en 1702564652

ConveyLinx-Ai Family
Users Guide
Version 2.0 — Jan 12, 2021
Copyright © 2021 PULSEROLLER

Table of Contents
1. About This Manual ................................................................................................................................. 6
2. Glossary of Terms .................................................................................................................................. 9
3. Getting Started ..................................................................................................................................... 13
4. Module Hardware.................................................................................................................................. 15
4.1. Identifying Module Components .................................................................................................... 16
4.1.1. ConveyLinx-Ai2..................................................................................................................... 17
4.1.2. ConveyLinx-Ai3-24-FC .......................................................................................................... 19
4.1.3. ConveyLinx-Ai3-24-RC ......................................................................................................... 21
4.2. Mounting Dimensions .................................................................................................................... 23
4.2.1. ConveyLinx-Ai2..................................................................................................................... 24
4.2.2. ConveyLinx-Ai3-24-FC .......................................................................................................... 26
4.2.3. ConveyLinx-Ai3-24-RC ......................................................................................................... 27
4.3. Motor and Logic Power ................................................................................................................. 28
4.3.1. Proper Grounding Practice .................................................................................................... 30
4.4. Module Power Connections ........................................................................................................... 31
4.4.1. ConveyLinx-Ai2..................................................................................................................... 32
4.4.2. ConveyLinx-Ai3-24-FC .......................................................................................................... 34
4.4.3. ConveyLinx-Ai3-24-RC ......................................................................................................... 35
4.4.4. Assembly Instructions ........................................................................................................... 36
4.5. Power Supply Sizing ..................................................................................................................... 37
4.6. Motor Ports ................................................................................................................................... 38
4.7. Sensor Ports ................................................................................................................................. 39
4.7.1. Electrical Connections for Sensor Port Aux I/O ..................................................................... 40
4.8. Ethernet Ports ............................................................................................................................... 42
4.9. LED Status Indicators.................................................................................................................... 44
4.10. Technical Specifications .............................................................................................................. 47
5. Auto-Configuration............................................................................................................................... 54
5.1. Device Connections to Modules .................................................................................................... 55
5.1.1. Examples that will generate errors ........................................................................................ 57
5.2. Motor Rotation Definition ............................................................................................................... 58
5.3. Node Connections for a Subnet..................................................................................................... 59
5.4. Installing EasyRoll......................................................................................................................... 61
5.5. ConveyLinx Ethernet Definition ..................................................................................................... 62
5.6. Connecting Your PC to the Network .............................................................................................. 64
5.7. Auto-Configuration Procedure ....................................................................................................... 65
5.8. Expected Results .......................................................................................................................... 71
5.9. What to do if things go wrong ........................................................................................................ 73
6. Default Settings and Operation ........................................................................................................... 74
6.1. Singulation Release Mode............................................................................................................. 75
6.2. Flex Zone Recognition .................................................................................................................. 76
6.3. Jam Conditions ............................................................................................................................. 78
6.3.1. Arrival Jam............................................................................................................................ 79
6.3.2. Sensor Jam........................................................................................................................... 81
6.4. Automatic Module Replacement .................................................................................................... 83
6.5. Reset to Factory Default Settings .................................................................................................. 86
7. EasyRoll Software ................................................................................................................................ 88

7.1. Main Screen .................................................................................................................................. 89
7.1.1. Node Navigation ................................................................................................................... 91
7.1.2. Node Identification ................................................................................................................ 92
7.1.3. ZPA Upstream/Downstream Zone Settings ........................................................................... 93
7.1.3.1. Release Mode .............................................................................................................. 94
7.1.3.1.1. Singulation Release.............................................................................................. 95
7.1.3.1.2. Train Release ....................................................................................................... 96
7.1.3.1.3. GAP Train Release............................................................................................... 97
7.1.3.2. T-Zone Settings ............................................................................................................ 98
7.1.3.3. ZPA Error and Information .......................................................................................... 101
7.1.3.4. Accumulate Control from Main Screen ........................................................................ 102
7.1.3.5. Settings Checkboxes .................................................................................................. 103
7.1.3.5.1. Disable Reset Delays ......................................................................................... 104
7.1.3.5.2. Disable Sensor Jam Auto Clear .......................................................................... 105
7.1.3.5.3. Disable Arrival Timeout ...................................................................................... 106
7.1.3.5.4. Disable Manual Operation .................................................................................. 107
7.1.4. Motor Settings..................................................................................................................... 109
7.1.4.1. Motor Type ................................................................................................................. 110
7.1.4.2. Brake Method ............................................................................................................. 111
7.1.4.3. Speed ......................................................................................................................... 112
7.1.4.4. Rotation Direction ....................................................................................................... 114
7.1.4.5. Acceleration/Deceleration ........................................................................................... 115
7.1.4.6. Motor Jog and Error Indicators.................................................................................... 116
7.1.5. Diagnostic Window ............................................................................................................. 119
7.2. Advanced Dialog ......................................................................................................................... 121
7.2.1. Look Ahead and Timing Tab ............................................................................................... 122
7.2.1.1. Look Ahead Slowdown Feature .................................................................................. 123
7.2.1.2. Jam & Auto Clear Timers ............................................................................................ 126
7.2.1.3. Run After Time/Distance ............................................................................................. 127
7.2.1.4. Induct Forward Time/Distance .................................................................................... 129
7.2.1.5. Sensor Debounce ....................................................................................................... 131
7.2.2. Upgrade Tab ....................................................................................................................... 132
7.2.3. Connections Tab ................................................................................................................. 135
7.2.4. Network Services Tab ......................................................................................................... 138
7.2.4.1. Discover & IP Address Set.......................................................................................... 139
7.2.4.2. Backup & Restore ....................................................................................................... 142
7.2.5. Special Services Tab .......................................................................................................... 145
7.2.6. Flex Zone Tab..................................................................................................................... 147
7.2.7. Sensors Tab ....................................................................................................................... 150
7.2.8. Extensions Tab ................................................................................................................... 151
7.2.9. Pin 2 Usage Tab ................................................................................................................. 155
7.2.9.1. Most Downstream Zone .............................................................................................. 156
7.2.9.2. Most Upstream Zone .................................................................................................. 157
7.2.9.3. Accumulate Intermediate Zone ................................................................................... 158
7.2.9.4. Lane Full Interface ...................................................................................................... 159
7.2.9.5. Most Upstream Zone Handshake Interlock.................................................................. 160
7.2.9.6. Most Downstream Zone Handshake Interlock ............................................................. 162
7.2.9.7. Inverting the Pin 2 Signals .......................................................................................... 163
8. ConveyMerge ...................................................................................................................................... 164

8.1. ConveyMerge Prerequisites and Requirements ........................................................................... 166
8.2. Network Architecture ................................................................................................................... 167
8.3. Sensor Placement ....................................................................................................................... 169
8.4. Merge Zone Module ................................................................................................................... 171
8.5. Merging Lines ............................................................................................................................. 174
8.6. Merge Configurations .................................................................................................................. 176
8.7. Merge Priority.............................................................................................................................. 177
8.8. T-Merge Settings......................................................................................................................... 178
8.9. Configuring Dynamic Priority Release ......................................................................................... 180
8.10. Enabling ConveyMerge from EasyRoll....................................................................................... 182
8.11. Conventional Spur Merge Example ........................................................................................... 184
8.12. T-Merge Example ...................................................................................................................... 186
8.13. Merge Line Full Example ........................................................................................................... 188
9. IOX Interface Module .......................................................................................................................... 190

9.1. Wake up and/or Lane Full Interface............................................................................................. 192
9.2. Wake up/Lane Full with Wired Terminals..................................................................................... 193
9.3. Wake up/Lane Full with Discrete Signals..................................................................................... 194
9.4. Wake up/Product on Zone Handshake Interlock .......................................................................... 195
9.5. Downstream/Product on Zone Handshake Interlock .................................................................... 196
9.6. Pin 2 Output on Aux I/O M8......................................................................................................... 197
9.7. Pin 2 Output on Wired Terminals................................................................................................. 198
10. PLC Developers Guide ..................................................................................................................... 199

10.1. Network Architecture ................................................................................................................. 200
10.2. Understanding Assemblies ........................................................................................................ 201
10.2.1. Modbus Assembly Instance Structure ............................................................................... 202
10.2.2. Ethernet I/P Assembly Instance Structure ......................................................................... 204
10.2.3. Profinet IO Assembly Instance Structrure .......................................................................... 205
10.2.4. Assembly Register Chart Legend ...................................................................................... 206
10.3. ZPA Mode Control ..................................................................................................................... 207
10.3.1. PLC Inputs for ZPA Mode ................................................................................................. 208
10.3.1.1. Local Zone Status ..................................................................................................... 209
10.3.1.2. Arrival/Departure Counts .......................................................................................... 210
10.3.1.3. Module Status........................................................................................................... 211
10.3.1.4. Tracking and Release Counts ................................................................................... 213
10.3.1.5. Forward and Reverse Tracking ................................................................................. 214
10.3.1.6. Port Inputs and ConveyStop Status .......................................................................... 215
10.3.2. PLC Outputs for ZPA Mode ............................................................................................... 216
10.3.2.1. Set Local Tracking .................................................................................................... 217
10.3.2.2. Accumulation Control................................................................................................ 219
10.3.2.3. Speed Control........................................................................................................... 221
10.3.2.4. Release and Status .................................................................................................. 222
10.3.2.5. Induct Tracking Forward and Reverse....................................................................... 223
10.3.2.6. Set Outputs and Motor Clear .................................................................................... 224
10.3.2.7. ConveyStop and Clear Jams..................................................................................... 226
10.3.2.8. Direction and Accumulation Mode ............................................................................. 227
10.3.2.9. ConveyMerge Interface............................................................................................. 228
10.3.3. ZPA Examples .................................................................................................................. 229
10.3.3.1. Basic Accumulate and Release with Tracking Data................................................... 230
10.3.3.2. Conveyor Setup for Simple Bar Code Reader ........................................................... 233
10.3.3.3. Upstream Accept Interface........................................................................................ 235
10.3.3.4. Downstream Discharge Interface .............................................................................. 237
10.3.3.5. Simple Divert Example.............................................................................................. 239
10.3.3.6. Merge onto ZPA Main Line ....................................................................................... 241
10.3.4. Reduced Size ZPA Mode Assemblies ............................................................................... 243
10.4. PLC I/O Mode Control ............................................................................................................... 245
10.4.1. Setting PLC I/O Mode in EasyRoll..................................................................................... 246
10.4.2. Optional Clear Connections Choice................................................................................... 247
10.4.3. Configuring Action for Loss of Communication .................................................................. 249
10.4.4. PLC Inputs for PLC I/O Mode ............................................................................................ 250
10.4.4.1. ConveyStop Status ................................................................................................... 251
10.4.4.2. Sensor Ports ............................................................................................................. 252
10.4.4.3. Left Motor Status ...................................................................................................... 253
10.4.4.4. Right Motor Status .................................................................................................... 257
10.4.4.5. Motor Ports Digital Status ......................................................................................... 258
10.4.4.6. Upstream / Downstream Status & Tracking ............................................................... 259
10.4.4.7. Servo Control Status................................................................................................. 260
10.4.5. PLC Outputs for PLC I/O Mode ......................................................................................... 261
10.4.5.1. ConveyStop Command & Clear Motor Error .............................................................. 262
10.4.5.2. Motor & Control Port Digital Output ........................................................................... 263
10.4.5.3. Left Motor Control ..................................................................................................... 264
10.4.5.4. Right Motor Control................................................................................................... 265
10.4.5.5. Set Status & Tracking ............................................................................................... 266
10.4.5.6. Set Sensor Port Input Mask ...................................................................................... 267
10.4.5.7. Servo Control............................................................................................................ 269
10.4.5.7.1. Servo Control Example ..................................................................................... 270
10.4.6. Reduced Size PLC I/O Mode Assemblies.......................................................................... 275
10.5. ConveyLogix Interface............................................................................................................... 277
10.5.1. ConveyLogix Assembly Inputs to PLC ............................................................................... 278
10.5.2. ConveyLogix Assembly Outputs from PLC ........................................................................ 279
10.6. Assemblies with Reset Protection.............................................................................................. 280
10.6.1. ZPA Mode Assembly Inputs with Reset Protection ............................................................ 281
10.6.2. ZPA Mode Assembly Outputs with Reset Protection ......................................................... 282
10.6.3. Reduced Size ZPA Mode Assemblies with Reset Protection ............................................. 284
10.6.4. PLC I/O Mode Assembly Inputs with Reset Protection ...................................................... 286
10.6.5. PLC I/O Mode Assembly Outputs with Reset Protection .................................................... 287
10.6.6. Reduced Size PLC I/O Mode Assemblies with Reset Protection........................................ 289
10.6.7. How to use Assemblies with Reset Protection ................................................................... 290
10.7. Motor Port as Digital I/O ............................................................................................................ 291
11. Setting Up Dual Motor Zones ........................................................................................................... 292

11.1. Two Ai MDRs Mechanically Coupled ......................................................................................... 293
11.1.1. ZPA Mode ......................................................................................................................... 294
11.1.2. PLC I/O Mode ................................................................................................................... 295
11.1.3. ConveyLogix Program....................................................................................................... 296
11.2. Two Ai Motors in One Roller Tube (Dual Drive) ......................................................................... 297
11.3. Two Motor Rollers in One Logical Zone Not Coupled ................................................................ 300
12. Connecting to Rockwell PLCs with Ethernet I/P ............................................................................. 302

12.1. Selecting Your Connection Method based upon Assembly ........................................................ 304
12.2. Using Generic Ethernet Module Method .................................................................................... 305
12.3. Procedure for Connecting using Generic Ethernet Module ........................................................ 306
12.3.1. Parameters for Each Assembly ......................................................................................... 307
12.4. Procedure for using EDS Method .............................................................................................. 308
12.5. Using Add On Instructions (AOI) with RSLogix 5000 ................................................................. 309
12.5.1. AOI Tag Descriptions ........................................................................................................ 310
12.5.1.1. ZPA Mode Inputs ...................................................................................................... 311
12.5.1.2. ZPA Mode Outputs ................................................................................................... 313
12.5.1.3. PLC I/O Mode Inputs ................................................................................................ 316
12.5.1.4. PLC I/O Mode Outputs.............................................................................................. 319
12.6. Using Logix 5000 MSG Instruction ............................................................................................ 322
12.6.1. Read MSG Instruction ....................................................................................................... 323
12.6.2. Write MSG Instruction ....................................................................................................... 325
12.6.3. Reading an Input Assembly with MSG Instruction ............................................................. 327
12.7. EDS Module Data Type Cross Reference.................................................................................. 329
PULSEROLLER ConveyLinx-Ai Family Users Guide - 2.0
1. About This Manual

Products Cover
Covered
ed in this Manual
ConveyLinx-Ai2 – All Article Numbers 3022-xxxx
ConveyLinx-Ai3-24-FC – Article Number 3023-0001
ConveyLinx-Ai3-24-R
ConveyLinx-Ai3-24-RC
C – Article Number 3023-0002
Page 6 of 329
Symbol Conventions
! This symbol indicates that special attention should be paid in order to ensure
correct use as well as to avoid danger, incorrect application of product, or
potential for unexpected results
* This symbol indicates important directions, notes, or other useful information for
the proper use of the products and software described herein
Important User Infor

Information
mation
! Modules contain ESD (Electrostatic Discharge) sensitive parts and components.

Static control precautions are required when installing, testing, servicing or
replacing these modules. Component damage may result if ESD control
procedures are not followed. If you are not familiar with static control
procedures, reference any applicable ESD protection handbook. Basic guidelines
are:
• Touch a grounded object to discharge potential static

• Wear an approved grounding wrist strap
• Do not touch connectors or pins on component boards
• Do not touch circuit components inside the equipment
• Use a static-safe workstation, if available
• Store the equipment in appropriate static-safe packaging when not in use
! Because of the variety of uses for the products described in this publication,
those responsible for the application and use of this control equipment must
satisfy themselves that all necessary steps have been taken to assure that each
application and use meets all performance and safety requirements, including
any applicable laws, regulations, codes, and standards
! The illustrations, charts, sample programs and layout examples shown in this
guide are intended solely for purposes of example. Since there are many
variables and requirements associated with any particular installation, Pulseroller
does not assume responsibility or liability (to include intellectual property
liability) for actual use based on the examples shown in this publication
Page 7 of 329
! Reproduction of the contents of this manual, in whole or in part, without written

permission of Pulseroller is prohibited
Not Included in this Manual
! Because system applications vary; this manual assumes users and application
engineers have properly sized their power distribution capacity per expected
motor loading and expected operational duty cycle. Please refer to conveyor
equipment and/or motor roller manufacturer’s documentation for power supply
sizing recommendations
How to Contact Us
Technical Support North & South America: [email protected]
Sales Support North & South America: [email protected]
Technical Support Global: [email protected]
Sales Support Global: [email protected]
Web Site: www.pulseroller.com
Page 8 of 329
2. Glossary of T
Ter
erms
ms
Ter
ermm Definition
A separate (usually wrapped or boxed) object to be transported by the

Carton conveyor. The terms tray, tote, load, or product may also be used
interchangeably in this document.
Conveyor controls architecture based upon modular distributed devices

ConveyLinx
connected via Ethernet network.
Conveyor control module that is part of the ConveyLinx family. Each module
ConveyLinx-Ai / can accommodate up to 2 MDR conveyor zones. The modules allow
ConveyLinx-Ai2 / connection for Senergy-Ai platform motor rollers and gear drives. The term
ConveyLInx-Ai3 Module will be used within this document and will refer to the ConveyLinx-Ai2
device
Dynamic Host Configuration Protocol A protocol for assigning IP addresses to

DHCP devices on a network from a pool of available IP’s. A dynamic IP address
changes each time the device connects to the network
Ethernet Roller Speed Control module – Conveyor control module that is part
of the ConveyLinx family. Each ERSC can accommodate up to 2 MDR
ERSC
conveyor zones. In this document the term module will be synonymous with
ERSC
Designed to “break-out” the RJ11 connection for easy installation. The

module has an amplifier to the output giving it up to 100mA output
ERSC
ERSC-SE4
-SE4 capabilities. Configurable diodes for the inputs to minimize leakage current to
and from the ERSC. Module also allows for external power source connection
for auxiliary devices.
Special sensor embedded within the brushless DC motor of an MDR used to

Hall Effect Sensor
provide motor rotor position feedback to the motor controller
The IP Code (International Protection Marking) specifies the device’s degree

of resistance to intrusions, dust and water. IP54 certified device must be fully
IP54
protected from splashed water, dust particles and completely protected from
contact
This is the name of a particular connector manufacturer that produces a

specific plug/socket arrangement for MDR connection to control cards. This
JST
name is accepted within the conveyor and MDR industry as a simple
description of the particular socket style used on ERSC hardware.
Light Emitting Diode – In the context of this document, LED’s are used on the
LED
ConveyLinx-Ai2 to provide visual indication of module status
Term used to describe how the signaling output circuit of a photo-sensor is

configured when it detects its reflected light. A photo-sensor that is light
Light / Dark
energized will activate its output circuit when it detects its reflected light. A
Ener
Energized
gized
dark energized photo-sensor will activate its output circuit when it does not
detect its reflected light
M8 This is the type of a connector, which has four connector pins and is used on
Page 9 of 329
the ConveyLinx Ai2 modules for both sensor connectors and MDR connectors
Motorized Drive Roller or Motor Driven Roller – Brushless DC motor and

MDR
gearbox assembly integrated into a single conveyor roller
Page 10 of 329
Control logic terminology to define the state of the output of a Boolean “on”
or “off” device. The term specifically describes the state of the output circuit
when the device’s sensing circuit is un-energized. In the context of photo-
sensors; a normally open wired sensor would have its output circuit
Nor
Normally
mally Open /
energized when it detected its reflected light and its output circuit would be
Nor
Normally
mally Closed
de-energized when it did not detect its reflected light. Conversely a photo-
sensor wired normally closed would energize its output circuit when it did not
see its reflected light and it would de-energize its output circuit when it did
detect its reflected light
Electronics term that indicates the type of transistor circuit used for a logical
input or output for controllers. NPN devices will provide a common or ground
NPN / PNP
connection when activated and a PNP device will provide a logic voltage
connection when activated
A device, mounted near the end of the conveyor zone to sense the presence
Photo
Photo-sensor
-sensor
of a carton on the zone
Programmable Logic Controller – A wide variety of industrial computing

PLC
devices that control automatic equipment
Pulse Width Modulation – a control scheme that utilizes high speed switching
PWM transistors to efficiently deliver power in a controlled fashion from the
ConveyLinx controller to MDR
Term used to describe the two basic types of photo-sensors. Retro-reflective

photo-sensors utilize a reflective target that must be aligned with the photo-
sensor such that the light emitted by the photo-sensor is reflected back to it.
Retr
etro
o-r
-reflective
eflective /
‘Reflex (or sometimes known as proximity) type photo-sensors emit light to
Refle
eflexx
be reflected back from an object located sufficiently close to the sensor. ‘For
both types of photo-sensors, when they detect their reflected light source,
their signaling output circuit changes state.
Registered Jack Style 11 / 12 – Standard connector / receptacle format

utilizing 4 or 6 pin connections. The typical standard connection for
RJ
RJ-11
-11 / RJ
RJ-12
-12
telephones. RJ-11 utilizes 4 pins and RJ-12 utilizes 6 pins but both styles use
the same physical size.
Registered Jack Style 45 – Standard connector / receptacle format utilizing 8

RJ
RJ-45
-45 pin connections. The typical standard for computer network cable
connections
PulseRoller brand proprietary motor control platform that provides electronic

intelligence inside the motor that can be read by ConveyLinx-Ai Family and
Sener
Senergy
gy-Ai
-Ai
MotionLinx-Ai Family control modules. The connection from the motor to the
controller is via 4-Pin M8 style connector
Conveyor control method for zoned controlled conveyor that dictates that
Singulation when a zone is discharging its carton, the upstream carton waiting to enter
Release must wait until the discharged carton is completely clear before it is allowed
to enter
A set of non-motorized conveyor rollers mechanically linked to an MDR. The

Slave R
Rollers
ollers MDR and slave rollers make up a physical zone. All of the slave rollers in a
zone rotate at the same speed and direction as the MDR because of their
Page 11 of 329
mechanical linkage
Transport Control Protocol / Internet Protocol – IP is the protocol which

oversees the transmission of information packets from device to device on an
TCP
CP/IP
/IP Ethernet network. TCP makes sure the packets have arrived and that the
message is complete. These two protocols are the basic language of the
Internet and are often referred to together as TCP/IP.
Conveyor control method for zone configured conveyor that dictates that
Train R
Release
elease when a zone is discharging, the upstream zone’s carton can move in unison
with the discharging carton.
A basic (linear or curved) cell of the conveyor consisting of a set of slave

Zone
rollers driven by one or more MDR’s and a single photo-sensor.
Zero Pressure Accumulation – Term that describes the conveyor controls and
ZP
ZPA
A mechanical scheme that will cause loads to queue on a conveyor in discrete
zones such that loads do not touch each other
Page 12 of 329
3. Getting Started
Purpose of this Manual
The purpose of this manual is to:
• Identify the components and ports available on a module

• Provide guidelines for proper installation and wiring
• Provide examples on basic inter-module connections for linear conveyor
• Introduce the EasyRoll software tool and provide instructions to configure and modify
parameters
Who Should Use this Manual?
This manual is intended for users who need basic product information and simple application
procedures to implement Modules to control simple linear conveyor.
You should have a basic understanding of electrical circuitry and familiarity with relay logic,
conveyor equipment, photo-sensors, etc. If you do not, obtain the proper training before using
this product.
What do you want to do?
The Basics
Learn about module hardware ports

Learn about power supply sizing
How to Auto-Configure your network of modules
Find out about what all the LED states mean
Learn about the different release modes and how to change them
Learn about Flex Zone
Learn about jam conditions
How to reset a module back to factory default
How to wire up a Wake Up interlock
How to wire up a Lane Full Interlock
How to Auto-Replace a module
Basic things you can do with EasyR

EasyRoll
oll
Learn about basic navigation through EasyRoll

Learn about ZPA settings and how to change them
How to change motor direction, speed, accel/decel, etc.
Learn about motor status and error indicators
How to change Jam Timers and Auto-Clear Timers
How to change how the module logic uses the block/clear output from your sensors
How to change your Aux I/O Pins to match the signals you are using
Page 13 of 329
Some advanced things you can do with EasyR

EasyRoll
oll
Learn how to discover modules on your network and change IP addresses

How to set up Look Ahead Slow Down feature
How to disable Flex Zone Recognition and why you may want to
How to set up an Extension or slave module
How to connect two separate networks together to operate in ZPA
How to backup and restore module settings
How to upgrade module firmware
Page 14 of 329
4. Module Har
Hardwar
dware
e
ConveyLinx Modules are designed to be installed and integrated into the conveyor’s
mechanical side frame assembly. The ConveyLinx Module is a controller for up to 2 Motorized
Drive Roller (MDR) conveyor zones. Each ConveyLinx Module provides connection points for 2
MDR units with their corresponding 2 photo-sensors as well as upstream and downstream
network and discreet interconnections to form a complete control system for zoned MDR
conveyors.
* The “left” and “right” naming convention for the module ports is based upon
facing the front of the ConveyLinx Module and is not to be confused with
direction of product flow on the conveyor. Product flow will be designated as
“upstream” and “downstream”
Learn more:
Identif
Identifying
ying ConveyLinx Module Components
Mounting Dimensions
Motor P
Ports
orts
Sensor P
Ports
orts
Ether
Ethernet
net P
Ports
orts
Power Connections
Power Supply Sizing
LED Status Indicators
Technical Specifications
Page 15 of 329
4.1. Identif
Identifying
ying Module Components
The ConveyLinx-Ai Family of controllers have very similar module components, but there are small
differences between the different models, so each module has its own page for component
identification.
ConveyLinx-Ai2
ConveyLinx-Ai3-24-FC
ConveyLinx-Ai3-24-R
ConveyLinx-Ai3-24-RCC
Page 16 of 329
4.1.1. ConveyLinx-Ai2
Item Description
24VDC Power Terminals with separate connections for Logic and Motors
Motor Left LED & Motor Right LED – Motor status indicators
&
Left Sensor & Right Sensor Status LED Indicators

