Pulseroller ConveyLinx-Ai2 User manual

ConveyLinx-Ai2 User's
Guide
Version 1.7 — Aug 20, 2020
opyright © 2020 PULSEROLLER

Table of Contents
1. About This Manual ................................................................................................................................. 3
2. Glossary of Terms .................................................................................................................................. 5
3. Getting Started ....................................................................................................................................... 8
4. Module Hardware.................................................................................................................................. 10
4.1. Identifying Module omponents .................................................................................................... 11
4.2. Mounting Dimensions.................................................................................................................... 13
4.3. Motor Ports ................................................................................................................................... 15
4.4. Sensor Ports ................................................................................................................................. 16
4.4.1. Electrical onnections for Sensor Port Aux I/O ..................................................................... 17
4.5. Ethernet Ports ............................................................................................................................... 19
4.6. Power onnections ....................................................................................................................... 21
4.7. Power Supply Sizing ..................................................................................................................... 25
4.8. LED Status Indicators.................................................................................................................... 26
4.9. Technical Specifications................................................................................................................ 29
5. Auto-Configuration............................................................................................................................... 35
5.1. Device onnections to Modules .................................................................................................... 36
5.1.1. Examples that will generate errors ........................................................................................ 38
5.2. Motor Rotation Definition............................................................................................................... 39
5.3. Node onnections for a Subnet..................................................................................................... 40
5.4. Installing EasyRoll......................................................................................................................... 42
5.5. onveyLinx Ethernet Definition ..................................................................................................... 43
5.6. onnecting Your P to the Network .............................................................................................. 45
5.7. Auto- onfiguration Procedure ....................................................................................................... 46
5.8. Expected Results .......................................................................................................................... 52
5.9. What to do if things go wrong ........................................................................................................ 54
6. Default Settings and Operation ........................................................................................................... 55
6.1. Singulation Release Mode............................................................................................................. 56
6.2. Flex Zone Recognition .................................................................................................................. 57
6.3. Jam onditions ............................................................................................................................. 59
6.3.1. Arrival Jam............................................................................................................................ 60
6.3.2. Sensor Jam........................................................................................................................... 62
6.4. Automatic Module Replacement .................................................................................................... 64
6.5. Reset to Factory Default Settings .................................................................................................. 66
7. EasyRoll Software ................................................................................................................................ 68
7.1. Main Screen.................................................................................................................................. 69
7.1.1. Node Navigation ................................................................................................................... 71

7.1.2. Node Identification ................................................................................................................ 72
7.1.3. ZPA Upstream/Downstream Zone Settings ........................................................................... 73
7.1.3.1. Release Mode .............................................................................................................. 74
7.1.3.1.1. Singulation Release.............................................................................................. 75
7.1.3.1.2. Train Release ....................................................................................................... 76
7.1.3.1.3. GAP Train Release............................................................................................... 77
7.1.3.2. T-Zone Settings ............................................................................................................ 78
7.1.3.3. ZPA Error and Information ............................................................................................ 81
7.1.3.4. Accumulate ontrol from Main Screen .......................................................................... 82
7.1.3.5. Settings heckboxes .................................................................................................... 83
7.1.3.5.1. Disable Reset Delays ........................................................................................... 84
7.1.3.5.2. Disable Sensor Jam Auto lear ............................................................................ 85
7.1.3.5.3. Disable Arrival Timeout ........................................................................................ 86
