Pulseroller ConveyLinx-Ai2 Quick start guide

Version 1.0
February 2019
For ConveyLinx Ai2 Firmware version 4.19 and higher
ConveyLinx module firmware and functionality is protected by U.S. and international patents.
For complete patent information visit www.pulseroller.com/patents
Publication ERSC-1521

3
Symbol Conventions
Publication ERSC-1521 Rev 1.0 – February 2019
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.
IMPORTANT USER INFORMATION
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.

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Connecting to Rockwell PLCs
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
February 2019
Initial Release
GLOBAL CONTACT INFORMATION

5
Table of Contents
Publication ERSC-1521 Rev 1.0 – February 2019
TABLE OF CONTENTS
Symbol Conventions...................................................................................................................................................3
Important User Information........................................................................................................................................3
Summary of Changes.................................................................................................................................................4
Global Contact Information........................................................................................................................................4
Table of Contents........................................................................................................................................................5
Preface .........................................................................................................................................................................6
Who Should Use This Manual?............................................................................................................................6
Prerequisites ...........................................................................................................................................................6
Not Included in This Manual .................................................................................................................................6
Introduction ..................................................................................................................................................................7
Ethernet I/P Guidelines..........................................................................................................................................8
Selecting Your Connection Method based upon Assembly .............................................................................8
Using Generic Ethenret Module Method ...............................................................................................................11
General Procedure for Connecting using Generic Ethernet Module ............................................................12
Example for Ai2 Module in ZPA Mode ..............................................................................................................12
Parameters for Each Assembly..........................................................................................................................16
Using EDS File Method............................................................................................................................................17
Selecting the Proper EDS File............................................................................................................................17
Installing ConveyLinx EDS File into RSLogix5000 ..........................................................................................18
Creating a ZPA Mode Ai2 Module in the Ethernet Tree .................................................................................20
Note ①- Data Type Size ...............................................................................................................................25
Note ②- RPI Settings ....................................................................................................................................25
Creating Other Connection Types .....................................................................................................................26
Using ERSC Add On Instructions (AOI) with RSLogix 5000 ..............................................................................27
Selecting the Proper AOI Instruction .................................................................................................................27
Installing the AOIs into RSLogix 5000...............................................................................................................28
Example for Assigning AOI to Ai2 Module in Your PLC Program .................................................................29
Assigning New Modules to AOI ..........................................................................................................................30
Enabling the Module for Operation ....................................................................................................................34
ZPA AOI Tag Descriptions ..................................................................................................................................36
PLC I/O AOI Tag Descriptions............................................................................................................................38
Using Logix5000 MSG Instruction..........................................................................................................................41
When to Use MSG Instructions ..........................................................................................................................41
Refresher on Assemblies ....................................................................................................................................41
Module Vs. Assembled Address with MSG Instructions ............................................................................42
Message Configuration for Reading from Ai2 Module Registers ..................................................................42
Message Configuration for Writing Data To Ai2 Module Register.................................................................43
Message Configuration for Reading Ai2 Assembled Registers.....................................................................44
Notes: .........................................................................................................................................................................45

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Connecting to Rockwell PLCs
PREFACE
WHO SHOULD USE THIS MANUAL?
This manual is intended for users who need to utilize a Rockwell PLC equipped with Ethernet I/P capability to connect
to a ConveyLinx Ethernet network to access module status and control conveyor operation.
PREREQUISITES
You should have reviewed and understood publication ConveyLinx-Ai2 PLC Developer’s Guide (Insight Automation
publication ERSC-1500) before utilizing this manual’s instructions to physically connect your Rockwell PLC to a
ConveyLinx network.
This manual also assumes you have a solid working knowledge of both Rockwell PLC’s and the RSLogix 5000 / RSLogix
Designer development environments.
NOT INCLUDED IN THIS MANUAL
Because system applications vary; this manual assumes users and application engineers
have properly sized their PLC’s Ethernet port capacity to accommodate the quantity of
ConveyLinx module connections desired. Please refer to
you particular PLC’s
specifications.
This manual is for ConveyLinx-Ai2 modules only. For information on how to connect
ConveyLinx ERSC modules please see publication Connecting ConveyLinx-Ai2 to Rockwell
PLCs (Insight Automation publication ERSC-1520)