&
Module Status LED Indicator
Module Power LED Indicator
Motor Left and Motor Right Port – 4-pin M8 style connector for MDR
& connection
Sensor Left and Sensor Right Port – M8 style connector for zone photo-sensor
& connection
Removable IP54 Power Compartment Cover
Module Replacement Button
Link Left and Link Right – RJ-45 style Ethernet network connection between
&
Page 17 of 329
modules including LED Indicators
Removable IP54 Ethernet RJ-45 Port Compartment Cover – Left and Right
IP54 Protection Shrouds for Ethernet cabling and power wiring

*
• Indicates items shipped unattached to the modue but are included in the module’s box
Page 18 of 329
4.1.2. ConveyLinx-Ai3-24-FC
Item Description
Mounting Bracket with FC cable routing channels
&

&
& connection
& connection
Page 19 of 329
Module Clamping brackets

*
& modules including LED Indicators

*
Page 20 of 329
4.1.3. ConveyLinx-Ai3-24-R
C
Item Description
Mounting Bracket with RC wire routing channels
&

&
& connection
& connection
Module Clamping brackets

*
Page 21 of 329
& modules including LED Indicators

*
Page 22 of 329
4.2. Mounting Dimensions

The ConveyLinx-Ai Family of controllers have very similar mounting dimensions, but there are
small differences between the different models, so each module has its own page for mounting
details.
ConveyLinx-Ai2
ConveyLinx-Ai3-24-R
Page 23 of 329
Mounting Hole Dimensions
Page 24 of 329
Page 25 of 329
Page 26 of 329
C
Page 27 of 329
4.3. Motor and L

Logic
ogic P
Power
ower
Regardless of the specific ConveyLinx Module , each is equipped with the ability to separate the
Motor power from the Logic power.
Connecting only Motor P

Power
ower
* Connecting only to Motor P

the logic circuits.
Power
ower will provide power to both the motor circuits and
Typical Motor Only P

Power
ower Connection Diagram
Connecting Motor P
Power
ower and L
Logic
ogic P
Power
ower Separately
* Providing a separate power connection to the Logic Power, you can keep the
logic and communications powered and active and disconnect the Motor Power
to assure all motors are disconnected such as in an E-Stop situation
Page 28 of 329
Typical Separate Motor and L

Logic
ogic P
Power
ower Connection Diagram
Page 29 of 329
4.3.1. Proper Gr
Grounding
ounding P
Practice
ractice
Whether logic and MDR are powered together or separately; the DC common (“-“) connections
on all power supplies should be connected together. One of the power supplies should have its
DC common connected to ground. Avoid connecting more than one power supply DC common
to ground because this can lead to unintended grounding loops.
Separate gr
groups
oups of module each power
powereded by single power supplies that ar
aree supplying both logic
and motor power
power.. Each supply has its DC commons tied together and connection to gr ground
ound fr
from
om a
single point
Separate gr
groups
oups of modules each with their rrespective
espective MDR power frfrom
om separate supplies with a
single common supply for each gr
group’s
oup’s logic power
power.. Each supply has its DC commons tied
together and connection to gr
ground
ound frfrom
om a single point
Page 30 of 329
4.4. Module P
Power
ower Connections
At a minimum, for any of the ConveyLinx Modules , you must supply at least the Motor P
Power
ower
connection. The Logic P
Power
ower connection is optional and used when you want to be able to
disconnect motor power and yet maintain module communication functionality.
There are differences between each of the ConveyLinx Module varieties:
ConveyLinx-Ai2
ConveyLinx-Ai3-24-R
Page 31 of 329
The protective shrouds (Item 17 as depicted in Identif
Identifying
ying Module Components ) will be
unattached to the module when shipped and are included in the module’s shipping box. These
shrouds are used to maintain an IP54 installation of the power and Ethernet wiring.
* 12 AWG (4.0 mm 2) Max wire size, 5-6 mm strip length
Power wir
wires
es ar
aree fed thr
through
ough the pr
protective
otective shr
shroud
oud (Item 17). The wir
wire
e ter
terminals
minals (Item 1) ar
aree
standar
standard d cage-clamp style
Page 32 of 329
Once wiring has been completed the power wiring compartment is then sealed by snapping into
place the P
Power
ower Compartment Cover (Item 12)
Page 33 of 329
AS-I Cable for P

Powering
owering Both L
Logic
ogic and Motors with One Cable
One AS-I Cable Each for Separate Motor and L

Logic
ogic P
Power
ower
Page 34 of 329
C
{R
{RC}
C} Mounting Brack
Bracket
et Shown W
Without
ithout W
Wir
ires
es
Module Mounting Brack

Bracket
et Shown with W
Wir
ires
es Installed
Page 35 of 329
4.4.4. Assembly Instructions

The assembly procedure is the same for either the ConveyLinx-Ai3-24-FC module or the
ConveyLinx-Ai3-24-R
ConveyLinx-Ai3-24-RCC module. Once the cabling is properly seated in the mounting mounting
bracket, the main module unit snaps into the bracket and the module clamping brack
brackets
ets are
installed and closed as shown:
Page 36 of 329
4.5. Power Supply Sizing

The current loading on the power supply for a group of ConveyLinx Modules depends upon the
Motor T
Type
ype selected. Each of the motor types available has an associated rated current that the
motor will draw at rated torque and maximum speed. Each Motor T
Type
ype also has an associated
allowed current draw that is available for a period of time upon the initial starting of the motor.
Theses current values and starting times are shown in the following chart:
BOOST
ECO ECO
ECO++ BOOST
8
Power supply load per Motor P

Port
ort at rated torque at
2.5 A 4.1 A 3.5 A 3.5 A
maximum speed
Power supply load per Motor P

Port
ort during motor starting
3.0 A 4.1 A 5.0 A 8.0 A
period
Duration of motor starting period 5.0 sec N/A 1.5 sec 3.0 sec
* Please note that the current values shown are per Motor Port, so if both Motor
Ports are being used on a given ConveyLinx Module, the current load seen by the
power supply for that module will be double the value shown.
* The current values are at rated speed and at rated torque. The current will be
less if rated torque is not required by the motor.
! Pulseroller assumes the user is aware of MDR power requirements for the
application and that the user and/or installer have properly sized 24VDC power
supplies and wiring based upon all applicable codes and standards. Pulseroller
also assumes installation will follow proper equipment grounding practices. “DC
common or -”on all power supplies should always be connected to ground.
Improper power supply sizing and/or improper grounding practices may produce
unexpected results
Page 37 of 329
4.6. Motor P
Ports
orts
Both ports utilize a 4-pin M8 male receptacle. Each receptacle is mechanically keyed to assure
proper orientation upon plugging in.
M8 4 P
Pin
in Male Motor P
Port
ort with Sener
Senergy
gy Ai Motor F
Female
emale Connector
Page 38 of 329
4.7. Sensor P
Ports
orts
Each sensor port is a standard M8 Female receptacle with standard pin-out:
Pin Signal Description
1 24VDC Module’s 24VDC Supply
I/O Signal – Input or Output Function configured with EasyRoll

2 Aux I/O
software
3 GND Module’s DC Common
Logical Input for Sensor’s state output – Auto detect for NPN or
4 Sensor Signal
PNP
Page 39 of 329
4.7.1. Electrical Connections for Sensor

Port Aux I/O
When connecting to either Sensor port with an M8 connector to access Pin 2 signal; you
typically will use a standard parallel type splitter cable assembly that breaks out each of the
available pins on the Module to their own M8 connection port. These splitter cables wire the
+24V and Common connections in parallel
* Splitter cables are commercially available from multiple sources. Click here for
information for Pulseroller IOX-2 Breakout/Splitter Module
Typical P
Parallel
arallel Splitter Cable Usage
Aux I/O P
Pin
in 2 as Input
When the Aux I/O Pin 2 is configured as an input, the circuit is NPN/PNP auto-sensing. The
signal can be connected to either +24V or 0V to operate.
Page 40 of 329
Aux I/O P
Pin
in 2 Input Connection Diagram
! Because the auto-sensing circuit requires a nominal voltage in order to operate,

there will be some small amount of leakage current possible between Module Pin
2 and Pin 3 (GND). Please use caution if you connect a load between Module Pin
2 and Pin 3.
Aux I/O P
Pin
in 2 as Output
When the Aux I/O Pin 2 is configured as an output, the circuit is NPN only and requires the load
to be connected to Pin 1 (+24V)
Aux I/O P
Pin
in 2 Output Connection Diagram
Page 41 of 329
4.8. Ether
Ethernet
net P
Ports
orts
Both ports are standard RJ-45 jacks conforming to standard Ethernet connection pin-out. In
order to maintain IP54 rating; Ethernet cables need to be equipped with protective shrouds.
Shown below are the Ethernet cables installed using shrouds to protect the RJ-45 connectors on
the Ethernet cables. Each module is shipped with 3 shrouds – 2 for the Ethernet Cables and 1
for the power wiring.
Ai2 Module with L

Lef
eftt & Right Ether
Ethernet
net Cable (Covers rremoved)
emoved)
Ai2 Module with L

Lef
eftt & Right Ether
Ethernet
net Cable with Covers attached
* Even though the images depict ConveyLinx-Ai2, the ConveyLinx-Ai3-24-FC and
Page 42 of 329
ConveyLinx-Ai3-24-R
ConveyLinx-Ai3-24-RCC modules utilize the exact same protective shrouds and
covers
How to install shr

shrouds
ouds on Ether
Ethernet
net cables
Assembly T
Tool
ool
Phoenix Contact P
Part
art Number 2891547 FL IP 54
* Tool must be purchased separately
Putting the shr

shroud
oud on the cable
2: Grip the
1: W
With
ith tool
handle to open
closed, place
the pins to
shr
shroud
oud on the
str
stretch
etch open the
pins
shr
shroud
oud
3: While
continuing to 4: R
Release
elease the
grip the handle, handle and the
insert the RJ
RJ-45
-45 pins close
cable thr
through
ough allowing them to
the shr
shroud
oud be rremoved
emoved
opening as fr
from
om the shrshroud
oud
shown
Page 43 of 329
4.9. LED Status Indicators

ConveyLinx Module status is indicated by several LED’s. All LED’s with the exception of the
Ethernet Link and Activity LEDs are multi-colored and context sensitive. The following sections
indicate the various meanings of all LED indicators.
* By definition Blinking is approximately 1⁄2 second on/off cycle and Flashing is

approximately 1⁄4 second on/off cycle.
If you need help finding where LED Items are located on the ConveyLinx Module
Communications
Indicator Item LED State Description
Ether
Ethernet
net L
Lef
eftt OFF No connection established
Link &
Solid Green Connection is established
Ether
Ethernet
net &
Right Link Blinking Green When data transmission activity is occurring
Motors
OFF Motor is not running and no faults detected
Solid Green Motor is running
If Motor is running – indicates current limit

If Motor is stopped – indicates motor is not
Solid Red
connected properly or is overheated
Power supply is under 18V or above 30V
Motor L
Lef
eftt & Motor is overloaded and the module is limiting
Blinking Red
Motor Right & current to reduce temperature
Motor short circuit detected between at least

Flashing Red two of the phase windings or Motor Power
supply is less than 10V
Solid Amber Module is booting up
Profinet enabled discover function initiated

Slow Blinking Red
from PLC
Page 44 of 329
Network & Module Status

Blinking Red Module is starting task processes
Blinking Green Module is ready
Flashing Green &

Module is in Failsafe Mode
Module Blinking Red
Status Flashing Red Auto-Configuration is in progress
Connection to peer lost or performing firmware

Blinking Amber
upgrade check
Solid Amber Firmware upgrade in progress
Sensors
Solid Green Sensor Input is energized
Solid Amber Module is booting up
When in ZPA Mode and when Sensor is blocked

– indicates external device (PLC/PC controller or
Flashing Green
EasyRoll) has accumulated the zone and
inhibiting release
Aux I/O Pin 2 is energized (when configured as

Solid Red
Sensors L
Lef
eftt an Input)
& Right &
Blinking Red Arrival Jam or missing sensor
Blinking Green/
Sensor Jam
Amber
Flashing Red network Stop condition
Flashing Amber Power supply is less than 10V
Profinet enabled discover function initiated

Slow Blinking Red
from PLC
Page 45 of 329
Power
Power supply for both Logic and Motors are

Solid Blue
Power connected
Blinking Blue Motor power supply is less than 18V
Special Cases
All Sensor & &

Flashing Red Module in stopped state
Motor
&
Lef
eftt Sensor ZPA zone on Left side of module is in
Flashing Green
&L
Lef
eftt Motor & Maintenance Mode*
Right Sensor
ZPA zone on Right side of module is in
& Right Flashing Green
& Maintenance Mode*
Motor
* *Maintenance mode only accessible via remote PLC.
Page 46 of 329
4.10. Technical Specifications
* Unless otherwise stated, all specification data is identical for ConveyLinx-Ai2

ConveyLinx-Ai3-24-FC, and ConveyLInx-Ai3-24-R
ConveyLInx-Ai3-24-RC C
ConveyLinx-Ai2,
Power Connection
ConveyLinx-Ai2
Power connector is Degson DG245-5.0, 12 AWG (4.0 mm 2) Max wire size, 5-6 mm strip length
Insulation Displacement for standard AS-Interface cable, optional separate cable for logic
power
ConveyLinx-Ai3-24-R
C
Insulation Displacement for Type MTW (or equivalent) wire. Motor Power 10 AWG (6.0 mm 2) 80
strand, insulation hardness 85 or less. Optional Logic Power 14 AWG (2.5 mm 2) 48 strand,
insulation hardness 85 or less.
Electrical R
Ratings
atings
Power supply voltage 24.0V +/- 10%
Standby current
< 120mA
consumption
Motor Starting Current ≤ 8A per Motor
Motor Rated Current ≤ 3A per Motor
Envir
Environmental
onmental R
Ratings
atings
! Operating outside these parameters may result in permanent ConveyLinx Module

failure or unexpected device behavior
Page 47 of 329
Minimum Operating Voltage 21
Maximum Operating
30V
Voltage
Storage temperature -25ºC to 70º C ( -13ºF to 160ºF)
Ambient Operating Standard Module: 0ºC to 40ºC ( 32°F to 104°F)

temperature Freezer Rated Module: -30ºC to 40ºC ( -22°F to 104°F)
Humidity 5% to 95% non-condensing
Vibration 0.152 mm (0.006 in.) displacement, 1G peak
Mechanical Shock 20G peak for 10ms duration (1.0 ms)
Enclosure IP Rating IP54
Maximum peak current 21.5A*
Maximum motor start

8A
current
*This is the maximum current that will be allowed by the hardware over current protection
circuitry. On board firmware limits the amount of current based on the quantity and motor
types connected
Certifications & Standar

Standards
ds
Programmable controllers — Part 2: Equipment requirements and
BDS EN 61131-2:2008
tests
Electromagnetic compatibility (EMC) — Part 6-2: Generic standards

BDS EN 61000-6-2:2006
– Immunity for industrial environments
BDS EN Electromagnetic compatibility (EMC) — Part 6-4: Generic standards

61000-6-4:2007+A1:2011 – Emission standard for industrial environments
Specification for radio disturbance and immunity measuring

BDS EN
apparatus and methods Part 2-1 Methods of measurement of
55016-2-1:2009+A1:2011
disturbances and immunity. Conducted disturbance measurements
BDS EN
Electromagnetic compatibility – Requirements for household
55014-1:2007+A1:2009
appliances, electric tools and similar apparatus — Part 1: Emission
+A2:2011
Electromagnetic compatibility (EMC) Part 4-2: Electromagnetic

BDS EN 61000-4-2:2009
discharge Immunity test
Electromagnetic compatibility (EMC) Part 4-4 Electrical fast

BDS EN 61000-4-4:2012
transient/burst immunity test.
BDS EN 61000-4-5:2007 Electromagnetic compatibility (EMC) Part 4-5 Surge immunity test.
Electromagnetic compatibility (EMC) Part 4-6 Immunity to

BDS EN 61000-4-6:2009
conducted disturbances, induced by radio-frequency field
Page 48 of 329
Electromagnetic compatibility (EMC) Part 4-11 Voltage dips, short

BDS EN 61000-4-11:2009
interruptions and voltage variations immunity tests
Page 49 of 329
Sensor P
Port
ort I/O
Each Module is equipped with two 4-pin female M8 style Sensor I/O ports primarily used to
connect a photo-electric sensor to the module. Each of these ports has one pin dedicated as an
input for the sensor (pin 4) and one Aux I/O pin (pin 2) that is configurable to be either an input
or an output.
Sensor Input Signal (M8 P

Pin
in 4)
The sensor input (pin 4) is auto-sensing for PNP or NPN circuit type such that both sourcing and
sinking current will activate the input based upon the following conditions:
Minimum ON Current 1.5 mA
Maximum OFF Current 0.4 mA
Aux I/O Signal (P

(Pin
in 2) when configur
configured
ed as as INPUT
When configured as an INPUT, the Aux I/O (pin 2) is auto-sensing for PNP or NPN circuit type
such that both sourcing and sinking current will activate the input based upon the following
conditions:
Minimum ON Current 1.5 mA
Maximum OFF Current 0.4 mA
Page 50 of 329
Aux I/O Signal (P

(Pin
in 2) when configur
configured
ed as an OUTPUT
When configured as an OUTPUT, the Aux I/O (Pin 2) provides an NPN only circuit as illustrated:
Sensor P
Port
ort 24VDC (P
(Pin
in 1) and GND (P
(Pin
in 3)
Pin 1 of each Sensor Port provides 24V for powering up a sensor device and/or for supplying the
load for the Aux I/O (Pin 2) when configured as an output. The available current for the two
control ports on the module is limited internally by a solid-state fuse. The maximum combined
current consumption for the two sensor ports is 100 mA.
! Current in excess of 100mA drawn from the sensor port’s 24V pin may cause
permanent damage to the sensor detection circuit. Care should be taken to avoid
excess loads, short circuits and miss-wiring of the sensor port.
Motor P
Port
ort
Supported motor types Senergy Ai
PWM frequency* 25 kHz +/- 0.1%
Maximum starting current 8A
Maximum rated current 3A
Coil-to-coil short, coil-to-Vcc short, overheating, over-voltage,

Motor Protection**
under-voltage, stall sensing and protection
• The PWM frequency is firmware version dependent
Page 51 of 329
! **During normal operation as an MDR port, the internal protection circuitry is not
capable of detecting a short-circuit between a BLDC coil output and ground. Such
a short-circuit will cause damage to the high-side bridge transistors. When
operating these outputs as general purpose outputs, the high-side transistors are
disabled, so a pin-to-ground short-circuit is not an issue
Motor P
Ports
orts in Digital Output Mode
Either the Left or Right (or both) Motor Ports can be configured to operate their respective
motor coil output transistors as 24V DC digital output signals. These digital output signals are
sinking type only and will accommodate up to 1A on a given output pin, but restricted to a total
of 1.5A for both pins on a given port.
For each of the Motor Ports, only 2 out of the 3 total motor coil output pins are available as
digital outputs for a total of 4 Motor Port digital outputs available per module. Please note that
these 2 available motor coil pins are differ
different
ent between the L
Lef
eftt and Right Motor P
Ports
orts as
illustrated:
Page 52 of 329
Ether
Ethernet
net
• 3 port integrated switch ( 2 external ports and 1 port for the on-board processor)
• Automatic speed setup (10Base-T / 100Base-TX)
• Automatic duplex configuration (Full / Half)
• Automatic straight/crossover cable detection ( Auto MDI/MDI-X)
• PAUSE frame support
• Back pressure flow control support
• Maximum segment length: 100m / 328ft
Supported P
Prrotocols
• Modbus/TCP
• EtherNet/IP
• Profinet IO
• CCLink IEF Basic
Page 53 of 329
5. Auto
Auto-Configuration
-Configuration
The purpose of Auto
Auto-Configuration
-Configuration for networked ConveyLinx controls is to provide a simple
and easy procedure for linear conveyor system commissioning. The Auto
Auto-Configuration
-Configuration
Procedur
oceduree requires the use of EasyR
EasyRoll
oll on a PC.
Connecting Devices to ConveyLinx Module

Connecting Nodes T
Together
ogether
Installing EasyR
EasyRoll
oll
ConveyLinx Ether
Ethernet
net Definition
Connecting Y
Your
our PC to Network
Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree
Linear Conveyor Definition

Auto-Configuration is only applicable to a Linear Conveyor arrangement. A Linear Conveyor
arrangement is defined as a single uninterrupted path of conveyor with no merge or diverts
mechanisms. A Linear Conveyor can include curved sections, but the flow of cartons on the
conveyor is continuous from in-feed zone to discharge zone. A networked ConveyLinx solution
can control more complex conveyor paths that include diverting and merging equipment by
utilizing external PLC/PC control and/or on-board ConveyLogix programming.
Example of a Linear Conveyor
Page 54 of 329
5.1. Device Connections to Modules

Before the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree can be performed; each individual ConveyLinx Module
needs to have its associated MDR’s and photo-sensors connected in the proper way for
expected operational results.
In general, each ConveyLinx Module detects which Sensor ports have a device connected and
will use this to determine its specific configuration once it has been instructed to self-configure
by the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree.
Before starting to configure your system to operate, each MDR and photo-sensor needs to be
properly connected to the ConveyLinx Modules mounted on the conveyor. Modules will
determine how to operate based upon how the photo-sensors and MDR’s are connected.
* The number of Sensors connected will determine the total number of Zones.
Once Auto
Auto-Configuration
-Configuration is complete, this number of Zones cannot be modified
or over-ridden without performing another Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree.
A single ConveyLinx Module can operate as a:
2 zone contr
controller
oller
with 2 MDR
MDR’s’s and
2 photo
photo-sensors
-sensors
1 zone contr
controller
oller
with 1 MDR and 1
photo
photo-sensor
-sensor on
Lef
eftt or Right Side
Page 55 of 329
1 zone contr
controller
oller
with 2 MDR
MDR’s’s and
1 photo
photo-sensor
-sensor
with Sensor on
Lef
eftt or Right Side
Page 56 of 329
5.1.1. Examples that will generate er

errrors
* These examples are not necessarily invalid and will not cause the Auto
Configuration procedure to fail or abort, but they will result in module errors in
ZPA Mode.
This module will configure

as a two zone module but
will generate a motor
connection error for the
missing motor on the Right
side

as a two zone module but
will generate a motor
missing motor on the Left
side

as a single zone module on
the Right side but will
generate a motor
missing motor on the Right
Side

as a single zone module on
the Left side but will
generate a motor
missing motor on the Left
Side
Page 57 of 329
5.2. Motor R
Rotation
otation Definition
The ConveyLinx Module uses a Clock-W
Clock-Wise
ise (CW) and Counter Clock-W
Clock-Wise
ise ((CCW
CCW)) motor rotation
definition. The reference for this distinction is based upon viewing the MDR from the cable exit
end of the roller.
Motor R
Rotation
otation Definition
* Auto Configuration P Prrocedur

oceduree will automatically adjust the motor rotation
direction based upon the flow established by the procedure as long as the cable
end of the roller is on the same side of the conveyor as the ConveyLinx Module.
If the rotation direction is not correct after the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree, you
can change it in EasyR
EasyRoll
oll. How to change the motor rotation direction
Page 58 of 329
5.3. Node Connections for a Subnet

With your motors and sensor connected to your individual ConveyLinx Modules, you will need
to connect the Ethernet network cabling from module to module in a daisy chain fashion. The
most upstream module in the direction of flow is node 1.
* Please note that the Flow is based upon the Ethernet cable routing during the
Auto
Auto-Configur
-Configure
ePPrrocedur
oceduree. The Flow direction cannot be changed or over-ridden.
The only way to change the Flow direction is to perform another Auto
Auto--
Configuration P
Prrocedur
oceduree
Subnet with L
Lef
eftt to Right Flow
Subnet with Right to L

Lef
eftt Flow
Page 59 of 329
Subnet showing one module on the opposite side of conveyor
Page 60 of 329
5.4. Installing EasyR

EasyRoll
oll
The files for EasyR
EasyRoll
oll can be downloaded for free at www
www.pulser
.pulseroller
oller.com
.com and will be typically in
a compressed (i.e. “.zip”) format. Once you have extracted the contents of the compressed file;
the result will be a folder named with the format “EasyRoll_Vx_nn” where x is the main version
number and the nn is the revision level. Inside this folder is a file named “Setup.exe”. Double
click this file to begin the install procedure. EasyRoll installs like any standard Windows
application and you will be prompted for typical Windows prompts. By accepting the defaults
for the prompts; EasyRoll will install on your local Operating System drive under the “ \Program
Files (x86)\Industrial Software\EasyRoll\” or “ \Program Files\Industrial Software\EasyRoll\
! Please note that some anti-virus and/or security updates block the usage of
WinPcap utility which is used by EasyRoll. It is recommended that when you run
“Setup.exe” that you “Run as Administrator”
Page 61 of 329
5.5. ConveyLinx Ether

Ethernet
net Definition
All ConveyLinx Modules communicate over Ethernet network and use TCP/IP based protocols for
normal function. All TCP/IP protocols require that each device on a network have a unique I.P.
address assigned to it in order to function properly.
An I.P. address is in the format of: A A A.BBB.CCC.DDD where A A A, BBB
BBB, CCC
CCC, and DDD are
numerical values between 0 and 255.
* For the purposes of ConveyLinx; the A A A.BBB.CCC portion of the I.P. address
taken together is defined as the Subnet
is defined as the Node
Node.
Subnet. The DDD value of the address minus 19
For example; if a module has an I.P. address of “192.168.25.20” then its Subnet address is
“192.168.25” and its Node is 1 (i.e. 20-19 = 1)
At the factory, each and every module is assigned an I.P. address that is used by automated
testing equipment and fixtures so that every module is verified prior to shipment. When a
module is taken “out of the box” it will still have this I.P. address stored in its memory.
When the Auto Configuration P

Prrocedur
oceduree is initiated; one of the many things that occur is that
each module is automatically assigned a new I.P. address. This I.P. address for all modules is
determined by the Subnet of the I.P. address already stored inside the most upstream module.
Even if all downstream modules from the most upstream have the same or different Subnet or
Node values; these downstream modules will have their Subnet changed to the existing Subnet
of the most upstream module. Furthermore, when the Auto Configuration Procedure occurs; the
most upstream module will also have its DDD octet value changed to 20. All downstream
Modules will then have their respective DDD values automatically set beginning with 21.
Page 62 of 329
An Example
Here is a 4-module network with possible I.P. addresses that could have been on the module
from the factory. Note that their Subnets could be different as well as there could be duplicate
addresses.
Once the Most Upstr

Upstream
eam Module is identified as the Selected Auto
Auto-Configuration
-Configuration Node and
when the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree is performed; all 4 modules will have their I.P. address
configured as shown.
* The Auto-Configuration Procedure will assign Nodes up to and including Node

240. Therefore, each Subnet is limited to 221 Nodes
Page 63 of 329
5.6. Connecting Y
Your
our PC to the Network
You can connect your PC to a ConveyLinx network with a standard RJ-45 Ethernet cable at
either end of the string of modules.
! It is highly recommended to connect the PC directly to the ConveyLinx network.

