Software example function blocks Prorunner mk5 - SIEMENS

SIEMENS example software function blocks

PRORUNNER mk5 with

encoder

Printing date : 3 februari 2022

Version : 4.5.1
Author : B. Jansen

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Software function blocks Prorunner mk5 - SIEMENS

1 Version control

Tabel 01: Version control

Revision Date Author Order number Reason for revision
1.0 19-10-2017 BJA Q17150 Initial preparation of description
1.1 19-3-2018 BJA Q18150 Amendment of description of
operation & sensors
- Prorunner mk5
Added conveyors
- Infeed conveyor RDC2
- Infeed conveyor RDC4
- Outfeed conveyor RDC2
- Outfeed conveyor MBC4
1.2 27-7-2018 BJA Q18150 Update with newest electrical
drawings
4.0 29-10-2018 BJA Q18150 Update encoder functionality
and trace functions
Update to V4.0 after internal
discussions.
4.1 05-02-2019 BJA Q19150 Update configuration of mk5
prorunner
Added checklist for
measurements configuration
and motor nameplate
Added outfeed conveyor RDC4
4.2 18-03-2020 GVI Q19150 -Fixed minor issue in speed
calculation.
- Added support for Interrol
Rollerdrive EC5000.
- Software now outputs
maintance status (Paragraph
6.10).
- minor improvements in
function description
4.3 07-12-2020 GVI Q19150 -Updated to TIA v15.1
-Updated reference offset
calculation due to change of
reference sensor position
- Fixed minor issue in empty
mode
-Minor improvements
4.4 29-04-2020 GVI Q19150 -Improvement in calculation of
infeed window
-Added RDC3 in- and outfeed
module example (still untested)
-Added GC1 in- and outfeed
module example (still untested)

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Software function blocks Prorunner mk5 - SIEMENS

4.5 08-12-2021 GVI/BJA Q19150 - Updates after feedback from

QS212382 (see changelogs for
more info)
- Merged Prmk5 standard and
Prmk5 encoder version in 1
project
- Added MBC4 infeed module
example (still untested)
4.5.1 25-01-2022 GVI Q19150 - Added description for MBC2 in
the RDC2 part of the
documentation and software

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Software function blocks Prorunner mk5 - SIEMENS

2 Table of contents

1 Version control.......................................................................................................................... 2
2 Table of contents ...................................................................................................................... 4
3 Introduction .............................................................................................................................. 9
3.1 Function of the document .............................................................................................. 9
3.2 Target audience ............................................................................................................... 9
3.3 Configuration sheet ....................................................................................................... 10
4 System description ................................................................................................................. 11
4.1 Basic operation of the Prorunner mk5.......................................................................... 11
4.2 Module description Prorunner mk5 ............................................................................. 13
4.3 Level determination modules Prorunner mk5 .............................................................. 15
4.4 Positioning of carriers Prorunner mk5 .......................................................................... 16
4.4.1 Encoder functionality ........................................................................................ 16
4.4.2 Carrier reference position ................................................................................. 17
4.4.3 Carrier in area of infeed module ....................................................................... 17
4.4.4 Carrier in area of outfeed module .................................................................... 18
4.4.5 Carrier in the area stop in the event of faults/blockages.................................. 18
4.4.6 Carrier in data transfer area .............................................................................. 19
4.5 Starting conveyor run Prorunner mk5 .......................................................................... 20
4.5.1 Transport by infeed module .............................................................................. 20
4.5.2 Transport by outfeed module ........................................................................... 22
4.6 Initialisation Prorunner mk5 ......................................................................................... 24
4.6.1 Flowchart initialisation Prorunner mk5 ............................................................ 25
4.7 Communication modules Prorunner mk5..................................................................... 26
4.7.1 Flow chart communication Prorunner mk5 ...................................................... 27
4.8 Chain stretch Prorunner mk5 ........................................................................................ 28
5 Hardware configuration .......................................................................................................... 29
5.1 Supported PLC types ..................................................................................................... 29
5.2 Cycle time ...................................................................................................................... 29
5.3 TIA Portal version .......................................................................................................... 29
6 Function block main module Prorunner mk5......................................................................... 30
6.1 Function block specifications ........................................................................................ 31
6.2 Flow chart Functionality main module ......................................................................... 32
6.3 Components main module Prorunner mk5 .................................................................. 33
6.4 Configuration main module Prorunner mk5 ................................................................. 34
6.5 Inputs main module Prorunner mk5............................................................................. 35
6.6 Outputs main module Prorunner mk5 .......................................................................... 36
6.7 Motor interface main module Prorunner mk5 ............................................................. 36
6.8 Status main module Prorunner mk5 ............................................................................. 37
6.9 Faults main module Prorunner mk5 ............................................................................. 38
6.10 Maintenance Prorunner mk5 ........................................................................................ 39
7 Function block encoder Prorunner mk5................................................................................. 40
7.1 Function block specifications ........................................................................................ 40
7.2 Flowchart diagram encoder .......................................................................................... 41
7.3 Inputs encoder .............................................................................................................. 42

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Software function blocks Prorunner mk5 - SIEMENS

7.4 Interfaces encoder ........................................................................................................ 43

8 Function block infeed module RDC2/MBC2 ........................................................................... 44
8.1 Function block specifications infeed module RDC2/MBC2 ........................................... 44
8.2 Components infeed module RDC2/MBC2..................................................................... 45
8.3 Flow chart functionality infeed module RDC2/MBC2 ................................................... 47
8.4 Configuration infeed module RDC2/MBC2 ................................................................... 48
8.5 Inputs infeed module RDC2/MBC2 ............................................................................... 49
8.6 Outputs infeed module RDC2/MBC2 ............................................................................ 49
8.7 Motor interface infeed module RDC2/MBC2................................................................ 50
8.8 Status infeed module RDC2/MBC2 ............................................................................... 50
8.9 Faults infeed module RDC2/MBC2 ................................................................................ 51
9 Function block infeed module RDC3 ...................................................................................... 53
9.1 Function block specifications infeed module RDC3 ...................................................... 54
9.2 Components infeed module RDC3 ................................................................................ 55
9.4 Flow chart functionality infeed module RDC3 .............................................................. 56
9.5 Configuration infeed module RDC3 .............................................................................. 57
9.6 Inputs infeed module RDC3 .......................................................................................... 58
9.7 Outputs infeed module RDC3 ....................................................................................... 59
9.8 Motor interface infeed module RDC3 ........................................................................... 59
9.9 Status infeed module RDC3........................................................................................... 60
9.10 Faults infeed module RDC3 ........................................................................................... 61
10 Function block infeed module RDC4 ...................................................................................... 63
10.1 Function block specifications infeed module RDC4 ...................................................... 64
10.2 Components infeed module RDC4 ................................................................................ 65
10.4 Flow chart functionality infeed module RDC4 .............................................................. 66
10.5 Configuration infeed module RDC4 .............................................................................. 67
10.6 Inputs infeed module RDC4 .......................................................................................... 68
10.7 Outputs infeed module RDC4 ....................................................................................... 69
10.8 Motor interface infeed module RDC4 ........................................................................... 69
10.9 Status infeed module RDC4........................................................................................... 70
10.10 Faults outfeed module RDC4 ........................................................................................ 71
11 Function block infeed module MBC4 ..................................................................................... 73
11.1 Function block specifications infeed module MBC4 ..................................................... 74
11.2 Components infeed module MBC4 ............................................................................... 75
11.3 Configuration infeed module MBC4 ............................................................................. 76
11.4 Inputs infeed module MBC4 ......................................................................................... 77
11.5 Outputs infeed module MBC4 ...................................................................................... 78
11.6 Motor interface infeed module MBC4 .......................................................................... 78
11.7 Status infeed module MBC4.......................................................................................... 79
11.8 Faults infeed module MBC4 .......................................................................................... 80
12 Function block outfeed module RDC2/MBC2 ........................................................................ 82
12.1 Function block specifications outfeed module RDC2/MBC2 ........................................ 83
12.2 Components outfeed module RDC2/MBC2 .................................................................. 84
12.3 Flow chart functionality outfeed module RDC2/MBC2 ................................................ 86
12.4 Configuration outfeed module RDC2/MBC2................................................................. 87
12.5 Inputs outfeed module RDC2/MBC2 ............................................................................ 88
12.6 Outputs outfeed module RDC2/MBC2 ......................................................................... 88

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Software function blocks Prorunner mk5 - SIEMENS

12.7 Motor interface outfeed module RDC2/MBC2 ............................................................. 89

12.8 Status outfeed module RDC2/MBC2 ............................................................................. 89
12.9 Faults outfeed module RDC2/MBC2 ............................................................................. 90
13 Function block outfeed module RDC3 .................................................................................... 92
13.1 Function block specifications outfeed module RDC4 ................................................... 93
13.2 Components outfeed module RDC4 ............................................................................. 94
13.4 Flow chart functionality outfeed module RDC3............................................................ 95
13.5 Configuration outfeed module RDC3 ............................................................................ 96
13.6 Inputs outfeed module RDC3 ........................................................................................ 97
13.7 Outputs outfeed module RDC3 ..................................................................................... 98
13.8 Motor interface infeed module RDC3 ........................................................................... 98
13.9 Status outfeed module RDC3 ........................................................................................ 99
13.10 Faults outfeed module RDC3 ...................................................................................... 100
14 Function block outfeed module RDC4 .................................................................................. 102
14.1 Function block specifications outfeed module RDC4 ................................................. 103
14.2 Components outfeed module RDC4 ........................................................................... 104
14.4 Flow chart functionality outfeed module RDC4.......................................................... 105
14.5 Configuration outfeed module RDC4 .......................................................................... 106
14.6 Inputs outfeed module RDC4 ...................................................................................... 107
14.7 Outputs outfeed module RDC4 ................................................................................... 108
14.8 Motor interface infeed module RDC4 ......................................................................... 108
14.9 Status outfeed module RDC4 ...................................................................................... 109
14.10 Faults outfeed module RDC4 ...................................................................................... 110
15 Function block outfeed module MBC4 ................................................................................. 112
15.1 Function block specifications outfeed module MBC4 ................................................ 113
15.2 Components outfeed module MBC4 .......................................................................... 114
15.4 Flow chart functionality outfeed module MBC4......................................................... 115
15.5 Configuration outfeed module MBC4 ......................................................................... 116
15.6 Inputs outfeed module MBC4 ..................................................................................... 117
15.7 Outputs outfeed module MBC4 .................................................................................. 118
15.8 Motor interface outfeed module MBC4 ..................................................................... 118
15.9 Status outfeed module MBC4 ..................................................................................... 119
15.10 Faults outfeed module MBC4 ..................................................................................... 120
16 Motor interface .................................................................................................................... 122
17 Checklist prorunner configuration........................................................................................ 123
18 Checklist motor configuration .............................................................................................. 124

Figuur 01: Main module Prorunner mk5........................................................................................ 13

Figuur 02: Sub-module(s) Prorunner mk5...................................................................................... 14
Figuur 03: Level determination Prorunner mk5 ............................................................................. 15
Figuur 04: Carrier reference position ............................................................................................. 17
Figuur 05: Carrier in area of infeed module ................................................................................... 17
Figuur 06: Function block main module......................................................................................... 30
Figuur 07: Components Prorunner mk5 (Main module) ............................................................... 33
Figuur 08: Function block infeed module RDC2/MBC2 ................................................................. 44
Figuur 09: Components infeed module RDC2 ................................................................................ 45

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Software function blocks Prorunner mk5 - SIEMENS

Figuur 10: Components infeed module MBC2 ............................................................................... 45

Figuur 11: Function block infeed module RDC3 ............................................................................. 53
Figuur 12: Components infeed module RDC3 ................................................................................ 55
Figuur 13: Function block infeed module RDC4 ............................................................................. 63
Figuur 14: Components infeed module RDC4 ................................................................................ 65
Figuur 15: Components infeed module RDC4 ................................................................................ 75
Figuur 16: Function block outfeed module RDC2/MBC2 ............................................................... 82
Figuur 17: Components outfeed module RDC2 ............................................................................. 84
Figuur 18: Function block outfeed module RDC3 .......................................................................... 92
Figuur 19: Components outfeed module RDC4 ............................................................................. 94
Figuur 20: Function block outfeed module RDC4 ........................................................................ 102
Figuur 21: Components outfeed module RDC4 ........................................................................... 104
Figuur 22: Function block outfeed module MBC4 ....................................................................... 112
Figuur 23: Components outfeed module MBC4 .......................................................................... 114

Tabel 01: Version control ................................................................................................................ 2

Tabel 02: PLC types ....................................................................................................................... 29
Tabel 03: Components main module............................................................................................ 33
Tabel 04: Configuration main module .......................................................................................... 34
Tabel 05: Inputs main module Prorunner mk5............................................................................. 35
Tabel 06: Outputs main module Prorunner mk5 .......................................................................... 36
Tabel 07: Motor interface main module Prorunner mk5 ............................................................. 36
Tabel 08: Status main module Prorunner mk5 ............................................................................. 37
Tabel 09: Faults list main module Prorunner mk5 ........................................................................ 38
Tabel 10: Inputs encoder Prorunner mk5 ..................................................................................... 42
Tabel 11: Interface encoder Prorunner mk5 ................................................................................ 43
Tabel 12: Components infeed module RDC2 ................................................................................ 46
Tabel 13: Components infeed module MBC2 ............................................................................... 46
Tabel 14: Configuration infeed module RDC2/MBC2 ................................................................... 48
Tabel 15: Inputs infeed module RDC2/MBC2 ............................................................................... 49
Tabel 16: Outputs infeed module RDC2 ....................................................................................... 49
Tabel 17: Motor interface infeed module RDC2 ........................................................................... 50
Tabel 18: Status infeed module RDC2/MBC2 ............................................................................... 50
Tabel 19: Faults list infeed module RDC2/MBC2 .......................................................................... 51
Tabel 20: Components infeed module RDC4 ................................................................................ 55
Tabel 21: Configuration infeed module RDC3 .............................................................................. 57
Tabel 22: Inputs infeed module RDC3 .......................................................................................... 58
Tabel 23: Outputs infeed module RDC3 ....................................................................................... 59
Tabel 24: Motor interface infeed module RDC3 ........................................................................... 59
Tabel 25: Status infeed module RDC3........................................................................................... 60
Tabel 26: Faults list infeed module RDC3 ..................................................................................... 61
Tabel 27: Components infeed module RDC4 ................................................................................ 65
Tabel 28: Configuration infeed module RDC4 .............................................................................. 67
Tabel 29: Inputs infeed module RDC4 .......................................................................................... 68
Tabel 30: Outputs infeed module RDC4 ....................................................................................... 69
Tabel 31: Motor interface infeed module RDC4 ........................................................................... 69
Tabel 32: Status infeed module RDC4........................................................................................... 70
Tabel 33: Faults list infeed module RDC4 ..................................................................................... 71
Tabel 34: Components infeed module RDC4 ................................................................................ 75

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Software function blocks Prorunner mk5 - SIEMENS

Tabel 35: Configuration infeed module MBC4 ............................................................................. 76

Tabel 36: Inputs infeed module MBC4 ......................................................................................... 77
Tabel 37: Outputs infeed module MBC4 ...................................................................................... 78
Tabel 38: Motor interface infeed module MBC4 .......................................................................... 78
Tabel 39: Status infeed module MBC4.......................................................................................... 79
Tabel 40: Faults list infeed module MBC4 .................................................................................... 80
Tabel 41: Components outfeed module RDC2 ............................................................................. 84
Tabel 42: Components outfeed module MBC2 ............................................................................ 85
Tabel 43: Configuration outfeed module RDC2/MBC2................................................................. 87
Tabel 44: Inputs outfeed module RDC2/MBC2 ............................................................................ 88
Tabel 45: Outputs outfeed module RDC2/MBC2 ......................................................................... 88
Tabel 46: Motor interface outfeed module RDC2/MBC2 ............................................................. 89
Tabel 47: Status outfeed module RDC2/MBC2 ............................................................................. 89
Tabel 48: Faults list outfeed module RDC2/MBC2 ....................................................................... 90
Tabel 49: Components infeed module RDC3 ................................................................................ 94
Tabel 50: Configuration outfeed module RDC3 ............................................................................ 96
Tabel 51: Inputs outfeed module RDC3 ........................................................................................ 97
Tabel 52: Outputs outfeed module RDC3 ..................................................................................... 98
Tabel 53: Motor interface infeed module RDC3 ........................................................................... 98
Tabel 54: Status outfeed module RDC3 ........................................................................................ 99
Tabel 55: Faults list outfeed module RDC3 ................................................................................. 100
Tabel 56: Components infeed module RDC4 .............................................................................. 104
Tabel 57: Configuration outfeed module RDC4 .......................................................................... 106
Tabel 58: Inputs outfeed module RDC4 ...................................................................................... 107
Tabel 59: Outputs outfeed module RDC4 ................................................................................... 108
Tabel 60: Motor interface infeed module RDC4 ......................................................................... 108
Tabel 61: Status outfeed module RDC4 ...................................................................................... 109
Tabel 62: Faults list outfeed module RDC4 ................................................................................. 110
Tabel 63: Components outfeed module MBC4 .......................................................................... 114
Tabel 64: Configuration outfeed module MBC4 ......................................................................... 116
Tabel 65: Inputs outfeed module MBC4 ..................................................................................... 117
Tabel 66: Outputs outfeed module MBC4 .................................................................................. 118
Tabel 67: Motor interface outfeed module MBC4 ..................................................................... 118
Tabel 68: Status outfeed module MBC4 ..................................................................................... 119
Tabel 69: Faults list outfeed module MBC4 ................................................................................ 120
Tabel 70: Motor control interface incoming commands  UDT_Motorcontrol_Status........... 122
Tabel 71: Motor control interface outgoing commands  UDT_Motorcontrol_Command .... 122
Tabel 72: Checklist heights ......................................................................................................... 123
Tabel 73: Checklist motor nameplate ......................................................................................... 124

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Software function blocks Prorunner mk5 - SIEMENS

3 Introduction

Read this chapter carefully before commissioning the software for the Prorunner mk5.