7.1.3.5.4. Disable Manual Operation .................................................................................... 87
7.1.4. Motor Settings....................................................................................................................... 89
7.1.4.1. Motor Type ................................................................................................................... 90
7.1.4.2. Brake Method ............................................................................................................... 91
7.1.4.3. Speed........................................................................................................................... 92
7.1.4.4. Rotation Direction ......................................................................................................... 94
7.1.4.5. Acceleration/Deceleration ............................................................................................. 95
7.1.4.6. Motor Jog and Error Indicators...................................................................................... 96
7.1.5. Diagnostic Window ............................................................................................................... 99
7.2. Advanced Dialog ......................................................................................................................... 101
7.2.1. Look Ahead and Timing Tab ............................................................................................... 102
7.2.1.1. Look Ahead Slowdown Feature .................................................................................. 103
7.2.1.2. Jam & Auto lear Timers ............................................................................................ 106
7.2.1.3. Run After Time/Distance............................................................................................. 107
7.2.1.4. Induct Forward Time/Distance .................................................................................... 109
7.2.1.5. Sensor Debounce ....................................................................................................... 111
7.2.2. Upgrade Tab....................................................................................................................... 113
7.2.3. onnections Tab................................................................................................................. 116
7.2.4. Network Services Tab ......................................................................................................... 119
7.2.4.1. Discover & IP Address Set.......................................................................................... 120
7.2.4.2. Backup & Restore....................................................................................................... 123
7.2.5. Special Services Tab .......................................................................................................... 126
7.2.6. Flex Zone Tab..................................................................................................................... 128
7.2.7. Sensors Tab ....................................................................................................................... 131
7.2.8. Extensions Tab ................................................................................................................... 132
7.2.9. Pin 2 Usage Tab ................................................................................................................. 136
7.2.9.1. Most Downstream Zone .............................................................................................. 137
7.2.9.2. Most Upstream Zone .................................................................................................. 138
7.2.9.3. Accumulate Intermediate Zone ................................................................................... 139

7.2.9.4. Lane Full Interface...................................................................................................... 141
7.2.9.5. Most Upstream Zone Handshake Interlock.................................................................. 142
7.2.9.6. Most Downstream Zone Handshake Interlock ............................................................. 144
7.2.9.7. Inverting the Pin 2 Signals .......................................................................................... 145
8. IOX Interface Module .......................................................................................................................... 146
8.1. Wake up and/or Lane Full Interface............................................................................................. 148
8.2. Wake up/Lane Full with Wired Terminals..................................................................................... 149
8.3. Wake up/Lane Full with Discrete Signals..................................................................................... 150
8.4. Wake up/Product on Zone Handshake Interlock .......................................................................... 151
8.5. Downstream/Product on Zone Handshake Interlock .................................................................... 152
8.6. Pin 2 Output on Aux I/O M8......................................................................................................... 153
8.7. Pin 2 Output on Wired Terminals................................................................................................. 154

1. About This Manual
Symbol Conventions
Important User Information
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
*
Modules contain ESD (Electrostatic Discharge) sensitive parts and components. Static
control precautions are required when installing, testing, servicing or replacing these
modules. omponent 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, Pulseroller does not assume responsibility or
liability (to include intellectual property liability) for actual use based on the examples shown
in this publication
!
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Not Included in this Manual
How to Contact Us
Technical Support North & South America: [email protected]
Sales Support North & South America: [email protected]
Technical Support Global: [email protected]
Sales Support Global: [email protected]
Web Site: www.pulseroller.com
Last modified: Aug 14, 2020
Reproduction of the contents of this manual, in whole or in part, without written permission
of Pulseroller is prohibited
!
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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2. Glossary of Terms
Term Definition
Carton A separate (usually wrapped or boxed) object to be transported by the conveyor. The
terms tray, tote, load, or product may also be used interchangeably in this document.
ConveyLinx onveyor controls architecture based upon modular distributed devices connected via
Ethernet network.
