Pulseroller ConveyLinx-IO User manual

Version 1.1
October 2017
Publication ERSC-1008
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-1008 Rev 1.1 – 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
M8
This is the type of a particular connector , 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
when it detects its reflectedlight. 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.
Normally Open /
Normally Closed
Control logic terminology to define the state of the output of a Boolean “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
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 emit light to be reflected
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

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ConveyLinx-IO User’s Guide
Publication ERSC-1008 Rev 1.1 – October 2017
RJ-45
Registered Jack Style 45 – Standard connector / receptacle format utilizing 8 pin
connections. The typical standard for computer network cable connections
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
protocols are the basic language of the Internet and are often referred to together as
TCP/IP.
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-1008 Rev 1.1 – 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-1008 Rev 1.1 – 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
March 2017
Initial Release
1.1
October 2017
Formatting update
GLOBAL CONTACT INFORMATION

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ConveyLinx-IO User’s Guide
Publication ERSC-1008 Rev 1.1 – 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
August 2016
Initial Release

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Table of Contents
Publication ERSC-1008 Rev 1.1 – 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 .......................................................................................................................................................................11
Who Should Use This Manual?..........................................................................................................................11
Purpose of This Manual.......................................................................................................................................11
Not Included in This Manual ...............................................................................................................................11
Introduction to ConveyLinx®...................................................................................................................................13
ConveyLinx® Concept.........................................................................................................................................13
ConveyLinx-Ai2 Module Features......................................................................................................................13
ConveyLinx-Ai2 Module Hardware Overview.......................................................................................................15
Hardware Connections.............................................................................................................................................16
Left and Right Male I/O Ports .............................................................................................................................16
Left and Right Female I/O Ports.........................................................................................................................17
Ethernet Left and Ethernet Right Ports.............................................................................................................18
Power Connections..............................................................................................................................................20
IP54 Installation................................................................................................................................................20
Logic and Output Power..................................................................................................................................20
Power Supply Common Grounding...............................................................................................................22
Status Indicators .......................................................................................................................................................23
Communications...................................................................................................................................................23
Network & Module Function................................................................................................................................23
Inputs ...................................................................................................................................................................23
Outputs...................................................................................................................................................................23
Power ...................................................................................................................................................................24
Auto-Configuration....................................................................................................................................................25
Installing EasyRoll tool on your PC....................................................................................................................25
ConveyLinx Ethernet Definition..........................................................................................................................25
Connecting Your PC to ConveyLinx Network ..................................................................................................27
Auto-Configuration Procedure............................................................................................................................27
Auto Configuration Results .................................................................................................................................31
Normal Results.................................................................................................................................................31
Trouble-Shooting Failed Auto-Configuration................................................................................................33
Low Voltage Fault.................................................................................................................................................33
Automatic Module Replacement ........................................................................................................................34
ConveyLinx Module Replacement Procedure Using EasyRoll .................................................................34
Module Replacement Using Replacement Button ......................................................................................38
EasyRoll Software Configuration Tool...................................................................................................................39
Introduction............................................................................................................................................................39
Basic Features..................................................................................................................................................39
Advanced Features..........................................................................................................................................39
Options for Configuring Your PC’s IP Address ................................................................................................40
Method 1 - Using DHCP Service for PC I.P. Address................................................................................40