3.1 Function of the document

This document attempts to clarify the functionality, operation and components of the Prorunner
mk5 for the purpose of commissioning the software function blocks.

3.2 Target audience

This document is intended for technical staff/engineers with knowledge of SIEMENS PLC
programming.

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Software function blocks Prorunner mk5 - SIEMENS

3.3 Configuration sheet

The Qimarox configuration sheet has an option to produce a PDF document containing all required
settings (Example is showed below)

If you don’t have this document, please contact Qimarox using the following email address
[email protected]; Please also mention the Qimarox serial number in the mail

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Software function blocks Prorunner mk5 - SIEMENS

4 System description

This chapter describes the system description of the Prorunner mk5.

Please read this carefully to get a clear picture of what the software function block supports.

4.1 Basic operation of the Prorunner mk5

The position of the carriers of the Prorunner mk5 are tracked precisely by means of an encoder.
With each pulse of the encoder, the positions of the carriers are updated with the calculated
distance travelled per pulse.
Before you can work with the Prorunner, you must complete the initialisation procedure. This puts
all infeed/outfeed modules in a safe/base position. After that, it is checked whether all carriers are
present, and their position is determined again.

In automatic mode, Prorunner runs continuously, provided no input/output conveyor blocks the
process.

As soon as a carrier enters the area of an infeed conveyor and the carrier is empty, the feeding in of
an object can start; this is only done if there is an object present on the infeed conveyor. The
Prorunner tells the infeed conveyor how much time is still available to start and complete the
infeed process. If the available time is greater than the time required, the infeed may start. As soon
as the infeed cycle starts the infeed conveyor will inform the Prorunner, this is done by handshake
commands.

When the infeed run is completed, information is made available by the infeed conveyor. This
information includes information relating to the desired discharge/outfeed level and other
customer-specific information.
If the infeed cycle takes too long, the Prorunner will stop rotating.

1. Previous carrier is above object height

4. Object picked up.

Destination and
information shall be
linked to carrier.

2. Object is 3. Start feeding

ready in when next carrier
is empty

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 Software function blocks Prorunner mk5 - SIEMENS

This information is pushed along by the Prorunner until the desired discharge level is reached and
there, too, this information is made available by the Prorunner to the outfeed transport module.

1. New carrier enters area of outfeed module

1. Previous carrier has passed

3. Conveyor is
2. Conveyor ready 4. Transport
may start object once
movement carrier has
passed

As soon as a carrier enters the area of an outfeed level, and the object on the carrier is also
destined for this level, the available time will be shared by the Prorunner.
The outfeed transport module can start its cycle if the available time is greater than the required
time. As soon as the outfeed transport module detects the object, it will make the information
available to the downstream transport. The outfeed module will start feeding the object out. This
must be completed before the next carrier enters the hazardous area, if its not completed the
Prorunner will stop rotating.

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Software function blocks Prorunner mk5 - SIEMENS

4.2 Module description Prorunner mk5

The software is made up of modules.

There is the main module and at least 2 sub-modules, of which, 1 infeed module and 1 outfeed
module. The main module can work with multiple infeed/outfeed modules.

Figuur 01: Main module Prorunner mk5

Carriers

The function of the main module (Prorunner mk5) is:

- Moving the carriers
- Keeping track of current position of carriers by means of an encoder
- Handling communication with the sub-modules (infeed/outfeed conveyors)
- Protecting the elevator drive Prorunner mk5 + carriers against serious damage

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Software function blocks Prorunner mk5 - SIEMENS

Figuur 02: Sub-module(s) Prorunner mk5

Fixed

Moveable

The function of the sub-module(s) (infeed/outfeed conveyors) is:

- Transporting object to desired position
- Handling communication with the main module
- Securing and monitoring its movements and conveyor runs
- Handling communication with upstream/downstream control systems / installations

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 Software function blocks Prorunner mk5 - SIEMENS

4.3 Level determination modules Prorunner mk5

Figuur 03: Level determination Prorunner mk5

Outfeed level 3
Infeed level 3

Outfeed level 2
Infeed level 2

Outfeed level 1

Infeed level 1

Infeed/outfeed modules must always be numbered from bottom to top.

Infeed modules are always on one side of the elevator and outfeed modules on the other side.
The transport side can be set for each module. In this case, the following can be set, as shown in the
following figure:

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Software function blocks Prorunner mk5 - SIEMENS

4.4 Positioning of carriers Prorunner mk5

4.4.1 Encoder functionality

To track the position of all carriers Qimarox installs by default a 24VDC encoder from SEW type
name; EI72.
This encoder gives 2 pulses per channel per motor rotation, so in total 4 pulses per motor rotation.
We also use the rising/falling edge detection of the encoder pulses, so we have 8 pulses per motor
rotation.
We choose this encoder because these pulses can still be detected by a normal PLC input without
the need of a special encoder / highspeed counter hardware. This frequency of the encoder is
below 50Hz (20ms) on 1500 rpm.

If you like to use an encoder with higher resolution specifications, you are responsible for the
position tracking and distance per pulse calculation!

A normal pulse train look like listed below;

This is an example of forward movement of the Prorunner

This is an example of backwards movement of the Prorunner

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 Software function blocks Prorunner mk5 - SIEMENS

4.4.2 Carrier reference position

The following figure shows the position at which the carrier is aligned with a fixed (calculated)
reference. When the reference sensor is triggered a fixed offset value is loaded in the carrier
position.
The ‘0’ position is at the heart of the lower chain wheel.
Each carrier is aligned once again after a complete cycle, so the position remains reliable.

Figuur 04: Carrier reference position

Direction of
Direction of
rotation
rotation

Infeed module

Reference position by sensor

‘0’ position carriers

4.4.3 Carrier in area of infeed module

The following figure can be used to determine whether a carrier is within the area of the infeed
module.
If a previous carrier is past the highest product point, the next carrier is made available to the
infeed module, only when it is empty.

Figuur 05: Carrier in area of infeed module

Area previous carrier passed

highest product
khu vực hãng vận chuyển trước đó đã đi qua
Minimum
khoảng cách
spacing
tối thiểu giữa
các sóng between
Carrier in area, ready for infeed
mang carriers
người vận chuyển trong khu vực, sẵn sàng cho việc cung cấp

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Software function blocks Prorunner mk5 - SIEMENS

4.4.4 Carrier in area of outfeed module

The following figure can be used to determine whether a carrier is within the area of the outfeed
module.
If a carrier is past the outfeed module then information has been transferred

Carrier in area
Minimum ready for
spacing outfeeding
người vận chuyển trong khu vực đã sẵn sàng
between cho
carriers Area previous carrier
beyond outfeed module

khu vực nhà cung cấp dịch vụ trước đó

ngoài mô-đun nguồn cấp dữ liệu

4.4.5 Carrier in the area stop in the event of faults/blockages

If a carrier enters the hazardous area at an infeed/outfeed module and there is a blockage/fault,
the carrier must stop. Stopping already happens in the yellow area so that the red area remains
free. This allows the Prorunner mk5 to make a controlled stop.
These areas apply to both manual and automatic mode.

Carrier (controlled)
Stopping area

Area carrier Prorunner

in hazardous area

Carrier (controlled)
Stopping area

If the PRORUNNER mk5 is blocked by a sub-module, Feedback of the following information is

shown; The level number, carrier number is and whether this has been done in manual or
automatic mode.

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 Software function blocks Prorunner mk5 - SIEMENS

4.4.6 Carrier in data transfer area

As soon as the carrier passes the infeed module (yellow area) and the infeed module has an object
ready, the Prorunner will take over information from the infeed module
Information:
- Destination level number
- Source level number
- Installation-dependent information (Optional, to be determined per installation)

Carrier in area of data transfer

&
Command object picked up (if present)

Area carrier still in area

infeed module
Direction of
rotation

As soon as the carrier has deposited/dropped an object onto the outfeed module, information is
transferred when it has passed the outfeed module.
As soon as the outfeed module has copied the information, which is indicated by the
communication interface, the Prorunner will delete the information.

Data transfer:
- Destination level number
- Source level number
- Installation-dependent information (Optional, to be determined per installation)

Direction of
rotation

Area carrier still in area

outfeed module

Carrier in area of data transfer

&
Command object deposited/dropped (if present)

These areas work in both automatic mode and manual mode!

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 Software function blocks Prorunner mk5 - SIEMENS

4.5 Starting conveyor run Prorunner mk5

Starting a conveyor run, through the infeed/outfeed sub-modules, depends on the carrier
availability of both the Prorunner mk5 and the status of the sub-module. Below it is explained for
each module how the availability is determined.

4.5.1 Transport by infeed module

If the infeed module has an object available, it notifies the PRORUNNER mk5 of this by means of the
communication interface. Once the previous carrier is past the point of highest object, the
remaining length/area of the carrier in the area of the infeed module is determined.
An available time is calculated using this remaining spacing between carrier and infeed module.
If the time required for the entire infeed procedure is less than the available time, the infeed
procedure may be started.

Previous carrier past highest

product
Minimum spacing
between carriers
&
Carrier in area of
infeed module Carrier in area available for infeed
module (Provided no object present)

Example:
Minimum length between carriers: 1500mm
Maximum height objects: 400mm
Height of infeed module: 2000mm
Carrier position: 900mm
Speed Prorunner: 0.5m/s

Carrier Prorunner in infeed module area:

Carrier position: < Height of infeed module + Maximum height objects
&
Carrier position > Height of infeed module – (Maximum height objects + Minimum length between
carriers)

Available time:
(Height of infeed module − Carrier position) / Speed Prorunner:
2000 – 900 = 1100 / 0,5 = 2.2s

The available time decreases when the Prorunner moves, until it falls below the required time.
On the next page you can find a trace overview of the availability time recorded on a testing
module.

20
Software function blocks Prorunner mk5 - SIEMENS

Red line = Available time

Blue line = Position of carriers
Green line = Carrier number
Brown line = Carrier passed infeed module

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Software function blocks Prorunner mk5 - SIEMENS

4.5.2 Transport by outfeed module

If the carrier has an object available for the relevant outfeed module, the Prorunner communicates
this through the communication interface to the outfeed module. Once the previous carrier is past
the point of the highest object, the remaining length/area of the carrier within the area of the
outfeed module is determined.
An available time is calculated using this remaining length.
This time does not limit the outfeed module. If an object on the carrier must go to this level, the
carrier will wait for the safe position above the outfeed module if it is not yet ready.
The available time only shows whether the outfeed module can complete its procedure/cycle
without stopping the Prorunner.

Carrier in area available for outfeed

Minimum length
module.
between carriers
&
Carrier in outfeed
module area
Previous carrier beyond outfeed module
and beyond data transfer area

Example:
Minimum length between carriers: 1500mm
Data transfer area: 300mm
Height of infeed module: 8000mm
Carrier position: 6800mm
Speed Prorunner: 0.5m/s

Carrier Prorunner in infeed module area:

Carrier position > Height of infeed module – (Data transfer area − Minimum length between
carriers)
&
Carrier position < Height of infeed module + Data transfer area

Available time:
(Height outfeed module − Carrier position) / Speed Prorunner
8000 – 6800 = 1200 / 0.5 = 2.4s

The available time decreases when the Prorunner moves.

On the next page you can find a trace overview of the availability time recorded on a testing
module.

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Software function blocks Prorunner mk5 - SIEMENS

Red line = Available time

Green line = Position of carriers
Blue line = Carrier number
Brown line = Carrier passed infeed module

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Software function blocks Prorunner mk5 - SIEMENS

4.6 Initialisation Prorunner mk5

To bring the Prorunner mk5 to the basic position and to ensure that the position of all carriers is
reliable, an initialisation procedure must be started.

The initialisation must be carried out:

 Prorunner is switched on.
 Prorunner encoder has proven to be unreliable. Possibilities: Mechanical obstructions,
pulses missed, incorrect follow-up of encoder pulses, distance between carriers does not
correspond to configuration.

During initialisation, all transport conveyors must be empty and in a safe position. This is checked
before the Prorunner can start to run.
Only the fixed outfeed conveyor (level 1) can be used to transport any remaining products out of
the system.

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Software example function blocks Prorunner mk5 - SIEMENS

4.6.1 Flowchart initialisation Prorunner mk5

kiểm tra độ dài chuỗi giữa các tàu sân bay

số lượng người vận chuyển

tổng chiều dài chuỗi đạt được

thủ tục khởi tạo đã hoàn tất

25
Software example function blocks Prorunner mk5 - SIEMENS

4.7 Communication modules Prorunner mk5

To achieve a smooth operation, the main module and sub-modules must communicate with each
other. This is done by means of a communication interface.

See the below for the communication overview.

The main module communicates with the encoder and sub-modules.

There is a separate software block for the encoder. For the encoder it is important that this is called
within certain time limits, otherwise there is a possibility that pulses will be missed. A separate time task
is reserved for this, which ensures that the encoder is called every 2 ms.
Communication runs in both directions between the main module and sub-modules in order to
determine when objects can be fed in and whether outfeed modules are ready to be received.
Different commands are used to monitor whether sub-modules complete everything within time limits;
if not, the main module is stopped.

A sub-module also communicates with the downstream transport system in order to

infeed/outfeed products in a controlled way. This communication also determines which
destination an object has, and it is possible to send information with it.

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Software example function blocks Prorunner mk5 - SIEMENS

4.7.1 Flow chart communication Prorunner mk5

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Software example function blocks Prorunner mk5 - SIEMENS

4.8 Chain stretch Prorunner mk5

The chain type used for the mk5 is subject to a chain stretch. This is caused by wear on the chain
bearings causing play which results in chain elongation.

To compensate for this, it is determined what the actual distance of a complete cycle is and what
the initial total chain length was.
This will produce a chain stretch as a percentage.

Example:
Chain length is originally 6 carriers x 1500mm chain length in between = 9000mm
The encoder counts the actual distance of a complete cycle = 9100mm

Percentage = (9100/9000 – 1/) * 100 = 1.11% stretch

This percentage is offset against the distance travelled per encoder pulse.
With this, the complete round that is made will again correspond to the initial total chain length.

The chain stretch percentage is only calculated when 10 complete rounds have been run. The
calculated percentage is the average of these 10 rounds.

Warning is created when chain stretch reaches > 2,5%

Alarm is created when chain stretch reaches > 5%

4.8. Căng xích Prorunner mk5

Loại xích được sử dụng cho mk5 phải chịu độ giãn của xích. Nguyên nhân là do dây xích bị mòn
vòng bi gây ra hiện tượng ma sát dẫn đến độ giãn dài của xích.
Để bù đắp cho điều này, người ta xác định khoảng cách thực tế của một chu trình hoàn chỉnh là bao nhiêu và
tổng chiều dài chuỗi ban đầu là
Điều này sẽ tạo ra độ giãn của chuỗi theo phần trăm.
Ví dụ:
Chiều dài chuỗi ban đầu là 6 sóng mang x chiều dài chuỗi 1500mm ở giữa = 9000mm
Bộ mã hóa đếm khoảng cách thực tế của một chu trình hoàn chỉnh = 9100mm
Tỷ lệ phần trăm = (9100/9000 – 1/) * 100 = 1,11% độ giãn
Tỷ lệ phần trăm này được bù đắp theo quãng đường di chuyển trên mỗi xung bộ mã hóa.
Với điều này, vòng hoàn chỉnh được thực hiện sẽ lại tương ứng với tổng chiều dài chuỗi ban đầu.
Phần trăm độ giãn của chuỗi chỉ được tính khi đã chạy đủ 10 vòng. Các
tỷ lệ phần trăm được tính là trung bình của 10 vòng này.
Cảnh báo được tạo khi độ giãn xích đạt > 2,5%
Cảnh báo được tạo khi độ giãn xích đạt > 5%

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Software function blocks Prorunner mk5 - SIEMENS

5 Hardware configuration

This chapter describes the hardware used to program/test the software function block.

5.1 Supported PLC types

Tabel 02: PLC types

Type PLC Article number Firmware Required cycle
version time
S7-1200 CPU 1212C DC/DC/DC 6ES7 212-1AE40-0XB0 V4.2 7-8 ms. (10 Max.)
S7-1500 CPU 1513-1 PN 6ES7 513-1AL01-0AB0 V2.1 1-2 ms. (6 Max.)

We recommend a standalone 1200 PLC, where the PLC is assigned to the Prorunner installation.
This to make sure no fluctuations in cycle time can cause

5.2 Cycle time

The required cycle time (see table above) was tested with a setup of 6 racks with 3 infeed modules
and 3 outfeed modules. This time will increase with a configuration of more carriers and sub-
modules and decrease with less.

5.3 TIA Portal version

The software is made in TIA Portal V14 + SP1. This is the minimum version that is needed.
V14 + SP1 supports the use of SCL networks in a LAD function block.

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Software function blocks Prorunner mk5 - SIEMENS

6 Function block main module Prorunner mk5

Figuur 06: Function block main module

With this software block the main module is called that works as described in Chapter 2.