ConveyLinx-Ai /
ConveyLinx-Ai2
onveyor control module that is part of the onveyLinx family. Each module can
accommodate up to 2 MDR conveyor zones. The modules allow connection for
Senergy-Ai platform motor rollers and gear drives. The term Module will be used within
this document and will refer to the onveyLinx-Ai2 device
DHCP
Dynamic Host onfiguration Protocol A protocol for assigning IP addresses to devices
on a network from a pool of available IP’s. A dynamic IP address changes each time the
device connects to the network
ERSC
Ethernet Roller Speed ontrol module – onveyor control module that is part of the
onveyLinx family. Each ERS can accommodate up to 2 MDR conveyor zones. In this
document the term module will be synonymous with ERS
ERSC-SE4
Designed to “break-out” the RJ11 connection for easy installation. The module has an
amplifier to the output giving it up to 100mA output capabilities. onfigurable diodes for
the inputs to minimize leakage current to and from the ERS . Module also allows for
external power source connection for auxiliary devices.
Hall Effect Sensor Special sensor embedded within the brushless D motor of an MDR used to provide
motor rotor position feedback to the motor controller
IP54
The IP ode (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
JST
This is the name of a particular connector manufacturer that produces a specific plug/
socket arrangement for MDR connection to control cards. This name is accepted within
the conveyor and MDR industry as a simple description of the particular socket style
used on ERS hardware.
LED Light Emitting Diode – In the context of this document, LED’s are used on the
onveyLinx-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 reflected light. A photo-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
M8 This is the type of a connector, which has four connector pins and is used on the
onveyLinx Ai2 modules for both sensor connectors and MDR connectors
MDR Motorized Drive Roller or Motor Driven Roller – Brushless D motor and gearbox
assembly integrated into a single conveyor roller
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Normally Open /
Normally Closed
ontrol 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. onversely
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
Electronics term that indicates the type of transistor circuit used for a logical input or
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 carton
on the zone
PLC Programmable Logic ontroller – 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 the onveyLinx controller to MDR
Retro-reflective /
Reflex
Term used to describe the two basic types of photo-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.
RJ-11 / RJ-12
Registered Jack Style 11 / 12 – Standard connector / receptacle format utilizing 4 or 6
pin connections. The typical standard connection for telephones. RJ-11 utilizes 4 pins
and RJ-12 utilizes 6 pins but both styles use the same physical size.
RJ-45 Registered Jack Style 45 – Standard connector / receptacle format utilizing 8 pin
connections. The typical standard for computer network cable connections
Senergy-Ai
PulseRoller brand proprietary motor control platform that provides electronic intelligence
inside the motor that can be read by onveyLinx-Ai and onveyLinx-Ai2 control
modules. The connection from the motor to the controller is via 4-Pin M8 style connector
Singulation
Release
onveyor control method for zoned controlled conveyor that dictates that when a zone
is discharging its carton, the upstream carton waiting to enter must wait until the
discharged carton is completely clear before it is allowed to enter
Slave Rollers
A set of non-motorized conveyor rollers mechanically linked to an MDR. The MDR 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 ontrol Protocol / Internet Protocol – IP is the protocol which oversees the
transmission of information packets from device to device on an Ethernet network. T P
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
T P/IP.
Train Release onveyor control method for zone configured conveyor that dictates that when a zone is
discharging, the upstream zone’s carton can move in unison with the discharging carton.
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Zone A basic (linear or curved) cell of the conveyor consisting of a set of slave rollers driven
by 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
Last modified: Aug 15, 2020
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3. Getting Started
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
Who Should Use this Manual?
This manual is intended for users who need basic product information and simple application procedures to
implement 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.
What do you want to do?
The Basics
Learn about module hardware ports
Learn about power supply sizing
How to Auto-Configure your network of modules
Find out about what all the LED states mean
Learn about the different release modes and how to change them
Learn about Flex Zone
Learn about jam conditions
How to reset a module back to factory default
How to wire up a Wake Up interlock
How to wire up a Lane Full Interlock
How to Auto-Replace a module
Basic things you can do with EasyRoll
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Learn about basic navigation through EasyRoll
Learn about ZPA settings and how to change them
How to change motor direction, speed, accel/decel, etc.