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ConveyLinx-IO User’s Guide
Publication ERSC-1008 Rev 1.1 – October 2017
Manual I.P. Address Configuration Methods ...............................................................................................41
Using EasyRoll to Locate Auto-Configuration Master ................................................................................41
Starting EasyRoll Application.....................................................................................................................41
Using the Network Services Utility............................................................................................................42
Method 2 - Change PC to Match Auto-Config Master............................................................................43
Method 3 - Change Auto-Config Master I.P. Address............................................................................44
EasyRoll Main Screen..........................................................................................................................................45
Connecting to ConveyLinx ..................................................................................................................................46
Node Navigation...............................................................................................................................................46
Node Identification ...........................................................................................................................................47
ConveyLinx-IO Transparency Mode..................................................................................................................48
Disabling Transparency Mode........................................................................................................................50
ConveyLinx Advanced Dialog.............................................................................................................................51
Invoking the ConveyLinx Advanced Dialog..................................................................................................51
Upgrade Tab.................................................................................................................................................51
Connections Tab..........................................................................................................................................54
Network Services.........................................................................................................................................54
Connecting to a Remote PLC Controller...............................................................................................................55
ConveyLinx Network Architecture......................................................................................................................55
Understanding Assemblies .................................................................................................................................55
Modbus Assembly Instance Structure...............................................................................................................56
Ethernet I/P Assembly Instance Structure........................................................................................................57
Profinet IO Assembly Instance Structure..........................................................................................................58
ConveyLinx IO Configuration Data ....................................................................................................................59
Register Chart Legend ....................................................................................................................................59
Configuration Assembly ..................................................................................................................................59
Note ①..........................................................................................................................................................60
Note ②..........................................................................................................................................................61
Note ③..........................................................................................................................................................61
Note ④..........................................................................................................................................................61
Input Assembly (ConveyLinx-IO PLC)......................................................................................................62
Note ⑤..........................................................................................................................................................62
Output Assembly (PLC ConveyLinx-IO)...................................................................................................62
Note ⑥..........................................................................................................................................................62
Appendix A – Module Specifications......................................................................................................................63
Module Dimensions..............................................................................................................................................63
Mounting Dimensions ..........................................................................................................................................64
Environmental and Electrical ..............................................................................................................................64
Inputs ...................................................................................................................................................................65
Outputs...................................................................................................................................................................65
Ethernet Specification..........................................................................................................................................65
Supported network protocols..............................................................................................................................65
Appendix B – Connecting to Rockwell Ethernet I/P PLC....................................................................................67
Appendix C – Connecting to Siemens Profinet-IO PLC......................................................................................69
Appendix D – Understanding IP Addresses and Subnets..................................................................................71
ConveyLinx, IP Addresses, and Subnets..........................................................................................................71
Configuration Example ........................................................................................................................................72
Notes: .........................................................................................................................................................................75

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Preface
Publication ERSC-1008 Rev 1.1 – 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-1008 Rev 1.1 – October 2017
INTRODUCTIONTOCONVEYLINX®
CONVEYLINX®CONCEPT
ConveyLinx control system as applied to conveyor control or some other industrial application is a series of
ConveyLinx-IO and ConveyLinx-Ai2 modules interconnected via standard Ethernet cabling.Anetworkof
ConveyLinx modulesareprimarilyusedasZPAconveyorcontrollers.ConveyLinx-IO is available to allow you to
place digital IO on the same network along with ConveyLinx conveyor control modules.
Each ConveyLinx-IO control module is equipped with up to 8 digital inputs / 8 digital outputs. ConveyLinx-IO
modules can optionally be easily configured with the EasyRoll software to be “transparent” to the conveyor flow to
ensure that ZPA conveyor is uninterrupted from upstream to downstream
FIGURE 1 - C O N V E Y L I NX ® CONCEPT WITH CONVEYLINX-AI2 M O D U L E S AND CONVEYLINX-IO MODULE
CONVEYLINX-AI2MODULE FEATURES
Each individual ConveyLinx-Ai2 module has the following features:
Built-in Ethernet switch
Modular M8 (female) style connection ports for I/O
Modular M8 (male) style connection ports for I/O
24VDC power connection with separate power supplies for logic and outputs
Context-sensitive multi-color LED indicators
Programmable option for push-pull type input devices
IP54 compliant
The first sections of this manual will describe in detail the hardware and connectivity requirements for ConveyLinx-
IO 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-1008 Rev 1.1 – October 2017
CONVEYLINX-AI2MODULE HARDWARE OVERVIEW
ConveyLinx-IO modules are designed to be installed and integrated on or near the mechanical equipment requiring
I/O interface to the control system. EachConveyLinx-IO provides connection points for up to 8 configurable digital
inputs or outputs, 24V power supply, and Ethernet network cables.
FIGURE 2 – CONVEYLINX-IO MODULE HARDWARE FEATU RE S I DE NT IF I C A TIO N
Item
Description
1
24VDC Power Terminals with separate connections for Logic and Motors
2 & 3
Left Male & Right Male I/O Port Status LED indicators
4 & 5
Left Female & Right Female I/O Port Status LED Indicators
6
Module Status LED Indicator
7
Module Power LED Indicator
8 & 9
Left & Right Male 4-pin M8 style connector for I/O connections
10 & 11
Left & Right Female M8 style connector for I/O connections
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
The “left” and “right” naming convention for the module ports is based upon facing the
module as shown.