Avoid trying to connect via Ethernet switches or wireless router/switches. If a
wireless switch is not setup properly then the Discover Feature will not work.
Also ensure that network firewall is turned off for proper discovery
Page 64 of 329
5.7. Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree
The direction of flow of the conveyor dictates how to begin the Auto-Configuration procedure.
The Module located at the most upstream or in-feed end of the conveyor is defined as the Auto-
Configuration Node. The Auto-Configuration procedure is initiated from the Auto-Configuration
Node. Because of its physical location on the conveyor path and physical location in the
Ethernet connection chain; the Auto-Configuration Node will automatically connect to all
downstream modules and set their I.P. address for communication.
Befor
Before
eYYou
ou Begin
• All sensors should be clear. Auto
Auto-Configuration
-Configuration assumes that state of the sensor is the
“zone empty” state
• Make sure you have no more than 221 ConveyLinx Modules connected. Auto
Auto--
Configuration will not configure past 221 ConveyLinx Modules in one network
• Make sure that there are no other Ethernet devices or switches connected in your string
of ConveyLinx Modules. After Auto
Auto-Configuration
-Configuration is complete and successful, you can
interrupt the Ethernet string with other devices and/or switches
The direction of flow of the conveyor dictates where to begin the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree.
The ConveyLinx Module located at the most upstream or in-feed end of the conveyor is the
module where the procedure must be initiated.. Because of its physical location on the
conveyor path and physical location in the Ethernet connection chain; the most upstream
ConveyLinx Module will automatically connect to all downstream ConveyLinx Modules and set
Page 65 of 329
their I.P. address for communication. Then the routine automatically sets the direction of flow.
! For the Auto-Configuration to work properly, all loads, totes, product, containers,
cartons, etc. must be removed from the entire conveyor path and all photo-
sensors must be aligned and adjusted so that none are detecting that their
respective zone is occupied. Failure to meet these conditions will produce
unexpected results
Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree
Start EasyR
EasyRoll
oll
V4.04 or higher
and invok
invoke
e the
Advanced
Dialog. In the
pop-up panel
select Network
Services and
click Discover
Page 66 of 329
After a few
seconds, the
discover
discovered
ed
Modules appear
in the module
table, click the
AutoConfig
button
Page 67 of 329
After a few
seconds each
Module is shown
in physical
topology or
order
der
fr
from
om the PC
If the most
upstr
upstream
eam
module is the
one closest to
the PC, select it,
then right click
and select
AutoConfig fr
from
om
Her
Heree. This will
start the
pr
procedur
ocedure.e.
Page 68 of 329
When the
pr
procedur
oceduree is
done, you will
see the tetext
xt go
fr
from
om rred
ed to black
and you will
notice that the
I.P
I.P.. addr
addresses
esses
have updated
per the dir
direction
ection
of flow
To Change the Dir

Direction
ection of Flow – Select the Module at the Opposite End of
the Network
If the most
upstr
upstream
eam
module is the
one farthest
fr
from
om the PC,
select it, then
right click and
select
AutoConfig fr from
om
Her
Here e. This will
start the
pr
procedur
ocedure.e.
Page 69 of 329
When the
pr
procedur
oceduree is
done, you will
see the tetext
xt go
fr
from
om rred
ed to black
and you will
notice that the
I.P
I.P.. addr
addresses
esses
have updated
per the dir
direction
ection
of flow
* Please note that the time to complete the Auto

Auto-Configuration
-Configuration P
Prrocedur
oceduree is
dependent on the number of modules being configured. Larger networks will take
more time than smaller networks
Page 70 of 329
5.8. Expected R
Results
esults
When the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree routine is complete, each ConveyLinx Module will
automatically reboot. When a ConveyLinx Module has been successfully configured and
rebooted, its Module Status LED will blink on and off green.
When the module has

been pr
properly
operly configur
configured
ed
and is operational, its
Module Status LED will
blink on and off Gr
Green
een
* Please note that the time to complete the Auto

Auto-Configuration
-Configuration P
Prrocedur
ocedure
dependent on the number of ConveyLinx Modules being configured. Larger
networks will take more time than smaller networks
e is
How to verif
verifyy success
Conveyor Operation
Place a carton on your empty conveyor so that it blocks the most upstream zone’s sensor. It
should convey all the way to the discharge end and the last most downstream zone should try
to convey it off the end of its zone. If this does not happen, then at the point where the carton
stops, check that module’s motor connection is sound and that the zone’s sensor is properly
aligned. If the sensor was not properly plugged in and powered when the Auto
Auto-Configuration
-Configuration
Procedur
oceduree was performed, you will have to perform the procedure again. If the sensor was
powered but is misaligned when the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree was performed, you can
either perform the procedure again or use EasyR
EasyRoll
oll to change the logical polarity of that
particular sensor.
Examine the Network
While the Auto

Auto-Configuration
-Configuration P
Prrocedur
oceduree is in process, you should see all of your modules’ LEDs
flashing on and off red. If this is not the case, then check your Ethernet cables and connections
and power connections.
Page 71 of 329
To verify that all the modules you expected to be configured are in fact configured, with
EasyR
EasyRoll
oll you can connect to your newly configured ConveyLinx Module network and perform a
Discover function. The Discover function will display all modules that it finds and from the list
your most upstream ConveyLinx Module should have the 4th octet of its IP Address as .20 and
you should see each module you configured in the list.
Page 72 of 329
5.9. What to do if things go wr

wrong
ong
Module Status LED

LEDss Blinking Gr
Green
een with une
unexpected
xpected rresults
esults
• Check that all sensors are operational and that all zones are clear then perform
procedure again. How to change block/clear sensor logic without having to perform
another Auto-Configuration
• Check all network and power connections and make sure there is 24V on each
ConveyLinx Module then try the Auto-Configuration procedure again
• Verify that all of the module sensor/motor combinations are valid. Check here to find
out what module set-ups will generate errors
Module Status LED is Blinking or Flashing R

Red
ed
• Make sure there are no other Ethernet devices (PC’s, Switches, Scanners, etc.)
connected between any of the module on your network. The Auto-Configuration
procedure aborts when it encounters a non ConveyLinx device along the network path
before reaching the last module. ConveyLinx Modules up to that point should be
configured properly but the remaining modules will not.
• When removing a ConveyLinx Module from an existing configured network that is
already operational; be sure to wait 1 or 2 minutes to allow the Ethernet Switches on
the modules to reset their MAC Address ARP table before attempting a new Auto-
Configuration procedure
Page 73 of 329
6. Default Settings and Operation

After Auto-Configuration, the modules on your newly configured network are in ZPA mode and
set to Singluation Release.
If all module and/or Network Status LED’s are blinking green; then to fully verify configuration
is to place a single carton onto the most upstream zone and see that it conveys to the
discharge zone. If it does, then the Auto-Configuration Procedure is successful.
Lear
earnn About:
Singulation Release Mode

Flex Zone Recognition
Jam Conditions
Automatic Module Replacement
How to Reset to Factory Defaults
Page 74 of 329
6.1. Singulation R
Release
elease Mode
Singulation Release is the mode where the ConveyLinx Module requires that its neighboring
downstream zone must be clear before it releases an item.
All 3 Cartons ar
aree accumulated
Carton 1 rreleases
eleases – Cartons 2
and 3 rremain
emain accumulated
When Carton 1 clears PE1

then Carton 2 rreleases
eleases
* View other ZPA Release Modes and how to change them
Page 75 of 329
6.2. Fle
Flexx Zone R
Recognition
ecognition
ConveyLinx Modules will automatically detect that a given carton is longer than one zone
length and automatically adjust accumulation control so that the longer carton occupies two
logical zones and will keep the next upstream carton from conveying into the longer carton.
! Flex Zone mode only functions in singulation release mode
All 3 Cartons ar
aree accumulated and the Zone at PE3 has Fle
Flexx Zone enabled
Carton 1 R
Releases
eleases – Even though PE3 is clear, because it has Fle
Flexx Zone enabled, Carton 2 rremains
emains
accumulated
When Carton 1’s leading edge rreaches

eaches PE1, Fle
Flexx Zone is clear
cleared
ed fr
from
om the Zone at PE3 and Carton
2 rreleases
eleases
! Please note that Flex Zone mode operates for carton lengths up to 2 zone
Page 76 of 329
lengths only. Operating conveyor system with cartons whose lengths are in
excess of 2 zone lengths may produce undesirable results such as excessive
detected jam conditions and faults.
How to disable Flex Zone operation with EasyRoll
Page 77 of 329
6.3. Jam Conditions

There are two (2) types of Jam conditions detected by the ConveyLinx Module:
Sensor Jam
Ar
Arrival
rival Jam
* Both of these Jam conditions utilize a Jam T Timer

imer that has to expire in order for
the condition to be active. Once either of these jam conditions becomes active;
they will automatically clear in the logic after the Auto Clear T
Time
ime has expired.
Both the Jam TTime
ime and Auto Clear T Time
ime values are 5 seconds each by default.
Please see How to Change Jam and Auto Clear Timers
Page 78 of 329
6.3.1. Ar
Arrival
rival Jam
When a carton leaves an upstream zone and is conveyed to its next downstream zone, this
upstream zone expects positive confirmation of carton arrival from the downstream zone. This
communication occurs automatically along the ConveyLinx network. If a new carton arrives at
this upstream zone while this upstream zone is waiting for a downstream arrival confirmation,
the new carton will accumulate on this upstream zone. If the upstream zone does not receive
this confirmation within the Jam T
Timer
imer interval, the ConveyLinx Module will produce an Ar
Arrival
rival
Jam fault. Once an Ar
Arrival
rival Jam occurs, the ConveyLinx Module will automatically hold any new
carton at the upstream zone for a pre-determined Auto Clear T
Time
ime Timer value and then
resume normal ZPA function. By default, the Jam T
Timer
imer and the Auto Clear T
Timer
imer values are set
to 5 seconds for each. This condition will be indicated on the corresponding Sensor LED on the
module
Carton 1 has lef

leftt PE1 and is on its way
to PE2 and because PE1 is clear,
Carton 2 is entering Zone 1
Carton 1 disappears but the Zone 2

motor continues to run for the Jam
Time period (5 sec. by default).
During this time Carton 2 ar
arrives
rives at
PE1 but Zone 1 stops because Jam
Timer is still timing
Page 79 of 329
When the Jam T Timer

imer e
expir
xpires,
es, the
Sensor LED blinks to indicate an
Ar
Arrival
rival Jam and k keeps
eeps blinking for the
Auto Clear TTime
ime (5 sec. by default).
When Auto Clear T Time
ime eexpir
xpires,
es, the
Ar
Arrival
rival Jam is rreset
eset and Carton 2 will
release if Zone 2 is empty
* How to Disable Arrival Jam
* How to change the Jam and Auto Clear Timers
Page 80 of 329
6.3.2. Sensor Jam

While a zone is releasing a carton; if this carton remains blocking the photo-sensor for the Jam
Timer period (default of 5 seconds), the ConveyLinx Module will detect a Sensor Jam. This will
be indicated on the corresponding Sensor LED on the module as shown here
Carton 1 is leaving Zone 1 but has got

stuck. Zone 1 and Zone 2 motors arare
e
running but PE1 is rremaining
emaining block
blocked
ed
When the Jam T Timer

imer has e
expir
xpired
ed (5
sec. by default) Zone 1 and Zone 2
motors stop and Zone 1 Sensor LED
flashes gr
green/amber
een/amber for the Auto
Clear T
Time
ime (5 sec. by default)
When the Auto Clear T Timer

imer has
expir
xpired,
ed, Zone 1 will start perfor
performing
ming
the Sensor Jam Auto Clear pr procedur
oceduree
Her
Here
e is what happens when Sensor Jam Auto Clear pr
procedur
ocedure
e occurs
1. Run the zone motor in reverse until the sensor is clear or 1 second has elapsed,
whichever happens first
2. Wait for the Auto Clear Timer to expire
Page 81 of 329
3. Run the zone motor forward to attempt discharge to the downstream zone (Attempt
#1 complete)
4. If sensor is still blocked after discharge attempt, the zone motor runs in reverse until
the sensor is clear or 1 second has elapsed, whichever happens first
#2 complete)
7. If sensor is still blocked after discharge attempt, the zone motor runs in reverse until
the sensor is clear or 1 second has elapsed, whichever happens first
#3 complete)
10. If sensor is still blocked after Attempt #3, the sensor must be cleared manually to
reset the Sensor Jam condition. Please note that if any of the discharge to
downstream attempts (steps 3, 6, or 9) are successful, the Sensor Jam condition is
automatically reset.
* If item is still blocking the sensor after Sensor Jam Auto Clear procedure is
complete you have to physically clear the jam by removing the item or you can
attempt another Auto Clear procedure
* The 5 second Jam Timer and Auto Clear Timer values are default settings. How to
change Jam and Auto Clear Timers in EasyRoll
* How to Disable Sensor Auto Clear Function
Page 82 of 329
6.4. Automatic Module R

Replacement
eplacement
Once a linear conveyor has been commissioned by Auto-Configuration Procedure, the
ConveyLinx Module store configuration data about its upstream and downstream neighboring
modules. This configuration data is automatically updated even if the linear conveyor has had
its parameters modified by the EasyRoll software. The ConveyLinx Module firmware uses this
feature to allow for easy module replacement so that the entire linear conveyor does not have
to be Auto-Configured again in order to replace a single ConveyLinx Module.
* Automatic Module Replacement procedure will work to replace a module on

systems with multiple subnets. You do not have to temporarily disconnect any
network connections or otherwise isolate the subnet where the replacement
procedure needs to occur
Module R
Replacement
eplacement Using EasyR
EasyRoll
oll
1. Disconnect existing module’s motor(s), network, photo-sensor(s), and power
connections. The order of disconnection does not matter.
2. Connect new module’s motor(s), sensor(s), network connections and power

connections.
3. Start EasyRoll V4.04 or higher. Invoke the Advanced Dialog and go to the Network
Services tab, click on the Discover button. All modules in the network should be
display. Click on AutoConfig button and after a few seconds
the topology of the ConveyLinx modules will be displayed.
4. Click on the module in the Tree View you want to add as the replacement module.
5. Right-Click and select Replace this Node from the menu to begin the replacement
process as shown. Note that you can also select the node from the list of modules on
the left-hand side and then click the
Replace Selected Node button.
6. Wait until Module performs its internal boot-up procedures which will be indicated
when the Module Status LED blinks on and off green.
Page 83 of 329
Module R
Replacement
eplacement Using R
Replacement
eplacement Button
Disconnect existing module’s

motor(s), network, photo-sensor(s),
and power connections. The order of
disconnection does not matter.
Connect new module’s motor(s),
sensor(s), network connections and
power connections. The Module
Replacement Button is located in the
Left Ethernet cable compartment.
Remove the compartment cover to
gain access to the button
With a pointed instrument (pencil or

small screwdriver) press and hold
the button for 2 seconds until the
Status LED flashes red and then
release the button
Page 84 of 329
* Please note that the Module Replacement Procedure (either with EasyRoll or
Replacement Button) can take a few minutes to complete. The replaced module
will restart itself a minimum of 4 times during the procedure. It will restart 5
times if firmware is being upgraded or downgraded
Page 85 of 329
6.5. Reset to F
Factory
actory Default Settings
There may be instances when you want to return a ConveyLinx Module to its “factory default”
state. The procedure to do this is the following:
1. Unplug all sensors, devices,

motors, and network cables
such that the only thing
connected is power
2. Press and hold the Module
Replacement Button until the
Module LED begins to flash
and then release
3. When the Module Status LED
blinks green, the procedure is
complete
Factory Default Settings

Item Value or Setting
IP: 192.168.21.20
IP Address Settings Subnet Mask: 255.255.128.0
Default Gateway: 192.168.202.1
Senergy ECO
Normal Braking
1 m/s Speed
Left & Right Motor Settings
CW Direction
30 mm Acceleration
30 mm Deceleration
Module Mode PLC I/O
JAM Timer = 5.00
Auto Clear Timer = 5.00

Look Ahead & Timing
Run After Timer = 5.00
Settings
Sensor Debounce = 0.10
All Induct Timers = 0.00
Page 86 of 329
Sensors Sensors are “ON is Blocked”
Connections All are Cleared
Page 87 of 329
7. EasyR
EasyRoll
oll Sof
Softwar
tware
e
We introduced the EasyRoll software in section Auto-Configuration. In that section the software
installation, connecting to your PC and using the Advanced Dialog to Discover and
AutoConfigure your modules was covered.
Page 88 of 329
7.1. Main Scr

Screen
een
Indicator Description
Network IP – This is where you enter the Subnet of the particular ConveyLinx
network you wish to connect
Node No. – This is where you enter a range of Nodes in which to connect.
Entering values here will cause the “Refresh” button to enable. Clicking this
button will cause the rest of the items (3, 4, and 5) to be populated
Upstream Zone / Downstream Zone – These selections allow you to change

the ZPA mode of the particular zone as well as several check boxes to change
the default operation of certain jam conditions, etc.
Page 89 of 329
Upstream Zone / Downstream Zone – Selector to cause the local zone to

Accumulate if a carton arrives and to cause the local zone to be in
Accumulate mode upon power up of the module
Left MDR / Right MDR – Selections for MDR type, braking options, speed,
acceleration, deceleration, etc.
Left MDR / Right MDR – Selector to click to jog the MDR, click again to stop
Left MDR / Right MDR – Visual indicators for various MDR status and
diagnostics information
Diagnostic Window – Click the graphic image to open a details Diagnostics

window
* Please note that some of the detailed information shown in this figure may be
different for your particular system and that most of these fields will be blank
until you actually initiate communications
Page 90 of 329
7.1.1. Node Navigation

Whatever value is entered in the From Node #
box will be the particular module Node data
shown in the remainder of the main screen.
The value entered in the To Node # box does
not have to be the actual “last” Node of the
network. If you enter a value higher than what
exists; an error message will display after you
click the Refr
efresh
esh button. For the example
shown; if there were only 4 Nodes installed and
you entered 6, you would receive 2 error
messages in succession after clicking the
Refr
efresh
esh button
Clicking the + and – buttons will increment /
decrement the Node value in the From Node #
box and display the module data for the new
Node selected. Please note that if you
increment past the value of the last physical
Node installed, you will receive an error
message
* Anywhere on the Main Screen where you see a Set All button next to a
parameter or data entry selection, all the nodes in the range entered in the From
Node # and To Node # will be updated with the same parameter or data entry
selection when you click the associated Set All button. A dialog box will appear
to confirm your selection.
Page 91 of 329
7.1.2. Node Identification
* EasyRoll main screen has a feature identified as “Blink & Wink” that allows you
to visually verify the Node you have selected
If a valid Node is selected in the From Node #

text box and its information is displayed on the
main screen; clicking the Blink & W Wink
ink switch
icon will signal the selected module to blink on
and off all of its LED indicators. Click the Blink &
Wink switch again to turn this off
! Please note that when Blink & Wink is active, the module stops all motors
Page 92 of 329
7.1.3. ZP
ZPA
A Upstr
Upstream/Downstr
eam/Downstream
eam Zone
Settings
On the main screen there are areas to configure the Upstr
Upstream
eam and Downstr
Downstream
eam Zone settings.
The Upstr
Upstream
eam and Downstr
Downstream
eam settings are set independent of one another so you can
customize your ZPA functionality based upon your specific needs.
Page 93 of 329
7.1.3.1. Release Mode
Selecting the pull-down bo

box
x
for ZP
ZPA
A Mode will show the
available selections.
Singulation is the default
configuration
* Selecting a new setting from the ZPA Mode drop down box immediately changes
the zone’s mode. If you want to set all Upstream zones for the range of nodes
entered in the Node No. text boxes, then click the Set All button. Similarly, you
can do the same operation in the “Downstream Zone” portion of the main
screen.
* Singulation Release Mode is the default setting and it is described in the Default
Settings and Operation section
* Please note that Singulation and Train Release Modes are configurable per Zone
and can be mixed on the same network
Page 94 of 329
7.1.3.1.1. Singulation R
Release
elease
* Singulation Mode is the default setting and it is described in the Default Settings
and Operation section
Page 95 of 329
7.1.3.1.2. Train R
Release
elease
All 3 Cartons ar
areeA
Accumulated
ccumulated
When Carton 1 rreleases

eleases – Cartons 2
and 3 also rrelease
elease at the same time
Select Train from the pull-down box

for Train Mode
! Please note that starting many zones in Train Release mode particularly with
heavy loads can cause voltage drops on your power supplies. Be sure to take
care in sizing your power supply needs. You should consider GAP Train Release
Mode if power supply sizing is a concern
Page 96 of 329
7.1.3.1.3. GAP T
Train
rain R
Release
elease
All 3 Cartons ar
areeA
Accumulated
ccumulated

eleases and Zone
2’s GAP time has e expir
xpired,
ed, Carton 2
will begin to rrelease.
elease. Carton 3
remains accumulated

eleases and Zone
3’s GAP timer has e
expir
xpired,
ed, Carton 3
will begin to rrelease
elease
When you select Gap T Train

rain from the
ZPA Mode drop-down box; the Gap
Timer data entry box and Set button
are enabled. Simply enter the
desired time value and click the Set
button to update the value in the
selected Node. In this example we
entered 0.35 seconds
! Please note the GAP time does not cr

create
eate a gap or cause any delay when items
are in transportation. The Gap timer is only activated when a given zone
accumulates an item and then it is allowed to release
* If more than one consecutive zone is configured as Gap T Train

rain; then each of these
zones will in turn require that their respective gap timers expire. If the time value
is long enough, the result may appear to be Singulation R Release
elease mode or even
Singluation Release with extra time delay. 0.2 to 0.3 seconds are typical values
used when you want to help balance the loading on your power supplies but still
have the operation be very close to Train R Release
elease Mode
Page 97 of 329
7.1.3.2. T-Zone Settings

In conveyor applications, transferring a carton at a right angle from one conveyor to another
often requires special lifting and lowering mechanisms. In certain applications, one conveyor
can simply drive its carton off of its downstream zone directly onto the upstream zone of
another conveyor that is perpendicularly oriented. This type configuration is commonly defined
as a T-Zone arrangement. ConveyLinx contains the logic to control a T-Zone arrangement
without requiring any external control interface or programming.
! Material handling considerations such as discharge conveyor speed and load

weight have to be analysed prior to implementing a T-Zone configuration. Be
sure to verify your mechanical design and carton characteristics before utilizing
a T-Zone arrangement.
The T
T-Zone
-Zone A
Accept
ccept T
Time
ime is the amount of time between the leading edge of the A Accepting
ccepting Zone’s
Sensor becoming block
blocked
ed and the starting of the A
Accepting
ccepting Zone’s motor
motor.. This time delay allows
the Sending Zone enought time to fully transfer the item into the A
Accepting
ccepting Zone.
Page 98 of 329
T-Zone Between 2 Separate Modules
Page 99 of 329
T-Zone on a Single Module
Enter the value and click the Set

button. In this example we entered
1.5 seconds. Whether to change the
Upstream Zone or Downstream Zone
value on the main screen is
dependent upon which zone is the
accepting zone
! The T-zone Accept time is always applied to the accepting zone
Page 100 of 329