Learn about motor status and error indicators
How to change Jam Timers and Auto-Clear Timers
How to change how the module logic uses the block/clear output from your
sensors
How to change your Aux I/O Pins to match the signals you are using
Some advanced things you can do with EasyRoll
Learn how to discover modules on your network and change IP addresses
How to set up Look Ahead Slow Down feature
How to disable Flex Zone Recognition and why you may want to
How to set up an Extension or slave module
How to connect two separate networks together to operate in ZPA
How to backup and restore module settings
How to upgrade module firmware
Last modified: Aug 04, 2020
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4. Module Hardware
Ai2 Modules are designed to be installed and integrated into the conveyor’s mechanical side frame
assembly. The Ai2 Module is a controller for up to 2 Motorized Drive Roller (MDR) conveyor zones. Each
Ai2 Module 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.
Learn more:
Identifying Ai2 Module Components
Mounting Dimensions
Motor Ports
Sensor Ports
Ethernet Ports
Power Connections
Power Supply Sizing
LED Status Indicators
Technical Specifications
Last modified: Aug 18, 2020
The “left” and “right” naming convention for the module ports is based upon facing the front
of the Ai2 Module and is not to be confused with direction of product flow on the conveyor.
Product flow will be designated as “upstream” and “downstream”
*
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4.1. Identifying Module Components
Item Description
24VD Power Terminals with separate connections for Logic and Motors
&Motor Left LED & Motor Right LED – Motor status indicators
&Left Sensor & Right Sensor Status LED Indicators
Module Status LED Indicator
Module Power LED Indicator
&Motor Left and Motor Right Port – 4-pin M8 style connector for MDR connection
&
Sensor Left and Sensor Right Port – M8 style connector for zone photo-sensor
connection
Removable IP54 Power ompartment over
Module Replacement Button
&
Link Left and Link Right – RJ-45 style Ethernet network connection between modules
including LED Indicators
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Removable IP54 Ethernet RJ-45 Port ompartment over – Left and Right
*IP54 Protection Shrouds for Ethernet cabling and power wiring
• Indicates items shipped unattached to the modue but are included in the module’s box
Last modified: Jul 21, 2020
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4.2. Mounting Dimensions
Mounting Hole Dimensions
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Last modified: Jul 20, 2020
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M8 4 Pin Male Motor Port with Senergy Ai Motor Female Connector
4.3. Motor Ports
Both ports utilize a 4-pin M8 male receptacle. Each receptacle is mechanically keyed to assure proper
orientation upon plugging in.
Last modified: Aug 04, 2020
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4.4. Sensor Ports
Each sensor port is a standard M8 Female receptacle with standard pin-out:
Pin Signal Description
1 24VD Module’s 24VD Supply
2 Aux I/O I/O Signal – Input or Output Function configured with EasyRoll software
3 GND Module’s D ommon
4 Sensor Signal Logical Input for Sensor’s state output – Auto detect for NPN or PNP
Last modified: Aug 05, 2020
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4.4.1. Electrical Connections for Sensor Port
Aux I/O
When connecting to either Sensor port with an M8 connector to access Pin 2 signal; you typically will use a
standard parallel type splitter cable assembly that breaks out each of the available pins on the Module to
their own M8 connection port. These splitter cables wire the +24V and ommon connections in parallel
Typical Parallel Splitter Cable Usage
Aux I/O Pin 2 as Input
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.
Splitter cables are commercially available from multiple sources. lick here for information
for Pulseroller IOX-2 Breakout/Splitter Module
*
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Aux I/O Pin 2 Input Connection Diagram
Aux I/O Pin 2 as Output
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)
Aux I/O Pin 2 Output Connection Diagram
Last modified: Aug 18, 2020
Because the auto-sensing circuit requires a nominal voltage in order to operate, there will
be some small amount of leakage current possible between Module Pin 2 and Pin 3 (GND).
Please use caution if you connect a load between Module Pin 2 and Pin 3.
!
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