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ConveyLinx-IO User’s Guide
Publication ERSC-1008 Rev 1.1 – October 2017
HARDWARE CONNECTIONS
LEFT AND RIGHT MALE I/O PORTS
Bothoftheseportsutilizea4-pin M8 male receptacle. Each receptacle is mechanically keyed to assure proper
orientation upon plugging in. Each of the two signal pins can be configured as a digital input or output.
FIGURE 3 - M8 MALE RECEPTACLE AND FEM ALE M8 CONNECTOR
Input Signal Wiring for Male Port
Output Signal Wiring for Male Port

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Hardware Connections
Publication ERSC-1008 Rev 1.1 – October 2017
LEFT AND RIGHTFEMALE I/OPORTS
Each port is a standard M8 Female receptacle. Each receptacle is mechanically keyed to assure proper orientation
upon plugging in.
FIGURE 4 - C O N V E Y L I NX -I O F E M A L E M 8 P O R T A N D MATING M8 CONNECTOR
Input Signal Wiring for Female Port
Output Signal Wiring for Female Port
The signals are defined by the following chart:
Pin
Signal
Description
1
24V DC
Module 24VDC Supply
2
I/O
Input or Output signal based upon port configuration
3
GND
Module DC Common
4
I/O
Input or Output signal based upon port configuration

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ConveyLinx-IO User’s Guide
Publication ERSC-1008 Rev 1.1 – October 2017
ETHERNETLEFT AND ETHERNETRIGHT PORTS
Both of these ports are standard RJ-45 jacks conforming to standard Ethernet connection pin-out. In order to
maintain IP54 rating; Ethernet cables need to be equipped with protective shrouds. Figure 5 shows Ethernet
cables installed using shrouds to protect the RJ-45 connectors on the Ethernet cables. Each module is shipped with
3 shrouds.
FIGURE 5 – CONVEYLINX-IO WITH LEFT & RIGHT ETHERNET CABLES (COVERS REMOVED)
FIGURE 6 - ETHERNET CABLES CONNECTED WITH COVERS ATT A C H E D

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Hardware Connections
Publication ERSC-1008 Rev 1.1 – October 2017
IP54 protective shroud requires a special tool to properly install
the shroud onto the RJ-45 connector. Figure 7 shows Phoenix
Contact item 2891547 FL IP 54 Assembly Tool.
This tool must be purchased separately
FIGURE 7 - PHOENIX CONTACT ETHERNET
SWITCH 2891547 FL IP 54 ASSEMBLY TOOL
FIGURE 8 - PROTECTIVE SHROUND PLACED ON TOOL
FIGURE 9 - SHROUND STRETCHED WITH TOOL
FIGURE 10 - INSERTING RJ-45 END THROUGH SHROUD
FIGURE 11 - S H R O U D R E M O V E D F R O M TOOL PINS
All Ethernet cables for connections between modules are recommended t o b e
shielded. Failure to use shielded cables may result in data loss and
unexpected results. Shown above are Ethernet cables with sealing shrouds
required for IP54 compliance.

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ConveyLinx-IO User’s Guide
Publication ERSC-1008 Rev 1.1 – October 2017
POWER CONNECTIONS
IP54INSTALLATION
Item 17 as depicted in Figure 2 may be unattached to the module when shipped and are included in the module’s
shipping box. These items are used to maintain an IP54 installation of the power and Ethernet wiring.
Power wires are fed through the
protective shroud (Item 17). The
wire terminals are standard cage-
clamp style.
Once wiring has been completed
the power wiring compartment is
then sealed by snapping into place
the Power Compartment Cover
(Item 18).
LOGICAND OUTPUTPOWER
The ConveyLinx IO module is designed to allow for separate power connections for module logic and digital
outputs power so that these can be powered by separate power supplies. For example, the digital outputs powe r
supply can switched off by anemergencystopcontrolsystemsothatalloutput devices have power removed.
With the outputs power separately switched off; the logic power supply can remain on so that the module’s
communications can remain active and report status to networked supervisory control system(s). Figure 13 shows
a diagram for separate logic and MDR power supplies and Figure 12 showsadiagramforasinglepower supply for
both logic and MDR power. Note that powering the Outputs terminal also powers the Logic.