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Software function blocks Prorunner mk5 - SIEMENS

6.1 Function block specifications

Block name: FB_PRORUNNER_mk5_Main

Block number: FB1050
Version: V4.2
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_MotorControl
UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Encoder_Configuration
UDT_Prorunner_mk5_Encoder_Handshake_Command
UDT_Prorunner_mk5_Encoder_Handshake_Status
UDT_Prorunner_mk5_Infeed_Handshake
UDT_Prorunner_mk5_Outfeed_Handshake
Function block call Cyclical (OB1)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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Software example function blocks Prorunner mk5 - SIEMENS

6.2 Flow chart Functionality main module

mạch an
toàn
trạng thái
phần
cứng

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Software example function blocks Prorunner mk5 - SIEMENS

6.3 Components main module Prorunner mk5

Figuur 07: Components Prorunner mk5 (Main module)

Motor Prorunner mk5

iE2

iB1

Carrier reference position

Tabel 03: Components main module

Code Type
iB1 Sensor Zero / basic position carrier (Position dependent on IME18-08BPSZC0K
primary direction of rotation)
E2 Encoder main module Prorunner EI72 build in from
SEW
iB3 Sensor/ photocell: Product position monitoring. GL6-P4211
This photocell monitors whether the product has completely C42-2
entered the infeed roller conveyor.

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Software function blocks Prorunner mk5 - SIEMENS

6.4 Configuration main module Prorunner mk5

The configuration consists of one UDT  UDT_Prorunner_mk5_Encoder_Configuration.
Everything can/will be determined from the Qimarox configuration sheet.
We strongly recommend using the PDF configuration sheets provided by Qimarox for this.

Tabel 04: Configuration main module

Naming Data Unit Description
type
Prorunner.Type Bool 0/1 0=Standard, 1=XL
Prorunner.Direction Bool 0/1 Direction of rotation of lift, seen from front
0=CW, 1=CCW
Prorunner.ColomnHeight Real mm. Total height of the Prorunner
Prorunner.SupportHeight Real mm. Height between floor and bottom of Prorunner
Prorunner.GearRation Real i [i] Gear ratio of the motor (see motor nameplate)
Prorunner.RPM Real rpm [rpm] Rotations of the motor per minute on 50Hz (see
motor nameplate)
Prorunner.InfeedLevels Int 0..99 Number of infeed sub-modules / levels
Prorunner.OutfeedLevels Int 0..99 Number of outfeed sub-modules / levels
Encoder.PulsesPerRevolution Int 1..1024 Number of pulses per motor revolution (EI72 = 4)
Options.CarrierObjectDetection Bool 0/1 Monitoring of empty carriers at checking position.
Options.CarrierCheckPosition Real mm. Checking position object detection on carrier (checking
by means of sensor iB3)
Carrier.Amount Int 0..99 Number of carriers present on Prorunner mk5
Carrier.LoweringAdapter Real mm. Minimum spacing between carriers
Carrier.MinimumSpacing Real mm. Minimum spacing between carriers
Carrier.MaximumSpacing Real mm. Maximum chain length between carriers
Carrier.TotalTravelLength Real mm. Total travel length of one carriers (complete modulo)
ObjectDimension.MaxHeight Real mm. Maximum height of objects
ObjectDimension.MaxLength Real mm. Maximum length of objects
ObjectDimension.MinLength Real mm. Minimum length of objects
ObjectDimension.MaxWidth Real mm. Maximum width of objects
Speed.Frequency Int Hz Number of Hertz of the motor (Nominal = 50 Hz)
Speed.Acceleration Int ms. Number of milliseconds to accelerate from standstill to
desired speed
Speed.Deceleration Int ms. Number of milliseconds to decelerate from current
speed to standstill

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Software function blocks Prorunner mk5 - SIEMENS

6.5 Inputs main module Prorunner mk5

Inputs are required for the system to function properly. Here the required sensors are declared,
and the status of the installation.

Tabel 05: Inputs main module Prorunner mk5

Naming Data Unit Description
type
iConfiguration UDT UDT_Prorunnner_mk5_Encoder_Configuration
UDT as discussed in section below. This contains all
requirements/settings for the installation to function properly
iEnabled Bool 0/1 System is switched on. Safety functions are operational,
hardware has no problems, and power supplies to any
controllers are switched on.
1 = Installation switched on
iReset Bool 0/1 Reset command to reset faults.
iInitialisationMode Bool 0/1 Start of initialisation procedure.
Must remain present until the initialisation procedure is
completed. Automatic / Manual mode is being ignored.
1=Initialisation is active
iAutomaticMode Bool 0/1 Installation is in automatic mode. The direction of rotation of
the PRORUNNER is only in the primary direction.
iManualMode Bool 0/1 Installation is in manual mode. Manual commands influence
the direction of rotation.
iManualUp Bool 0/1 Command for upward movement (seen from input modules)
in manual mode
iManualDown Bool 0/1 Command for downward movement (seen from input
modules) in manual mode
iB1 Bool 0/1 Carrier reference position
iB3 Bool 0/1 Empty carriers message by means of photocell detection
(optional)
iReset_Maintenance Bool 0/1 Reset the time until maintenance. (Use after providing
servicing the Prorunner)

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Software function blocks Prorunner mk5 - SIEMENS

6.6 Outputs main module Prorunner mk5

Outputs must be declared by the customer.
Outputs provide feedback such as faults, status and communication.

Tabel 06: Outputs main module Prorunner mk5

Naming Data Unit Description
type
oAlarm Bool 0/1 Fault active
oAlarmCode Int 0 Active fault code (See chapter ‘Faults’ for the correct
overview)
oAlarmFeedback Word 0 Active fault feedback for HMI. One bit is reserved for each
fault. Fault 1 = bit 0, fault 2 = bit 1, etc.
oStatus Int 0 See chapter ‘Status Prorunner mk5’ for further information.

oOperating_Hours Dint # Displays the total movement time of the Prorunner

oHours_Until_Maintenance Dint # Displays the remaining operating hours until it is advised to

perform maintenance on the Prorunner
oMaintenance_Required Bool 0/1 Signal that maintenance interval is due, and maintenance is
advised.

6.7 Motor interface main module Prorunner mk5

One motor is used for the main module. All commands are prepared via this motor interface to
handle different forms of motor actuation.
For more information, please refer to chapter ‘16 - Motor interface’

We recommend carrying out the motor in conjunction with a frequency controller because there
are different requirements for actuation:
 Mechanism is less loaded if engine starts slower by means of acceleration
 Quickstop must be possible <= 100ms.
Quickstop = quickest possible stop with pre-defined deceleration in controller
 Energize must be possible (This is not a requirement, but more an extra
function/security)
Energize = Motor must be capable of being energized without moving; this is used to keep
the lift in place if the brake is not functioning properly.

The software block has been tested with a SEW frequency controller:  Movitrac B  MC07B0015-4-
5A3-S0
This one used a 1.5kW motor. Communication can be done through S-Bus or I/O

Tabel 07: Motor interface main module Prorunner mk5

Naming Data Unit Description
type
xProrunner UDT UDT_MotorControl
Motor interface Prorunner

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Software function blocks Prorunner mk5 - SIEMENS

6.8 Status main module Prorunner mk5

The status of the Prorunner is output, giving the user a clear picture of the status/movements of
the Prorunner mk5.

Tabel 08: Status main module Prorunner mk5

Description
Code

0 NO ACTION / SWITCHED OFF:

Prorunner switched off / no mode active
1 FAULT:
Prorunner blocked by fault
2 WAITING:
Prorunner ready for use / start
3 MANUAL OPERATION / MANUAL MODE:
Prorunner in manual mode
4 TURNING / AUTOMATIC MODE:
Prorunner moving and ready
5 EMPTY SIGNAL:
PRORUNNER waits at infeed level until infeed conveyor indicates that an object is ready for infeeding.
6 STOPPED DUE TO INFEED TIME PERIOD OR BLOCKING OF INFEED MODULE:
Prorunner waits for safe position under or above the relevant infeed module until the infeed module
indicates it has an object ready for picking up or is no longer blocked.
7 STOPPED DUE TO OUTFEED MODULE REMAINING BUSY OR BLOCKAGE OUTFEED MODULE:
Prorunner waits for safe position above or under the relevant outfeed module until outfeed module
indicates it no longer has an object or is no longer blocked.
10 INITIALISATION PROCEDURE ACTIVE
Prorunner busy with initialisation procedure.
11 INITIALISATION PROCEDURE READY
Prorunner ready with initialisation procedure.

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 Software function blocks Prorunner mk5 - SIEMENS

6.9 Faults main module Prorunner mk5

The software function block issues an outfeed signal and a fault code in the event of a fault.
With the outfeed signal ‘oAlarm’ it is possible to indicate a fault by, for example, switching on a red
lamp. With the fault code ‘oAlarmCode’ you can indicate this better.
With the fault word ‘oAlarmFeedback’ you can generate a clearly defined fault message by means
of an HMI. The faults are divided over 16 bits. Code 1 = bit 0 ... Code 16 = bit 15.
Below is the list of faults that may be active with explanation/result and solution.
Some faults are only possible when selecting the relevant options.

Tabel 09: Faults list main module Prorunner mk5

Description / Cause Effect Solution
Code

5 Movement of Prorunner blocked. Prorunner is blocked. Quickstop Check Prorunner for blockages, if
Encoder detects no pulses within functionality is activated (if no blockages can be determined:
maximum time limits. possible) Check the operation/adjustment
Initialisation must be carried out encoder.
again. Check whether encoder function
block is called fast enough on the
PLC; this must be <= 2ms.
Give the reset command to reset
the fault (iReset).
6 Prorunner moving in wrong Prorunner is blocked. Check direction of rotation
direction; the encoder detects Quickstop functionality is activated encoder Prorunner.
incorrect direction of rotation. (if possible) Give the reset command to reset
Initialisation must be carried out the fault (iReset).
again.
7 Movement of PRORUNNER seen Prorunner is blocked. Check mechanical adjustment
while motor not being controlled. Energize functionality is activated (Rem) PRORUNNER.
(if possible) Give the reset command to reset
Initialisation must be carried out the fault (iReset).
again.
8 Configuration is not entered Prorunner is blocked. Check configuration settings.
correctly Initialisation is not possible. Make sure that everything is
entered correctly and not below
the minimum value.
10 Carrier not seen within maximum Prorunner is blocked. Quickstop Check settings chain lengths in the
distance margin between carriers. functionality is activated (if configuration; check this against
possible) the actual distance between the
Initialisation must be carried out carriers.
again. Check mechanical tolerances of
the carrier re the reference
sensor.
Give the reset command to reset
the fault.

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 Software function blocks Prorunner mk5 - SIEMENS

Description / Cause Effect Solution

Code

11 Unknown carrier reported. Prorunner is blocked. Check settings chain lengths in the
Distance between carriers below Quickstop functionality is activated configuration; check this against
the minimum distance margin (if possible) the actual distance between the
between carriers Initialisation must be carried out carriers.
again. Check sensor i = MM-B1, since
sensor was triggered earlier than
usual.
Give the reset command to reset
the fault.
12 Carrier not empty, during Automatic operation is stopped. Remove object from carrier.
inspection in combination with Give the reset command to reset
sensor iB3. the fault.
13 Fault controller/inverter Automatic operation is stopped. Check operation/fault
PRORUNNER. controller/drive.
Make sure that it is ready for
operation again.
Give the reset command to reset
drive fault.
Wait until the controller is ready
again.
14 Initialisation necessary Prorunner is blocked. Perform initialisation
15 Initialisation procedure TIMEOUT: Initialisation has not been Check status sub infeed/outfeed
Procedure takes longer than the completed. modules, and restart procedure
total chain length with +50% Automatic / Manual mode is not
margin! possible!
16 Initialisation procedure ERROR: Initialisation has not been Check adjustment sensor iB1
 Not all carriers seen by completed. PRORUNNER.
sensor iB1 Automatic / Manual mode is not Check configuration PRORUNNER.
 Chain length between possible! Restart procedure by giving
carriers is too short initialisation command again.
 Chain length between
carriers is too long
 Total chain length is
incorrect

6.10 Maintenance Prorunner mk5

During normal operation, the software will count the operating hours of the Prorunner. If this time
exceeds the maintenance interval, the Prorunner should be serviced. The Software block is
equipped with in- and outputs to generate an maintenance required warning and reset the
maintenance data.

Please use the maintenance required bit to generate a warning on the HMI screen. Refer to
paragraph 6.5 and 6.6 for more information regarding this.

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Software function blocks Prorunner mk5 - SIEMENS

7 Function block encoder Prorunner mk5

With this software block, the encoder processing is called up. This block must be specially called,
because of the high/higher frequency of the encoder. This must be approximately 4ms.

7.1 Function block specifications

Block name: FB_ Prorunner_mk5_Encoder

Block number: FB1051
Version: V4.1
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Customer_Information
UDT_Prorunner_mk5_Encoder_Handshake_IN
UDT_Prorunner_mk5_Encoder_Handshake_OUT
Function block call Time interrupt 4ms (OB1050 – Time interrupt)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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Software example function blocks Prorunner mk5 - SIEMENS

7.2 Flowchart diagram encoder

xung trong hướng quay cửa sổ thời gian cực đại

điều chỉnh sóng

mang vị trí với
khoảng cách trên
mỗi xung

vị trí người
vận chuyển
đến trọng tài
bù đắp vị trí

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Software example function blocks Prorunner mk5 - SIEMENS

7.3 Inputs encoder

Inputs are required for the system to function properly. The required sensors and the
communication interface with the Prorunner are declared here.

Some inputs must be called via peripheral addressing. Explanation can be found here:  Siemens -
Where and when do you need peripheral addressing?

Tabel 10: Inputs encoder Prorunner mk5

Naming Data Unit Description
type
iE2_A Bool 0/1 Pulse A encoder - for this, always use the input from the input
periphery. Example: ‘i=MM-E2-A’:P
This queries the actual status of the input instead of the
saved status of the input in the normal cycle of the PLC.
Adding the ‘:P’ takes care of this.
iE2_B Bool 0/1 Pulse B encoder - for this, always use the input from the input
periphery. Example: ‘i=MM-E2-B’:P
This queries the actual status of the input instead of the
saved status of the input in the normal cycle of the PLC.
Adding the ‘:P’ takes care of this.
iB1 Bool 0/1 Carrier reference position - for this, always use the input from
the input periphery. Example: ‘i=MM-B1’:P
This queries the actual status of the input instead of the
saved status of the input in the normal cycle of the PLC.
Adding the ‘:P’ takes care of this.

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Software function blocks Prorunner mk5 - SIEMENS

7.4 Interfaces encoder

With the interface, information is exchanged between encoder and main module.
These interfaces are used for:
- Communication encoder  Prorunner
- Updating carriers PRORUNNER

Tabel 11: Interface encoder Prorunner mk5

Naming Data Unit Description
type
xHS_Commands UDT UDT_Prorunner_mk5_Encoder_Handshake_Command
This is the communication interface (HandShakes) of
PRORUNNER  Encoder.
This is a direct reference to the DB of the main module.
xHS_Status UDT UDT_Prorunner_mk5_Encoder_Handshake_Status
This is the communication interface (HandShakes) of Encoder
 PRORUNNER.
This is a direct reference to the DB of the main module.
xCarrier UDT_Prorunner_mk5_Carrier
This is a direct reference to the DB of the main module.
This allows the encoder to directly update the position of the
carriers.
xMotorControl_Prorunner UDT UDT_MotorControl
Motor interface Prorunner

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Software function blocks Prorunner mk5 - SIEMENS

8 Function block infeed module RDC2/MBC2

Figuur 08: Function block infeed module RDC2/MBC2

With this software block, the infeed module RDC2/MBC2 is called.

‘RDC2’ stands for: Roller Drive Conveyor type 2  Fixed position
‘MBC2’ stands for: Multi Belt Conveyor type 2  Fixed position

8.1 Function block specifications infeed module RDC2/MBC2

Block name: FB_Prorunner_mk5_Infeed_RDC2/MBC2

Block number: FB1062
Version: V4.1
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_MotorControl
UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Customer_Information
UDT_Prorunner_mk5_Infeed_Configuration
UDT_Prorunner_mk5_Infeed_Handshake
Function block call Cyclical (OB1)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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Software function blocks Prorunner mk5 - SIEMENS

8.2 Components infeed module RDC2/MBC2

Figuur 09: Components infeed module RDC2

iB7 iB15

xConveyor

Figuur 10: Components infeed module MBC2

iB7

iB15
xConveyor

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Software function blocks Prorunner mk5 - SIEMENS

Tabel 12: Components infeed module RDC2

Code Type
iB15 Sensor/ photocell: Product position monitoring. GL6-P4211
This photocell monitors whether the product has completely C42-2
entered the infeed roller conveyor.
iB7 Sensor/ photocell: Product on infeed. GL6-P4211
This photocell detects whether the product has entered the C42-2
infeed roller conveyor
xConveyor Actuation roller conveyor Drivecontrol 20/54
+ Rollerdrive
Tabel 13: Components infeed module MBC2
Code Type
iB15 Sensor/ photocell: Product position monitoring. GT6
This photocell monitors whether the product has completely
entered the infeed conveyor.
iB7 Sensor/ photocell: Product on infeed. GT6
This photocell detects whether the product has entered the
infeed conveyor
xConveyor Actuation multi belt conveyor SEW

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Software example function blocks Prorunner mk5 - SIEMENS

8.3 Flow chart functionality infeed module RDC2/MBC2

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Software example function blocks Prorunner mk5 - SIEMENS

8.4 Configuration infeed module RDC2/MBC2

Configuration according to UDT_Prorunner_mk5_Infeed_Configuration

Tabel 14: Configuration infeed module RDC2/MBC2

Naming Data type Unit Description
Module.Level Int 1..20 Level number.
Module.Height Real mm. Exact height of the conveyor,
measured from the ground floor
Options.LowspeedPickup Bool 0/1 Picking up by using lower speed
(1=active)
Conveyor.Speed Real m/s. Speed of conveyor track at rated
actuation (metre per second)
Conveyor.Length Real mm. Exact length of infeed conveyor
Transport.CycleTime Real s. Time necessary to perform
infeed transport.
Transport.Speed Int Hz Number of Hertz (Nominal = 50
Hz)
Transport.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Transport.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill

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8.5 Inputs infeed module RDC2/MBC2

Inputs must be declared by the customer. Inputs provide information such as configuration, status
of installation, status sensors, manual pushbutton and communication signals with downstream
transport
Tabel 15: Inputs infeed module RDC2/MBC2
Naming Data Unit Description
type
iConfiguration UDT UDT as discussed in section above
iEnabled Bool 0/1 System is switched on. Safety functions are operational
and power supplies to the controllers are switched on.
iReset Bool 0/1 Reset command to reset faults.
iInitialisationMode Bool 0/1 Start of initialisation procedure.
iAutomaticMode Bool 0/1 Installation is in automatic mode. Operation is
influenced by the sensors and communication with the
infeed/outfeed conveyor.
iManualMode Bool 0/1 Installation is in manual mode. The operation is
influenced by the manual commands.
iManualConveyor Bool 0/1 Command for manual actuation of roller conveyor
iB7 Bool 0/1 Sensor that detects that product is on infeed.
iB15 Bool 0/1 Sensor for product position monitoring.
iDownStream_ObjectReady Bool 0/1 Communication signal of downstream transport:
Object ready for infeeding.
iDownStream_ObjectDestination Int 1..20 Communication signal of downstream transport:
Object destination level.
iDownStream_ObjectInformation UDT Communication signal of downstream transport:
‘UDT_Prorunner_mk5_Customer_Information’
Any information that can be sent along with each
object.