7.1.3.3. ZP
ZPA
A Er
Errror and Infor
Information
mation
There is an Er
Errror and Infor
Information
mation area in the upper right corner in both the Upstream and
Downstream Zone areas of the Main Scr
Screen
een. There is an indicator that shows if a Jam condition
is active (either Ar
Arrival
rival Jam or Sensor Jam). There is a numerical indicator of all occurrences of
any Jam conditions since the last module power cycle. There is also a Clear button to allow you
to clear a Sensor Jam if it is active.
* The Clear button is a convenience so you do not have to go the zone in question
and remove or otherwise clear the item from the zone sensor. If Sensor Jam Auto
Clear is enabled, clicking the Clear button will re-initiate this procedure.
Page 101 of 329

7.1.3.4. Accumulate Contr

Control
ol fr
from
om Main
Scr
Screen
een
Clicking the Accumulate switch icon will place the zone in accumulation mode and the next
carton that arrives at that zone will stop and remain until you click the switch again to turn off
the accumulation mode
Clicking the icon will initiate the

Accumulate function and the icon will
highlight and change state
Clicking the icon again will turn off the

Accumulate function
* When you set Accumulate from EasyRoll, this is saved to the module’s flash
memory so that when you cycle power on the module, it will power up in the
accumulated state.
Page 102 of 329

7.1.3.5. Settings Checkbo

Checkbox
xes
Both the Upstr
Upstream
eam and Downstr
Downstream
eam ZPA Zones have Settings check boxes to allow you to
customize some of the ZPA behavior. These settings can apply to only the zone you are
connected to and viewing or you can apply the same settings to multiple modules in a range of
module nodes.
Disable R
Reset
eset Delays
Disable Sensor Jam Auto Clear
Disable Ar
Arrival
rival T
Timeout
imeout
Disable Manual Operation
Page 103 of 329

7.1.3.5.1. Disable R
Reset
eset Delays
Any individual zone or group of zones can be configured to ignore the Auto Clear Time delay for
either or both of the Arrival Jam and Sensor Jam.
Clicking either or both check-boxes

will cause the zone’s logic to ignore
the Auto Clear T Time
ime delay for the
particular jam condition
! Selecting either of these options will not eliminate the detection of the particular
jam condition; it simply eliminates the default Auto Clear TTime
ime delay the logic
utilizes before automatically clearing the condition.
Page 104 of 329

7.1.3.5.2. Disable Sensor Jam Auto Clear

Sensor Jam Auto Clear Procedure describes how the logic will make 3 attempts to clear a
Sensor Jam if one occurs. There may be instances at specific zones or range of zones where
you do not want this functionality to happen. There is a check box that allows you to disable
this functionality
Clicking the Disable Sensor Jam Auto

Clear check box will disable the 3
attempts to clear the Sensor Jam and
will cause the zone to remain in the
jam state until the sensor is cleared
manually
* You can also attempt to clear a Sensor Jam using the Clear button for the Zone
Page 105 of 329

7.1.3.5.3. Disable Ar
Arrival
rival T
Timeout
imeout
Arrival Jam describes how default zone to zone logic utilizes the Jam Time value for the
discharging zone to wait for the accepting zone to indicate successful arrival of the carton into
the accepting zone. In certain applications for a given zone, you may want to disable this
functionality
Clicking the Disable Ar

Arrival
rival T
Timeout
imeout
check box will prevent the discharging
zone from registering an Ar Arrival
rival Jam
condition. Upstream cartons will not
wait to enter the discharging zone
once a carton has left the discharging
zone
Page 106 of 329

7.1.3.5.4. Disable Manual Operation

In normal ZPA operation, if a zone is in Accumulation (either by external device or if Aux I/O Pin
2 is set to Accumulate) and the carton is subsequently manually removed from the conveyor;
the zone downstream of the accumulated zone will run in an attempt to “find the lost carton”.
In certain applications or situations where manually removing cartons from accumulated zones
is expected; you can disable the running of the downstream zone to “find the lost carton”
Without Disable Manual Operations bo

box
x check
checked
ed
Carton accumulated in Upstr

Upstream
eam
Zone by Aux I/O P Pin
in 2 A
Accumulate
ccumulate
signal or e
exter
xternal
nal network signal
If carton is rremoved
emoved frfrom
om Upstr
Upstream
eam
Zone, the Downstr
Downstream
eam Zone will run
to “find the missing carton
carton”.
”. R
Run
un time
is the duration of the Jam T Timer
imer
setting (5 sec. by default)
With Disable Manual Operations bo

box
x check
checked
ed
You first navigate the main screen to

the zone you want to prevent from
running when it’s upstream
neighboring zone has its carton
removed. Clicking the Disable Manual
Operations check box will prevent this
zone from running when its upstream
neighbor has an accumulated carton
manually removed
Page 107 of 329

When you check the Disable Manual

Operations check-bo
check-box x for the
Downstr
Downstream
eam Zone, then it will not run
when upstr
upstream
eam carton is rremoved
emoved
Page 108 of 329

7.1.4. Motor Settings

The motor settings for the current selected module can be modified on the Main Screen
* Please note that the Motor Settings grouped by motor plugged into the physical
Left and Right sides of the module and are not based upon Upstream or
Downstream product flow.
Page 109 of 329

7.1.4.1. Motor T
Type
ype
The Motor Type pull-down box lists all motor brand and types whose profiles are available for
the module. Senergy-Ai ECO is the default setting upon completion of the Auto-Configuration
Procedure. The new settings are downloaded to the selected Node upon selecting a new item
from the list.
In this example, clicking Set All will

download the selected setting to the
Left MDR of all modules entered in the
range of Nodes at the top of the main
screen in the From Node # / T To
o Node
# boxes. If for example these boxes
had the values of 1 and 6; changing
the selection in the Motor T
Type
ype pull
down will change Node 1 and clicking
Set All will change Nodes 2 thru 6 to
the same setting as Node 1
! Please consult the Pulseroller Catalog Senergy Ai motor documentation and

review your application if you are unsure as to which motor-type setting to use
Page 110 of 329

7.1.4.2. Brak
Brake
e Method
The Brak
Brakee Method pull-down box lists all the holding brake methods available for the module.
Nor
Normal
mal is the default setting upon completion of the Auto-Configuration Procedure. The new
settings are downloaded to the selected Node upon selecting a new item from the list.

download the selected setting to the
Left MDR of all modules entered in the
range of Nodes at the top of the main
screen in the From Node # / T To
o Node
# boxes. If for example these boxes
had the values of 1 and 6; changing
the selection in the Brak
Brakee Method pull
down will change Node 1 and clicking
Set All will change Nodes 2 thru 6 to
the same setting as Node 1
Method Description
Once the controls have decelerated the rotor to a stop, the motor coil are internally
connected. The permanent magnet forces in the rotor and the mechanical inertia of the
Nor
Normal
mal gearbox holds the rotor in place. This is the MDR industry standard holding brake
method and is often termed short circuit or shunt. Nor
Normal
mal is the default factory setting
for all module zones from the Auto-Configuration Procedure
Once the controls have decelerated the rotor to a stop, the motor coils are internally
Free
disconnected and only the mechanical gearbox inertia holds the rotor in place
When the controls have decelerated the rotor to a stop, the processor notes the Hall
Servo Effect sensor status. If the Hall Effect sensor status changes indicating a change in
Brak
Brake
e position of the rotor, the controls will inject current into the motor coils in the proper
sequence to move the rotor back to its original stop position
! Servo Brake function utilizes motor power and depending on the torque
demanded by the motor to hold the load the potential for heat build-up exists
Page 111 of 329

7.1.4.3. Speed
The Speed setting value is in meters per second (m/s). The Senergy-Ai motor roller contains
data as to its gear reduction ratio and roller diameter that is readable by the ConveyLinx
Module. EasyR
EasyRoll
oll then uses this information to indicate whether the speed you enter is valid for
the connected roller.
Setting Speed V
Value
alue
For our example roller, entering a

value of “0.300” for the speed and
clicking Set will set the speed to 0.3
m/s for the roller. If the background of
the speed entry box remains white,
then the speed is valid for the roller
part number detected by the module
Speed Setting T
Too
oo High

speed of 2 m/s is over its allowable
maximum speed. The background of
the speed entry box will change to red
indicating the speed setting is too
high
* Setting the speed too high will result in the motor running at is maximum
defined speed
Speed Setting T
Too
oo L
Low
ow

speed of 0.1 m/s is under its allowable
minimum speed. The background of
the speed entry box will change to
blue indicating the speed setting is
too low
* Setting the speed too low will result in the motor running at is minimum defined
speed
Page 112 of 329

Setting Same Speed for Multiple Modules
Type in the desired speed in m/s. You

can also use the Set All button to set
the entered speed to each motor in
the From Node # / TTo
o Node # boxes.
In this example the Left MDRs from
nodes 1 thru 6 will each get the same
speed setting
Page 113 of 329

7.1.4.4. Rotation Dir

Direction
ection
This setting is either Clock-Wise (CW
CW) or Counter-Clock Wise (CCW
CCW)and is determined for each
module based upon the Auto-Configuration Procedure results. Please refer to section Motor
Rotation Definition for details on how to determine rotation direction with respect to MDR
installed orientation.
Selecting a direction from the drop-

down box immediately sets the
rotation direction. You can also use
the Set All button to set the selected
rotation direction to each motor in the
From Node # / T To
o Node # boxes. In
this example the Left MDRs from
nodes 1 thru 6 will each get the same
CW/CCW rotation direction setting
* Please note that if you change the Rotation Dir

Direction
ection and this module goes
through another Auto Configuration procedure, the Rotation Dir Direction
ection setting will
not reset back to default. It will remain unchanged at the last selected setting.
Page 114 of 329

7.1.4.5. Acceleration/Deceleration
Acceleration and Deceleration settings are fields you enter values similar to Speed. The units of
the value you enter are in mm which means that the control will accelerate and decelerate for
the distance specified within the controller’s current limits and the mechanical limits of the
connected drive train.

download the selected setting to the Left
MDR of all modules entered in the range of
Nodes at the top of the main screen in the
From Node # / T To
o Node # boxes. If for
example these boxes had the values of 1
and 6; changing the selection in the Motor
Type pull down will change Node 1 and
clicking Set All will change Nodes 2 thru 6
to the same setting as Node 1
Page 115 of 329

7.1.4.6. Motor Jog and Er

Errror Indicators
Motor Jog (R
(Run)
un) F
Function
unction
In EasyRoll, the Left and Right motors have their own Run buttons on the Main Screen. These
are used to temporarily run the motors for verification of function and diagnostics.
Click the Run icon to turn on the

motor*
When Run is activated the icon

highlights. Click the icon again to tur
turnn
the motor off
* Explanation of unexpected rotation direction when you run a motor from this jog
function
Page 116 of 329

Er
Errror Indicators
In EasyRoll, the Left and Right motors have their own status indicators on the Main Screen.
These are used to provide visual indication of certain conditions. There is also status indicators
for the Sensors connected to the Left and Right sides of the modules.
Sensor Connection Occurs when the particular side of the module was Auto Configured as a
Error zone and the sensor is unplugged or otherwise not drawing power
Occurs when the sensor health/gain signal on pin 2 of the Sensor port
Sensor Gain Error changes state from its Auto-Configuration state. This is only applicable if
the Aux I/O Pin 2 Usage has been set to “Sensor Error (DI)”
A running numerical counter that increments for each occurrence of

Error Counter
connection or gain errors. Counter resets to 0 upon power cycle
Motor Connection Occurs when a motor that is expected to be connected becomes

Error disconnected by either unplugging or internal damage
Voltage drop [<18V] Occurs if the incoming power to the module drops below 18 volts
Motor short circuit Occurs if the module detects a short circuit condition
Indicator turns Yellow if the motor is delivering the maximum torque

Max. Torque
according to the selected motor profile
Occurs if motor is commanded to run and is in a stalled condition for

Overload
more than 20 seconds
Occurs when the motor is commanded to run and the rotor is not
Motor Stalled
turning at least at 10% of its set speed
Occurs if one or more of the 3 Hall Effect Sensors does not produce a
Motor Sensor Error
signal or does not change state when motor is running
Page 117 of 329

Occurs when the calculated motor temperature has exceeded 105°C or

Overheat
the module temperature has exceeded 90°C
A running numerical counter that increments for each occurrence of any

Motor Error Counter
of the motor error conditions. Counter resets to 0 upon power cycle
Overvoltage [>30V] Occurs when the incoming power to the module exceeds 30V
Page 118 of 329

7.1.5. Diagnostic W
Window
indow
Diagnostic W
Window
indow Example
You can navigate to the next or previous module’s Diagnostic Window by clicking
the + and – buttons
Displays the current ZPA status of the zone and the state of the sensor
Displays the status of the upstream and downstream zones to the selected
module. Note that the values depicted below the text (“00 00” in the example)
indicate the contents of the Tracking Registers.
Displays the current input voltage to the module as well as the count of the
number of times the power supply went below 18 volts but did not completely
shut off. This is useful for diagnosing possible power supply issues
Displays the current state of each Sensor Port input signals
Displays current status of each motor. Please note that this data is also shown on
the main screen as well
Page 119 of 329

Accumulation Status
If a carton is accumulated on a particular zone, the Diagnostic Window will indicate a reason for
the accumulated state. Also note that in situations where an external device (PLC or PC
controller) or the Accumulate icon on the Main Screen has been activated; the Sensor LED on
the module for the stopped carton’s zone will be fast blinking green. You can then consult the
Diagnostic Window for more detailed information on the exact reason
As shown in this e example,

xample,
for the upstr
upstream
eam zone on
the selected Module, it
shows ““PLC
PLC”” as the rreason
eason
a carton is stopped at this
zone even though its
immediate downstr
downstream
eam
zone is empty
Motor R
Roller
oller Infor
Information
mation
One very useful featur

feature
e of
the Diagnostics window is
that you can mouse-over
the image of each rroller
oller
and a pop-up will display
the pertinent motor
parameters as well as the
part number and serial
number of the connected
roller as shown
Page 120 of 329

7.2. Advanced Dialog

The Advanced Dialog is where you can make further changes to module operation and access
utilities to help maintain your system of modules.
To invoke the ConveyLinx Advanced Dialog you can do any of the following:
• Click Advanced Dialog button

• Press F2
• Simultaneously press [Ctrl] [Shift] U
The ConveyLinx A Advanced

dvanced Dialog
pops up over the Main scr
screen
een display
and defaults to show the Look Ahead
&TTiming
iming tab
Page 121 of 329

7.2.1. Look Ahead and T

Timing
iming T
Tab
ab
The Look Ahead and Timing Tab contains 4 sections of settings pertaining to ZPA functionality:
Look Ahead
Jam & Auto Clear T
Timers
imers
Run A
Affter & Induct
Sensor Debounce
Page 122 of 329

7.2.1.1. Look Ahead Slowdown F

Featur
eaturee
The Look Ahead feature configures the logic to “look ahead” to its next downstream zone and if
it is occupied when a carton is entering its zone, the module will dynamically adjust the MDR to
the selected speed. This feature in intended to be used in higher speed applications were
increased stopping distance is required to keep cartons from over-travelling their stop
positions. This function can be applied per zone or for multiple zones
A carton is accumulated and stopped at Zone 1 and another carton is conveying at nor
normal
mal set
speed
When carton rreaches

eaches end of Zone 3, Zone 2 will wak
wake
e up and run at the L
Look
ook Ahead Speed
Page 123 of 329

Click the checkbox to enable the Look Ahead feature for the selected Node.
Clicking the Set buttons will download the setting to the respective zone on the
selected Node. The value entered for the Slow Down Speed is in percent of the
Zone’s normal speed as set on the main screen. In this example, the Slow
Down Speed speed will be proportional to 80% of 0.300 m/s. Also note there is
a Set All button that will apply the settings to the range of Nodes entered
Page 124 of 329

Fast R
Release
elease T
Time
ime
The Fast R
Release
elease T
Time
ime option allows you to set a delay before the Slow Down Speed is engaged
for the slow-down zone
When Zone 2 wak

wakeses up it will run at nor
normal
mal set
speed until the Fast RRelease
elease T Time
ime has e
expir
xpired,
ed,
then it will switch to run at the Slow Down
Speed
To use the Fast R

Release
elease T
Time
ime option, click the
Fast R
Release
elease T
Time
ime checkbox and enter a time
value (in seconds) into the entry box. In this
example we entered 0.5 seconds. Click Set to
write the changes to the module and use the
Set All feature as desired
Page 125 of 329

7.2.1.2. Jam & Auto Clear T

Timers
imers
The Jam T
Timer
imer for a given Upstream or Downstream zone is used for both detecting an Arrival
Jam and a Sensor Jam. The Jam T
Timer
imer should be set as the maximum expected time it takes for
a carton to travel from one zone to the next plus a small addition to prevent nuisance jam
occurrences. The default value for the Jam Timer is 5 seconds and the valid range of values is
from 1 seconds to 65 seconds.
The Auto Clear T

Timer
imer is the amount of time that the logic maintains the jam condition before
auto resetting the jam. The default value for the Auto Clear Timer is 5 seconds and the valid
range of values is from 0 seconds to 65 seconds
Enter new values for either or both

the Jam TTimer
imer and/or Auto Clear
Timer and click the corresponding
Set button for each. The Set All
button will apply these same
settings for the range of modules
indicated at the top of the dialog
Page 126 of 329

7.2.1.3. Run A
Affter T
Time/Distance
ime/Distance
The Run A
Affter time value is used by the logic for normal zone discharge. This is the amount of
time the zone’s MDR will continue run after its photo-sensor has been clear when discharging
to the next downstream zone.
This extra run time allows the zone to

run so that the trailing edge of the
carton can completely pass the photo-
sensor and fully enter the next zone.
This value is adjustable to
compensate for special conditions
where a zone photo-sensor is required
to be placed farther upstream or
downstream
* Please note that Run After does not affect throughput rate. A longer Run After
time will not prevent an upstream item from entering the zone.
Run A
Affter T
Time
ime
Enter new values for upstream and/

or downstream Run A Affter time and
click the corresponding Set button.
The default is 5 seconds and the
valid range is 0 to 65 seconds. The
Set All button will apply these same
indicated at the top of the dialog. In
this example we changed the Run
After time to 1.00 seconds and using
the Set All button to update this
setting in Nodes 3 thru 4
Page 127 of 329

Run A
Affter Distance
EasyRoll provides the option to change the Run A

Affter metric to be distance based instead of
time based. When the metric is distance, the value entered is millimetres instead of seconds
Select Distance from the drop-down

box and enter new values for
upstream and/or downstream Run
After distance and click the
corresponding Set button. The
default is 1000 mm and the valid
range is 0 to 65,535. The Set All
this example we changed the Run
After distance to 100 mm and using
the Set All button to update this
setting in Nodes 3 thru 4.
Page 128 of 329

7.2.1.4. Induct F
Forwar
orwarddT
Time/Distance
ime/Distance
Induct F
Forwar
orward
d value is used to cause the MDR to continue to run after the zone’s photo-sensor
has been blocked when receiving a carton from upstream.
This value is adjustable per zone to

compensate for special conditions
when for example a zone’s photo-
sensor needs to be placed farther
upstream from the discharge end of
the zone
Induct F
Forwar
orwarddT
Time
ime
Enter new values for upstream and/

or downstream Induct F Forwar
orward d time
and click the corresponding Set
button. The default is 0 seconds and
the valid range is 0 to 65 seconds.
The Set All button will apply these
same settings for the range of
modules indicated at the top of the
dialog. In this example we are
changing the Induct F Forwar
orwardd time to
1.00 seconds for both the upstream
and downstream zones and updating
this setting to Nodes 3 thru 4
Page 129 of 329

Induct F
Forwar
orwardd Distance
Select Distance from the drop down

box and enter new values for
upstream and/or downstream Induct
Forwar
orwardd pulses and click the
corresponding Set button. The
default is 0 mm and the valid range
is 0 to 65,535 mm. The Set All
this example we are changing the
Induct FForwar
orwardd distance to 100 mm
for both the upstream and
downstream zones and updating this
setting to Nodes 3 thru 4
Page 130 of 329

7.2.1.5. Sensor Debounce

Sensor Debounce setting is the time the logic holds the state of its Sensor inputs after a
change of state. Keep in mind this is not a delay prior to detecting a carton when it first blocks
the sensor. The module will detect the leading edge of a carton and hold this state for the
Sensor Debounce time period. Similarly, when the trailing edge of the carton clears the sensor,
the logic holds this state for the Sensor Debounce time period.
Enter the desired value in seconds

and click the Set button. The default
is 0.1 seconds and the valid range is
0 to 2 seconds. Please note this
setting applies to both the Lef
eftt and
Right Sensor ports. The Set All
this example we are changing the
Sensor Debounce time to 0.30
seconds and updating this setting
using the Set All button for Nodes 3
thru 4.
Page 131 of 329

7.2.2. Upgrade T
Tab
ab
The Upgrade tab screen gives access to the module firmware utility. Over time, enhancements
and features may be added to the ConveyLinx family of products. These features and
enhancements are typically made available to customers in the form of firmware upgrade files
that need to be uploaded to your modules. These files are available for download from our
website. Once you have downloaded the desired file, the Upgrade utility allows you to browse
for it and then select a single Node or group of Nodes to upload
* VER
VERYY COOL
COOL:: Please note that if you upgrade firmware, all of each module’s
settings (motors, speeds, ZPA options, etc.) are preserved
Upon selecting the

Upgrade screen tab,
EasyRoll fills in the I.P.
address of the range of
Nodes entered on the
main screen. Click the
Browse button to open a
file selection dialog
window
Page 132 of 329

With the Open dialog

displayed, navigate to the
location on your PC where
you placed the firmware
upgrade file you received.
Select the file and click
Open
In this example, we clicked

Upload ALL so the selected
firmware upgrade file will
be sent to all 6 Nodes. The
Output window will update
the progress of the file
uploading process. The
time it takes for this
process will vary
depending upon how
many Nodes are being
uploaded
Page 133 of 329

When all Nodes report

back to the Output window
with a status of Done; then
the upload is complete
and you can close the
ConveyLinx Advanced
Dialog window
* Please note that you typically arrive at the Upgrade tab from the Network
Services tab where you select the modules first and click the Upgrade button
there. That will automatically take you to the Upgrade tab and populate the
Selected Devices list box on the Upgrade tab with your selection from the
Network Services tab
Page 134 of 329

7.2.3. Connections T
Tab
ab
The Connections utility uses EasyRoll to instruct a given module to make a logical connection
to another module that it otherwise would not have made during the Auto-Configuration
Procedure. For applications where you have more than one Subnet, this would be the way to
logically connect the most downstream Node of one Subnet to the most upstream Node of
another Subnet
Connecting T
Two
wo Subnets T
Together
ogether
Here is a typical boundary between two Subnets. The most downstream Node of the first
Subnet has an I.P. address of 192.168.21.23 and the most upstream Node of the second Subnet
has an I.P. address of 192.168.22.20.
By simply connecting an Ethernet cable between these two boundary Nodes and then using
EasyRoll to establish the “logical” connection between the two Subnets; you can achieve
seamless flow between the two networks. The procedure requires that you have to instruct
Node at 192.168.21.23 to convey cartons to Node at 192.168.22.20, and likewise you have to
instruct Node at 192.168.22.20 to accept cartons from Node at 192.168.21.23
Page 135 of 329

Navigate to Node 4 of the

192.168.21 subnet (i.e.
192.168.20.25). Notice that the
module’s network data appears in
the center. Also notice that the
Downstream connection for this
Node is None
Enter 192.168.22.20 as the I.P.

address for Node 4’s new
Downstream connection. Click Apply
to make the change. Please note
that it will take a few seconds for
this to complete
Page 136 of 329

Navigate to Node 1 of the

192.168.22 subnet (i.e.
192.168.22.20). Notice that the
module’s network data appears in
the center. Also notice that the
Upstream connection for this Node is
None
Enter 192.168.21.23 as the I.P.

address for Node 1’s new Upstream
connection. Click Apply to make the
change. Please note that it will take
a few seconds for this to complete
Page 137 of 329

7.2.4. Network Services T

Tab
ab
The Network Services screen provides multiple functions related to module and network
management. These functions are:
• Discover and IP Address Set

• Backup and Restore
• Firmware Upgrade
Page 138 of 329

7.2.4.1. Discover & IP A

Addr
ddress
ess Set
One of the features of EasyRoll is that it has a utility called Discover that allows your PC to go
and find any modules that may be physically connected to you network regardless of the I.P.
address settings of your PC or the I.P. address settings of the modules
Clicking the Discover button will

cause the list box to populate with
all the modules in all Subnets that
your PC can see out on the network
Page 139 of 329

The drop-down box at the top of the

list box lets you filter the list by
Subnet
To change the IP Address, Subnet

Mask, etc. of a module, double click
it from the list and its data can be
modified
Page 140 of 329

Once you have edited the data, click

the Set button and the changes are
sent to the module
Page 141 of 329

7.2.4.2. Back
Backup
up & R
Restor
estoree
ou have the ability to select a Subnet or all Subnets discovered and generate a Back
Backup
up file that
will contain all the parameters and settings for each module included in the selection. This
means all motor settings (speed, acceleration, deceleration, braking, etc.), ZPA settings,
Advanced Dialog settings, etc. are captured in this file that can be saved on your PC.
Conversely you can use this Back
Backup
up file to Restor
estoree settings to a Subnet or all Subnets in the
event settings are inadvertently modified or you simply want to return your modules to a
previously known state
To perform a backup, click the Select