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Introduction
Publication ERSC-1521 Rev 1.0 – February 2019
INTRODUCTION
This manual will provide instructions on how to connect your Rockwell Ethernet I/P capable PLC to a network of
ConveyLinx modules. There are three basic methods for connecting ConveyLinx to Rockwell PLCs:
•Use Generic Ethernet Device
•Import EDS and optionally import and use AOIs
•Use MSG Instruction
All three methods can be used for ConveyLinx modules in ZPA mode and in PLC I/O mode. However, the MSG
Instruction method does not maintain a constant connection to a ConveyLinx module and should not be used for
“time critical” operations.
This manual is for ConveyLinx-Ai2 and NOT for ConveyLinx-
ERSC. For information on how to work with ConveyLinx-ERSC,
see publication ERSC-1520 Conecting ConveyLinx-ERSC to
Rockwell PLCs


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Connecting to Rockwell PLCs
ETHERNET I/P GUIDELINES
Each Allen-Bradley PLC has 2 metrics for limiting maintained Ethernet I/P communications to remote devices:
•Fixed quantity of TCP connections available on its Ethernet Port
•Fixed quantity of I/O data table memory available for connected devices
If the limit of either of these quantities is reached, the PLC processor will indicate I/O communications fault on one
or more instances of device declaration. For ConveyLinx device declarations utilizing either ZPA or PLC I/O Mode
instances, in general the PLC limitation on TCP connections will be reached before I/O data table memory limit is
realized.
For example, for a CompactLogix L3x series processor, the documented quantity of TCP connections available on its
Ethernet Port is 32. The processor always keeps one TCP connection in reserve for programming terminal access,
etc. An L3x series processor can accept 31 full-time ConveyLinx Connections as generic I/O modules utilizing any
combination of ZPA mode and PLC I/O Mode instances.
When a ConveyLinx module is attached as a “full-time generic I/O module” to the PLC, the connection is continually
maintained and data is exchanged at a minimum RPI value (referred to as an implicit connection). If the PLC cannot
communicate with the ConveyLinx module for any reason, the PLC’s I/O tree will register a fault. It is possible for
the PLC to communicate via Ethernet I/P with any ConveyLinx module it can physically reach over its Ethernet port
without the module being “full-time connected as a generic I/O module”. This is accomplished with a Logix5000
MSG instruction (referred to as explicit connection).
Reserve Ethernet I/P TCP connections for ConveyLinx modules in PLC I/O Mode and for
key ZPA Mode modules where permanent accumulate/query/release functionality is
required.
Use MSG Instruction to gather less time-
critical data for things such as status and
diagnostics.
For more information on determining the design and capacity of your Ethernet I/P
network; please refer to Allen-Bradley document EtherNet/IP Performance Application
Solution (Rockwell publication ENET-AP001D-EN-P).
SELECTING YOUR CONNECTION METHOD BASED UPON ASSEMBLY
As described in the ConveyLinx-Ai2 PLC Developer’s Guide (publication ERSC 1520), the data that you exchange with
your PLC and a given ConveyLinx module depends on the mode of the module and how you want to use it. The I/O
data to be exchanged are arranged in register Assemblies and depending on the assembly, will dictate whether you
can connect using the EDS file method or the Generic Ethernet Module method.
All available assemblies can be connected utilizing the Generic Ethernet Module method and only selected
assemblies are available from the EDS file installation

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Introduction
Publication ERSC-1521 Rev 1.0 – February 2019
All available assemblies can be connected utilizing the Generic Ethernet
Module method. Only a selected few assemblies are available from the
EDS file installation.
Assembly Pair
Available from
EDS File
Installation
Available as
Generic
Ethernet
Module
ZPA Mode Assembly Inputs
ZPA Mode Assembly Outputs


ZPA Mode Assembly Inputs with Reset Protection
ZPA Mode Assembly Outputs with Reset Protection


Reduced Size ZPA Mode Assembly Inputs
Reduced Size ZPA Mode Assembly Outputs

Reduced Size ZPA Mode Assembly Inputs with Reset Protection
Reduced Size ZPA Mode Assembly Outputs with Reset Protection

PLC I/O Mode Assembly Inputs
PLC I/O Mode Assembly Outputs


PLC I/O Mode Assembly Inputs with Reset Protection
PLC I/O Mode Assembly Outputs with Reset Protection


Reduced Size PLC I/O Mode Assembly Inputs
Reduced Size PLC I/O Mode Assembly Outputs

Reduced Size PLC I/O Mode Assembly Inputs with Reset Protection
Reduced Size PLC I/O Mode Assembly Outputs with Reset Protection