8.6 Outputs infeed module RDC2/MBC2

Outputs must be declared by the customer. Outputs provide feedback such as faults, status and
communication signals with downstream transport.
Tabel 16: Outputs infeed module RDC2
Naming Data Unit Description
type
oAlarm Bool 0/1 Fault active
oAlarmCode Int 0 Active fault code (See chapter ‘Faults’ for the correct
overview)
oAlarmFeedback Word 0 Active fault feedback for HMI. One bit is reserved for each
fault. Fault 1 = bit 0, fault 2 = bit 1, etc.
oStatus Int 0 See chapter ‘Status Prorunner mk5’ for further information.
oDownStream_Start Bool 0/1 Communication signal to downstream transport:
Infeed module ready/busy for transport to the end of the
roller conveyor
oDownStream_MotorIsRunn Bool 0/1 Communication signal to downstream transport:
ing Infeed module roller conveyor running. If this signal stops,
the roller conveyor downstream must also stop.

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8.7 Motor interface infeed module RDC2/MBC2

One motor is used for the infeed module. All commands are prepared via this motor interface to
handle different forms of motor actuation.
For more information, please refer to chapter ‘16 - Motor interface’

Tabel 17: Motor interface infeed module RDC2

Naming Data Unit Description
type
xConveyor UDT UDT_MotorControl
Motor interface infeed module RDC2/MBC2

8.8 Status infeed module RDC2/MBC2

The status of the infeed module is output, giving the user a clear picture of the status/movements
of the infeed module

Tabel 18: Status infeed module RDC2/MBC2

Description / Cause
Code

0 NO ACTION:
Infeed module switched off / no mode active
1 MANUAL OPERATION:
Infeed module in manual mode
3 INITIALISATION PROCEDURE ACTIVE:
Infeed module busy with initialisation procedure.
4 INITIALISATION PROCEDURE READY:
Infeed module finished with initialisation procedure.
5 CONFIGURATION CHECK:
Infeed module finished with initialisation procedure.
6 RESTART / START-UP PROCEDURE:
Procedure after fault; this involves checking whether an object is present and whether it is correctly
positioned.
7 FAULT:
Infeed module blocked by fault
10 WAITING:
Infeed module ready for use, object infeeding can be started
15 OBJECT INFEEDING BUSY:
Infeed module busy with object infeeding.
16 OBJECT ACCEPTED ON INFEED CONVEYOR:
Infeed module has received object on belt (sensor iB15)
17 OBJECT PRESENT ON INFEED CONVEYOR:
Infeed module in the process of moving object to the end of the roller conveyor (sensor iB7 covered and
iB15 uncovered).
18 WAIT UNTIL OBJECT HAS BEEN PICKED UP:
Infeed module waits until Prorunner mk5 has picked up object. Information is also made available in this
status/step.

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8.9 Faults infeed module RDC2/MBC2

With the outfeed signal ‘oAlarm’ it is possible to indicate a fault by, for example, switching on a red
lamp. With the fault code ‘oAlarmCode’ you can indicate this better.
With the fault word ‘oAlarmFeedback’ you can generate a clearly defined fault message by means
of an HMI. The faults are divided over 16 bits. Code 1 = bit 0 ... Code 16 = bit 15.
Below is the list of faults that may be active with explanation/result and solution.

Tabel 19: Faults list infeed module RDC2/MBC2

Description / Cause Effect Solution
Code

1 Feeding object in is taking too long. Automatic operation is stopped. Put the object down manually in
Sensor object detection does not Command to PRORUNNER that the sensors; iB15 uncovered, iB7
see the object within time limits infeed module is blocked. covered.
Start-up procedure of infeed Give the reset command to reset
conveyor must be carried out. the fault. Resetting is not possible
if sensor iB15 is covered.
2 Object fed in too fast. Automatic operation is stopped. Check for unknown objects.
It is possible that the product is too Command to PRORUNNER that Put the object down manually in
long and/or that an unknown infeed module is blocked. the sensors; iB15 uncovered, iB7
object has been seen. Start-up procedure of infeed covered.
conveyor must be carried out. Give the reset command to reset
the fault. Resetting is not possible
if sensor iB15 is covered.
3 Unknown object detected. Automatic operation is stopped. Check for unknown objects.
Sensors triggered while the infeed Command to PRORUNNER that Give the reset command to reset
module is not busy with this step. infeed module is blocked. the fault. Resetting is not possible
Start-up procedure of infeed if sensor iB15 is covered.
conveyor must be carried out.
4 Object too small. Automatic operation is stopped. Check object length.
iB15 triggered for too short. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the shortest infeed module is blocked. the fault.
product length. Start-up procedure of infeed Resetting is not possible if sensor
conveyor must be carried out. iB15 is covered.
5 Object too big. Automatic operation is stopped. Check object length.
iB15 triggered for too long. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the longest infeed module is blocked. the fault.
product length Start-up procedure of infeed Resetting is not possible if sensor
conveyor must be carried out. iB15 is covered.
6 Unknown destination of object on Automatic operation is stopped. Remove object from infeed
infeed conveyor. Command to PRORUNNER that conveyor and check
This must higher than ‘0’ and less infeed module is blocked. communication with downstream
than or equal to the number of Start-up procedure of infeed transport.
levels present. conveyor must be carried out. Give the reset command to reset
the fault.
Resetting is not possible if sensor
iB15 is covered.
8 Configuration is not entered Automatic operation is stopped. Check configuration settings.
correctly Command to PRORUNNER that Make sure that everything is
infeed module is blocked. entered correctly and not below
the minimum value.

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Description / Cause Effect Solution

Code

9 Start-up procedure time-out. Automatic operation is stopped. Put the object down manually in
Sensor iB15 does not become Command to PRORUNNER that the sensors; iB15 uncovered, iB7
untriggered. infeed module is blocked. covered.
Give the reset command to reset
the fault.
13 Fault controller/drive conveyor Automatic operation is stopped. Check operation/fault
track. Command to PRORUNNER that controller/drive.
infeed module is blocked. Make sure that it is ready for
(Depending on position) operation again.
Give the reset command to reset
the fault.
15 Initialisation procedure: object still Initialisation has not been Empty the conveyor track.
detected on conveyor track. completed. Restart procedure by giving
initialisation command again.

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9 Function block infeed module RDC3

Figuur 11: Function block infeed module RDC3

With this software block, the infeed module RDC4 is called.

RDC3 stands for: Tilting Rollerdrive Conveyor type 3  Moveable

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9.1 Function block specifications infeed module RDC3

Block name: FB_Prorunner_mk5_Infeed_RDC3

Block number: FB1065
Version: V0.9
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_MotorControl
UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Customer_Information
UDT_Prorunner_mk5_Infeed_Configuration
UDT_Prorunner_mk5_Infeed_Handshake
Function block call Cyclical (OB1)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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9.2 Components infeed module RDC3

Figuur 12: Components infeed module RDC3

oY2/oY3
iB7

iB4 iB1

iB15

xConveyor

Tabel 20: Components infeed module RDC4

Code Type
iB15 Sensor/ photocell: Product position monitoring. GL6-P4211
This photocell monitors whether the product has completely entered C42-2
the infeed roller conveyor.
iB7 Sensor/ photocell: Product on infeed. GL6-P4211
This photocell detects whether the product has entered the infeed C42-2
roller conveyor
iB1 Inductive approach: Wait for position (from Prorunner) SMT-8M-A-PS-24V-E-1-
Sensor detection that horizontal movement is in waiting position. This N-M12
is the position in which no object can be entered, and the conveyor is
in a safe position for the Prorunner carriers.
iB3 Inductive approach: Low-speed infeed position SMT-8M-A-PS-24V-E-1-
Sensor detection that horizontal movement should switch to waiting N-M12
position to low speed.
xConveyor Actuation roller conveyor Drivecontrol 20/54
Rollerdrive
oY2/oY3 Actuation tilting movement Pneumatic Valve

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9.4 Flow chart functionality infeed module RDC3

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9.5 Configuration infeed module RDC3

Configuration according to UDT_Prorunner_mk5_Infeed_Configuration

Tabel 21: Configuration infeed module RDC3

Naming Data type Unit Description
Module.Level Int 1..20 Level number.
Module.Height Real mm. Exact height of the conveyor
measured from the floor
Options.LowspeedPickup Bool 0/1 Picking up by using lower speed
(1=active)
Conveyor.Speed Real m/s. Speed of conveyor track at rated
actuation (metre per second)
Conveyor.Length Real mm. Exact length of infeed conveyor
Transport.CycleTime Real s. Time necessary to perform
infeed transport.
Transport.Speed Int Hz Number of Hertz (Nominal = 50
Hz)
Transport.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Transport.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill
Movement.CycleTime Real s. Time needed to tilt conveyor
between infeed position and
waiting position.

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9.6 Inputs infeed module RDC3

Inputs must be declared by the customer. Inputs provide information such as configuration, status
of installation, status sensors, manual pushbutton and communication signals with downstream
transport

Tabel 22: Inputs infeed module RDC3

Naming Data Unit Description
type
iConfiguration UDT UDT as discussed in section above
iEnabled Bool 0/1 System is switched on. Safety functions are operational
and power supplies to the controllers are switched on.
iReset Bool 0/1 Reset command to reset faults.
iInitialisationMode Bool 0/1 Start of initialisation procedure.
iAutomaticMode Bool 0/1 Installation is in automatic mode. Operation is
influenced by the sensors and communication with the
infeed/outfeed conveyor.
iManualMode Bool 0/1 Installation is in manual mode. The operation is
influenced by the manual commands.
iManualConveyor Bool 0/1 Command for manual actuation of roller conveyor
iManualForwards Bool 0/1 Command manual actuation of horizontal movement
to the infeed position
iManualBackwards Bool 0/1 Command manual actuation of horizontal movement
to the waiting position
iB1 Bool 0/1 Sensor for detection of waiting position
iB4 Bool 0/1 Sensor for detection of infeed position
iB7 Bool 0/1 Sensor for position of entered product
iB15 Bool 0/1 Sensor for product position control
iDownStream_ObjectReady Bool 0/1 Communication signal of downstream transport:
Object ready for infeeding.
iDownStream_ObjectDestination Int 1..20 Communication signal of downstream transport:
Object destination level.
iDownStream_ObjectInformation UDT Communication signal of downstream transport:
‘UDT_Prorunner_mk5_Customer_Information’
Any information that can be sent along with each
object. This UDT can be configured by yourself.

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9.7 Outputs infeed module RDC3

Exits must be declared by the customer. Outputs provide feedback such as faults, status and
communication signals with downstream transport.

Tabel 23: Outputs infeed module RDC3

Naming Data Unit Description
type
oAlarm Bool 0/1 Fault active
oAlarmCode Int 0 Active fault code (See chapter ‘Faults’ for the correct
overview)
oAlarmFeedback Word 0 Active fault feedback for HMI. One bit is reserved for each
fault. Fault 1 = bit 0, fault 2 = bit 1, etc.
oStatus Int 0 See chapter ‘Status Prorunner mk5’ for further information.

oDownStream_Start Bool 0/1 Communication signal to downstream transport:

Infeed module ready/busy for transport to the end of the
roller conveyor
oDownStream_MotorIsRunn Bool 0/1 Communication signal to downstream transport:
ing Infeed module roller conveyor running. If this signal stops,
the roller conveyor downstream must also stop.
oY2 Bool 0/1 Tilt the conveyor to the wait (upwards) position

oY3 Bool 0/1 Tilt the conveyor to the infeed (downwards) position

9.8 Motor interface infeed module RDC3

Two motors are used for the infeed module. All commands are prepared via this motor interface to
handle different forms of motor actuation.
For more information, please refer to chapter ‘16 - Motor interface’

Tabel 24: Motor interface infeed module RDC3

Naming Data Unit Description
type
xConveyor UDT UDT_MotorControl
Motor interface roller conveyor infeed module RDC4

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9.9 Status infeed module RDC3

The status of the infeed module is output, giving the user a clear picture of the status/movements
of the infeed module RDC3

Tabel 25: Status infeed module RDC3

Description / Cause
Code

0 NO ACTION:
Infeed module switched off / no mode active
1 MANUAL OPERATION:
Infeed module in manual mode
3 INITIALISATION PROCEDURE ACTIVE:
Infeed module busy with initialisation procedure.
4 INITIALISATION PROCEDURE READY:
Infeed module finished with initialisation procedure.
5 CONFIGURATION CHECK:
Infeed module finished with initialisation procedure.
6 RESTART / START-UP PROCEDURE:
Procedure after fault; this involves checking whether an object is present and whether it is correctly
positioned.
7 FAULT:
Infeed module blocked by fault
10 WAITING:
Infeed module ready for use, object infeeding can be started
11 MOVEMENT TO INFEED POSITION:
Infeed module busy with horizontal movement to infeed position
12 AT INFEED POSITION:
Infeed module ready for transport of object
13 MOVEMENT TO WAITING POSITION:
Infeed module busy with horizontal movement to waiting position
14 AT WAIT POSITION:
Infeed module in waiting position.
15 OBJECT INFEEDING BUSY:
Infeed module busy with object infeeding.
16 OBJECT ACCEPTED ON INFEED CONVEYOR:
Infeed module has received object on belt (sensor iB15)
17 OBJECT PRESENT ON INFEED CONVEYOR:
Infeed module in the process of moving object to the end of the roller conveyor (sensor iB7 covered and
iB15 uncovered).
18 WAIT UNTIL OBJECT HAS BEEN PICKED UP:
Infeed module waits until Prorunner mk5 has picked up object. Information is also made available in this
status/step.

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9.10 Faults infeed module RDC3

With the outfeed signal ‘oAlarm’ it is possible to indicate a fault by, for example, switching on a red
lamp. With the fault code ‘oAlarmCode’ you can indicate this better.
With the fault word ‘oAlarmFeedback’ you can generate a clearly defined fault message by means
of an HMI. The faults are divided over 16 bits. Code 1 = bit 0 ... Code 16 = bit 15.
Below is the list of faults that may be active with explanation/effect and solution.

Tabel 26: Faults list infeed module RDC3

Description / Cause Effect Solution
Code

1 Feeding object in is taking too long. Automatic operation is stopped. Put the object down manually in
Sensor object detection does not Command to PRORUNNER that the sensors; iB15 uncovered, iB7
see the object within time limits infeed module is blocked. covered.
Start-up procedure of infeed Give the reset command to reset
conveyor must be carried out. the fault. Resetting is not possible
if sensor iB15 is covered.
2 Object fed in too fast. Automatic operation is stopped. Check for unknown objects.
It is possible that the product is too Command to PRORUNNER that Put the object down manually in
long and/or that an unknown infeed module is blocked. the sensors; iB15 uncovered, iB7
object has been seen. Start-up procedure of infeed covered.
conveyor must be carried out. Give the reset command to reset
the fault. Resetting is not possible
if sensor iB15 is covered.
3 Unknown object detected. Automatic operation is stopped. Check for unknown objects.
Sensors triggered while the infeed Command to PRORUNNER that Give the reset command to reset
module is not busy with this step. infeed module is blocked. the fault. Resetting is not possible
Start-up procedure of infeed if sensor iB15 is covered.
conveyor must be carried out.
4 Object too small. Automatic operation is stopped. Check object length.
iB15 triggered for too short. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the shortest infeed module is blocked. the fault.
product length Start-up procedure of infeed Resetting is not possible if sensor
conveyor must be carried out. iB15 is covered.
5 Object too big. Automatic operation is stopped. Check object length.
iB15 triggered for too long. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the longest infeed module is blocked. the fault.
product length Start-up procedure of infeed Resetting is not possible if sensor
conveyor must be carried out. iB15 is covered.
6 Unknown destination of object on Automatic operation is stopped. Remove object from infeed
infeed conveyor. Command to PRORUNNER that conveyor and check
This must higher than ‘0’ and less infeed module is blocked. communication with downstream
than or equal to the number of Start-up procedure of infeed transport.
levels present. conveyor must be carried out. Give the reset command to reset
the fault.
Resetting is not possible if sensor
iB15 is covered.
8 Configuration is not entered Automatic operation is stopped. Check configuration settings.
correctly Command to PRORUNNER that Make sure that everything is
infeed module is blocked. entered correctly and not below
the minimum value.