ALL button to select all the items in
the list. In this example we are going
to backup Subnet 192.168.29. Once
all modules are highlighted, click the
Back
Backupup button.
A Save As dialog will appear and you

provide a filename and location to
save the file
Page 142 of 329

Conversely, if you have a Back

Backupup file
that you want to use to get your
Subnet’s settings restored; click the
Select ALL button and then click the
Restor
estoree button.
An “Open File” dialog will appear for

you to navigate to the location of
your backup file, select it and click
“Open”.
* Please note that the Restor

estore
e function will only restore settings to modules that
have a matching Serial Number in the Back
Backup
up file. For situations where module
serial number are different but functionality still needs to be restored, you will
need to use the Restor
estore
e by IP function
Restor
estoree by IP F
Function
unction
Because the default Restor

estoree function restores settings by module Serial Number only, in
situations such as duplicating a Subnet or restoring functionality from an older backup where
some of the modules were replaced since the Back
Backup
up file was generated, you need to restore
Page 143 of 329

the settings by IP address instead of by module Serial Number. To do this you follow the same
restore procedure as previously shown except you click the Restor
estoree by IP button instead of the
Restore button
Back
Backup
up and R
Restor
estoreeR
Recommendations
ecommendations and T
Tips
ips
Sometimes there are situations where just because a software application will allow you to do
something does not always mean that you should. The Back
Backup
up and Restor
estoree functions in
EasyRoll can fall into this scenario. Even though you can technically create a backup file for a
few or even a single module from within a Subnet of many modules, it is not recommended
that you do so. ConveyLinx support engineer’s experience to date has indicated that when
customers perform Back
Backup
up and Restor
estoree functions for, at a minimum, all modules in a Subnet
Subnet,
you will have fewer or no problems with your ConveyLinx networks. Systems that were once
working and then start producing unexpected results often stem from performing a Restor
estoree
function to a small portion of modules instead of the entire Subnet and/or starting with a
backup file that did not include all modules in the Subnet
Subnet. So, here is a list of tips:
• When you perform a Back

Backup
up; at a minimum, select all modules in a given Subnet
• When you perform a Restor
estoree; at a minimum, select all modules in a given Subnet
• Perform a new Back
Backup
up after you make any settings changes to one or more modules in a
Subnet
• Perform a new Back
Backup
up after every time you perform an Auto Configure Procedure
Page 144 of 329

7.2.5. Special Services T

Tab
ab
Clear Motor Short Cir
Circuit
cuit Er
Errror
Another function on the Special Services tab is a button used to clear an MDR short circuit
error. This particular error is not logically cleared based upon an elapsed period timeout or
other such reset. An MDR short circuit error requires that either the module be powered down
and then powered back up or by clicking the Reset button on this tab. This function is made
available in EasyRoll as a convenience so you don’t have to cycle the power on the module.
There is not a separate Reset button

for left and right motors. One button
will perform the function for either or
both motors.
Page 145 of 329

Touch & Go
The Touch & Go function is available in ZPA mode and when activated causes the MDR in the
activated zone to sense rotational movement of the MDR in its default direction. If this
rotational movement (such as someone pushing a carton onto the zone) is of sufficient duration
and speed; the zone will “wake up” as if its upstream interlock had been energized. You enable
this function by checking the appropriate Upstream or Downstream checkbox in the Touch & Go
area.
You can set this functionality for

either or both the Upstream and
Downstream Zones in the direction
of flow. In this example we checked
the Upstream zone
! Touch & Go is only applicable for ZPA mode. Do NOT use Touch & Go with Servo
Braking
Page 146 of 329

7.2.6. Fle
Flexx Zone T
Tab
ab
The Fle
Flexx Zone feature is enabled by default when you perform the Auto Configure Procedure.
There can be certain situations such as higher speed applications and/or applications where a
large percentage of cartons are at a length very close to the zone length where a “false
triggering” of a flex zone condition can occur. In these situations, when product needs to
accumulate, you may see several zones unoccupied because of this false triggering. For these
applications where accumulation density is paramount, you can disable Flex Zone to eliminate
this false triggering situation.
! Please note that Flex Zone function has to be enabled or disabled for the entire
subnet. It cannot be disabled or enabled on a per zone basis or for a group of
zones within the same subnet.
Click the appropriate button to

either Disable or Enable Flex Zone
based upon the Subnet’s current
status as indicated. Because this
function applies to all modules in the
Subnet, it does not matter what
module you were connected to when
you invoked the Advanced Dialog in
order to disable or enable Fle
Flexx Zone
Page 147 of 329

Inter Module Communication T

Time
ime
The Inter Module Communication T
Time
ime value is used to adjust the behavior of the Flex Zone
operation. In situations where carton lengths can be close to the length of the zones (i.e.
distance between photoeyes), you may want to adjust Flex Zone operation so that it either
engages or not in these situations.
Typically there are one or two driven rollers past the sensor in a Zone. If you
have cartons that encroach upon these rollers when accumulated in the
downstream zone, you may want Fle Flex
x Zone to engage so that the next
upstream carton will not enter the zone (Zone A in the example), thus not
running these rollers underneath the accumulated carton.
Page 148 of 329

The value entered is in msec and it

can be thought of as an amount of
time added to the logic after the
trailing edge of the sensor in order
to simulate increasing the carton
length. Please note that this value
will be set the same for each module
in the Subnet.
* Please note this value has nothing to do with speeding up or slowing down the
actual speed of communications between modules
Page 149 of 329

7.2.7. Sensors T
Tab
ab
The Sensors tab displays the status of how the two sensor signals were configured during the
Auto Configuration Procedure. If for some reason one or more of the sensors was not configured
properly during the Auto Configuration Procedure; for example they were not aligned with their
reflector or there was an obstruction blocking the sensor at the time the procedure was
performed, the Sensors Tab will allow you to change the sensor’s configuration without
requiring you to re-perform the Auto Configuration P
Prrocedur
oceduree for the entire subnet. For
example, if all the sensors on the system are light energized normally open then the
corresponding zone’s sensor graphic on this tab will show Off Blocked.
Click the appropriate icon to change

either or both sensor’s blocked
signal state. Note that you can make
the same change for a group of
modules by clicking the Set All
Sensors this W
Way
ay button
Page 150 of 329

7.2.8. Extensions T
Tab
ab
The Extensions Tab allows you to extend or “slave” single or multiple zones to one “master”
zone. An example situation could be that you have for example certain length zones and on a
given conveyor line there is a need for an extra partial zone that is too short to be a functional
zone that accumulates a carton, but at the same time it is long enough that mechanically you
need to have an MDR in that zone. In this situation you would like to provide a module and an
MDR but no sensor and you want this zone to run its MDR when either its adjacent upstream or
downstream zone is also running. In essence you want to make this partial zone a logical
extension to one of its neighbors.
Example for Using Extensions for a Lif

Liftt Gate
A common use of the Extension mode configuration available from the Connections tab
selection is for a powered lift gate. In this example the module on the lifting or gate portion of
conveyor has an MDR and no photo-sensors. Normal operation when the gate is down is for the
MDR on the gate to run when its immediate downstream zone runs so as to create “one long
logical zone”. This means that if a carton is accumulated on the upstream zone of Node
192.168.21.23; a carton arriving at the downstream zone of Node 192.168.21.21 will stop and
accumulate and no loads will ever be logically accumulated or stopped on the gate portion. In
order to accomplish this, all we need to do is instruct Node 192.168.21.22 to be an Extension of
its downstream neighbor Node 192.168.21.23
Lif
Liftt Gate Example
Page 151 of 329

In the Advanced Dialog, navigate to

Node 3 and click the Extensions Tab.
Notice that Node 3’s IP address
192.168.21.22 is filled in. In the
drop-down box, select Downstream
and click Apply. Note that this may
take a few seconds to complete
After clicking Apply, the screen will

update and show you that the
module has been configured as an
extension or “slave” of its
downstream neighbor
Page 152 of 329

Now if you navigate back to Node 2

and look at the Connections Tab, you
can see that the downstream
connection of Node 2 is now Node 4
instead of Node 3
And then when you navigate to

Node 4
4, you can see that its
upstream connection is now Node 2
instead of Node 3
Page 153 of 329

And when you navigate to Node 3 3,

you can see that it is configured as
an Extension of Node 4
Page 154 of 329

7.2.9. Pin 2 Usage T

Tab
ab
Pin 2 on each of the two Sensor port’s M8 connector on the Module is configurable as to its
potential function. This pin can function as either an input or an output. The default “out-of-the-
box” usage for Pin 2 is “Not Used”. Using the Pin 2 Usage screen from the ConveyLinx
Advanced Dialog allows you to select one of the following functions for each zone on the
module:
• None: No ZPA Function but is available to be read as input by remote PLC

• Accumulate: Input for local zone accumulate command
• Wake up: Input for local zone wake-up signal
• Wake-up with Timeout
• Lane Full Interface: Input for local Lane Full Interface signal
• Module Error Output
• Product on Zone Output
• Sensor Error Output
• Mirror Pin 4
Depending on how the module is configured, you can independently select which of these
functions you want to reside on which of the two available sensor port Pin 2 signals.
Page 155 of 329

7.2.9.1. Most Downstr

Downstream
eam Zone
Please note that by default and without any intervention, the most downstream zone will
always try to discharge product. To control this, you need to utilize the Aux I/O Pin 2 signal for
the most downstream zone as an Accumulate input.
Assuming the most downstream

zone is connected to the right side
of the module; we set the Right Aux
I/O Pin 2 to Accumulate from the
drop-down box and make sure we
click the “DOWN” arrow to indicate
that the Right Pin 2 signal is to be
associated with the Downstream
Zone. When the Right Pin 2 signal is
energized, the downstream zone will
stop when an item arrives on its
sensor
Page 156 of 329

7.2.9.2. Most Upstr

Upstream
eam Zone
By default and without any intervention, the most upstream zone will never turn on to accept
new product. To cause the most upstream zone to run to accept an item with a wired signal,
you need to utilize the Aux I/O Pin 2 for the upstream zone as a Wak
ake-up
e-up input.
Assuming the most upstream zone is

connected to the left side of the
module; we set the Left Pin 2 to
Wak
ake
e up from the drop-down box
and make sure we click the UP arrow
to indicate that the Left Pin 2 signal
is to be associated with the
Upstream Zone. When the Left Pin 2
signal is energized, the upstream
zone will run to accept an item
Page 157 of 329

7.2.9.3. Accumulate Inter

Intermediate
mediate Zone
By default, and without intervention; all zones in between the most upstream and most
downstream zones always try to convey items downstream if the next downstream zone is
clear. To cause an intermediate zone to accumulate based upon a wired signal, you need to
utilize the Aux I/O Pin 2 signal for the zone in questions as an Accumulate input.
Assuming the intermediate zone we

want to accumulate is the upstream
zone and the upstream zone is
connected to the Left side of the
module; we set the Left Aux I/O Pin 2
to Accumulate from the drop down
box and make sure we click the “UP”
arrow to indicate that the Left Pin 2
signal is to be associated with the
is energized, the upstream zone will
accumulate the next item that
arrives
Page 158 of 329

7.2.9.4. Lane F
Full
ull Interface
A special case of the accumulate signal for the most downstream zone is referred to as Lane
Full Interface. When Lane Full Interface is used on the most downstream zone; the input signal
is treated with a block and clear timer such that when the signal is energized, the signal must
remain energized for the “block” timer duration. When the block timer expires, then the zone is
set to accumulate. Similarly, when the signal is de-energized, the signal must remain de-
energized for the “clear” timer duration. When the clear time expires, the zone is set to release
as normal. The Lane Full Interface also disables the Arrival Jam detection logic such that no
arrival verification signal from downstream is required. This means that if the signal is off (and
the clear time has expired) items arriving at the most downstream sensor will immediately
release.

of the module; we set the Right Aux
I/O Pin 2 to Lane F Full
ull Interface from
the drop-down box and make sure
we click the “DOWN” arrow to
indicate that the Right Pin 2 signal is
to be associated with the
Downstream Zone. The signal must
be energized for the Block time
period before cartons will stop and
accumulate and the signal must be
de-energized for the Clear time
period before cartons will be allowed
to release. In this example, we
entered 5 seconds for the Block
Time and 6 seconds for the Clear
Time
Page 159 of 329

7.2.9.5. Most Upstr

Upstream
eam Zone Handshak
Handshake
e
Interlock
In applications where the equipment feeding the most upstream zone of ConveyLinx controlled
conveyor requires a handshake interlock to know when the most upstream zone of the
ConveyLinx controlled conveyor is empty and ready to accept a new item, this can be achieved
by utilizing both the Left and Right Aux I/O Pin signals. One of the Aux I/O Pin 2 signals needs to
be set as an input to Wak
akee Up the zone and the other signal needs to be configured as an
output to indicate whether there is Product on Zone. When this Product on Zone output is
energized, then the feeding equipment knows that the most upstream zone is occupied and is
not ready to accept a new item.
Assuming the most upstream zone is

connected to the left side of the
module; we set the Left Pin 2 to
Wak
ake
e up from the drop-down box
and make sure we click the UP arrow
to indicate that the Left Pin 2 signal
is to be associated with the
signal is energized, the upstream
zone will run to accept an item
Page 160 of 329

Then we select Product on Zone for

the Right Pin 2 signal and click the
diagonal arrow to indicate that this
signal is to reflect the status of the
Upstream zone
Page 161 of 329

7.2.9.6. Most Downstr

Downstream
eam Zone Handshak
Handshake
e
Interlock
In applications where the equipment accepting product from the most downstream zone of
ConveyLinx controlled conveyor requires a handshake interlock to know when the most
downstream zone of the ConveyLinx controlled conveyor is occupied and ready to discharge
the item, this can be achieved by utilizing both the Left and Right Aux I/O Pin signals. One of
the Aux I/O Pin 2 signals needs to be set as an input to Accumulate the zone and the other
signal needs to be configured as an output to indicate whether there is Product on Zone. When
this Product on Zone output is energized, then the accepting equipment knows that the most
downstream zone is occupied and is ready to discharge the item.

of the module; we set the Right Pin 2
to Accumulate from the drop-down
box and make sure we click the
“DOWN” arrow to indicate that the
Right Pin 2 signal is to be associated
with the Downstream Zone.
Similarly, we select Product on Zone
for the Left Pin 2 signal and click the
diagonal arrow to indicate that this
signal is to reflect the status of the
Downstream zone
Page 162 of 329

7.2.9.7. Inverting the P

Pin
in 2 Signals
On this dialog, you can also invert

the meaning of the electrical signal
by checking the Invert box for either
or both Pins. In this example,
because we have the Invert box
checked for both Pin signals, their
respective functions will be
activated when their signal is
electrically OFF.
Note that the Invert function works
similarly for the output signals. If
Product on Zone is selected as a
function, with the Invert box checked
when the zone is occupied, the
electrical signal will be OFF. With the
Invert box checked, when the zone is
clear, the electrical signal will be ON
Page 163 of 329

8. ConveyMer
ConveyMerge
ge
ConveyMer
ConveyMerge
ge is an optional functionality layer built on top of ConveyLinx’s ZP
ZPA
A logic. Users can
enable and configure it using EasyR
EasyRoll
oll software. ConveyMer
ConveyMerge
ge behaves the same as ZPA logic,
but allows you to define a special Mer
Merge
ge Zone that can have up to three upstream zones
connected to it. ConveyMer
ConveyMerge
ge also has simple priority schemes for the multiple upstream zones
as well as the ability to dynamically change those priorities on-the-fly by utilizing the Mer
Merge
ge
Line F
Full
ull option. It also takes care of passing tracking information properly and has Jam
Condition detection.
ConveyMer
ConveyMerge
ge Components
ConveyMer
ConveyMerge
ge can accommodate product merge control from one or two conveyor paths onto a
single take-away conveyor path as shown:
Component Description
Powered conveyor section that accepts an item from any one of the 3
Mer
Merge
ge Zone
possible upstream sources
Term to describe the 3 in-line conveyor sections – Center Line, Mer

Merge
ge Zone
Main Line
and Dischar
Discharge
ge Zone
Part of Center Line that is one of three possible sources of items that can flow
into the Mer
Merge
ge Zone. This term is used in the configuration screen of EasyR
EasyRoll
oll
Center Line
to designate the network that serves as the trunk line that contains the
Mer
Merge
ge Zone
Dischar
Discharge
ge Zone Part of the Center Line that is downstream of the Mer
Merge
ge Zone. This conveyor
Page 164 of 329

section accepts the item from the Mer

Merge
ge Zone
One of the three possible conveyor sections that can discharge items into the
Lef
eftt Line
Mer
Merge
ge Zone
One of the three possible conveyor sections that can discharge items into the
Right Line
Mer
Merge
ge Zone
Page 165 of 329

8.1. ConveyMer
ConveyMerge
ge P
Prrer
erequisites
equisites and
Requir
equirements
ements
Please Note – ConveyMer
ConveyMerge
ge works for ALL ConveyLinx
Family Modules
Module Fir
irmwar
mware
e
ConveyLinx-ERSC 4.25 and later
ConveyLinx-HTF 4.25 and later
ConveyLinx-Ai2 4.20 and later
ConveyLinx-Ai3-24-xx 4.20 and later
The following items are the prerequisites and constraints required to provide a fully functioning
automatic conveyor merge:
• EasyR
EasyRoll
oll version 4.3 or greater
• Only (1) one Mer
Merge
ge Zone is allowed for any given single module
• Mer
Merge
ge Zone cannot have any Extension (slaved) zone
• All ConveyLinx modules controlling Mer
Merge
ge Zone, Lef
eftt Line discharge, Right Line discharge,
and Center Line discharge must be in ZP
ZPA
A mode
• Left, Right, and Center Lines discharges cannot also be included in another instance of
ConveyMer
ConveyMerge
ge
Page 166 of 329

8.2. Network Ar
Architectur
chitecture
e
All lines (Center, Lef
eftt, and Right) must be on separate subnets of modules, as shown. Each
subnet should be Auto
Auto-Configur
-Configured
ed separately and then connected together with an Ethernet
switch. Keep in mind that the separate subnets will have to be able to communicate with each
other so special care must be taken when setting up the IP Network Mask before performing
the Auto
Auto-Configuration
-Configuration P
Prrocedur
oceduree.
* A good starting point is the default mask of 255.255.128.0. With this setting you
can vary the third octet in the ranges 0-127 and 128-254 and all three lines will
be able to communicate with each other as long as the third octets of their IP
addresses are in the same range (either 0-127 or 128-254).
Ar
Architectur
chitecturee Summary
• The Center Line is a separate subnet of modules that have been Auto
Auto-Configur
-Configured
ed. The
Mer
Merge
ge Zone and the Dischar
Discharge
ge Zone are part of this subnet. The Center Line can consist
of any number of ConveyLinx Modules and the actual position of the Mer
Merging
ging Zone can be
on any ConveyLinx Module within the subnet
• The Dischar
Discharge
ge Zone has to be the zone immediately downstream of the Mer
Merge
ge Zone.
However, the Dischar
Discharge
ge Zone can be on either the same ConveyLinx Module as the Mer
Merge
ge
Page 167 of 329

Zone or on the adjacent downstream ConveyLinx Module from the Mer

Merge
ge Zone’s
ConveyLinx Module
• The Lef
eftt Line is a separate subnet of modules and its most downstream zone has to
physically discharge on to the Mer
Merge
ge Zone
• The Right Line is a separate_* subnet*_ of modules and its most downstream zone has to
physically discharge on to the Mer
Merge
ge Zone
• All three subnets must be connected to a common Ethernet switch only after each subnet
has been Auto
Auto-Configur
-Configured
ed.
Page 168 of 329

8.3. Sensor Placement
! It is very important for the internal ConveyMer

by only one sensor at a time
ConveyMerge
ge logic, that the product is seen
Conventional Spur Mer

Merge
ge Sensor Placement
Page 169 of 329

90° T
T-Mer
-Merge
ge Sensor Placement
Page 170 of 329

8.4. Mer
Merge
ge Zone Module
Depending on the physical arrangement of actual zones on the Center Line, the Mer
Merge
ge Zone
can be assigned to either the Upstream or Downstream zone of its particular ConveyLinx
Module. It can also be assigned to a ConveyLinx Module that is configured as a single zone ZPA
controller.
In all 4 of these e xamples, Node 2 is the Mer

examples, Merge
ge Zone’s contr
controlling
olling
ConveyLinx Module
* Images show ConveyLinx-ERSC modules but functions are applicable to all

ConveyLinx Family modules
Mer
Merge
ge Zone on Upstr
Upstream
eam Zone
Page 171 of 329

Mer
Merge
ge Zone on Downstr
Downstream
eam Zone
Page 172 of 329

Single Zone Module

Whenever an ConveyLinx Module has been Auto
Auto-Configur
-Configured
ed as a single zone
zone; regardless of
whether the single zone is connected to the right side or left side of the ConveyLinx Module,
the logical designation for the zone on the this module is always the Upstream Zone. Shown
below are examples of a single zone module using the left and right sides of the module
respectively.
Mer
Merge
ge Zone on a Single Zone Module's L
Lef
eftt Side
Mer
Merge
ge Zone on a Single Zone Module's Right Side
Page 173 of 329

8.5. Mer
Merging
ging Lines
The Lef
eftt Line and Right Line are set up in a similar fashion to the Center Line. Each of these
lines are in their own separate subnet that is both different from each other and different from
the Center Line. Regardless of whether these merging lines are an Conventional Spur
arrangement or a 90˚ T-Merge arrangement; the conveyor zone that discharges product onto
the Mer
Merge
ge Zone must be the most downstream zone if its particular subnet. The following
figures illustrate this for an Conventional Spur Left Line and a 90˚ T-Mer
-Merge
ge Left Line
respectively. The same would apply if these were Right Line examples as well.

Page 174 of 329

Page 175 of 329

8.6. Mer
Merge
ge Configurations
The Mer
Merge
ge Configurations available from within in EasyR
EasyRoll
oll are:
• Lef
eftt Line Only with either Conventional (spur discharge) or T-Mer
-Merge
ge (90˚ discharge)
• Right Line Only with either Conventional (spur discharge) or T-Mer
-Merge
ge (90˚ discharge)
• Both Lef
eftt and Right Lines with either Conventional (spur discharge) or T-Mer
-Merge
ge (90˚
discharge) for each
Page 176 of 329

8.7. Mer
Merge
ge P
Priority
riority
EasyR
EasyRoll
oll provides the ability to adjust which of the merging lines receives priority.
EasyR
EasyRoll
oll P
Priority
riority
Description
Selection
The logic monitors the arrival status in each of the zones that discharge in to
the Mer
MergeZone
geZone. The first product that arrives at any of these lines will be
First Come FFirst
irst
allowed to convey into the Mer
MergeZone
geZone. When the MerMergeZone
geZone is clear, the
Served
next line that has had a product arrive will be allowed to convey into the
Mer
MergeZone
geZone
The Center Line will be allowed to release as long as product arrives at the
Center Line’s zone sensor prior to the previously released product having not
cleared the Mer
MergeZone
geZone. When the MerMerge
ge Zone is clear and if there is no
Center Line
product sensed on the center line zone; then the Lef eftt and/or Right Lines will
Priority
be allowed to release if product has arrived at their respective sensors. As
long as no product is arriving on the Center Line, if Lef
eftt and Right Lines are
enabled, these will operate as First Come FFirst
irst Served between them
The Lefeftt Line will be allowed to release as long as product arrives at the Lefeftt
Line’s most downstream sensor prior to the previously released product
having not cleared the Mer MergeZone
geZone. When the Mer Merge
ge Zone is clear and if there
is no product sensed on the Lef eftt Line’s most downstream sensor; then the
Lef
eftt Line P
Priority
riority
Center and/or Right Line will be allowed to release if product has arrived at
their respective sensors. As long as no product is arriving on the Lef eftt Line, if
the Right Line is enabled, the Center and Right will operate as First Come
First Served between them
The Right Line will be allowed to release as long as product arrives at the
Right Line’s most downstream sensor prior to the previously released product
having not cleared the Mer MergeZone
geZone. When the Mer Mergege Zone is clear and if there
is no product sensed on the Right Line’s most downstream sensor; then the
Right Line P
Priority
riority
Center and/or Lef eftt Line will be allowed to release if product has arrived at
their respective sensors. As long as no product is arriving on the Right Line, if
the Lef
eftt Line is enabled, the Center and Lef eftt will operate as First Come FFirst
irst
Served between them
Page 177 of 329

8.8. T-Mer
-Merge
ge Settings
For a T-Mer
-Merge
ge, the discharging conveyor is arranged perpendicular to the Mer
Merge
ge Zone and this
discharging conveyor needs to “throw” the product across the Merge Zone’s rollers. In order to
mitigate carton alignment issues, the logic controls need to make sure that it keeps the Mer
Merge
ge
Zone’s rollers stopped until the discharging conveyor has completely finished “throwing” the
product onto the Mer
Merge
ge Zone. In order to accommodate various conveyor speeds and material
handling situations; EasyR
EasyRoll
oll provides some timer adjustments to facilitate proper T-Mer
-Merge
ge
functionality.
Accept T
Timeout
imeout
This timer specifies how much time the Mer

Merge
ge Zone will wait after its sensor is blocked until the
logic allows it’s motor to run. Once the timer has expired, the Merge Zone’s motor will be
allowed to run. Keep in mind that conditions downstream of the Mer
Merge
ge Zone also dictate if the
motor is allowed to run.
Send T
Timeout
imeout
This timer specifies how much time the discharging zone has to wait after the Mer
Merge
ge Zone
sensor is clear before it is allowed to release the next product into the Mer
Merge
ge Zone. This timer
helps ensure that the Mer
Merge
ge Zone is clear when sensor placement cannot guarantee that the
zone is clear.
Page 178 of 329

