
connected to either +24V or 0V to operate as shown in Figure 6.

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FIGURE 6 - AUX I/O PIN 2 INPUT CONNECTION DIAGRAM
Because the auto-sensing circuit requires a nominal voltage in order to operate, there will
be some small amount of leakage current possible between Pin 2 and Pin 3 (GND). Please
use caution if you connect a load between Pin 2 and Pin 3.
AUXI/OPIN2ASOUTPUT
When the Aux I/O Pin 2 is configured as an output, the circuit is NPN only and requires the load to be connected to
Pin 1 (+24V) as shown in Figure 7.
FIGURE 7 - AUX I/O PIN2 OUTPUT CONNECTION DIAGRAM