ConveyLogix Assembly Inputs
ConveyLogix Assembly Outputs



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Using Generic Ethenret Module Method
Publication ERSC-1521 Rev 1.0 – February 2019
USING GENERIC ETHENRET MODULE METHOD
When using the Generic Ethernet Module construct in RSLogix 5000, you must supply configuration information
about the device you are trying to connect. The following sections show the step by step procedure to connect a
module for each set of Input and Output Assemblies described in publication ERSC-1506 ConveyLinx-Ai2 PLC
Developer’s Guide.
Each Assembly defined for ConveyLinx-Ai2 has a corresponding Assembly Instance value used when configuring your
Generic Ethernet Module in your RSLogix 5000 environment. The following chart is a reference showing all the
available Assemblies and their respective Instance Values used when connecting as a Generic Ethernet Device.
Assembly
Instance Values
ZPA Mode Assembly Inputs
105
ZPA Mode Assembly Outputs
106
ZPA Mode Assembly Inputs with Reset Protection
305
ZPA Mode Assembly Outputs with Reset Protection
306
Reduced Size ZPA Mode Assembly Inputs
119
Reduced Size ZPA Mode Assembly Outputs
120
Reduced Size ZPA Mode Assembly Inputs with Reset Protection
319
Reduced Size ZPA Mode Assembly Outputs with Reset Protection
320
PLC I/O Mode Assembly Inputs
107
PLC I/O Mode Assembly Outputs
108
PLC I/O Mode Assembly Inputs with Reset Protection
307
PLC I/O Mode Assembly Outputs with Reset Protection
308
Reduced Size PLC I/O Mode Assembly Inputs
117
Reduced Size PLC I/O Mode Assembly Outputs
118
Reduced Size PLC I/O Mode Assembly Inputs with Reset Protection
317
Reduced Size PLC I/O Mode Assembly Outputs with Reset Protection
318
ConveyLogix Assembly Inputs
121
ConveyLogix Assembly Outputs
122

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Connecting to Rockwell PLCs
GENERAL PROCEDURE FOR CONNECTING USING GENERIC ETHERNET MODULE
All assembly pairs can be connected to a single ERSC using the same procedure within RSLogix 5000 environment:
1. Create a New Module in your Ethernet Tree
2. Select Generic Ethernet Module from the list of devices
3. Enter name and I.P. Address
4. Select the correct Comm Data type
5. Enter Input Assembly Instance Value and Size
6. Enter Output Assembly Instance Value and Size
7. Enter desired RPI value
For example, if you need to attach to 5 Ai2 modules that are in ZPA Mode, each module will have to have a unique
name and I.P. address (step 3) and steps 4, 5, 6, and 7 will use the same values for each ERSC.
EXAMPLE FOR AI2MODULE IN ZPA MODE
This section will provide the set-by-step procedure for creating an instance of an Ai2 module into the I/O
configuration for an Allen-Bradley CompactLogix processor in RSLogix 5000 software.
Step #1
Add a New Module to the processor’s I/O
configuration by highlighting the processor’s
local Ethernet port in the I/O configuration
tree.
Right-clicking will show the context menu.
Select “New Module…”

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Using Generic Ethenret Module Method
Publication ERSC-1521 Rev 1.0 – February 2019
Step #2
From the Select Module pop-
up window, clear the filters,
select the Communication
check box, scroll to and select
“Generic Ethernet Module”
and click Create, which will
open up the New Module
window
Step #3 thru #6
Fill in the Name and IP Address
fields. The Name will be the
ModuleName that will appear in
your program Tag Database for
any addressing.
Select Comm Format to be
“Data – INT”
Fill in the Connection
Parameters as shown.
Configuration parameter is
always Instance 1 and Size 0
It is very important to select Comm Format data type to be INT
or interface to Ai2 module will not operate correctly!
❸
❸
❹
❺
❻

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Connecting to Rockwell PLCs
Step #7
Set RPI to a value no lower than
10ms. 200 ms is typical for ZPA
Interface. You may also optionally
select Unicast Connection.
Click “Apply” to update the value
and then “OK” to exit the window.
Once you have completed the configuration of your Ai2 module, you can see the input and output registers in your
Controller Tags screen. The register format and order within their respective Input/Output arrays match up exactly
with the Assembly descriptions provided in the ConveyLinx-Ai2 PLC Developer’s Guide publication.
For our example, we created an Ai2 module named “Ai2_Conveyor_1”. Figure 1 and Figure 2 show the Input and
Output register arrays for this module. You can access the data registers directly in your user program.
FIGURE 1 - GENERIC MODULE ERSC INPUT DATA ARRAY
❼