Page 179 of 329

8.9. Configuring Dynamic P

Priority
riority R
Release
elease
In situations where the full status of a given merge line needs to determine merge priority,
ConveyMer
ConveyMerge
ge provides the ability to monitor the status of one or all merging lines and base the
release priority accordingly. EasyR
EasyRoll
oll provides the option to select a given upstream zone on a
given line as the Monitor Zone. When the Monitor Zone becomes occupied for a given time
value; its line will be given release priority into the Mer
Merge
ge Zone. There are two adjustable time
values for this function:
EasyR
EasyRoll
oll Selection Description
Specified the amount of time the Monitor Zone must be occupied before the
Monitor Zone’s line will receive priority to release into the Mer
Merge
ge Zone. This
Block T
Timeout
imeout timer starts when the Monitor Zone first becomes accumulated (sensor
blocked and motor stopped) and continues to time as long as the Monitor
Zone stays accumulated
Specified amount of time that the priority release will continue to be active
Clear T
Timeout
imeout once the priority release has begun. When this time value expires, the
priority setting will return to its original EasyR
EasyRoll
oll configured setting
* If multiple lines are configured for Dynamic P

Block T
Timers
imers have expired; ConveyMer
ConveyMerge
Priority
riority and each of their respective
ge logic will revert to the First Come F
Serve release mode until one or more of the releasing lines’ Clear T Timer
First
imer has
irst
expired
Dynamic P
Priority
riority R
Release
elease Example
Please refer to Figure A and Figure B below. In EasyR
EasyRoll
oll, Node 2 upstream zone of the Center
Line has been selected as the Mer
Merge
ge Zone and the merge type is Up Left. The EasyR
EasyRoll
oll setting
for priority is Center Line P
Priority
riority. Also in EasyRoll, the Mer
Merge
ge Line F
Full
ull function has been
enabled as assigned to Node 3 downstream zone of the Lef
eftt Line.
With the Mer
Merge
ge Line F
Full
ull feature enabled on the Lef
eftt Line; once Left Line Node 3 downstream
zone remains accumulated for the Block T
Timer’s
imer’s timeout (Figure A); priority will dynamically
change to the Lef
eftt Line. This Left Line priority will remain in effect until the Clear T
Timer’s
imer’s
timeout has expired (Figure B). When this occurs, the priority will automatically revert to the
EasyR
EasyRoll
oll configured priority (Center Line in this example).
In this example, if we did not enable the Mer

Merge
ge Line F
Full
ull function for the Lef
eftt Line and if there
was a steady flow of product on the Center Line; the Lef
eftt Line would never be able to release
because the default priority in EasyRoll was set to Center Line.
Page 180 of 329


Figur
iguree A - Mer
Merge
ge Line F
Full
ull Block T
Timer
imer
Figur
iguree B - Mer
Merge
ge Line F
Full
ull Clear T
Timer
imer
Page 181 of 329

8.10. Enabling ConveyMer

ConveyMerge
ge fr
from
om EasyR
EasyRoll
oll
• Open EasyR
EasyRoll
oll
• Connect and navigate to the ConveyLinx Module that will control the Mer
Merge
ge Zone.
• Press CTRL
CTRL+SHIF
+SHIFT+M
T+M to open the ConveyMer
ConveyMerge
ge Configuration Scr
Screen
een
Item Description
Navigation Buttons for Node selection
Drop down selector for Mer

Merge
ge T
Type
ype – Left, Right, or Both
Page 182 of 329

Drop down for Mer

Merge
ge P
Priority
riority
Display of IP Address for the ConveyLinx Module selected that will contain the Mer
Merge
ge
Zone
User button to click to apply the settings to the affected modules
User button to cancel any changes made and close the screen
Field to enter the IP Address of the Lef

eftt Line’s most downstream ConveyLinx Module
Checkbox to enable Mer

Merge
ge Line F
Full
ull functions
IP Address of the ConveyLinx Module that contains the zone being defined as the
Monitor Zone for the Mer
Merge
ge Line F
Full
ull function
Radio buttons to select whether the upstream or downstream zone of the ConveyLinx
Module identified in Item 9 will be used as the Monitor Zone
Field to enter the IP Address of the Right Line’s most downstream ConveyLinx Module
User checkbox to select T-Mer

-Merge
ge type
Graphical representation of the merge. Please note this will update and change as
settings and configuration is modified
Mer
Merge
ge Line F
Full
ull Block T
Timer
imer preset value
Mer
Merge
ge Line F
Full
ull Clear T
Timer
imer preset value
T-Mer
-Merge
ge A
Accept
ccept T
Timer
imer preset value
T-Mer
-Merge
ge Send T
Timer
imer preset value
Page 183 of 329

8.11. Conventional Spur Mer

Merge
ge Example
In this example we are going to configure the Lef
eftt Line to be standard spur angle merge onto
the Center Line and we will set the Mer
Merge
ge P
Priority
riority to be First Come F
First
irst Served

The Mer
Merge
ge Zone is the upstream zone of the module at 192.168.25.28 and the most
downstream ConveyLinx Module for the Lef
eftt Line is at 192.168.24.31. Here is the ConveyMer
ConveyMerge
ge
Configuration Scr
Screen
een with these values entered
Page 184 of 329

The last step is to click the Apply button to send the changes to the affected ConveyLinx
Modules
* Please note that after clicking the “Apply” button, if the configuration has
changed, the affected modules will reboot. It will take a few seconds for the
reboot to finish and some or all of the affected zones may briefly run their
motors
Page 185 of 329

8.12. T-Mer
-Merge
ge Example
In this example we are going to configure the Right Line to be a T-Mer
-Merge
ge onto the Center Line
and we will set the Mer
Merge
ge P
Priority
riority to be First Come F
First
irst Served

The Mer
Merge
ge Zone is the upstream zone of the module at 192.168.25.28 and the most
downstream ConveyLinx Module for the Right Line is at 192.168.26.58. Here is the
ConveyMer
ConveyMerge
ge Configuration Scr
Screen
een with these values entered
Page 186 of 329

Page 187 of 329

8.13. Mer
Merge
ge Line F
Full
ull Example
In this example we have the Lef
eftt Line configured as standard spur angle merge and the Mer
Merge
ge
Priority to be Center Line

The Mer
Merge
ge Zone is the upstream zone of ConveyLinx Module 192.168.25.28 and the Lef
eftt Line’s
most downstream node is 192.168.24.31 and we want this line to have the Mer
Merge
ge Line F
Full
ull
function enabled. On the Lef
eftt Line, we would like for the upstream zone of ConveyLinx Module
192.168.24.25 to be the Merge Line Full function’s Monitor Zone. We would also like that once
the Monitor Zone has been accumulated (or blocked) for 5 seconds, we want the Lef
eftt Line to
release for 5 seconds and then return the priority to the Center Line. Here is the ConveyMer
ConveyMerge
ge
Configuration Scr
Screen
een with the values entered for this example:
Page 188 of 329

Page 189 of 329

9. IO
IOX
X Interface Module
In the section Electrical Connections for Sensor Port Aux I/O, it is shown how to use off the shelf
commercially available M8 cable accessories to gain access to the Aux I/O pin on the sensor
ports. Pulseroller offers a Breakout/Splitter Module Accessory that offers the same cable splitter
functionality as the commercially available M8 units along with breaking out some of the
signals to convenient wire terminal access for flying lead devices.
The IO
IOX
X-2 Interface Module provides a convenient plug and play means to separate the zone
sensor and Aux I/O signals on the Module’s sensor port. The IO
IOX
X-2 utilizes M8 style connection
headers so you can connect your M8 style zone sensor as well as M8 style cable (or additional
sensor) for access to the Aux I/O Pin 2 signal. The IO
IOX
X-2 also contains wire terminal access for
the Aux I/O Pin 2 signals for complete flexibility.
Mounting Dimensions
Page 190 of 329

Wiring Diagrams
Electrical Schematic
Page 191 of 329

9.1. Wak
ake
e up and/or Lane F
Full
ull Interface
Page 192 of 329

9.2. Wak
ake
e up/Lane F
Full
ull with W
Wir
ired
ed
Ter
erminals
minals
Page 193 of 329

9.3. Wak
ake
e up/Lane F
Full
ull with Discr
Discrete
ete
Signals
Page 194 of 329

9.4. Wak
ake
e up/P
up/Prroduct on Zone Handshak
Handshake
e
Interlock
Page 195 of 329

9.5. Downstr
Downstream/P
eam/Prroduct on Zone
Handshak
Handshakee Interlock
Page 196 of 329

9.6. Pin 2 Output on Aux I/O M8
Page 197 of 329

9.7. Pin 2 Output on W

Wir
ired
ed T
Ter
erminals
minals
Page 198 of 329

10. PLC Developers Guide

This section defines the data connectivity available between ConveyLinx Modules and remote
control devices such as PLC
PLCss and PCs
Click Links to L
Lear
earn
n Mor
Moree
Network Ar
Architectur
chitecture
e
Understanding Assemblies
ZP
ZPA
A Mode Contr
Control
ol
PLC I/O Mode Contr
Control
ol
ConveyL
ConveyLogix
ogix Interface
Assemblies with R
Reset
eset P
Prrotection
Motor P
Port
ort as Digital I/O
Page 199 of 329

10.1. Network Ar
Architectur
chitecture
e
Each ConveyLinx Module communicates to its adjacent modules and to any connected PC or
PLC via Ethernet physical media. ConveyLinx Modules recognize (3) TCP/IP based protocols:
Modbus TCP
CP,, P
Prrofinet I/O, and Ether
Ethernet
net I/P. Modbus TCP is the “native” protocol for
communications between ConveyLinx Modules and the EasyR
EasyRoll
oll PC software. When ConveyLinx
Modules are used even for basic ZPA control with no external connections to a PC or PLC, they
utilize Modbus TCP for inter-module communication. Ether
Ethernet
net I/P is recognized by ConveyLinx
Modules and any given ConveyLinx Module can be attached to an Ethernet I/P capable PLC
(Allen-Bradley ControlLogix or CompactLogix platforms) and be recognized as a Generic
Ether
Ethernet
net Module or explicitly as an ConveyLinx Module by using a Pulseroller provided EDS file.
Profinet I/O is recognized by ConveyLinx Modules and can be attached to any Profinet I/O
capable PLC (applicable Siemens platforms) using a Pulseroller provided GSDXML file.
* All protocols access the same internal data locations on a given ConveyLinx
Module.
Each ConveyLinx Module’s internal data structure is arranged and addressed as Modbus
Holding R
Registers
egisters. The on-board communication and control processes attach logical meanings
to each holding register and read and write data to specific registers to initiate and/or react to
events. Certain registers contain information as to how the ConveyLinx Module is configured
(MDR type, speed, direction, etc.) for its local controls. Other registers are used for inter-
module communications for conveyor operation. For example, when an upstream ConveyLinx
Module has a Carton ready to discharge to its neighboring downstream ConveyLinx Module, the
upstream ConveyLinx Module will write a specific value to a specific address in the downstream
ConveyLinx Module’s internal registers. The downstream ConveyLinx Module’s on board logic
monitors these registers and knows that a specific value means that an upstream Carton is
coming and to engage the proper control logic to convey the Carton.
Because ConveyLinx utilizes an open architecture (Modbus TCP) for inter-module
communications; with proper definition and expected usage of certain register address
locations, external control devices (PC’s and PLC’s) can easily interact with ConveyLinx
Modules to monitor and control various points along the conveyor path.
Page 200 of 329

10.2. Understanding Assemblies

The Modbus Holding Registers described above will be defined as Module R
Register
egister A
Addr
ddresses
esses
and are used for the function of the ConveyLinx Module regardless of if any remote PLC or PC is
connected. There are 512 Module Register Addresses that are used for the operation of the
ConveyLinx Module and these can be thought of as “physical” module address locations.
However, many of these are not applicable, required, or should even be made available to a
remote PLC.
An Assembly is a grouping of some subset of these 512 Module registers based upon the
relevance of the data. For example, the ZPA Input Assembly groups together 21 Module
registers out of the 512 that are relevant for ZPA Inputs. This relevant data from within the
Module’s 512 registers are not necessarily in consecutive address locations and are scattered
throughout the 512 addresses. The Assembly groups them together so they can be read
efficiently all at once.
Page 201 of 329

10.2.1. Modbus Assembly Instance

Structur
Structuree
Each ConveyLinx Module utilizes Modbus register architecture for remote data access over
Ethernet. Modbus TCP is a simple protocol for data exchange based upon a query/response
mechanism. Each ConveyLinx Module’s memory structure contains a fixed array of internal
data locations that are constructed as Modbus Holding R
Registers
egisters. Each ConveyLinx Module has
a fixed reserve of Holding R
Registers
egisters with each capable of holding a 16-bit numerical integer
value. Modbus TCP protocol provides for read/write access to any available Holding R
Register
egister.
The structure of these registers allows for individual ConveyLinx Module’s to read from and
write to specific register address locations to achieve inter-module communications. Certain
registers are read from and written to by the EasyR
EasyRoll
oll software in order to monitor and/or
change default configuration values such as MDR speed, direction, type, etc.
* Modbus TCP addressing convention utilizes a “4:xxxx” notation. The “4:” in

Modbus protocol designates that the address is a Holding Register and the xxxx
is a numerical value representing the offset or index for a specific location. The
“xxxx” values used in this document are to be interpreted as if they are for a
Modbus PLC which means that the first register address is “4:0001” and that
there is no “4:0000” register. Some PLC data structures and PC development
environments utilize the “4:0000” designation and their indexes will be offset by
1. Please refer to your PLC or PC application documentation for the Modbus
convention used on their platforms.
Supported Modbus TCP Service Codes

Any Modbus TCP capable PC or PLC can connect to any ERSC visible on its network and access
Input and Output Holding Register Assemblies. The ERSC supports the following Modbus TCP
Service Codes:
• Service Code 3 – Read Holding Register (up to 45 registers per instruction)
• Service Code 6 – Write Single Register
• Service Code 16 – Write Multiple Registers (up to 45 registers per instruction)
• Service Code 23 – Read/Write Multiple Registers (up to 45 registers per instruction)
Properly A
Addr
ddressing
essing Assembly R
Registers
egisters
In the ConveyLinx Module, the Assembly Registers are “virtual” in that they are not “physical”
Module Register Addresses and as such are not directly addressable. The ConveyLinx Module
firmware intercepts the request and builds the assembly data in order to transmit it to the
requesting device. Because of this, you must always address an Assembly by using the first
Page 202 of 329

address in the assembly in order for the ConveyLinx Module to return any data.
! When using Input and Output Assemblies with Modbus TCP PLC, it is important to
always use the first address shown in the assembly group as the beginning
register to read or write regardless of which register in the assembly is needed
by the PLC. Trying to access Input or Output Assemblies starting with any
register in the assembly other than the first register will cause the ConveyLinx
Module to return an error
For example, for ZPA Mode Assembly Inputs, if you only need to read register 4:1504; your I/O
connection set-up in your PLC must use the starting address of 4:1500 and a sufficient length
of registers to read (in this example at least 5 registers) in order to get to the desired register.
If you set up your PLC to start reading at 4:1504, the ConveyLinx Module will return an error
Page 203 of 329

10.2.2. Ether
Ethernet
net I/P Assembly Instance
Structur
Structuree
When an ConveyLinx Module is attached to an external Ethernet I/P controller (Logix 5000
based PLC), it is done so as a Generic Ethernet I/O device or by installing EDS file(s) provided
by Pulseroller.
* For purposes of working with assemblies, we will be describing them in terms of

them connected as Generic Ethernet I/O devices. For details on how to use EDS
files and Add On Instructions (AOIs), you can go to Connecting to Rockwell PLCs
section
Part of this procedure in the PLC is to instruct the Generic device as to which data configuration
or instance of Ethernet I/P the Generic device is to use to report and respond to data to and
from the PLC. From this point forward, it is assumed the reader is familiar with Allen-Bradley
Logix platform addressing notation:
:O
:O.Data[Inde
.Data[Index].Bit
x].Bit
:I.Data[Inde
:I.Data[Index].Bit
x].Bit
Where:
• ModuleName is the user-defined name of the device
• “O.Data” indicates data written by the PLC to the device
• “I.Data” indicates data read by the PLC from the device
• “[Index].Bit” indicates the word and bit within the image. If the bit notation is absent the
notation refers to the entire word data type
These Assembly Instances group the appropriate Module R

Register
egister A
Addr
ddress
ess registers into
contiguous Input and Output array images that fit into the Allen-Bradley Logix 5000 controller
tags
Learn more about connecting to Rockwell PLCs
Page 204 of 329

10.2.3. Profinet IO Assembly Instance

Structrur
Structruree
Prior to connecting any modules to a Profinet IO capable (Siemens) PLC, a GSDXML
configuration file needs to be installed in your PLC programming software (i.e. STEP 7 or TIA
Portal). The GSDXML file contains, among other things, the definition of memory size required
when connecting a module to a Siemens PLC with Profinet IO. When assigning an individual
module to a PLC, you decide what memory address to use. The GSDXML file stipulates that
each module requires 64 bytes of input data from the module to the PLC and 64 bytes of output
data from the PLC to the module. When assigning an individual module to a PLC, you decide
what physical PLC memory address to use as the beginning of these 64-byte blocks.
In all of the charts showing module data registers and their assigned function, for Profinet IO
these are indicated as “Byte 0, Byte 1,…Byte 32”, etc. These are offsets from the starting
address in the Siemens PLC memory assigned by the Siemens programming software when the
module was installed into the network. For example, if a module’s inputs are installed
beginning at %IB256, then from our charts, the data for “Byte 6 and Byte 7” would be at
addresses %IB262 and %IB263 respectively.
Learn more about connecting to Siemens PLCs
Page 205 of 329

10.2.4. Assembly R
Register
egister Chart L
Legend
egend
All of the Assemblies are organized in charts that show:
• The Name of the register and its Module Address

• The Assembled Address for Modbus TCP, Ethernet IP, and Profinet
• Description of the register’s usage
The Assembled Addresses are shown in specific notation familiar to the specific protocol per
the following examples:
M: 4:1500 Indicates Modbus TCP addr

addressing
essing notation for Holding R
Registers
egisters
E: I.Data [0] Indicates Ether
Ethernet
net IP addr
addressing
essing notation for R
Rockwell
ockwell RSL
RSLogix
ogix T
Tags
ags
Indicates P
Prrofinet I/O addr
addressing
essing notation for P
Prrofinet IO memory
P: Byte 0 (Hi) Byte 1 (L
(Lo)
o)
location offset
Page 206 of 329

10.3. ZP
ZPA
A Mode Contr
Control
ol
When an ConveyLinx Module is in its default ZP
ZPA
A mode, an external networked PLC or PC
controller can connect to the ConveyLinx Module and perform the following:
• Instruct either or both the upstream and downstream zone to accumulate the next Carton
that arrives
• Receive indication that a new Carton has arrived at either zone
• Receive indication that a Carton has departed from either zone
• Read tracking data associated with Carton at accumulated zone
• Update tracking data associated with Carton at accumulated zone
• Instruct accumulated zone to release Carton and accumulate on next Carton arrival
• Change the MDR speed for either zone
• Remove accumulation control and return zone to normal operation
• Read fault and error status of either zone or motor
• Optionally take over control of either or both Control Ports
Notes about Assemblies in ZP

ZPA
A Mode
When an ConveyLinx Module is in ZP
ZPA
A Mode, its primary task is to operate its local conveyor
zones and respond to its immediate upstream and downstream conditions. External PLC
controller interaction with an ConveyLinx Module in ZP
ZPA
A mode is intended to be for decision
point monitoring and general status data gathering. Upstream and Downstream zones work
exactly the same for zone control, only the register addresses are different depending on which
zone (or both) that need to be controlled
* In general, when utilizing ZP

ZPAA Mode registers; “upstream” and “downstream”
registers are logically determined by conveyor flow after the system has been
Auto
Auto-Configur
-Configured
ed and will not necessarily be associated with the module’s
physical “left” or “right” side’s connections. For motor and port specific I/O
items, register’s description will explicitly indicate “left” or “right”.
* For modules that are auto-configured as single zone, regardless of whether the
left or right side is physically used as the single zone; external controller must
use the “Upstream” control registers to interface with the single zone
Page 207 of 329

10.3.1. PLC Inputs for ZP

ZPA
A Mode
This Assembly contains the output from the ERSC that is provided as input to the PLC. You can
select which area of the assembly to view below.
Local Zone Status

Ar
Arrival/Departur
rival/Departure
e Counts
Module Status
Tracking and R
Release
elease Counts
Forwar
orwardd and R
Reverse
everse T
Tracking
racking
Port Inputs and ConveyStop Status
Page 208 of 329

10.3.1.1. Local Zone Status

Register Name / Assembled A
Addr
ddress
ess for
Description
Module AAddr
ddress
ess PLC
Local Status
M: 4:1500 (L(Lo
o Byte)
Upstream Zone
E: I.Data [0] (L
(Loo Byte)
Forward Direction
P: Byte 1
4:0116 Unsigned Value of Byte:
Local Status 0×01 = Zone sensor clear and motor stopped
M: 4:1500 (Hi Byte)
Upstream Zone
E: I.Data [0] (Hi Byte)
Reverse Direction 0×02 = Zone sensor clear, motor running,
P: Byte 0
4:0116 accepting from upstream zone
Local Status
Downstream M: 4:1501 (L(Lo
o Byte) 0×04 = Zone sensor blocked, motor running,
Zone Forward E: I.Data [1] (L
(Loo Byte) discharging to downstream zone
Direction P: Byte 3
4:0196 0×05 = Zone sensor blocked and motor stopped
Local Status 0×06 = Busy (state during ConveyStop active

Downstream M: 4:1501 (Hi Byte) mode)
Zone Reverse E: I.Data [1] (Hi Byte)
Direction P: Byte 2
4:0196
The values 0xXX01 thru 0xXX06 are shown because these are the possible logical values used
for inter-module communication. External networked devices (PLC or PC) monitoring these
registers may; depending on their scan rate, not actually see each of these values change in
sequence as a Carton is conveyed from zone to zone, even though the inter-module
communications and ZPA is functioning normally.
* IMPORTANT NOTE: Status register values utilize both the HIGH BYTE and the LOW
BYTE of the 16-Bit integer value. The HIGH BYTE is used for zone status for
reversing conveyor applications and MAY CONTAIN DATA. PLC/PC programmers
working with single direction conveyor applications who also are working with
the entire 16-bit register data MUST MASK THE HIGH BYTE or otherwise ignore
the high byte in processing status data from these registers.
* For PLC/PC programming purposes, you can only depend on seeing values
0xXX01 and 0xXX05 in program logic for determining zone status. The values
0xXX02 and 0xXX04 may not always be visible to PLC/PC from inter-module
communication depending upon speed of the conveyor, length of the zone, and/
or location of the zone sensors.
Page 209 of 329

10.3.1.2. Ar
Arrival/Departur
rival/Departure
e Counts
Register Name / Assembled
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Arrival Count M: 4:1502

Local Upstream E: I.Data [2]
Zone P: Byte 4 (Hi) Unsigned Integer Value:
4:0106 Byte 5 (L
(Lo)
o)
Arrival Count • Increments by 1 each time a Carton ararrives

rives in the
M: 4:1504 zone
Local
E: I.Data [4] • Value rolls over from 65,535 back to 0
Downstream
P: Byte 8 (Hi)
Zone
Byte 9 (L
(Lo)
o)
4:0186
Departure Count M: 4:1503

Local Upstream E: I.Data [3]
Zone P: Byte 6 (Hi)
4:0107 Byte 7 (L
(Lo)
o) Unsigned Integer Value:
Departure Count • Increments by 1 each time a Carton departs the zone

M: 4:1505
Local • Value rolls over from 65,535 back to 0
E: I.Data [5]
Downstream
P: Byte 10 (Hi)
Zone
Byte 11 (L
(Lo)
o)
4:0187
Page 210 of 329

10.3.1.3. Module Status

Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Bitwise Value – Read Only

bit 0 = Module Reset Flag – 1 when module resets,
0 when PLC connected
bit 1 = Reserved
bit 2 = Over-Voltage – Input Power > 30V
bit 3 = Left Motor Error – bits 7 thru 15 indicate
specific
error
bit 4 = Ethernet Connections NOT OK
bit 5 = Upstream Jam Error
bit 6 = Left Sensor Error
M: 4:1506 bit 7 = Low Voltage Error – Input Power < 18V
Module Status
E: I.Data [6] bit 8 = Left Motor Over-heated – Calculated
Word 1
P: Byte 12 (Hi) temperature
4:0088
Byte 13 (L
(Lo)
o) over 120°C
bit 9 = Left Motor Over-current – Over limit for selected
MDR
bit 10 = Left Motor Short Circuit
bit 11 = Left Motor Not Connected
bit 12 = Left Motor Overload –Motor has been stalled
for
more than 20 seconds
bit 13 = Left Motor Stalled – MDR slower than 10% of
selected speed
bit 14 = Left Motor Hall Sensor Error
bit 15 = Left Motor Not Used

bit 0 = Reserved
bit 1 = Reserved
bit 2 = Over-Voltage – Input Power > 30V
bit 3 = Right Motor Error – bits 7 thru 15 indicate
specific
error
bit 4 = Reserved
M: 4:1507 bit 5 = Downstream Jam Error
Module Status
E: I.Data [7] bit 6 = Right Sensor Error
Word 2
P: Byte 14 (Hi) bit 7 = Low Voltage Error – Input Power < 18V
4:0089
Byte 15 (L
(Lo)
o) bit 8 = Right Motor Over-heated – Calculated
temperature over 120°C
bit 9 = Right Motor Over-current – Over limit for
selected
MDR
bit 10 = Right Motor Short Circuit
bit 11 = Right Motor Not Connected
bit 12 = Right Motor Overload –Motor has been
stalled for more than 20 seconds
Page 211 of 329

bit 13 = Right Motor Stalled – MDR slower than 10% of

selected speed
bit 14 = Right Motor Hall Sensor Error
bit 15 = Right Motor Not Used
Page 212 of 329