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Description / Cause Effect Solution

Code

9 Start-up procedure time-out. Automatic operation is stopped. Put the object down manually in
Sensor iB15 does not become Command to PRORUNNER that the sensors; iB15 uncovered, iB7
untriggered. infeed module is blocked. covered.
Give the reset command to reset
the fault.
10 Movement to waiting position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB1 sensor
Give the reset command to reset
the fault.
11 Movement to infeed position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB4 sensor
Give the reset command to reset
the fault.
12 Position horizontal movement no Automatic operation is stopped. Check adjustment/operation of
longer correct. Command to PRORUNNER that the iB1 & iB4 sensor.
infeed module is blocked. Give the reset command to reset
the fault.
13 Fault controller/drive conveyor Automatic operation is stopped. Check operation/fault
track. Command to PRORUNNER that controller/drive.
infeed module is blocked. Make sure that it is ready for
(Depending on position) operation again.
Give the reset command to reset
the fault.
14 Fault controller/drive horizontal See fault 13 See fault 13
movement.
15 Initialisation procedure: object still Initialisation has not been Empty the conveyor track.
detected on conveyor track. completed. Restart procedure by giving
initialisation command again.
16 Initialisation procedure: Safe Initialisation has not been Check the movement of the
position not reached completed. infeed module.
Check operation and adjustment
of position indicator sensors.
Restart procedure by giving
initialisation command again.

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10 Function block infeed module RDC4

Figuur 13: Function block infeed module RDC4

With this software block, the infeed module RDC4 is called.

RDC4 stands for: Roller Drive Conveyor type 4  Moveable

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10.1 Function block specifications infeed module RDC4

Block name: FB_Prorunner_mk5_Infeed_RDC4

Block number: FB1064
Version: V1.2
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_MotorControl
UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Customer_Information
UDT_Prorunner_mk5_Infeed_Configuration
UDT_Prorunner_mk5_Infeed_Handshake
Function block call Cyclical (OB1)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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10.2 Components infeed module RDC4

Figuur 14: Components infeed module RDC4

xMotion

iB1

iB7 iB15 iB2

iB3

xConveyor iB4

Tabel 27: Components infeed module RDC4

Code Type
iB15 Sensor/ photocell: Product position monitoring. GL6-P4211
This photocell monitors whether the product has completely entered C42-2
the infeed roller conveyor.
iB7 Sensor/ photocell: Product on infeed. GL6-P4211
This photocell detects whether the product has entered the infeed C42-2
roller conveyor
iB1 Inductive approach: Wait for position (from Prorunner) IME18-08BPSZC0K
Sensor detection that horizontal movement is in waiting position. This
is the position in which no object can be entered, and the conveyor is
in a safe position for the Prorunner carriers.
iB2 Inductive approach: Low speed waiting position IME18-08BPSZC0K
Sensor detection that horizontal movement should switch to waiting
position to low speed.
iB4 Inductive approach: Infeed position (In Prorunner) IME18-08BPSZC0K
Sensor detection that horizontal movement is at Infeed position. This is
the position in which an object can be fed in.
iB3 Inductive approach: Low-speed infeed position IME18-08BPSZC0K
Sensor detection that horizontal movement should switch to waiting
position to low speed.
xConveyor Actuation roller conveyor Drivecontrol 20/54
Rollerdrive
xMotion Actuation horizontal movement SEW drive
See Qimarox info

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10.4 Flow chart functionality infeed module RDC4

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10.5 Configuration infeed module RDC4

Configuration according to UDT_Prorunner_mk5_Infeed_Configuration

Tabel 28: Configuration infeed module RDC4

Naming Data type Unit Description
Module.Level Int 1..20 Level number.
Module.Height Real mm. Exact height of the conveyor
measured from the floor
Options.LowspeedPickup Bool 0/1 Picking up by using lower speed
(1=active)
Conveyor.Speed Real m/s. Speed of conveyor track at rated
actuation (metre per second)
Conveyor.Length Real mm. Exact length of infeed conveyor
Transport.CycleTime Real s. Time necessary to perform
infeed transport.
Transport.Speed Int Hz Number of Hertz (Nominal = 50
Hz)
Transport.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Transport.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill
Movement.CycleTime Real s. Time needed to move conveyor
track between infeed position
and waiting position.
Movement.InfeedPosition Real mm. Position: infeed position
Movement.BasicPosition Real mm. Position: waiting position
Movement.Speed Real m/s. Speed of movement
Movement.HighSpeed Int Hz Number of Hertz (Nominal = 50
Hz)
Movement.LowSpeed Int Hz Number of Hertz (Nominal = 50
Hz)
Movement.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Movement.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill

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10.6 Inputs infeed module RDC4

Inputs must be declared by the customer. Inputs provide information such as configuration, status
of installation, status sensors, manual pushbutton and communication signals with downstream
transport

Tabel 29: Inputs infeed module RDC4

Naming Data Unit Description
type
iConfiguration UDT UDT as discussed in section above
iEnabled Bool 0/1 System is switched on. Safety functions are operational
and power supplies to the controllers are switched on.
iReset Bool 0/1 Reset command to reset faults.
iInitialisationMode Bool 0/1 Start of initialisation procedure.
iAutomaticMode Bool 0/1 Installation is in automatic mode. Operation is
influenced by the sensors and communication with the
infeed/outfeed conveyor.
iManualMode Bool 0/1 Installation is in manual mode. The operation is
influenced by the manual commands.
iManualConveyor Bool 0/1 Command for manual actuation of roller conveyor
iManualForwards Bool 0/1 Command manual actuation of horizontal movement
to the infeed position
iManualBackwards Bool 0/1 Command manual actuation of horizontal movement
to the waiting position
iB1 Bool 0/1 Sensor for detection of waiting position
iB2 Bool 0/1 Sensor for detection of low speed waiting position
iB3 Bool 0/1 Sensor for detection of low-speed infeed position
iB4 Bool 0/1 Sensor for detection of infeed position
iB7 Bool 0/1 Sensor for position of entered product
iB15 Bool 0/1 Sensor for product position control
iDownStream_ObjectReady Bool 0/1 Communication signal of downstream transport:
Object ready for infeeding.
iDownStream_ObjectDestination Int 1..20 Communication signal of downstream transport:
Object destination level.
iDownStream_ObjectInformation UDT Communication signal of downstream transport:
‘UDT_Prorunner_mk5_Customer_Information’
Any information that can be sent along with each
object. This UDT can be configured by yourself.

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10.7 Outputs infeed module RDC4

Exits must be declared by the customer. Outputs provide feedback such as faults, status and
communication signals with downstream transport.

Tabel 30: Outputs infeed module RDC4

Naming Data Unit Description
type
oAlarm Bool 0/1 Fault active
oAlarmCode Int 0 Active fault code (See chapter ‘Faults’ for the correct
overview)
oAlarmFeedback Word 0 Active fault feedback for HMI. One bit is reserved for each
fault. Fault 1 = bit 0, fault 2 = bit 1, etc.
oStatus Int 0 See chapter ‘Status Prorunner mk5’ for further information.

oDownStream_Start Bool 0/1 Communication signal to downstream transport:

Infeed module ready/busy for transport to the end of the
roller conveyor
oDownStream_MotorIsRunn Bool 0/1 Communication signal to downstream transport:
ing Infeed module roller conveyor running. If this signal stops,
the roller conveyor downstream must also stop.

10.8 Motor interface infeed module RDC4

Two motors are used for the infeed module. All commands are prepared via this motor interface to
handle different forms of motor actuation.
For more information, please refer to chapter ‘16 - Motor interface’

Tabel 31: Motor interface infeed module RDC4

Naming Data Unit Description
type
xConveyor UDT UDT_MotorControl
Motor interface roller conveyor infeed module RDC4
xMotion UDT UDT_MotorControl
Motor interface horizontal movement infeed module RDC4

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10.9 Status infeed module RDC4

The status of the infeed module is output, giving the user a clear picture of the status/movements
of the infeed module RDC4

Tabel 32: Status infeed module RDC4

Description / Cause
Code

0 NO ACTION:
Infeed module switched off / no mode active
1 MANUAL OPERATION:
Infeed module in manual mode
3 INITIALISATION PROCEDURE ACTIVE:
Infeed module busy with initialisation procedure.
4 INITIALISATION PROCEDURE READY:
Infeed module finished with initialisation procedure.
5 CONFIGURATION CHECK:
Infeed module finished with initialisation procedure.
6 RESTART / START-UP PROCEDURE:
Procedure after fault; this involves checking whether an object is present and whether it is correctly
positioned.
7 FAULT:
Infeed module blocked by fault
10 WAITING:
Infeed module ready for use, object infeeding can be started
11 MOVEMENT TO INFEED POSITION:
Infeed module busy with horizontal movement to infeed position
12 AT INFEED POSITION:
Infeed module ready for transport of object
13 MOVEMENT TO WAITING POSITION:
Infeed module busy with horizontal movement to waiting position
14 AT WAIT POSITION:
Infeed module in waiting position.
15 OBJECT INFEEDING BUSY:
Infeed module busy with object infeeding.
16 OBJECT ACCEPTED ON INFEED CONVEYOR:
Infeed module has received object on belt (sensor iB15)
17 OBJECT PRESENT ON INFEED CONVEYOR:
Infeed module in the process of moving object to the end of the roller conveyor (sensor iB7 covered and
iB15 uncovered).
18 WAIT UNTIL OBJECT HAS BEEN PICKED UP:
Infeed module waits until Prorunner mk5 has picked up object. Information is also made available in this
status/step.

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10.10 Faults outfeed module RDC4

With the outfeed signal ‘oAlarm’ it is possible to indicate a fault by, for example, switching on a red
lamp. With the fault code ‘oAlarmCode’ you can indicate this better.
With the fault word ‘oAlarmFeedback’ you can generate a clearly defined fault message by means
of an HMI. The faults are divided over 16 bits. Code 1 = bit 0 ... Code 16 = bit 15.
Below is the list of faults that may be active with explanation/effect and solution.

Tabel 33: Faults list infeed module RDC4

Description / Cause Effect Solution
Code

1 Feeding object in is taking too long. Automatic operation is stopped. Put the object down manually in
Sensor object detection does not Command to PRORUNNER that the sensors; iB15 uncovered, iB7
see the object within time limits infeed module is blocked. covered.
Start-up procedure of infeed Give the reset command to reset
conveyor must be carried out. the fault. Resetting is not possible
if sensor iB15 is covered.
2 Object fed in too fast. Automatic operation is stopped. Check for unknown objects.
It is possible that the product is too Command to PRORUNNER that Put the object down manually in
long and/or that an unknown infeed module is blocked. the sensors; iB15 uncovered, iB7
object has been seen. Start-up procedure of infeed covered.
conveyor must be carried out. Give the reset command to reset
the fault. Resetting is not possible
if sensor iB15 is covered.
3 Unknown object detected. Automatic operation is stopped. Check for unknown objects.
Sensors triggered while the infeed Command to PRORUNNER that Give the reset command to reset
module is not busy with this step. infeed module is blocked. the fault. Resetting is not possible
Start-up procedure of infeed if sensor iB15 is covered.
conveyor must be carried out.
4 Object too small. Automatic operation is stopped. Check object length.
iB15 triggered for too short. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the shortest infeed module is blocked. the fault.
product length Start-up procedure of infeed Resetting is not possible if sensor
conveyor must be carried out. iB15 is covered.
5 Object too big. Automatic operation is stopped. Check object length.
iB15 triggered for too long. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the longest infeed module is blocked. the fault.
product length Start-up procedure of infeed Resetting is not possible if sensor
conveyor must be carried out. iB15 is covered.
6 Unknown destination of object on Automatic operation is stopped. Remove object from infeed
infeed conveyor. Command to PRORUNNER that conveyor and check
This must higher than ‘0’ and less infeed module is blocked. communication with downstream
than or equal to the number of Start-up procedure of infeed transport.
levels present. conveyor must be carried out. Give the reset command to reset
the fault.
Resetting is not possible if sensor
iB15 is covered.
8 Configuration is not entered Automatic operation is stopped. Check configuration settings.
correctly Command to PRORUNNER that Make sure that everything is
infeed module is blocked. entered correctly and not below
the minimum value.

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Description / Cause Effect Solution

Code

9 Start-up procedure time-out. Automatic operation is stopped. Put the object down manually in
Sensor iB15 does not become Command to PRORUNNER that the sensors; iB15 uncovered, iB7
untriggered. infeed module is blocked. covered.
Give the reset command to reset
the fault.
10 Movement to waiting position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB1 sensor
Give the reset command to reset
the fault.
11 Movement to infeed position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB4 sensor
Give the reset command to reset
the fault.
12 Position horizontal movement no Automatic operation is stopped. Check adjustment/operation of
longer correct. Command to PRORUNNER that the iB1 & iB4 sensor.
infeed module is blocked. Give the reset command to reset
the fault.
13 Fault controller/drive conveyor Automatic operation is stopped. Check operation/fault
track. Command to PRORUNNER that controller/drive.
infeed module is blocked. Make sure that it is ready for
(Depending on position) operation again.
Give the reset command to reset
the fault.
14 Fault controller/drive horizontal See fault 13 See fault 13
movement.
15 Initialisation procedure: object still Initialisation has not been Empty the conveyor track.
detected on conveyor track. completed. Restart procedure by giving
initialisation command again.
16 Initialisation procedure: Safe Initialisation has not been Check the movement of the
position not reached completed. infeed module.
Check operation and adjustment
of position indicator sensors.
Restart procedure by giving
initialisation command again.

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11 Function block infeed module MBC4

With this software block, the infeed module MBC4 is called.

MBC4 stands for: Multibelt conveyor 4  Moveable

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11.1 Function block specifications infeed module MBC4

Block name: FB_Prorunner_mk5_Infeed_MBC4

Block number: FB1066
Version: V0.1
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_MotorControl
UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Customer_Information
UDT_Prorunner_mk5_Infeed_Configuration
UDT_Prorunner_mk5_Infeed_Handshake
Function block call Cyclical (OB1)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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11.2 Components infeed module MBC4

Figuur 15: Components infeed module RDC4

iB1
iB7
iB2

iB3

iB4

iB15

xConveyor
iB5

xMotion

Tabel 34: Components infeed module RDC4

Code Type
iB15 Sensor/ photocell: Product position monitoring. GL6-P4211
This photocell monitors whether the product has completely entered C42-2
the infeed roller conveyor.
iB7 Sensor/ photocell: Product on infeed. GL6-P4211
This photocell detects whether the product has entered the infeed C42-2
roller conveyor
iB1 Inductive approach: Wait for position (from Prorunner) IM-18
Sensor detection that horizontal movement is in waiting position. This
is the position in which an object can be entered, and the conveyor is
in a safe position for the Prorunner carriers.
iB2 Inductive approach: Wait for position (from Proruner) low speed IM-18
Sensor detection that switches the shuttle to low speed when moving
to the wait position

iB3 Inductive approach: Infeed position (from Proruner) low speed IM-18
Sensor detection that switches the shuttle to low speed when moving
to the infeed position

iB4 Inductive approach: Infeed position (from Prorunner) IM-18

Sensor detection that horizontal movement is at infeed position so a
carrier of the Prorunner can pick up the object
iB5 Sensor/ photocell: Product picked up from conveyor GL6
xConveyor Actuation roller conveyor SEW
xMotion Actuation Shuttle movement SEW

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11.3 Configuration infeed module MBC4

Configuration according to UDT_Prorunner_mk5_Infeed_Configuration

Tabel 35: Configuration infeed module MBC4

Naming Data type Unit Description
Module.Level Int 1..20 Level number.
Module.Height Real mm. Exact height of the conveyor
measured from the floor
Options.LowspeedPickup Bool 0/1 Picking up by using lower speed
(1=active)
Conveyor.Speed Real m/s. Speed of conveyor track at rated
actuation (metre per second)
Conveyor.Length Real mm. Exact length of infeed conveyor
Transport.CycleTime Real s. Time necessary to perform
infeed transport.
Transport.Speed Int Hz Number of Hertz (Nominal = 50
Hz)
Transport.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Transport.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill
Movement.CycleTime Real s. Time needed to move shuttle
between infeed position and
waiting position.
Movement.Speed Real m/s. Speed of movement
Movement.HighSpeed Int Hz Number of Hertz (Nominal = 50
Hz)
Movement.LowSpeed Int Hz Number of Hertz (Nominal = 50
Hz)
Movement.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Movement.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill

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11.4 Inputs infeed module MBC4

Inputs must be declared by the customer. Inputs provide information such as configuration, status
of installation, status sensors, manual pushbutton and communication signals with downstream
transport

Tabel 36: Inputs infeed module MBC4

Naming Data Unit Description
type
iConfiguration UDT UDT as discussed in section above
iEnabled Bool 0/1 System is switched on. Safety functions are operational
and power supplies to the controllers are switched on.
iReset Bool 0/1 Reset command to reset faults.
iInitialisationMode Bool 0/1 Start of initialisation procedure.
iAutomaticMode Bool 0/1 Installation is in automatic mode. Operation is
influenced by the sensors and communication with the
infeed/outfeed conveyor.
iManualMode Bool 0/1 Installation is in manual mode. The operation is
influenced by the manual commands.
iManualConveyor Bool 0/1 Command for manual actuation of roller conveyor
iManualForwards Bool 0/1 Command manual actuation of horizontal movement
to the infeed position
iManualBackwards Bool 0/1 Command manual actuation of horizontal movement
to the waiting position
iB1 Bool 0/1 Sensor for detection of waiting position (stop)
iB2 Bool 0/1 Sensor for detection of waiting position (low speed)
iB3 Bool 0/1 Sensor for detection of infeed position (low speed)
iB4 Bool 0/1 Sensor for detection of infeed position (stop)
iB5 Bool 0/1 Sensor for detection of product picked up
iB7 Bool 0/1 Sensor for position of entered product
iB15 Bool 0/1 Sensor for product position control
iDownStream_ObjectReady Bool 0/1 Communication signal of downstream transport:
Object ready for infeeding.
iDownStream_ObjectDestination Int 1..20 Communication signal of downstream transport:
Object destination level.
iDownStream_ObjectInformation UDT Communication signal of downstream transport:
‘UDT_Prorunner_mk5_Customer_Information’
Any information that can be sent along with each
object. This UDT can be configured by yourself.