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Using Generic Ethenret Module Method
Publication ERSC-1521 Rev 1.0 – February 2019
FIGURE 2 - GENERIC MODULE ERSC OUTPUT DATA ARRAY

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Connecting to Rockwell PLCs
PARAMETERS FOR EACH ASSEMBLY
Please note that for all Assemblies and all versions of firmware the
Instance value for the “Configuration” parameter is always “1” and its size
is always “0”.
The following chart shows each available Assembly and its corresponding Input and Output Instance values and data
sizes:
Assembly
Type
Instance Value
Size Value
ZPA Mode Assembly
Input
105
21
Output
106
25
ZPA Mode Assembly with Reset Protection
Input
305
21
Output
306
25
Reduced Size ZPA Mode Assembly
Input
119
12
Output
120
15
Reduced Size ZPA Mode Assembly with Reset Protection
Input
319
12
Output
320
15
PLC I/O Mode Assembly
Input
107
23
Output
108
27
PLC I/O Mode Assembly with Reset Protection
Input
307
23
Output
308
27
Reduced Size PLC I/O Mode Assembly
Input
117
9
Output
118
9
Reduced Size PLC I/O Mode Assembly with Reset Protection
Input
317
9
Output
318
9
ConveyLogix Assembly
Input
121
16
Output
122
16

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Using EDS File Method
Publication ERSC-1521 Rev 1.0 – February 2019
USING EDS FILE METHOD
SELECTING THE PROPER EDS FILE
The first step is to select the proper EDS file based upon the firmware version of your ConveyLinx-Ai2 modules. Our
Pulseroller.com website contains all EDS files for download including older versions. The following chart lists
firmware version, operation mode, and EDS file cross-reference information:
Ai2 Firmware
Operational Mode
EDS File
4.19 and later
ZPA & PLC I/O Mode
ConveyLinxAi_V5_1.eds
Please note that there may be updates since publication of this document. Please go to
pulseroller.com to download the latest versions of EDS files when available.
For best results, you should remove any previous Ai2 EDS file(s) you may
have installed in your RSLogix 5000 environment before
installing the
version described in this section.
Also, delete all unused module data types from your program especially
if you are modifying or starting with an existing program
Installing the EDS file provided by Insight Automation into your RSLogix 5000 environment will allow you to select
the Ai2 module from your list of known devices without having to use the Generic Ethernet Module method. The
EDS file contains the Instance and size parameters so you do not have to fill in this information. When you connect
to an Ai2 module, the data is arranged in assembled registers as described in the ConveyLinx-Ai2 PLC Developer’s
Guide publication with the data appearing in your Controller Tags similarly to how the data appears when you
connect to an Ai2 module as a Generic Ethernet Module.

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Connecting to Rockwell PLCs
INSTALLING CONVEYLINX EDS FILE INTO RSLOGIX5000
Step 1
With RSLogix5000 open, select Tools
from the menu and EDS Hardware
Installation Tool
Step 2
Select the Register an EDS file(s) radio
button and click next
Step 3
Select the Register a single file radio
button and click Browse and then
browse to the location on your PC
where you downloaded the EDS file.
Click Next to continue.
Note: Filename shown is for example only. The
filename you select will be based upon the
filename table shown at the beginning of this
section.

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Using EDS File Method
Publication ERSC-1521 Rev 1.0 – February 2019
Step 4
This window should appear with the
green check indicating there were no
errors. Click Next to continue.
Note: Filename shown is for example only. The
filename you select will be based upon the
filename table shown at the beginning of this
section
Step 5
A window appears indicating the
graphic image included in the EDS file.
This image will be used if you want to
show network topology in RSNetworx.
You can change to your own icon if you
wish. Click Next to Continue
Step 6
RSLogix5000 asks if you want to
complete the installation. Click Next to
proceed.

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Connecting to Rockwell PLCs
Step 7
RSLogix5000 lets you know when it is
done by showing this window. Click
Finish.
Please refer to applicable Rockwell Software documentation for further details and
information for removing and installing EDS files.
CREATING A ZPA MODE AI2MODULE IN THE ETHERNET TREE
Once you have installed the EDS file into your RSLogix 5000 environment, you can now add specific instances of Ai2
modules into your project. You follow a similar procedure as described for the Generic Ethernet Module method.
We are going to show adding a ZPA mode Ai2 module to your program as an example.
Step 1
Right click on your Ethernet
Tree and select New Module
to open the Select Module
Type window.