10.3.1.4. Tracking and R

Release
elease Counts
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Current Upstream M: 4:1508 When Carton is accumulated in UPSTREAM zone:

Zone Tracking E: I.Data [8] Value = Tracking data word #1 (16-bit integer) for the
Word 1 P: Byte 16 (Hi) Carton currently accumulated and stopped in the
4:0119 Byte 17 (L
(Lo)
o) module’s Upstream zone
Current Upstream M: 4:1509 When Carton is accumulated in UPSTREAM zone:

Zone Tracking E: I.Data [9] Value = Tracking data word #2 (16-bit integer) for the
Word 2 P: Byte 18 (Hi) Carton currently accumulated and stopped in the
4:0120 Byte 19 (L
(Lo)
o) module’s Upstream zone
Current When Carton is accumulated in DOWNSTREAM zone:

M: 4:1510
Downstream
E: I.Data [10] Value = Tracking data word #1 (16-bit integer) for the
Zone Tracking
P: Byte 20 (Hi) Carton currently accumulated and stopped in the
Word 1
Byte 21 (L
(Lo)
o) module’s Downstream zone
4:0199
Current When Carton is accumulated in DOWNSTREAM zone:

M: 4:1511
Downstream
E: I.Data [11] Value = Tracking data word #2 (16-bit integer) for the
Zone Tracking
P: Byte 22 (Hi) Carton currently accumulated and stopped in the
Word 2
Byte 23 (L
(Lo)
o) module’s Downstream zone
4:0200
Current Release M: 4:1512 Copy of the current value in the Release Upstream output
Count for E: I.Data [12] register which can be used by PLC logic to confirm
Upstream Zone P: Byte 24 (Hi) release count prior to writing new data to the Release
4:0105 Byte 25 (L
(Lo)
o) Upstream output register
Current Release
M: 4:1513 Copy of the current value in the Release Downstream
Count for
E: I.Data [13] output register which can be used by PLC logic to confirm
Downstream
P: Byte 26 (Hi) release count prior to writing new data to the Release
Zone
Byte 27 (L
(Lo)
o) Downstream output register
4:0185
Page 213 of 329

10.3.1.5. Forwar
orwardd and R
Reverse
everse T
Tracking
racking
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
When ERSC is discharging to Non-ConveyLinx controlled

Get Tracking M: 4:1514 conveyor:
Forward Direction E: I.Data [14] Value = Tracking data word #1 (16-bit integer) for the
Word 1 P: Byte 28 (Hi) Carton that has just discharged from the local
4:0201 Byte 29 (L
(Lo)
o) downstream zone when local conveyor is operating in
default or “forward” direction

Forward Direction E: I.Data [15] Value = Tracking data word #2 (16-bit integer) for the
4:0202 Byte 31 (L
(Lo)
default or “forward” direction

Reverse Direction E: I.Data [16] Value = Tracking data word #1 (16-bit integer) for the
4:0121 Byte 33 (L
(Lo)
opposite of default or “reverse” direction

Reverse Direction E: I.Data [17] Value = Tracking data word #2 (16-bit integer) for the
4:0122 Byte 35 (L
(Lo)
opposite of default or “reverse” direction
Page 214 of 329

10.3.1.6. Port Inputs and ConveyStop

Status
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Bitwise Value – Read Only:

bit 0 = Left Sensor Port – Aux I/O (M8 Pin 2)
M: 4:1518
Sensor & Control bit 2 = Right Sensor Port – Aux I/O (M8 Pin 2)
E: I.Data [18]
Port Inputs bit 4 = Left Sensor Port – Sensor Signal (M8 Pin4)
P: Byte 36 (Hi)
4:0035 bit 6 = Right Sensor Port – Sensor Signal (M8 Pin 4)
Byte 37 (L
(Lo)
o)
bit 15 = 2 sec on / 2 sec off heatbeat
All other bits reserved
M: 4:1519
E: I.Data [19]
Reserved
P: Byte 38 (Hi)
Byte 39 (L
(Lo)
o)

bit 0 – 4 Reserved
bit 5 = Stop active on another module in Stop Group
M: 4:1520 bit 6 = Stop active due to lost communication
ConveyStop
E: I.Data [20] connection
Status
P: Byte 40 (Hi) bit 7 = Stop active due to lost PLC connection
4:0019
Byte 41 (L
(Lo)
o) bit 8 = Stop active on local module’s Left Control Port
bit 9 = Stop active on local module’s Right Control Port
bit 10 = Stop active due to Stop Command from PLC
* The values for the signals on the Sensor ports (bit 0, bit 2, bit 4, and bit 6) are
determined by the module’s initial Auto-Configuration results and the bit values
are set to a 1 when sensor is blocked and 0 when sensor is clear regardless of
the sensor type used. For example, each Sensor port Pin 4 signal is for the
sensor’s output. If the sensor is light energized, N.O. then the electrical signal on
Pin 4 is ON when the sensor is clear and OFF when the sensor is blocked.
However, when reading bit 4 or bit 6 in this register, the bit will be a 1 when the
sensor is blocked and 0 when the sensor is clear
Page 215 of 329

10.3.2. PLC Outputs for ZP

ZPA
A Mode
This Assembly contains the output from the PLC that is provided as input to the ERSC. You can
select which area of the assembly to view below.
Set L
Local
ocal T
Tracking
racking
Accumulation Contr
Control
ol
Speed Contr
Control
ol
Release and Status
Induct T
Tracking
racking F
Forwar
orward
d and R
Reverse
everse
Set Outputs and Motor Clear
ConveyStop and Clear Jams
Dir
Direction
ection and A
Accumulation
ccumulation Mode
ConveyMer
ConveyMerge
ge Interface
Page 216 of 329

10.3.2.1. Set L
Local
ocal T
Tracking
racking
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Set Local M: 4:1600

Upstream Zone E: O
O.Data
.Data [0] Write value for 16-bit integer tracking data word #1 for
Tracking Word 1 P: Byte 0 (Hi) the Carton accumulated in the Upstream Zone
4:0132 Byte 1 (L
(Lo)
o)
Set Local M: 4:1601

Upstream Zone E: O
O.Data
Tracking Word 2 P: Byte 2 (Hi) the Carton accumulated in the Upstream Zone
4:0133 Byte 3 (L
(Lo)
o)
Set Local
M: 4:1602
Downstream
E: O
O.Data
Zone Tracking
P: Byte 4 (Hi) the Carton accumulated in the Downstream Zone
Word 1
Byte 5 (L
(Lo)
o)
4:0212
Set Local
M: 4:1603
Downstream
E: O
O.Data
Zone Tracking
P: Byte 6 (Hi) the Carton accumulated in the Downstream Zone
Word 2
Byte 7 (L
(Lo)
o)
4:0213
Writing T
Tracking
racking Details
Because the ConveyLinx Module is connected as I/O, the PLC inherently is always trying to
update the Output image on (at least) RPI intervals. In order to prevent the PLC from
inadvertently overwriting the “real” tracking data registers; the Assembly Output
implementation utilizes the holding register locations shown and automatically updates the
“real” tracking registers with this new data only upon release of the Carton from the zone.
Included in this automatic functionality are two special reserved values that can be used for
convenience:
• Set both tracking rregisters

egisters shown to 0: This will instruct the module to not modify the
existing “real” tracking data and allow it to continue downstream “as-is” when the Carton
is released.
• Set both tracking rregisters

egisters shown to 0xFFFF
0xFFFF:: This will instruct the module to clear the
“real” tracking data and when the Carton is released, the “real” tracking data will be “0”
in both registers.
Page 217 of 329

! Both word 1 and word 2 of the tracking data in question must have 0xFFFF
written to it in order to signal the module to clear the tracking data. If only one
word has 0xFFFF written to it and the other does not, the value of 0xFFFF will be
the new tracking data for that word.
Page 218 of 329

10.3.2.2. Accumulation Contr

Control
ol
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Accumulation M: 4:1604 Bitwise Values:

Control for Local E: O
O.Data
.Data [4] bit 00 = Set/Clear Accumulation Mode for Local Zone
Upstream Zone P: Byte 8 (Hi) bit 08 = Accumulate adjacent upstream zone
4:0104 Byte 9 (L
(Lo)
o) bit 09 = Set Arrival Confirmation for adjacent
downstream zone
Accumulation bit 10 = Jog zone in default direction
M: 4:1605
Control for Local bit 11 = Jog zone in opposite of default direction
E: O
O.Data
.Data [5]
Downstream bit 12 = Wake up Local Zone
P: Byte 10 (Hi)
Zone bit 13 = Enable Maintenance Mode
Byte 11 (L
(Lo)
o)
4:0184 All other bits reserved
Notes for A
Accumulation
ccumulation Contr
Control
ol Bits
Bit 8 – A
Accumulate
ccumulate A
Adjacent
djacent Upstr
Upstream
eam Zone
Setting this bit will cause the next upstream zone of the local module to accumulate. This next
upstream zone can be either on the local module or the downstream zone of the adjacent
upstream module.
Bit 9 – Set Ar
Arrival
rival Confir
Confirmation
mation for Downstr
Downstream
eam Zone
By default, for ZPA operation, ConveyLinx requires a confirmation from the downstream zone
when a Carton is discharged. Without this confirmation, the releasing zone will detect a jam
condition. This bit is used in applications where the Carton is removed from the conveyor
(either manually or say by a PLC controlled external mechanism such as a pusher or diverter)
and the PLC needs to “confirm” the removal of the Carton in order to satisfy the ZPA
confirmation logic.
Bits 10 & 11 – Jog Contr

Controls
ols
These bits can be used by the PLC to jog the local zone for specialized applications when local
movement of the Carton on a zone is required. An example would be once a Carton has arrived
in the local zone, the PLC determines that the Carton needs to be re-positioned or perhaps
squared up against a PLC controlled pop-up stop.
! Jog control bits over

over-ride
-ride ZP
ZPA
A logic control and should be used with caution!
Improper usage of jog controls can produce unexpected results and/or damage to
Page 219 of 329

product and equipment
Bit 12 – W
Wak
ake
e Up L
Local
ocal Zone
Setting this bit will cause the local zone to “wake up” and run to accept a carton the same as if
it’s upstream ConveyLinx Module had written a status value of “4”. This function would be
useful for a merge onto a main line of ZPA conveyor.
Bit 13 – Enable Maintenance Mode
Setting this bit will place the local zone in maintenance mode. In this mode the motor will not
run regardless of zone conditions. The zone upstream of this local zone will receive a “busy”
status to inhibit release of any item into this local zone. While in this state, the SEN and Motor
LEDs will flash on and off in green color.
Page 220 of 329

10.3.2.3. Speed Contr

Control
ol
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
M: 4:1606
Set Left Motor
E: O
O.Data
.Data [6]
Speed Value in mm/sec for MDR or RPM x 10 for PGD:
P: Byte 12 (Hi)
4:0040 Range: Depends upon the Ai-MDR or PGD connected
Byte 13 (L
(Lo)
o)
MDR Example: 400 = 0.4 m/s
M: 4:1607 PGD Example: 400 = 40 RPM
Set Right Motor
E: O
O.Data
.Data [7] 0 = Remain at last non-zero value entered
Speed
P: Byte 14 (Hi)
4:0064
Byte 15 (L
(Lo)
o)
* Leaving these registers at “0” will instruct the module to use its configured
speed. Any non-zero value will instruct the nodule to use this non zero value as
the speed reference. The speed will stay at this reference until this register is
changed to a new non zero value or set to “0”. When this register is set to “0”,
the module will continue to use the last non zero value it was given. Setting this
value to “0” will not cause the motor to run at “0” speed
Page 221 of 329

10.3.2.4. Release and Status

Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Release and When bit 0 of Accumulation Control for Local Upstream

Accumulate on M: 4:1608 Zone is set:
Next Arrival for E: O
O.Data
.Data [8] Changing the value in this register will cause the
Local Upstream P: Byte 16 (Hi) Carton accumulated in this zone to release and the
Zone Byte 17 (L
(Lo)
o) zone will be armed to automatically accumulate the
4:0105 next Carton that arrives
Release and When bit 0 of Accumulation Control for Local Downstream

Accumulate on Zone is set:
M: 4:1609
Next Arrival for
E: O
O.Data
.Data [9] Changing the value in this register will cause the
Local
P: Byte 18 (Hi) Carton accumulated in this zone to release and the
Downstream
Byte 19 (L
(Lo)
o) zone will be armed to automatically accumulate the
Zone
4:0185 next Carton that arrives
Only used when local module is accepting loads from

Non-ConveyLinx controlled conveyor:
M: 4:1610
Set Status for Set value to 4 to cause the local upstream zone to run
E: O
O.Data
.Data [10]
Upstream Induct to accept the Carton being delivered by the non-
P: Byte 20 (Hi)
4:0134 ConveyLinx controlled conveyor. Set value to 1 to
Byte 21 (L
(Lo)
o)
cause the local upstream zone to accept the tracking
data written in Set Induct Tracking Word 1 / Word 2
Only used when local module is discharging loads to Non-

ConveyLinx controlled conveyor:
Set Status for M: 4:1611
Downstream E: O
O.Data
.Data [11] • Set value to 5 to cause the local downstream zone
Discharge P: Byte 22 (Hi) to accumulate and hold any Carton that arrives
4:0232 Byte 23 (L
(Lo)
o)
• Set value to 1 to allow the local downstream zone to
release the Carton
Page 222 of 329

10.3.2.5. Induct T
Tracking
racking F
Forwar
orwardd and
Reverse
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

Set Induct M: 4:1612
Tracking Forward E: O
O.Data
.Data [12]
Set value for 16-bit integer tracking word #1 for
Direction Word 1 P: Byte 24 (Hi)
Carton leaving non-ConveyLinx controlled conveyor that
4:0139 Byte 25 (L
(Lo)
o)
is in transit to arrive on the local upstream zone when
conveyor is running in default or “forward” direction

Tracking Forward E: O
O.Data
.Data [13]
Set value for 16-bit integer tracking word #2 for
Direction Word 2 P: Byte 26 (Hi)
Carton leaving non-ConveyLinx controlled conveyor that
4:0140 Byte 27 (L
(Lo)
o)
is in transit to arrive on the local upstream zone when
conveyor is running in default or “forward” direction

Tracking Reverse E: O
O.Data
.Data [14] Set value for 16-bit integer tracking word #1 for
Direction Word 1 P: Byte 28 (Hi) Carton leaving non-ConveyLinx controlled conveyor that
4:0237 Byte 29 (L
(Lo)
o) is in transit to arrive on the local upstream zone when
conveyor is running in opposite of default or “reverse”
direction

Tracking Reverse E: O
O.Data
.Data [15] Set value for 16-bit integer tracking word #2 for
Direction Word 2 P: Byte 30 (Hi) Carton leaving non-ConveyLinx controlled conveyor that
4:0238 Byte 31 (L
(Lo)
o) is in transit to arrive on the local upstream zone when
conveyor is running in opposite of default or “reverse”
direction
Page 223 of 329

10.3.2.6. Set Outputs and Motor Clear

Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
M: 4:1616
Logical 1 or 0:
Clear Motor Error E: O
O.Data
.Data [16]
1 = send reset command
4:0022 P: Byte 32 (Hi)
0 = clear reset command
Byte 33 (L
(Lo)
o)
Bitwise Value:
bit 08 = Left Aux I/O (Pin 2) Usage: 0 = Use as Input /
1 = Use as Output
M: 4:1617 bit 09 = Right Aux I/O (Pin 2) Usage: 0 = Use as Input /
Set Aux I/O
E: O
O.Data
.Data [17] 1 = Use as Output
Outputs
P: Byte 34 (Hi) bit 12 = Left Aux I/O (Pin 2) as Output: 1 = ON, 0 =
4:0063
Byte 35 (L
(Lo)
o) OFF (only if bit 8 is ON)
bit 13 = Right Aux I/O (Pin 2) as Output: 1 = ON, 0 =
OFF (only if bit 9 is ON)
M: 4:1618
E: O
O.Data
.Data [18]
Reserved
P: Byte 36 (Hi)
Byte 37 (L
(Lo)
o)
Clear Motor Er
Errror
Errors deemed “fatal” for the module (motor short circuit and Hall Effect sensor fault) require
either removal of power to reset or remote reset by PLC. Setting bit 0 of this register to 1 will
initiate this remote error reset from the PLC to the local module. Setting this bit will reset a
fatal error on either (or both) the left or right MDR.
! PLC must continuously set bit 0 = 1 in the Clear Motor Er

500 msec for the module to recognize the reset command
Errror register for at least
Aux I/O Outputs
In certain applications, it may be desired to have the PLC actuate a device along the conveyor
(i.e. illuminate a light or energize a solenoid coil, etc.). With the ConveyLinx network this can
be done without installing a separate PLC I/O system to do this. In EasyR
EasyRoll
oll, simply select NONE
from the Aux I/O Pin 2 Usage tab and this allows the PLC to have access to the Aux I/O pin and
configure it to be either an input or an output and use it accordingly.
Page 224 of 329

* If you make any selection other than “None” for the Aux I/O Pin 2 Usage, the PLC
has no access to use or configure the Aux I/O Pin 2.
Page 225 of 329

10.3.2.7. ConveyStop and Clear Jams

Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Integer Value:
M: 4:1619 0 = No Command
ConveyStop
E: O
O.Data
.Data [19] 1 = Command local module’s Stop Group to
Command Word
P: Byte 38 (Hi) go to Stopped State
4:0020
Byte 39 (L
(Lo)
o) 2 = Command Local Module’s Stop Group to
Clear Stopped State
Clear Sensor Jam M: 4:1620 Use when PLC detects a local Upstream jam in Module
for Local E: O
O.Data
.Data [20] Status Word #1 Bit 5:
Upstream Zone P: Byte 40 (Hi) PLC creates transition from 0 to 1 to send command to
4:0109 Byte 41 (L
(Lo)
o) local upstream zone to clear the jam condition
Clear Sensor Jam

M: 4:1621 Use when PLC detects a local Downstream jam in Module
for Local
E: O
O.Data
.Data [21] Status Word #2 Bit 5:
Downstream
P: Byte 42 (Hi) PLC creates transition from 0 to 1 to send command to
Zone
Byte 43 (L
(Lo)
o) local downstream zone to clear the jam condition
4:0189
* Please note that for the Clear Sensor Jam registers, the function requires the PLC
to make a transition from 0 to 1 in the register to initiate another auto-clear
cycle. Holding the value to 1 will not cause the retry to continue indefinitely.
Each attempt requires a new transition from 0 to 1
Page 226 of 329

10.3.2.8. Dir
Direction
ection and A
Accumulation
ccumulation Mode
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Used to change direction of flow or accumulation mode

for a contiguous group of zones beginning with the local
upstream / downstream zone
Direction &
Accumulation M: 4:1622
Value for Low Byte of Register:
Mode Control for E: O
O.Data
.Data [22]
Local Upstream P: Byte 44 (Hi) 0 = Normal Function
Zone Byte 45 (L
(Lo)
o)
1 = Accumulate Zones
4:0365
2 = Accumulate Zones
3 = Change Accumulation Release Mode
4 = Return Release Mode to Configured Default
10 = Set Direction to Configured Default (Forward)
Direction & 11 = Set Direction to opposite of Configured default
Accumulation (Reverse)
M: 4:1623
Mode Control for
E: O
O.Data
.Data [23]
Local
P: Byte 46 (Hi) Value for High Byte of Register:
Downstream
Byte 47 (L
(Lo)
o)
Zone Number of ZONES beginning with the local Upstream /
4:0375 Downstream Zone for which the Low Byte value is
applied – from 1 to 220. If ALL ZONES in the subnet
need to be controlled then leave the High Byte = “0”
Page 227 of 329

10.3.2.9. ConveyMer
ConveyMerge
ge Interface
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
ONL
ONLY
Y AVAIL
AILABLE
ABLE for FIRMW
FIRMWARE
ARE 4.25 and HIGHER
Used to dynamically modify a ConveyMerge configuration

already established with EasyRoll
Bitwise Values:
Bit 15: Set to enable PLC control of ConveyMerge
Bit 4: Set to disable release from Center line
M: 4:1624 Bit 5: Set to disable release from Left line

ConveyMerge
E: O
O.Data
.Data [24]
Interface Bit 6: Set to disable release from Right line
P: Byte 48 (Hi)
4:0387
Byte 49 (L
(Lo)
o) Bits 0 thru 3 are interpreted as a numerical value to
change the release priority:
Value:
0 = First come, first served release
1 = Center Line has priority
2 = Left Line has priority
3 = Right Line has priority
Page 228 of 329

10.3.3. ZP
ZPA
A Examples
Page 229 of 329

10.3.3.1. Basic A
Accumulate
ccumulate and R
Release
elease
with T
Tracking
racking Data
Here is a typical arrangement of an upstream or downstream zone on an ConveyLinx Module in
ZPA mode that is not the most upstream or most downstream zone in a given network. This
example will show how to cause a Carton to accumulate, how to detect a Carton has arrived,
how to write tracking data, and finally how to release the Carton. For this example, the PLC
must establish ZPA Mode Assembly Input/Output connections to Module B as shown
Upstr
Upstream
eam Zone Example
First, let’s assume we want to accumulate any Carton that arrives on the upstream zone of
Module B. With the PLC:
1. Set bit 0 in Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to instruct this
zone to accumulate any Carton that arrives.
2. Monitor Ar
Arrival
rival Count L
Local
ocal Upstr
Upstream
eam Zone and Departur
Departuree Count L
Local
ocal Upstr
Upstream
eam
Zone registers. On the leading edge when these two values become not equal, the
PLC knows there is a new arrival. Note that as long as a Carton is physically
occupying the upstream zone, these two values will not be equal.
3. Upon a successful arrival of a Carton in the upstream zone, then tracking data in
Cur
Currrent Upstr
Upstream
eam Zone T
Tracking
racking W
Wor
ordd 1 and Cur
Currrent Upstr
Upstream
eam Zone T
Tracking
racking W
Wor
ordd2
Page 230 of 329

will be valid for the newly arrived Carton.