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11.5 Outputs infeed module MBC4

Exits must be declared by the customer. Outputs provide feedback such as faults, status and
communication signals with downstream transport.

Tabel 37: Outputs infeed module MBC4

Naming Data Unit Description
type
oAlarm Bool 0/1 Fault active
oAlarmCode Int 0 Active fault code (See chapter ‘Faults’ for the correct
overview)
oAlarmFeedback Word 0 Active fault feedback for HMI. One bit is reserved for each
fault. Fault 1 = bit 0, fault 2 = bit 1, etc.
oStatus Int 0 See chapter ‘Status Prorunner mk5’ for further information.

oDownStream_Start Bool 0/1 Communication signal to downstream transport:

Infeed module ready/busy for transport to the end of the
roller conveyor
oDownStream_MotorIsRunn Bool 0/1 Communication signal to downstream transport:
ing Infeed module roller conveyor running. If this signal stops,
the roller conveyor downstream must also stop.

11.6 Motor interface infeed module MBC4

Two motors are used for the infeed module. All commands are prepared via this motor interface to
handle different forms of motor actuation.
For more information, please refer to chapter ‘16 - Motor interface’

Tabel 38: Motor interface infeed module MBC4

Naming Data Unit Description
type
xConveyor UDT UDT_MotorControl
Motor interface multi belt conveyor infeed module MBC4
xMotion UDT UDT_MotorControl
Motor interface shuttle movement

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11.7 Status infeed module MBC4

The status of the infeed module is output, giving the user a clear picture of the status/movements
of the infeed module MBC4

Tabel 39: Status infeed module MBC4

Description / Cause
Code

0 NO ACTION:
Infeed module switched off / no mode active
1 MANUAL OPERATION:
Infeed module in manual mode
3 INITIALISATION PROCEDURE ACTIVE:
Infeed module busy with initialisation procedure.
4 INITIALISATION PROCEDURE READY:
Infeed module finished with initialisation procedure.
5 CONFIGURATION CHECK:
Infeed module finished with initialisation procedure.
6 RESTART / START-UP PROCEDURE:
Procedure after fault; this involves checking whether an object is present and whether it is correctly
positioned.
7 FAULT:
Infeed module blocked by fault
10 WAITING:
Infeed module ready for use, object infeeding can be started
11 MOVEMENT TO INFEED POSITION:
Infeed module busy with horizontal movement to infeed position
12 AT INFEED POSITION:
Infeed module ready for transport of object
13 MOVEMENT TO WAITING POSITION:
Infeed module busy with horizontal movement to waiting position
14 AT WAIT POSITION:
Infeed module in waiting position.
15 OBJECT INFEEDING BUSY:
Infeed module busy with object infeeding.
16 OBJECT ACCEPTED ON INFEED CONVEYOR:
Infeed module has received object on belt (sensor iB15)
17 OBJECT PRESENT ON INFEED CONVEYOR:
Infeed module in the process of moving object to the end of the roller conveyor (sensor iB7 covered and
iB15 uncovered).
18 WAIT UNTIL OBJECT HAS BEEN PICKED UP:
Infeed module waits until Prorunner mk5 has picked up object. Information is also made available in this
status/step.

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11.8 Faults infeed module MBC4

With the outfeed signal ‘oAlarm’ it is possible to indicate a fault by, for example, switching on a red
lamp. With the fault code ‘oAlarmCode’ you can indicate this better.
With the fault word ‘oAlarmFeedback’ you can generate a clearly defined fault message by means
of an HMI. The faults are divided over 16 bits. Code 1 = bit 0 ... Code 16 = bit 15.
Below is the list of faults that may be active with explanation/effect and solution.

Tabel 40: Faults list infeed module MBC4

Description / Cause Effect Solution
Code

1 Feeding object in is taking too long. Automatic operation is stopped. Put the object down manually in
Sensor object detection does not Command to PRORUNNER that the sensors; iB15 uncovered, iB7
see the object within time limits infeed module is blocked. covered.
Start-up procedure of infeed Give the reset command to reset
conveyor must be carried out. the fault. Resetting is not possible
if sensor iB15 is covered.
2 Object fed in too fast. Automatic operation is stopped. Check for unknown objects.
It is possible that the product is too Command to PRORUNNER that Put the object down manually in
long and/or that an unknown infeed module is blocked. the sensors; iB15 uncovered, iB7
object has been seen. Start-up procedure of infeed covered.
conveyor must be carried out. Give the reset command to reset
the fault. Resetting is not possible
if sensor iB15 is covered.
3 Unknown object detected. Automatic operation is stopped. Check for unknown objects.
Sensors triggered while the infeed Command to PRORUNNER that Give the reset command to reset
module is not busy with this step. infeed module is blocked. the fault. Resetting is not possible
Start-up procedure of infeed if sensor iB15 is covered.
conveyor must be carried out.
4 Object too small. Automatic operation is stopped. Check object length.
iB15 triggered for too short. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the shortest infeed module is blocked. the fault.
product length Start-up procedure of infeed Resetting is not possible if sensor
conveyor must be carried out. iB15 is covered.
5 Object too big. Automatic operation is stopped. Check object length.
iB15 triggered for too long. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the longest infeed module is blocked. the fault.
product length Start-up procedure of infeed Resetting is not possible if sensor
conveyor must be carried out. iB15 is covered.
6 Unknown destination of object on Automatic operation is stopped. Remove object from infeed
infeed conveyor. Command to PRORUNNER that conveyor and check
This must higher than ‘0’ and less infeed module is blocked. communication with downstream
than or equal to the number of Start-up procedure of infeed transport.
levels present. conveyor must be carried out. Give the reset command to reset
the fault.
Resetting is not possible if sensor
iB15 is covered.
8 Configuration is not entered Automatic operation is stopped. Check configuration settings.
correctly Command to PRORUNNER that Make sure that everything is
infeed module is blocked. entered correctly and not below
the minimum value.

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Description / Cause Effect Solution

Code

9 Start-up procedure time-out. Automatic operation is stopped. Put the object down manually in
Sensor iB15 does not become Command to PRORUNNER that the sensors; iB15 uncovered, iB7
untriggered. infeed module is blocked. covered.
Give the reset command to reset
the fault.
10 Movement to waiting position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB1 sensor
Give the reset command to reset
the fault.
11 Movement to infeed position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB4 sensor
Give the reset command to reset
the fault.
12 Position horizontal movement no Automatic operation is stopped. Check adjustment/operation of
longer correct. Command to PRORUNNER that the iB1 & iB4 sensor.
infeed module is blocked. Give the reset command to reset
the fault.
13 Fault controller/drive conveyor Automatic operation is stopped. Check operation/fault
track. Command to PRORUNNER that controller/drive.
infeed module is blocked. Make sure that it is ready for
(Depending on position) operation again.
Give the reset command to reset
the fault.
14 Fault controller/drive horizontal See fault 13 See fault 13
movement.
15 Initialisation procedure: object still Initialisation has not been Empty the conveyor track.
detected on conveyor track. completed. Restart procedure by giving
initialisation command again.
16 Initialisation procedure: Safe Initialisation has not been Check the movement of the
position not reached completed. infeed module.
Check operation and adjustment
of position indicator sensors.
Restart procedure by giving
initialisation command again.

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12 Function block outfeed module RDC2/MBC2

Figuur 16: Function block outfeed module RDC2/MBC2

With this software block, the outfeed module RDC2/MBC2 is called.

‘RDC2’ stands for: Roller Drive Conveyor type 2  Fixed position
‘MBC2’ stands for: Multi Belt Conveyor type 2  Fixed position

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12.1 Function block specifications outfeed module RDC2/MBC2

Block name: FB_Prorunner_mk5_Outfeed_RDC2/MBC2

Block number: FB1072
Version: V4.1
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_MotorControl
UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Customer_Information
UDT_Prorunner_mk5_Outfeed_Configuration
UDT_Prorunner_mk5_Outfeed_Handshake
Function block call Cyclical (OB1)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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12.2 Components outfeed module RDC2/MBC2

Figuur 17: Components outfeed module RDC2

xConveyor

iB16
iB8

Tabel 41: Components outfeed module RDC2

Code Type
iB8 Sensor/Photocell: Product on outfeed GL6-P4211
This photocell monitors whether a product is present on the C42-2
outfeed conveyor.
iB16 Sensor/photocell; Product has left module GL6-P4211
This photocell detects whether the product has run out on the C42-2
outfeed conveyor
xConveyor Actuation roller conveyor Drivecontrol 20/54
Rollerdrive

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iB8

iB16

xConveyor

Tabel 42:
Components outfeed module MBC2
Code Type
iB8 Sensor/Photocell: Product on outfeed GT6
This photocell monitors whether a product is present on the
outfeed conveyor.
iB16 Sensor/photocell; Product has left module GT6
This photocell detects whether the product has run out on the
outfeed conveyor
xConveyor Actuation conveyor SEW

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12.3 Flow chart functionality outfeed module RDC2/MBC2

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12.4 Configuration outfeed module RDC2/MBC2

Configuration according to UDT_Prorunner_mk5_Outfeed_Configuration

Tabel 43: Configuration outfeed module RDC2/MBC2

Naming Data type Unit Description
Module.Level Int 1..20 Level number.
Module.Height Real mm. Exact height of the belt,
measured from the floor
Options.LowspeedDropoff Bool 0/1 Drop off by means of use of
lower speed (1=active)
Conveyor.Speed Real m/s. Speed of conveyor track at rated
actuation (metre per second)
Conveyor.Length Real mm. Exact length of outfeed conveyor
Transport.CycleTime Real s. Time needed to perform outfeed
transport.
Transport.Speed Int Hz Number of Hertz (Nominal = 50
Hz)
Transport.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Transport.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill

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12.5 Inputs outfeed module RDC2/MBC2

Inputs must be declared by the customer.
Inputs provide information such as configuration, status of installation, status sensors, manual
pushbutton and communication signals with upstream transport
Tabel 44: Inputs outfeed module RDC2/MBC2
Naming Data Unit Description
type
iConfiguration UDT UDT as discussed in section above
iEnabled Bool 0/1 System is switched on. Safety functions are operational
and power supplies to the controllers are switched on.
iReset Bool 0/1 Reset command to reset faults.
iInitialisationMode Bool 0/1 Start of initialisation procedure.
iAutomaticMode Bool 0/1 Installation is in automatic mode. Operation is
influenced by the sensors and communication with the
infeed/outfeed conveyor.
iManualMode Bool 0/1 Installation is in manual mode. The operation is
influenced by the manual commands.
iManualConveyor Bool 0/1 Command for manual actuation of roller conveyor
iB8 Bool 0/1 Sensor for registering product presence
iB16 Bool 0/1 Sensor for detection of product running out onto
outfeed conveyor
iUpStream_Ready Bool 0/1 Communication signal of upstream transport:
Transport system ready to receive object
iUpStream_Running Bool 0/1 Communication signal of upstream transport:
Transport system systems ready & transport running.

12.6 Outputs outfeed module RDC2/MBC2

Exits must be declared by the customer.
Outputs provide feedback such as faults, status and communication signals with upstream
transport.
Tabel 45: Outputs outfeed module RDC2/MBC2
Naming Data Unit Description
type
oAlarm Bool 0/1 Fault active
oAlarmCode Int 0 Active fault code (See chapter ‘Faults’ for the correct
overview)
oAlarmFeedback Word 0 Active fault feedback for HMI. One bit is reserved for each
fault. Fault 1 = bit 0, fault 2 = bit 1, etc.
oStatus Int 0 See chapter ‘Status Prorunner mk5’ for further information.
oUpStream_ObjectReady Bool 0/1 Communication signal to the upstream transport:
Object ready for outfeed.
oUpStream_ObjectSource Int 1..20 Communication signal to the upstream transport:
Object source level.
oUpStream_ObjectInformati UDT Communication signal to the upstream transport:
on ‘UDT_Prorunner_mk5_Customer_Information’
Additional information that was sent with the object.

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12.7 Motor interface outfeed module RDC2/MBC2

One motor is used for the outfeed module. All commands are prepared via this motor interface to
handle different forms of motor actuation.
For more information, please refer to chapter ‘16 - Motor interface’

Tabel 46: Motor interface outfeed module RDC2/MBC2

Naming Data Unit Description
type
xConveyor UDT UDT_MotorControl
Motor interface outfeed module RDC2/MBC2

12.8 Status outfeed module RDC2/MBC2

The status of the outfeed module is output, giving the user a clear picture of the status/movements
of the outfeed module RDC2/MBC2.

Tabel 47: Status outfeed module RDC2/MBC2

Description / Cause
Code

0 NO ACTION:
Outfeed module switched off / no mode active
1 MANUAL OPERATION:
Outfeed module in manual mode
3 INITIALISATION PROCEDURE ACTIVE:
Outfeed module busy with initialisation procedure.
4 INITIALISATION PROCEDURE READY:
Outfeed module finished with initialisation procedure.
5 CONFIGURATION CHECK:
Outfeed module finished with initialisation procedure.
6 RESTART / START-UP PROCEDURE:
Procedure after fault; this involves checking whether an object is present and whether it is correctly
positioned.
7 FAULT:
Outfeed module blocked by fault
10 WAITING:
Outfeed module ready for use; depositing objects allowed
15 OBJECT ACCEPTED ON OUTFEED TRACK:
Outfeed module has received object on track (sensor iB8)
16 OBJECT TRANSPORT BUSY
Outfeed module in the process of moving object to the end of the conveyor track (sensor iB16 covered)
17 OBJECT AT END OF TRACK:
Object at end of the conveyor track, waiting for iB16 to be uncovered.

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12.9 Faults outfeed module RDC2/MBC2

With the outfeed signal ‘oAlarm’ it is possible to indicate a fault by, for example, switching on a red
lamp. With the fault code ‘oAlarmCode’ you can indicate this better.
With the fault word ‘oAlarmFeedback’ you can generate a clearly defined fault message by means
of an HMI. The faults are divided over 16 bits. Code 1 = bit 0 ... Code 16 = bit 15.
Below is the list of faults that may be active with explanation/result and solution.

Tabel 48: Faults list outfeed module RDC2/MBC2

Description / Cause Effect Solution
Code

1 Object outfeeding is taking too Automatic operation is stopped. Remove object manually from the
long. Command to PRORUNNER that conveyor track
outfeed module is blocked. Give the reset command to reset
Start-up procedure of outfeed the fault. Resetting is not possible
conveyor must be carried out. if sensor iB8 or iB16 is covered.
2 No drop off detected, while carrier Automatic operation is stopped. Check if object is correctly aligned
declares that it has an object Command to PRORUNNER that on the carrier so the photocells
present outfeed module is blocked. detect the object.
Start-up procedure of outfeed If no object is present, reset the
conveyor must be carried out. alarm
3 Unknown object detected. Automatic operation is stopped. Check for unknown objects.
Sensors triggered while the outfeed Command to PRORUNNER that Give the reset command to reset
module is not busy with the outfeed module is blocked. the fault. Resetting is not possible
corresponding step. Start-up procedure of outfeed if sensor iB8 or iB16 is covered.
conveyor must be carried out.
4 Object too small. Automatic operation is stopped. Check object length.
iB16 triggered for too short. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the outfeed module is blocked. the fault.
minimum product length Start-up procedure of outfeed Resetting is not possible if sensor
conveyor must be carried out. iB8 or iB16 is covered.
5 Object too big. Automatic operation is stopped. Check object length.
iB16 triggered for too long. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the outfeed module is blocked. the fault.
maximum product length Start-up procedure of outfeed Resetting is not possible if sensor
conveyor must be carried out. iB8 or iB16 is covered.
8 Configuration is not entered Automatic operation is stopped. Check configuration settings.
correctly Command to PRORUNNER that Make sure that everything is
outfeed module is blocked. entered correctly and not below
the minimum value.
9 Start-up procedure time-out. Automatic operation is stopped. Remove object manually; iB8
Sensor iB8 & iB16 does not become Command to PRORUNNER that uncovered & iB16 uncovered.
untriggered. outfeed module is blocked. Give the reset command to reset
the fault.
13 Fault controller/drive conveyor Automatic operation is stopped. Check operation/fault
track. Command to PRORUNNER that controller/drive.
outfeed module is blocked. Make sure that it is ready for
(Depending on position) operation again.
Give the reset command to reset
the fault.

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Description / Cause Effect Solution

Code

15 Initialisation procedure: object still Initialisation has not been Empty the conveyor track.
detected on conveyor track. completed. Restart procedure by giving
initialisation command again.

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13 Function block outfeed module RDC3

Figuur 18: Function block outfeed module RDC3

With this software block, the outfeed module RDC3 is called.

RDC3 stands for: Tilting Roller Drive Conveyor type 3  Moveable

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13.1 Function block specifications outfeed module RDC4

Block name: FB_Prorunner_mk5_Outfeed_RDC3

Block number: FB1076
Version: V0.9
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_MotorControl
UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Outfeed_Configuration
UDT_Prorunner_mk5_Outfeed_Handshake
Function block call Cyclical (OB1)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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13.2 Components outfeed module RDC4

Figuur 19: Components outfeed module RDC4

oY2/ iB1
oY3 xConveyor

iB4

iB8
iB16

Tabel 49: Components infeed module RDC3

Code Type
iB16 Sensor/ photocell: Product position monitoring. GL6-P4211
This photocell monitors whether the product has completely left the C42-2
outfeed roller conveyor.
iB8 Sensor/ photocell: Product on infeed. GL6-P4211
This photocell detects whether the product is dropped on the outfeed C42-2
conveyor
iB1 Inductive approach: Wait for position (from Prorunner) SMT-8M-A-PS-24V-E-1-
Sensor detection that horizontal movement is in waiting position. This N-M12
is the position in which no object can be entered, and the conveyor is
in a safe position for the Prorunner carriers.
iB4 Inductive approach: Outfeed position (In Prorunner) SMT-8M-A-PS-24V-E-1-
Sensor detection that horizontal movement is at outfeed position. This N-M12
is the position in which an object can be transported.
xConveyor Actuation roller conveyor Drivecontrol 20/54
Rollerdrive
oY2/oY3 Actuation tilting movement Air valve

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13.4 Flow chart functionality outfeed module RDC3

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13.5 Configuration outfeed module RDC3

Configuration according to UDT_Prorunner_mk5_outfeed_Configuration

Tabel 50: Configuration outfeed module RDC3

Naming Data type Unit Description
Module.Level Int 1..20 Level number.
Module.Height Real mm. Exact height of the conveyor
measured from the floor
Options.LowspeedDropoff Bool 0/1 Drop off by means of use of
lower speed (1=active)
Conveyor.Speed Real m/s. Speed of conveyor track at rated
actuation (metre per second)
Conveyor.Length Real mm. Exact length of outfeed conveyor
Transport.CycleTime Real s. Time needed to perform outfeed
transport.
Transport.Speed Int Hz Number of Hertz (Nominal = 50
Hz)
Transport.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Transport.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill
Movement.CycleTime Real s. Time needed to tilt conveyor
between outfeed position and
waiting position.

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13.6 Inputs outfeed module RDC3

Inputs must be declared by the customer. Inputs provide information such as configuration, status
of installation, status sensors, manual pushbutton and communication signals with downstream
transport

Tabel 51: Inputs outfeed module RDC3

Naming Data Unit Description
type
iConfiguration UDT UDT as discussed in section above
iEnabled Bool 0/1 System is switched on. Safety functions are operational
and power supplies to the controllers are switched on.
iReset Bool 0/1 Reset command to reset faults.
iInitialisationMode Bool 0/1 Start of initialisation procedure.
iAutomaticMode Bool 0/1 Installation is in automatic mode. Operation is
influenced by the sensors and communication with the
infeed/outfeed conveyor.
iManualMode Bool 0/1 Installation is in manual mode. The operation is
influenced by the manual commands.
iManualConveyor Bool 0/1 Command for manual actuation of roller conveyor
iManualForwards Bool 0/1 Command manual actuation of horizontal movement
to the infeed position
iManualBackwards Bool 0/1 Command manual actuation of horizontal movement
to the waiting position
iB1 Bool 0/1 Sensor for detection of waiting position
iB4 Bool 0/1 Sensor for detection of infeed position
iB8 Bool 0/1 Sensor for detection object present outfeed conveyor
iB16 Bool 0/1 Sensor for detection object left outfeed conveyor
iUpStream_Ready Bool 0/1 Communication signal of upstream transport:
Transport system ready to receive object
iUpStream_Running Bool 0/1 Communication signal of upstream transport:
Transport system systems ready & transport running.

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13.7 Outputs outfeed module RDC3

Exits must be declared by the customer. Outputs provide feedback such as faults, status and
communication signals with downstream transport.

Tabel 52: Outputs outfeed module RDC3

Naming Data Unit Description
type
oAlarm Bool 0/1 Fault active
oAlarmCode Int 0 Active fault code (See chapter ‘Faults’ for the correct
overview)
oAlarmFeedback Word 0 Active fault feedback for HMI. One bit is reserved for each
fault. Fault 1 = bit 0, fault 2 = bit 1, etc.
oStatus Int 0 See chapter ‘Status Prorunner mk5’ for further information.

oUpStream_ObjectReady Bool 0/1 Communication signal to the upstream transport:

Object ready for outfeed.
oUpStream_ObjectSource Int 1..20 Communication signal to the upstream transport:
Object source level.
oY2 Bool 0/1 Tilt the conveyor to the wait (upwards) position

oY3 Bool 0/1 Tilt the conveyor to the outfeed (downwards) position

13.8 Motor interface infeed module RDC3

Two motors are used for the infeed module. All commands are prepared via this motor interface to
handle different forms of motor actuation.
For more information, please refer to chapter ‘16 - Motor interface’

Tabel 53: Motor interface infeed module RDC3

Naming Data Unit Description
type
xConveyor UDT UDT_MotorControl
Motor interface roller conveyor infeed module RDC4

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13.9 Status outfeed module RDC3

The status of the output module is output, giving the user a clear picture of the status/movements
of the outfeed module RDC3

Tabel 54: Status outfeed module RDC3

Description / Cause
Code

0 NO ACTION:
Infeed module switched off / no mode active
1 MANUAL OPERATION:
Infeed module in manual mode
3 INITIALISATION PROCEDURE ACTIVE:
Infeed module busy with initialisation procedure.
4 INITIALISATION PROCEDURE READY:
Infeed module finished with initialisation procedure.
5 CONFIGURATION CHECK:
Infeed module finished with initialisation procedure.
6 RESTART / START-UP PROCEDURE:
Procedure after fault; this involves checking whether an object is present and whether it is correctly
positioned.
7 FAULT:
Infeed module blocked by fault
10 WAITING:
Infeed module ready for use, object infeeding can be started
11 MOVEMENT TO OUTFEED POSITION:
Infeed module busy with horizontal movement to outfeed position
12 AT OUTFEED POSITION:
Outfeed module ready for dropoff of product
13 MOVEMENT TO WAITING POSITION:
Infeed module busy with horizontal movement to waiting position
14 AT WAIT POSITION:
Infeed module in waiting position.
15 ACCEPT PRODUCT ON OUTFEED CONVEYOR:
Product detected (iB8) on outfeed module, request outfeed clearance from upstream
16 OBJECT TRANSPORT:
Upstream able to receive object, start transport with rollerconveyor
17 OBJECT ON END OUTFEED CONVEYOR:
Object detected on end of conveyor (iB16) wait until object is gone

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13.10 Faults outfeed module RDC3

With the outfeed signal ‘oAlarm’ it is possible to indicate a fault by, for example, switching on a red
lamp. With the fault code ‘oAlarmCode’ you can indicate this better.
With the fault word ‘oAlarmFeedback’ you can generate a clearly defined fault message by means
of an HMI. The faults are divided over 16 bits. Code 1 = bit 0 ... Code 16 = bit 15.
Below is the list of faults that may be active with explanation/effect and solution.

Tabel 55: Faults list outfeed module RDC3

Description / Cause Effect Solution
Code

1 Object outfeeding is taking too Automatic operation is stopped. Remove object manually from the
long. Command to PRORUNNER that conveyor track
outfeed module is blocked. Give the reset command to reset
Start-up procedure of outfeed the fault. Resetting is not possible
conveyor must be carried out. if sensor iB8 or iB16 is covered.
2 No drop off detected, while carrier Automatic operation is stopped. Check if object is correctly aligned
declares that it has an object Command to PRORUNNER that on the carrier so the photocells
present outfeed module is blocked. detect the object.
Start-up procedure of outfeed If no object is present, reset the
conveyor must be carried out. alarm
3 Unknown object detected. Automatic operation is stopped. Check for unknown objects.
Sensors triggered while the outfeed Command to PRORUNNER that Give the reset command to reset
module is not busy with the outfeed module is blocked. the fault. Resetting is not possible
corresponding step. Start-up procedure of outfeed if sensor iB8 or iB16 is covered.
conveyor must be carried out.
4 Object too small. Automatic operation is stopped. Check object length.
iB16 triggered for too short. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the outfeed module is blocked. the fault.
minimum product length Start-up procedure of outfeed Resetting is not possible if sensor
conveyor must be carried out. iB8 or iB16 is covered.
5 Object too big. Automatic operation is stopped. Check object length.
iB16 triggered for too long. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the outfeed module is blocked. the fault.
maximum product length Start-up procedure of outfeed Resetting is not possible if sensor
conveyor must be carried out. iB8 or iB16 is covered.
8 Configuration is not entered Automatic operation is stopped. Check configuration settings.
correctly Command to PRORUNNER that Make sure that everything is
infeed module is blocked. entered correctly and not below
the minimum value.
9 Start-up procedure time-out. Automatic operation is stopped. Put the object down manually in
Sensor iB16 does not become Command to PRORUNNER that the sensors; iB16 uncovered, iB8
untriggered. infeed module is blocked. uncovered.
Give the reset command to reset
the fault.
10 Movement to waiting position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB1 sensor
Give the reset command to reset
the fault.

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Description / Cause Effect Solution

Code

11 Movement to outfeed position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB4 sensor
Give the reset command to reset
the fault.
12 Position horizontal movement no Automatic operation is stopped. Check adjustment/operation of
longer correct. Command to PRORUNNER that the iB1 & iB4 sensor.
infeed module is blocked. Give the reset command to reset
the fault.
13 Fault controller/drive conveyor Automatic operation is stopped. Check operation/fault
track. Command to PRORUNNER that controller/drive.
infeed module is blocked. Make sure that it is ready for
(Depending on position) operation again.
Give the reset command to reset
the fault.
14 Fault controller/drive horizontal See fault 13 See fault 13
movement.
15 Initialisation procedure: object still Initialisation has not been Empty the conveyor track.
detected on conveyor track. completed. Restart procedure by giving
initialisation command again.
16 Initialisation procedure: Safe Initialisation has not been Check the movement of the
position not reached completed. infeed module.
Check operation and adjustment
of position indicator sensors.
Restart procedure by giving
initialisation command again.

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14 Function block outfeed module RDC4

Figuur 20: Function block outfeed module RDC4

With this software block, the outfeed module RDC4 is called.

RDC4 stands for: Roller Drive Conveyor type 4  Moveable

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14.1 Function block specifications outfeed module RDC4

Block name: FB_Prorunner_mk5_Outfeed_RDC4

Block number: FB1075
Version: V4.1
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_MotorControl
UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Outfeed_Configuration
UDT_Prorunner_mk5_Outfeed_Handshake
Function block call Cyclical (OB1)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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14.2 Components outfeed module RDC4

Figuur 21: Components outfeed module RDC4

xMotion

iB1

iB8 iB16 iB2

iB3

xConveyor iB4

Tabel 56: Components infeed module RDC4

Code Type
iB16 Sensor/ photocell: Product position monitoring. GL6-P4211
This photocell monitors whether the product has completely left the C42-2
outfeed roller conveyor.
iB8 Sensor/ photocell: Product on infeed. GL6-P4211
This photocell detects whether the product is dropped on the outfeed C42-2
conveyor
iB1 Inductive approach: Wait for position (from Prorunner) IME18-08BPSZC0K
Sensor detection that horizontal movement is in waiting position. This
is the position in which no object can be entered, and the conveyor is
in a safe position for the Prorunner carriers.
iB2 Inductive approach: Low speed waiting position IME18-08BPSZC0K
Sensor detection that horizontal movement should switch to waiting
position to low speed.
iB3 Inductive approach: Low-speed Outfeed position IME18-08BPSZC0K
Sensor detection that horizontal movement should switch to waiting
position to low speed.
iB4 Inductive approach: Outfeed position (In Prorunner) IME18-08BPSZC0K
Sensor detection that horizontal movement is at outfeed position. This
is the position in which an object can be transported.
xConveyor Actuation roller conveyor Drivecontrol 20/54
Rollerdrive
xMotion Actuation horizontal movement SEW drive
See Qimarox info

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14.4 Flow chart functionality outfeed module RDC4

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14.5 Configuration outfeed module RDC4

Configuration according to UDT_Prorunner_mk5_outfeed_Configuration

Tabel 57: Configuration outfeed module RDC4

Naming Data type Unit Description
Module.Level Int 1..20 Level number.
Module.Height Real mm. Exact height of the conveyor
measured from the floor
Options.LowspeedDropoff Bool 0/1 Drop off by means of use of
lower speed (1=active)
Conveyor.Speed Real m/s. Speed of conveyor track at rated
actuation (metre per second)
Conveyor.Length Real mm. Exact length of outfeed conveyor
Transport.CycleTime Real s. Time needed to perform outfeed
transport.
Transport.Speed Int Hz Number of Hertz (Nominal = 50
Hz)
Transport.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Transport.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill
Movement.CycleTime Real s. Time needed to move conveyor
track between outfeed position
and waiting position.
Movement.InfeedPosition Real mm. Position: outfeed position
Movement.BasicPosition Real mm. Position: waiting position
Movement.Speed Real m/s. Speed of movement
Movement.HighSpeed Int Hz Number of Hertz (Nominal = 50
Hz)
Movement.LowSpeed Int Hz Number of Hertz (Nominal = 50
Hz)
Movement.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Movement.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill

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14.6 Inputs outfeed module RDC4

Inputs must be declared by the customer. Inputs provide information such as configuration, status
of installation, status sensors, manual pushbutton and communication signals with downstream
transport

Tabel 58: Inputs outfeed module RDC4

Naming Data Unit Description
type
iConfiguration UDT UDT as discussed in section above
iEnabled Bool 0/1 System is switched on. Safety functions are operational
and power supplies to the controllers are switched on.
iReset Bool 0/1 Reset command to reset faults.
iInitialisationMode Bool 0/1 Start of initialisation procedure.
iAutomaticMode Bool 0/1 Installation is in automatic mode. Operation is
influenced by the sensors and communication with the
infeed/outfeed conveyor.
iManualMode Bool 0/1 Installation is in manual mode. The operation is
influenced by the manual commands.
iManualConveyor Bool 0/1 Command for manual actuation of roller conveyor
iManualForwards Bool 0/1 Command manual actuation of horizontal movement
to the infeed position
iManualBackwards Bool 0/1 Command manual actuation of horizontal movement
to the waiting position
iB1 Bool 0/1 Sensor for detection of waiting position
iB2 Bool 0/1 Sensor for detection of low speed waiting position
iB3 Bool 0/1 Sensor for detection of low-speed infeed position
iB4 Bool 0/1 Sensor for detection of infeed position
iB8 Bool 0/1 Sensor for detection object present outfeed conveyor
iB16 Bool 0/1 Sensor for detection object left outfeed conveyor
iUpStream_Ready Bool 0/1 Communication signal of upstream transport:
Transport system ready to receive object
iUpStream_Running Bool 0/1 Communication signal of upstream transport:
Transport system systems ready & transport running.

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14.7 Outputs outfeed module RDC4

Exits must be declared by the customer. Outputs provide feedback such as faults, status and
communication signals with downstream transport.

Tabel 59: Outputs outfeed module RDC4

Naming Data Unit Description
type
oAlarm Bool 0/1 Fault active
oAlarmCode Int 0 Active fault code (See chapter ‘Faults’ for the correct
overview)
oAlarmFeedback Word 0 Active fault feedback for HMI. One bit is reserved for each
fault. Fault 1 = bit 0, fault 2 = bit 1, etc.
oStatus Int 0 See chapter ‘Status Prorunner mk5’ for further information.

oUpStream_ObjectReady Bool 0/1 Communication signal to the upstream transport:

Object ready for outfeed.
oUpStream_ObjectSource Int 1..20 Communication signal to the upstream transport:
Object source level.

14.8 Motor interface infeed module RDC4

Two motors are used for the infeed module. All commands are prepared via this motor interface to
handle different forms of motor actuation.
For more information, please refer to chapter ‘16 - Motor interface’

Tabel 60: Motor interface infeed module RDC4

Naming Data Unit Description
type
xConveyor UDT UDT_MotorControl
Motor interface roller conveyor infeed module RDC4
xMotion UDT UDT_MotorControl
Motor interface horizontal movement infeed module RDC4

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14.9 Status outfeed module RDC4

The status of the output module is output, giving the user a clear picture of the status/movements
of the outfeed module RDC4

Tabel 61: Status outfeed module RDC4

Description / Cause
Code

0 NO ACTION:
Infeed module switched off / no mode active
1 MANUAL OPERATION:
Infeed module in manual mode
3 INITIALISATION PROCEDURE ACTIVE:
Infeed module busy with initialisation procedure.
4 INITIALISATION PROCEDURE READY:
Infeed module finished with initialisation procedure.
5 CONFIGURATION CHECK:
Infeed module finished with initialisation procedure.
6 RESTART / START-UP PROCEDURE:
Procedure after fault; this involves checking whether an object is present and whether it is correctly
positioned.
7 FAULT:
Infeed module blocked by fault
10 WAITING:
Infeed module ready for use, object infeeding can be started
11 MOVEMENT TO OUTFEED POSITION:
Infeed module busy with horizontal movement to outfeed position
12 AT OUTFEED POSITION:
Outfeed module ready for dropoff of product
13 MOVEMENT TO WAITING POSITION:
Infeed module busy with horizontal movement to waiting position
14 AT WAIT POSITION:
Infeed module in waiting position.
15 ACCEPT PRODUCT ON OUTFEED CONVEYOR:
Product detected (iB8) on outfeed module, request outfeed clearance from upstream
16 OBJECT TRANSPORT:
Upstream able to receive object, start transport with rollerconveyor
17 OBJECT ON END OUTFEED CONVEYOR:
Object detected on end of conveyor (iB16) wait until object is gone

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14.10 Faults outfeed module RDC4

With the outfeed signal ‘oAlarm’ it is possible to indicate a fault by, for example, switching on a red
lamp. With the fault code ‘oAlarmCode’ you can indicate this better.
With the fault word ‘oAlarmFeedback’ you can generate a clearly defined fault message by means
of an HMI. The faults are divided over 16 bits. Code 1 = bit 0 ... Code 16 = bit 15.
Below is the list of faults that may be active with explanation/effect and solution.

Tabel 62: Faults list outfeed module RDC4

Description / Cause Effect Solution
Code

1 Object outfeeding is taking too Automatic operation is stopped. Remove object manually from the
long. Command to PRORUNNER that conveyor track
outfeed module is blocked. Give the reset command to reset
Start-up procedure of outfeed the fault. Resetting is not possible
conveyor must be carried out. if sensor iB8 or iB16 is covered.
2 No drop off detected, while carrier Automatic operation is stopped. Check if object is correctly aligned
declares that it has an object Command to PRORUNNER that on the carrier so the photocells
present outfeed module is blocked. detect the object.
Start-up procedure of outfeed If no object is present, reset the
conveyor must be carried out. alarm
3 Unknown object detected. Automatic operation is stopped. Check for unknown objects.
Sensors triggered while the outfeed Command to PRORUNNER that Give the reset command to reset
module is not busy with the outfeed module is blocked. the fault. Resetting is not possible
corresponding step. Start-up procedure of outfeed if sensor iB8 or iB16 is covered.
conveyor must be carried out.
4 Object too small. Automatic operation is stopped. Check object length.
iB16 triggered for too short. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the outfeed module is blocked. the fault.
minimum product length Start-up procedure of outfeed Resetting is not possible if sensor
conveyor must be carried out. iB8 or iB16 is covered.
5 Object too big. Automatic operation is stopped. Check object length.
iB16 triggered for too long. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the outfeed module is blocked. the fault.
maximum product length Start-up procedure of outfeed Resetting is not possible if sensor
conveyor must be carried out. iB8 or iB16 is covered.
8 Configuration is not entered Automatic operation is stopped. Check configuration settings.
correctly Command to PRORUNNER that Make sure that everything is
infeed module is blocked. entered correctly and not below
the minimum value.
9 Start-up procedure time-out. Automatic operation is stopped. Put the object down manually in
Sensor iB16 does not become Command to PRORUNNER that the sensors; iB16 uncovered, iB8
untriggered. infeed module is blocked. uncovered.
Give the reset command to reset
the fault.
10 Movement to waiting position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB1 sensor
Give the reset command to reset
the fault.

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Description / Cause Effect Solution

Code

11 Movement to outfeed position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
infeed module is blocked. the iB4 sensor
Give the reset command to reset
the fault.
12 Position horizontal movement no Automatic operation is stopped. Check adjustment/operation of
longer correct. Command to PRORUNNER that the iB1 & iB4 sensor.
infeed module is blocked. Give the reset command to reset
the fault.
13 Fault controller/drive conveyor Automatic operation is stopped. Check operation/fault
track. Command to PRORUNNER that controller/drive.
infeed module is blocked. Make sure that it is ready for
(Depending on position) operation again.
Give the reset command to reset
the fault.
14 Fault controller/drive horizontal See fault 13 See fault 13
movement.
15 Initialisation procedure: object still Initialisation has not been Empty the conveyor track.
detected on conveyor track. completed. Restart procedure by giving
initialisation command again.
16 Initialisation procedure: Safe Initialisation has not been Check the movement of the
position not reached completed. infeed module.
Check operation and adjustment
of position indicator sensors.
Restart procedure by giving
initialisation command again.

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15 Function block outfeed module MBC4

Figuur 22: Function block outfeed module MBC4

With this software block, the outfeed module MBC4 is called.

MBC4 stands for: Multi Belt Drive type 4  Moveable

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15.1 Function block specifications outfeed module MBC4

Block name: FB_Prorunner_mk5_Outfeed_MBC4

Block number: FB1084
Version: V1.2
Required PLC blocks: TON_TIMER
Required PLC data types: UDT_MotorControl
UDT_Prorunner_mk5_Carrier
UDT_Prorunner_mk5_Customer_Information
UDT_Prorunner_mk5_Infeed_Configuration
UDT_Prorunner_mk5_Infeed_Handshake
Function block call Cyclical (OB1)
Optimised block access Yes/No
Programming language LAD, SCL
STEP7 version TIA Portal V14 + SP1

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15.2 Components outfeed module MBC4

Figuur 23: Components outfeed module MBC4

xConveyor

iB16
xMotion

iB8 iB1

iB2

iB7 iB3

iB4

Tabel 63: Components outfeed module MBC4

Code Type
iB8 Sensor/photocell: Product present on track GL6-P4211
C42-2
iB16 Sensor/photocell: Product run out onto conveyor GL6-P4211
C42-2
iB1 Inductive approach: Wait for position (from Prorunner) IME18-08BPSZC0K
Sensor detection that horizontal movement is in waiting position. This
is the position in which no object can be entered, and the conveyor is
in a safe position for the Prorunner carriers.
iB2 Inductive approach: Low speed waiting position IME18-08BPSZC0K
Sensor detection that horizontal movement should switch to waiting
position to low speed.
iB3 Inductive approach: Low-speed outfeed position IME18-08BPSZC0K
Sensor detection that horizontal movement should switch to waiting
position to low speed.
iB4 Inductive approach: Outfeed position (In Prorunner) IME18-08BPSZC0K
Sensor detection that horizontal movement is at Infeed position. This is
the position in which an object can be fed in.
iB7 Sensor/probe: Product deposited on rake GTB6-P4211

xConveyor Actuation roller conveyor SEW drive

See Qimarox info
xMotion Actuation horizontal movement SEW drive
See Qimarox info

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15.4 Flow chart functionality outfeed module MBC4

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15.5 Configuration outfeed module MBC4

Configuration according to UDT_Prorunner_mk5_Outfeed_Configuration

Tabel 64: Configuration outfeed module MBC4

Naming Data type Unit Description
Module.Level Int 1..20 Level number.
Module.Height Real mm. Exact height of the conveyor
measured from the floor
Options.LowspeedDropoff Bool 0/1 Drop off by means of use of
lower speed (1=active)
Conveyor.Speed Real m/s. Speed of conveyor track at rated
actuation (metre per second)
Conveyor.Length Real mm. Exact length of outfeed conveyor
Transport.CycleTime Real s. Time needed to perform outfeed
transport.
Transport.Speed Int Hz Number of Hertz (Nominal = 50
Hz)
Transport.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Transport.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill
Movement.CycleTime Real s. Time needed to move conveyor
track between outfeed position
and waiting position.
Movement.InfeedPosition Real mm. Position: outfeed position
Movement.BasicPosition Real mm. Position: waiting position
Movement.Speed Real m/s. Speed of movement
Movement.HighSpeed Int Hz Number of Hertz (Nominal = 50
Hz)
Movement.LowSpeed Int Hz Number of Hertz (Nominal = 50
Hz)
Movement.Acceleration Int ms. Number of milliseconds to
accelerate from standstill to
desired speed
Movement.Deceleration Int ms. Number of milliseconds to
decelerate from current speed to
standstill

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15.6 Inputs outfeed module MBC4

Inputs must be declared by the customer.
Inputs provide information such as configuration, status of installation, status sensors, manual
pushbutton and communication signals with upstream transport

Tabel 65: Inputs outfeed module MBC4

Naming Data Unit Description
type
iConfiguration UDT UDT as discussed in section above
iEnabled Bool 0/1 System is switched on. Safety functions are operational
and power supplies to the controllers are switched on.
iReset Bool 0/1 Reset command to reset faults.
iInitialisationMode Bool 0/1 Start of initialisation procedure.
iAutomaticMode Bool 0/1 Installation is in automatic mode. Operation is
influenced by the sensors and communication with the
infeed/outfeed conveyor.
iManualMode Bool 0/1 Installation is in manual mode. The operation is
influenced by the manual commands.
iManualConveyor Bool 0/1 Command for manual actuation of roller conveyor
iManualForwards Bool 0/1 Command manually actuation of horizontal movement
to outfeed position
iManualBackwards Bool 0/1 Command manual actuation of horizontal movement
to the waiting position
iB1 Bool 0/1 Sensor for detection of waiting position
iB2 Bool 0/1 Sensor for detection of low speed waiting position
iB3 Bool 0/1 Sensor for detection of low-speed prorunner position
iB4 Bool 0/1 Sensor for detection of prorunner position
iB7 Bool 0/1 Sensor for detection object dropped off
iB8 Bool 0/1 Sensor for detection object present outfeed conveyor
iB16 Bool 0/1 Sensor for detection object left outfeed conveyor
iUpStream_Ready Bool 0/1 Communication signal of upstream transport:
Transport system ready to receive object
iUpStream_Running Bool 0/1 Communication signal of upstream transport:
Transport system systems ready & transport running.

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15.7 Outputs outfeed module MBC4

Exits must be declared by the customer.
Outputs provide feedback such as faults, status and communication signals with upstream
transport.

Tabel 66: Outputs outfeed module MBC4

Naming Data Unit Description
type
oAlarm Bool 0/1 Fault active
oAlarmCode Int 0 Active fault code (See chapter ‘Faults’ for the correct
overview)
oAlarmFeedback Word 0 Active fault feedback for HMI. One bit is reserved for each
fault. Fault 1 = bit 0, fault 2 = bit 1, etc.
oStatus Int 0 See chapter ‘Status Prorunner mk5’ for further information.
oUpStream_ObjectReady Bool 0/1 Communication signal to the upstream transport:
Object ready for outfeed.
oUpStream_ObjectSource Int 1..20 Communication signal to the upstream transport:
Object source level.
oUpStream_ObjectInformati UDT Communication signal to the upstream transport:
on ‘UDT_Prorunner_mk5_Customer_Information’
Additional information that was sent with the object.

15.8 Motor interface outfeed module MBC4

Two motors are used for the outfeed module. All commands are prepared via this motor interface
to handle different forms of motor actuation.
For more information, please refer to chapter ‘16 - Motor interface’

Tabel 67: Motor interface outfeed module MBC4

Naming Data Unit Description
type
xConveyor UDT UDT_MotorControl
Motor interface roller conveyor outfeed module RDC4
xMotion UDT UDT_MotorControl
Motor interface horizontal movement outfeed module RDC4

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15.9 Status outfeed module MBC4

The status of the outfeed module is output, giving the user a clear picture of the status/movements
of the outfeed module MBC4

Tabel 68: Status outfeed module MBC4

Description / Cause
Code

0 NO ACTION:
Outfeed module switched off / no mode active
1 MANUAL OPERATION:
Outfeed module in manual mode
3 INITIALISATION PROCEDURE ACTIVE:
Outfeed module busy with initialisation procedure.
4 INITIALISATION PROCEDURE READY:
Outfeed module finished with initialisation procedure.
5 CONFIGURATION CHECK:
Outfeed module finished with initialisation procedure.
6 RESTART / START-UP PROCEDURE:
Procedure after fault; this involves checking whether an object is present and whether it is correctly
positioned.
7 FAULT:
Outfeed module blocked by fault
10 WAITING:
Outfeed module ready for use; feeding object in can be started
11 MOVEMENT TO INFEED POSITION:
Outfeed module busy with horizontal movement to infeed position
12 AT INFEED POSITION:
Outfeed module ready for transport of object
13 MOVEMENT TO WAITING POSITION:
Outfeed module busy with horizontal movement to waiting position
14 AT WAIT POSITION:
Outfeed module waiting at waiting position.
15 OBJECT ACCEPTED ON OUTFEED TRACK:
Outfeed module has received object on track (sensor iB8)
16 OBJECT TRANSPORT BUSY
Outfeed module in the process of moving object to the end of the conveyor track (sensor iB16 covered)
17 OBJECT AT END OF TRACK:
Object at end of the conveyor track, waiting for iB16 to be uncovered.

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15.10 Faults outfeed module MBC4

With the outfeed signal ‘oAlarm’ it is possible to indicate a fault by, for example, switching on a red
lamp. With the fault code ‘oAlarmCode’ you can indicate this better.
With the fault word ‘oAlarmFeedback’ you can generate a clearly defined fault message by means
of an HMI. The faults are divided over 16 bits. Code 1 = bit 0 ... Code 16 = bit 15.
Below is the list of faults that may be active with explanation/result and solution.

Tabel 69: Faults list outfeed module MBC4

Description / Cause Effect Solution
Code

1 Object outfeeding is taking too Automatic operation is stopped. Remove object manually from the
long. Command to PRORUNNER that conveyor track
outfeed module is blocked. Give the reset command to reset
Start-up procedure of outfeed the fault. Resetting is not possible
conveyor must be carried out. if sensor iB8 or iB16 is covered.
3 Unknown object detected. Automatic operation is stopped. Check for unknown objects.
Sensors triggered while the outfeed Command to PRORUNNER that Give the reset command to reset
module is not busy with the outfeed module is blocked. the fault. Resetting is not possible
corresponding step. Start-up procedure of outfeed if sensor iB8 or iB16 is covered.
conveyor must be carried out.
4 Object too small. Automatic operation is stopped. Check object length.
iB16 triggered for too short. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the outfeed module is blocked. the fault.
minimum product length Start-up procedure of outfeed Resetting is not possible if sensor
conveyor must be carried out. iB8 or iB16 is covered.
5 Object too big. Automatic operation is stopped. Check object length.
iB16 triggered for too long. Command to PRORUNNER that Give the reset command to reset
Time is calculated with the outfeed module is blocked. the fault.
maximum product length Start-up procedure of outfeed Resetting is not possible if sensor
conveyor must be carried out. iB8 or iB16 is covered.
8 Configuration is not entered Automatic operation is stopped. Check configuration settings.
correctly Command to PRORUNNER that Make sure that everything is
outfeed module is blocked. entered correctly and not below
the minimum value.
9 Start-up procedure time-out. Automatic operation is stopped. Put the object down manually in
Sensor iB15 does not become Command to PRORUNNER that the sensors; iB15 uncovered, iB7
untriggered. outfeed module is blocked. covered.
Give the reset command to reset
the fault.
10 Movement to waiting position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
outfeed module is blocked. the iB1 sensor
Give the reset command to reset
the fault.
11 Movement to outfeed position is Automatic operation is stopped. Check why this is taking too long.
taking too long Command to PRORUNNER that Check adjustment/operation of
outfeed module is blocked. the iB4 sensor
Give the reset command to reset
the fault.

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Description / Cause Effect Solution

Code

12 Position horizontal movement no Automatic operation is stopped. Check adjustment/operation of

longer correct. Command to PRORUNNER that the iB1 & iB4 sensor.
outfeed module is blocked. Give the reset command to reset
the fault.
13 Fault controller/drive conveyor Automatic operation is stopped. Check operation/fault
track. Command to PRORUNNER that controller/drive.
outfeed module is blocked. Make sure that it is ready for
(Depending on position) operation again.
Give the reset command to reset
the fault.
14 Fault controller/drive horizontal See fault 13 See fault 13
movement.
15 Initialisation procedure: object still Initialisation has not been Empty the conveyor track.
detected on conveyor track. completed. Restart procedure by giving
initialisation command again.
16 Initialisation procedure: Safe Initialisation has not been Check the movement of the
position not reached completed. outfeed module.
Check operation and adjustment
of position indicator sensors.
Restart procedure by giving
initialisation command again.

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16 Motor interface
All commands are prepared through the motor interface to handle different motor controls.
The motor interface handles the communication with the motor used to control the respective
function.
The motor is controlled by means of commands and settings. The motor provides necessary
feedback to maintain interaction through status information.

Tabel 70: Motor control interface incoming commands  UDT_Motorcontrol_Status

Naming Data Unit Description
type
Status.AtTargetSpeed Bool 0/1 Motor is running at desired speed
Status.MotorIsRunning Bool 0/1 Motor is running. In the case of a controller, this is used to
check whether the output stage is actually running.
Status.Blocked Bool 0/1 Motor/Drive blocked
Status.Pulse Bool 0/1 Motor/Drive has moved itself 1cm (10mm)
Status.ActualSpeed Real m/s. Speed in meter per second on which the Prorunner is rotating
Status.ActualFrequency Real Hz Number of Hertz (frequency) what the motor is currently
running at.

Tabel 71: Motor control interface outgoing commands  UDT_Motorcontrol_Command

Naming Data Unit Description
type
Command.Enable Bool 0/1 Switch on motor control
Command.Reset Bool 0/1 Reset motor control faults
Command.QuickStop Bool 0/1 Stop motor quickly due to faults. (0.1 sec deceleration)
Command.Energize Bool 0/1 Pre-magnetise motor
Command.Forward Bool 0/1 Run motor forward, or send up
Command.Reverse Bool 0/1 Run motor backwards, or send down
Command.HighSpeed Bool 0/1 Use high speed (if this is fixed in the motor itself)
Command.Settings.Speed Int Hz Number of Hertz of rated speed (Rated = 50 Hz)
Command.Settings.Accelerat Int ms Number of milliseconds to accelerate from standstill to
ion desired speed
Command.Settings.Decelera Int ms Number of milliseconds to decelerate from current speed to
tion standstill

We recommend to carrying out all asynchronous motors with a frequency controller because
there are different requirements for control:
 Mechanism is less loaded if engine starts slower by means of acceleration
 Quickstop must be possible
Quickstop = quickest possible stop with pre-defined deceleration in controller
This should be set to less than or equal to 0.1 second.

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17 Checklist prorunner configuration

Tabel 72: Checklist heights

Nr Description Unit Configuration
1. Height between ground mm "DB_Prorunner_mk5_Configuration".Main.Prorunner.ColomnHeig
floor and column ht
Prorunner
2. Total height of column mm "DB_Prorunner_mk5_Configuration".Main.Prorunner.SupportHeig
prorunner ht
3. Reference sensor position mm Standard model = 595mm
XL model = 750 mm
4. Infeed level mm "DB_Prorunner_mk5_Configuration".Infeed[1].Module.Height
From ground floor to top
of rollers (Example)
5. Outfeed level mm "DB_Prorunner_mk5_Configuration".Outfeed[1].Module.Height
From ground floor to top
of rollers (Example)

2
5

3 4
1 1

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18 Checklist motor configuration

Tabel 73: Checklist motor nameplate

Nr Description Unit Configuration
1. Rotation per minute on rpm "DB_Prorunner_mk5_Configuration".Main.Prorunner.RPM
50Hz
2. Gearratio i "DB_Prorunner_mk5_Configuration".Main.Prorunner.GearRatio

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