4. The PLC may then decide that this tracking data is to be updated. The PLC can then
write new tracking data to registers Set L
Local
ocal Upstr
Upstream
eam Zone T
Tracking
racking W
Wor
ordd 1 and Set
Local Upstr
Upstream
eam Zone T
Tracking
racking W
Wor
ordd2
5. When the PLC is ready to release the Carton in the upstream zone, it should read the
value in the Cur
Currrent R
Release
elease Count for Upstr
Upstream
eam Zone register, add 1 to this value,
and then write this new value to Release and A
Accumulate
ccumulate on Ne
Next
xt Ar
Arrival
rival for L
Local
ocal
Upstr
Upstream
eam Zone register. When Module B sees this new value in this register, it will
release the Carton in the upstream zone and automatically accumulate the next new
Carton that arrives. Please note that if the downstream conditions from Module B are
full when this new value is written, Module B will remember that it was instructed to
release and will release the Carton when downstream conditions become clear
without any further signal from the PLC.
6. The PLC can detect when the Carton has departed the sensor on Module B upstream
zone by examining the values in Ar
Arrival
rival Count L
Local
ocal Upstr
Upstream
Departuree
Count L
Local
ocal Upstr
Upstream
eam Zone registers. On the leading edge of when these two values
are equal, the PLC will know that the Carton has departed the zone sensor in Module
B upstream zone.
If the PLC wants to cancel the accumulation control for Module B upstream zone:
PLC can reset bit 0 in Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register. This will
signal Module B to release any Carton accumulated and not accumulate the next Carton
that arrives at Module B upstream zone.
* Please note that if any new tracking data has been written to Set L
Upstr
Upstream
Wor
ord
eam Zone TTracking
racking W
Wor
ord
d 1 and/or Set LLocal
ocal Upstr
Upstream
eam Zone T
Local
ocal
Tracking
racking
d 2 and accumulation control is then canceled by resetting bit 0, this
data will NOT be assigned to the Carton when it is released. The ONL
ONLY Y way to
pass tracking data to a Carton is by following Step 5 above
Downstr
Downstream
eam Zone Example
First, let’s assume we want to accumulate any Carton that arrives on the upstream zone of
Module B. With the PLC:
Control
ol for L
Local
ocal Downstr
Downstream
eam Zone register to instruct this
zone to accumulate any Carton that arrives.
2. Monitor Ar
Arrival
rival Count L
Local
ocal Downstr
Downstream
Departuree Count L
Local
ocal
Downstr
Downstream
eam Zone registers. On the leading edge when these two values become not
equal, the PLC knows there is a new arrival. Note that as long as a Carton is
physically occupying the downstream zone, these two values will not be equal.
3. Upon a successful arrival of a Carton in the downstream zone, then tracking data in
Cur
Currrent Downstr
Downstream
eam Zone T
Tracking
racking W
Wor
ordd 1 and Cur
Currrent Downstr
Downstream
eam Zone T
Tracking
racking
Page 231 of 329

Wor
ordd 2 will be valid for the newly arrived Carton.
4. The PLC may then decide that this tracking data is to be updated. The PLC can then
write new tracking data to registers Set L
Local
ocal Downstr
Downstream
eam Zone T
Tracking
racking W
Wor
ordd 1 and
Set L
Local
ocal Downstr
Downstream
eam Zone T
Tracking
racking W
Wor
ordd 2.
5. When the PLC is ready to release the Carton in the downstream zone, it should read
the value in the Cur
Currrent R
Release
elease Count for Downstr
Downstream
eam Zone register, add 1 to this
value, and then write this new value to Release and A
Accumulate
ccumulate on Ne
Next
xt Ar
Arrival
rival for
Local Downstr
Downstream
eam Zone register. When Module B sees this new value in this register,
it will release the Carton in the upstream zone and automatically accumulate the next
new Carton that arrives. Please note that if the downstream conditions from Module B
are full when this new value is written, Module B will remember that it was instructed
to release and will release the Carton when downstream conditions become clear
without any further signal from the PLC.
6. The PLC can detect when the Carton has departed the sensor on Module B
downstream zone by examining the values in Ar
Arrival
rival Count L
Local
ocal Downstr
Downstream
eam Zone
and Departur
Departuree Count L
Local
ocal Downstr
Downstream
eam Zone registers. On the leading edge of when
these two values are equal, the PLC will know that the Carton has departed the zone
sensor in Module B downstream zone.
If the PLC wants to cancel the accumulation control for Module B downstream zone:
PLC can reset bit 0 in Accumulation Contr
Control
ol for L
Local
ocal Downstr
Downstream
eam Zone register. This will
signal Module B to release any Carton accumulated and not accumulate the next Carton
that arrives at Module B downstream zone.
* Please note that if any new tracking data has been written to Set L
Downstr
Downstream
eam Zone T
Tracking WWor
ord
Tracking
racking W
Wor
ordd 1 and/or Set L
Local
ocal Downstr
Downstream
Local
ocal
eam Zone
d 2 and accumulation control is then canceled by resetting bit 0,
this data will NOT be assigned to the Carton when it is released. The ONL
ONLYY
way to pass tracking data to a Carton is by following Step 5 above
Page 232 of 329

10.3.3.2. Conveyor Setup for Simple Bar

Code RReader
eader
This example shows how to set up the conveyor control to easily singulate cartons through a
bar code scanning region
In this example, Module B must be logically configured as a single zone. This can be either a
single long zone with one MDR and one sensor, or a single long zone with 2 MDRs and one
sensor.
For this example to work properly; the discharging zone of Module A and the single zone of
Module B must be in the default Singluation R
Release
elease mode (not Train mode). Module A must
also not have its Ar
Arrival
rival Jam disabled />
Page 233 of 329

Because of built-in ZPA functionality, when a Carton leaves Module A discharge zone, Module A
waits until it receives confirmation from Module B that the Carton arrived. If a new Carton
arrives at Module A, it will accumulate until this arrival confirmation occurs. Because Module B
is a single long zone, the space for what would have been the upstream zone for Module B (if it
was configured as two zones) will now essentially be left clear when a Carton is accumulated
on Module B. This is the area where the bar code scanner is located. In this configuration, any
new arrival at Module B will be assured to be the Carton associated with the last scan from the
bar code reader. For this example, the PLC must establish a connection with Module B and then
simply follow the zone control as described for basic accumulate and release
Page 234 of 329

10.3.3.3. Upstr
Upstream
eam A
Accept
ccept Interface
This example describes how to use a PLC to control the “wake-up” and passing of tracking data
to the most upstream zone of a ConveyLinx controlled conveyor
For this example, the PLC must establish a connection with Module A
A. When PLC is ready to
transfer a Carton from the PLC controlled conveyor to the Upstream Zone of the MDR Conveyor,
the PLC logic must:
1. Write a “4” into Set Status for Upstr

Upstream
eam Induct register. This will cause the upstream zone
of Module A to run to accept Carton.
PE-1, write tracking data to Set Induct T
2. When Carton clears PE-1 Tracking
racking F
Forwar
orward
d Dir
Direction
ection
Wor
ordd 1 and Set Induct T
Tracking
racking F
Forwar
orward
d Dir
Direction
ection W
Wor
ordd2
PE-1, write a “1” to Set Status for Upstr
3. When Carton clears PE-1 Upstream
eam Induct register. When
Module A sees this register change to “1”, it knows that the tracking data written to Set
Induct T
Tracking
racking F
Forwar
orward
dWWor
ordd 1 and Set Induct T
Tracking
racking F
Forwar
orward
dWWor
ordd 2 is valid and when
the Carton reaches the sensor in its upstream zone, the tracking data will be correctly
inducted
* Module A must see the Set Status for Upstr
Wor
ord
Upstream
eam Induct register change from 4 to
1 in order to recognize the tracking data written to Set Induct T Tracking
racking FForwar
orward
d registers. If using the clearing of PE-1 to initiate the write of “1” the Set
d
Status for Upstr

Upstream
eam Induct register in the PLC logic; the physical length of the
Carton must be less that the distance between PE-1 and Module A’s upstream
zone sensor because Module A inducts the tracking data upon the Carton arriving
at its upstream sensor and if Set Status for Upstr
Upstream
eam Induct has not changed
from 4 to 1, the tracking data will not be valid.
Page 235 of 329

! If a value of “4” is in the Set Status for Upstr

Upstream
eam Induct register at the same
time the Carton reaches the local upstream zone’s sensor; the local upstream
zone will assume the Carton is physically longer than one zone and will invoke
it’s on board Fle
Flex
x Zone logic and behave accordingly. Please refer to the
ConveyLinx User’s Guide for description of Flex Zone operation. To reliably
transfer tracking data and ensure single Carton induction to the local upstream
zone, the PLC programmer must ensure proper use of the Set Status for
Upstr
Upstream
eam Induct register
Page 236 of 329

10.3.3.4. Downstr
Downstream
eam Dischar
Discharge
ge Interface
This example shows how to control the discharge of a Carton from the most downstream zone
of a ConveyLinx controlled conveyor. This example also shows how to properly accept the
tracking data from the ConveyLinx module. For this example, the PLC must establish a
connection with Module X
X.
1. To hold any Carton that arrives at Module X downstream zone, the PLC writes a “5” to Set
Status for Downstr
Downstream
eam Dischar
Discharge
ge register. This tells Module X that downstream conditions
are “full and stopped” so it will not try to release any loads downstream.
2. When the PLC controlled conveyor is ready to accept a Carton from the MDR downstream
zone, it writes a “1” to Set Status for Downstr
Downstream
eam Dischar
Discharge
ge register. This tells Module X
that downstream conditions are clear and if it has a Carton on its downstream zone, it will
run to release it downstream.
3. When the Carton clears the local sensor in Module X Downstream Zone, the tracking data
for that Carton will be populated in Get T
Tracking
racking F
Forwar
orward
d Dir
Direction
ection W
Wor
ordd 1 and Get
Tracking F
Forwar
orward
d Dir
Direction
ection W
Wor
ordd 2 registers.
4. When Carton arrives at PE-2, the PLC writes a “5” to Set Status for Downstr
Downstream
eam Dischar
Discharge
ge
register. This tells Module X that the Carton successfully transferred. If this is not done,
then Module X will produce an Ar
Arrival
rival Jam condition.
Optional Step:
If the application is such that the PLC would like to inhibit a new Carton from entering Module X
downstream zone for whatever reason, there is a way to accumulate the next upstream zone to
the Module X downstream zone. The PLC can set bit 8 in the Accumulation Contr
Control
ol for L
Local
ocal
Downstr
Downstream
eam Zone and this will cause the adjacent upstream zone to accumulate (whether this
Page 237 of 329

zone is on Module X or next adjacent upstream ConveyLinx Module). To return the accumulated
upstream zone to normal operation; the PLC simply resets bit 8 in this register
* Please note that if Module X is configured as a single zone

8 in the Accumulation Contr
Control
ol for L
zone module only has an upstr
upstream
Local
ocal Upstr
Upstream
zone, then you must set bit
eam Zone register because a single
eam zone and no downstr
downstream
eam zone
zone.
Page 238 of 329

10.3.3.5. Simple Divert Example

This example shows how to use a PLC to control a simple divert mechanism to divert a Carton
from a ZPA zone and capture its tracking. This example also illustrates how to use the set
downstream arrival function with the PLC to keep the discharging module from generating a
jam condition when the Carton is moved from the ZPA zone to the divert lane. The PLC will be
connected to Module B.
* This example assumes that the tracking data arriving from each new Carton
arrival at Module B Upstream Zone contains a value that will indicate to the PLC
that a Carton does or does not need to divert. However, it is not required that
the PLC use Carton tracking data be used to determine when to divert a Carton.
The PLC can use whatever criteria it needs to make a divert decision.
Prepare Module B Upstream Zone:

Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to instruct this zone to
accumulate any Carton that arrives.
2. Monitor Ar
Arrival
rival Count L
Local
ocal Upstr
Upstream
Departuree Count L
Local
ocal Upstr
Upstream
eam Zone
registers. On the leading edge when these two values become not equal, the PLC knows
there is a new arrival. Note that as long as a Carton is physically occupying the upstream
Page 239 of 329

zone, these two values will not be equal.

3. Upon a successful arrival of a Carton in the upstream zone, then tracking data in Cur
Currrent
Upstr
Upstream
eam Zone T
Tracking
racking W
Wor
ordd 1 and Cur
Currrent Upstr
Upstream
eam Zone T
Tracking
racking W
Wor
ordd 2 will be valid
for the newly arrived Carton
If the PLC determines that the newly arrived carton needs to divert:
1. Set bit 8 of Accumulation Contr

Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register. This will keep Module
A from releasing a Carton to Module B while the divert operation is in progress.
2. PLC will then initiate it’s divert mechanism.
PE-1, the PLC will then set bit 9 of the Accumulation Contr
3. When carton reaches PE-1 Control
ol for
Local Upstr
Upstream
eam Zone register. This will tell Module B that the carton “successfully arrived
at its downstream position”.
PE-1, then the PLC should clear bit 9 of the Accumulation Contr
4. Once carton has cleared PE-1 Control
ol
for L
Local
ocal Upstr
Upstream
eam Zone register.
5. PLC then can clear bit 8 of the Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to
instruct Module A that it is OK to allow the next carton to enter Module B’s upstr
upstream
eam
zone.
If the PLC deter

determines
mines that the newly ar
arrived
rived carton does not need to divert:
The PLC can simply modify Carton’s tracking data if desired and release the Carton as
described in Basic A
Accumulate
ccumulate and R
Release
elease section
* Do not release the Carton by clearing bit 0 of Accumulation Contr

Upstr
Upstream
Control
ol for L
eam Zone in your PLC program. Follow the procedure in the “Basic
Accumulate and R Release
elease” example
Basic
Local
ocal
Page 240 of 329

10.3.3.6. Mer
Merge
ge onto ZP
ZPA
A Main Line
This example shows how to perform a simple merge with only a single module connection to
the PLC. In this example the PLC only needs to connect to Module C and from this connection,
the PLC can monitor conditions on Module A as well as “wake-up” Module C / Module B zone to
accept a carton from the merging curve section.
1. With no PLC intervention, as long as cartons arrive into Module A they will be conveyed to
Module C/B and onto Module D in normal ZPA fashion.
2. To verify that Module C (and by extension Module B) is ready to accept a carton from the
merge curve; the PLC needs to know that Module C’s zone is clear and stopped by
examining Local Status Upstr
Upstream
eam Zone F
Forwar
orward
d Dir
Direction
ection register (Low Byte). When the
low byte of this register equals 1, the zone is clear and stopped.
3. When the PLC needs to convey a carton from the merging curve, the PLC needs to set bit
8 in Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to accumulate the adjacent
upstream zone, in this example setting bit 8 will cause Module A downstr
downstream
eam zone to
accumulate any carton that arrives.
4. When the PLC is ready to release a carton from the PLC Contr
Controlled
olled Conveyor spur, the PLC
sets bit 12 in the Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register to wake up the
Module C zone (along with Module B’s zones because Module B is an extension of Module
C).
5. When the PLC sees the low byte of the Local Status Upstr
Upstream
eam Zone F
Forwar
orward
d Dir
Direction
ection
Page 241 of 329

register change to a value of 4 or 5, the PLC knows that the carton made it to Module C’s
zone sensor and must then reset bit 12 in the Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam
Zone register. Either of these values will indicate a successful arrival at Module C
6. Upon reset of bit 12 of the Accumulation Contr
Control
ol for L
Local
ocal Upstr
Upstream
eam Zone register, the
PLC can reset bit 8 of the same register to indicate to Module A that it is OK to continue
normal ZPA function
Page 242 of 329

10.3.4. Reduced Size ZP

ZPA
A Mode Assemblies
For some PLC controllers, the data size footprint required for a given assembly can be a limiting
factor on how many devices can connect to a given controller. ConveyLinx includes input/
output assemblies with fewer registers that contain basic functions in applications where the
full functionality of the Standard ZPA Mode Assemblies is not required. The Reduced Size
Assemblies provide basic accumulation and release control along with module diagnostic data
while removing the interfaces for reading/writing tracking data.
ZP
ZPA
A Mode Inputs to PLC
Assembled Assembled Assembled
Module
Register Name Modbus EIP Profinet
Addr
ddress
ess
Addr
ddress
ess Addr
ddress
ess Addr
ddress
ess
Byte 0 (Hi)
4:0116 Local Status Upstream Zone 4:2900 I.Data [0]
Byte 1 (L
(Lo)
o)
Byte 2 (Hi)
4:0196 Local Status Downstream Zone 4:2901 I.Data [1]
Byte 3 (L
(Lo)
o)
Byte 4 (Hi)
4:0106 Arrival Count Local Upstream Zone 4:2902 I.Data [2]
Byte 5 (L
(Lo)
o)
Byte 6 (Hi)
4:0107 Departure Count Local Upstream Zone 4:2903 I.Data [3]
Byte 7 (L
(Lo)
o)
Byte 8 (Hi)
4:0186 Arrival Count Local Downstream Zone 4:2904 I.Data [4]
Byte 9 (L
(Lo)
o)
Byte 10 (Hi)
4:0187 Departure Count Local Downstream Zone 4:2905 I.Data [5]
Byte 11 (L
(Lo)
o)
Byte 12 (Hi)
4:0088 Module Status Word 1 4:2906 I.Data [6]
Byte 13 (L
(Lo)
o)
Byte 14 (Hi)
4:0089 Module Status Word 2 4:2907 I.Data [7]
Byte 15 (L
(Lo)
o)
Byte 16 (Hi)
4:0105 Current Release Count for Upstream Zone 4:2908 I.Data [8]
Byte 17 (L
(Lo)
o)
Byte 18 (Hi)
4:0185 Current Release Count for Downstream Zone 4:2909 I.Data [9]
Byte 19 (L
(Lo)
o)
Byte 20 (Hi)
4:0035 Sensor Port Inputs 4:2910 I.Data [10]
Byte 21 (L
(Lo)
o)
Byte 22 (Hi)
Reserved 4:2911 I.Data [11]
Byte 23 (L
(Lo)
o)
Page 243 of 329

ZP
ZPA
A Mode Outputs fr
from
om PLC
Module
Addr
ddress
ess
Addr
ddress
ess Addr
ddress
ess Addr
ddress
ess
Byte 0 (Hi)
4:0104 Accumulation Control for Local Upstream Zone 4:3000 O.Data0 Byte 1 (L
(Lo)
o)
Accumulation Control for Local Downstream Byte 2 (Hi)

4:0184
Zone
4:3001 O.Data1 Byte 3 (L
(Lo)
o)
Byte 4 (Hi)
4:0040 Set Left MDR Speed 4:3002 O.Data2 Byte 5 (L
(Lo)
o)
Byte 6 (Hi)
4:0064 Set Right MDR Speed 4:3003 O.Data3 Byte 7 (L
(Lo)
o)
Release and Accumulate on Next Arrival for Byte 8 (Hi)

4:0105
Local Upstream Zone
(Lo)
o)
Release and Accumulate on Next Arrival for Byte 10 (Hi)

4:0185
Local Downstream Zone
(Lo)
o)
Byte 12 (Hi)
4:0134 Set Status for Upstream Induct 4:3006 O.Data6 Byte 13 (L
(Lo)
o)
Byte 14 (Hi)
4:0232 Set Status for Downstream Discharge 4:3007 O.Data7 Byte 15 (L
(Lo)
o)
Byte 16 (Hi)
4:0022 Clear Motor Error 4:3008 O.Data8 Byte 17 (L
(Lo)
o)
Byte 18 (Hi)
4:0063 Set Aux I/O Outputs 4:3009 O.Data9 Byte 19 (L
(Lo)
o)
Byte 20 (Hi)
Reserved 4:3010 O.Data10 Byte 21 (L
(Lo)
o)
Clear Sensor Jam Command for Local Byte 22 (Hi)

4:0109
Upstream Zone
4:3011 O.Data11 Byte 23 (L
(Lo)
o)
Clear Sensor Jam Command for Local Byte 24 (Hi)

4:0189
Downstream Zone
4:3012 O.Data12 Byte 25 (L
(Lo)
o)
Direction & Accumulation Mode Control for Byte 26 (Hi)

4:0365
Local Upstream Zone
4:3013 O.Data13 Byte 27 (L
(Lo)
o)
Direction & Accumulation Mode Control for Byte 28 (Hi)

4:0375
Local Downstream Zone
4:3014 O.Data14 Byte 29 (L
(Lo)
o)
Page 244 of 329

10.4. PLC I/O Mode Contr

Control
ol
When an ConveyLinx Module is in PLC I/O mode, all automatic functions of detecting loads and
running motors are suspended by the local ConveyLinx Module’s on-board logic and the
external controller must explicitly read inputs and write data output to cause motors to run.
The following items are available for external controller when the ConveyLinx Module is in PLC
I/O Mode:
• Status of all available digital inputs on Sensor Ports (2 dedicated as inputs and 2
configurable as inputs)
• Module voltage reading
• Left and Right motor status of frequency, current, and calculated temperature
• Left and Right motor diagnostic error status word
• Control of Aux I/O digital outputs
• Ability to independently run both Left and Right motors
• Ability to set speed, acceleration, deceleration, and Braking method for Left and Right
motors
• Ability to configure one or both motor ports to digital output mode
• Ability to remotely clear fatal motor error condition
• Ability to instruct module to stop motor outputs
• Ability to interface with upstream and downstream ZPA modules for status and
tracking
* When an ConveyLinx Module is placed in PLC I/O mode; it suspends all of its
internal ZPA logic control. Any sensors or motors connected to the module will
require explicit interaction with an external controller. The external controller will
have typical Ethernet-based remote I/O performance from an ConveyLinx Module
when in PLC I/O mode
Page 245 of 329

10.4.1. Setting PLC I/O Mode in EasyR

EasyRoll
oll
Individual modules must be placed into PLC I/O Mode from the EasyR
EasyRoll
oll software tool. This is
done by invoking the Advanced Dialog and using the Connections tab
From the main screen, first enter the

correct Subnet into the “Network IP”
boxes and the correct Node you
want to connect. Invoke the
ConveyLinx Advanced Dialog and
select the Connections tab. Note
that the Node is being viewed is in
the center and it is greyed out.
Select the “PLC I/O Controlled”
checkbox. With this checked the
“Clear Connections” checkbox
becomes enabled. Check or Uncheck
the ““Clear
Clear Connections” checkbo
checkboxx
depending upon your application
application.
Click “Apply” to initiate the change.
The module will restart and this may
take several seconds to complete
! IMPORTANT NOTE: Once a given module has been placed in PLC I/O mode, the
ONLY way to return it to ZPA mode is to perform an Auto-Configuration procedure
or Restore from a backup file with EasyRoll. There is no “undo” or “reset”
function for this action
Page 246 of 329

10.4.2. Optional Clear Connections Choice

The decision to “Clear Connections” is based upon the application. When a string of modules
are Auto-Configured, each successive module in the string establishes a logical upstream /
downstream connection with its neighbor module’s. These connections provide the basis for
the logical flow of inter-module status data for ZPA functionality. However, if a single module
node within a string of ZPA configured nodes needs to be utilized in PLC I/O mode, these logical
connections can remain in place and be used to PLC programmer’s advantage.
When You DO NOT Clear Connections

You
By NOT clearing the connections, the module in PLC I/O will maintain its inter-module data
exchange. This could be advantageous for applications where you want to control a specialized
conveyor section such as a right angle transfer or merge conveyor with an ERSC in PLC I/O
mode. For example, if the PLC I/O mode module is being either fed or feeds conveyors
controlled by modules in standard ZPA mode, these modules will populate PLC I/O configured
module’s registers with their respective status data. Likewise, the PLC can manipulate the PLC
I/O configured module’s zone status registers and these registers will automatically be written
to the adjacent modules by virtue of these already established connections without requiring
the PLC to explicitly perform the messaging.
Page 247 of 329

When You DO Clear Connections

You
If you choose the option to “Clear Connections”, this automatic data transfer of status is
inhibited. This means that for a module in PLC I/O mode whose connections have been cleared;
its status registers are not automatically written to its adjacent neighbors. Clearing the
connections could be advantageous when utilizing several modules in a row configured as PLC
I/O where having this additional inter-module communication is not required and would only
add to unnecessary communication bandwidth usage.
Page 248 of 329

10.4.3. Configuring A
Action
ction for L
Loss
oss of
Communication
When changing the mode of a given ConveyLinx Module to PLC I/O mode in EasyRoll, you are
given the option to select the behavior of the ConveyLinx Module’s outputs upon loss of
communications with the PLC.
Select “Don’t Change” if you want

module’s logical outputs and MDR’s
to remain in the state they were in
at the time of the communication
loss
Select “All OFF” to instruct the

ConveyLinx Module to turn off all
logical outputs and stop all MDR’s at
the time of communication loss.
Upon re-establishing
communications with the PLC, the
ConveyLinx Module will
automatically resume having its
outputs and MDR’s controlled by PLC
command
Page 249 of 329

10.4.4. PLC Inputs for PLC I/O Mode

These Topics show the data coming from the ConveyLinx Module and provided as input to the
PLC:
ConveyStop Status
Sensor & Contr
Control
ol P
Ports
orts
Lef
eftt Motor Status
Right Motor Status
Motor P
Ports
orts Digital Status
Upstr
Upstream
eam / Downstr
Downstream
eam Status & T
Tracking
racking
Servo Contr
Control
ol Status
Page 250 of 329

10.4.4.1. ConveyStop Status

Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

bit 05 = Stop active on another module in Stop Group
M: 4:1700 bit 06 = Stop active due to lost communication
ConveyStop
E: I.Data [0] connection
Status Word
P: Byte 0 (Hi) bit 07 = Stop active due to lost PLC connection
4:0019
Byte 1 (L
(Lo)
o) bit 08 = Reserved
bit 09 = Reserved
bit 10 = Stop active due to Stop Command from PLC
Page 251 of 329

10.4.4.2. Sensor P
Ports
orts
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC

bit 00 = Left Sensor Port – Aux I/O (M8 Pin 2)
M: 4:1701
Sensor Port bit 02 = Right Sensor Port – Aux I/O (M8 Pin 2)
E: I.Data [1]
Inputs bit 04 = Left Sensor Port – Sensor Signal (M8 Pin 4)
P: Byte 2 (Hi)
4:0035 bit 06 = Right Sensor Port – Sensor Signal (M8 Pin 4)
Byte 3 (L
(Lo)
o)
bit 15 = 2 sec on / 2 sec off heartbeat
All other bits Reserved
M: 4:1702
Sensor Detect E: I.Data [2]
bit 0 = Device is connected to Right Sensor Port
4:0036 P: Byte 4 (Hi)
bit 1 = Device is connected to Left Sensor Port
Byte 5 (L
(Lo)
o)
M: 4:1703
Value in mV of Module Power Supply
Module Voltage E: I.Data [3]
Range: 0 to 35000
4:0024 P: Byte 6 (Hi)
Example: 23500 = 23.5 Volts
Byte 7 (L
(Lo)
o)
* The electrical logic state of the signal on the Sensor/Control Port pins are bit-wise
exclusive OR (XOR) with the bits set in the Sensor P Port
ort Input Signal Condition
Mask register to arrive at the bit values seen in the Sensor P Port
ort Inputs register.
This allows the PLC programmer to control whether an electrically energized
condition results in a logical 1 or a logical 0 in the Sensor PPort
ort Inputs register.
This same relationship is also mirrored by the state of the input’s corresponding
LED indicator
Page 252 of 329

10.4.4.3. Lef
eftt Motor Status
Register Name /
Assembled A
Addr
ddress
ess for PLC Description
Module AAddr
ddress
ess
M: 4:1704
Left Motor Integer Value in mA for the current the motor is
E: I.Data [4]
Current drawing
P: Byte 8 (Hi)
4:0055 Example: 1900 = 1.9 Amps
Byte 9 (L
(Lo)
o)
M: 4:1705
Left Motor Integer value in Hz for the electrical frequency
E: I.Data [5]
Frequency the motor is running
P: Byte 10 (Hi)
4:0056 Example: 300 = 300 Hz
Byte 11 (L
(Lo)
o)
M: 4:1706 High Byte / Low Byte of temperatures in °C

Left Motor
E: I.Data [6] High Byte = Calculated motor temperature
Temperature
P: Byte 12 (Hi) Low Byte = Temperature reading from the on
4:0057
Byte 13 (L
(Lo)
o) board sensor

bit 0 = Motor Rotation Status
bit 2 = Port in Digital Mode
bit 3 = Reserved
bit 4 = Reserved
bit 5 = Board Overheat
M: 4:1707
bit 6 = Over-voltage
Left Motor Status E: O
O.Data
.Data [7]
bit 7 = Low Voltage
4:0058 P: Byte 14 (Hi)
bit 8 = Over-heated
Byte 15 (L
(Lo)
o)
bit 9 = Over-current
bit 10 = Short Circuit
bit 11 = Motor Not Connected
bit 12 = Overloaded
bit 13 = Stalled
bit 14 = Sensor Error
bit 15 = Motor Not Used
Motor Speed and Speed Status

bit 00 thru bit 13 = Numerical value or
current speed
M: 4:1723
Left Motor Real * For MDR value is in mm/sec
E: O
O.Data
.Data [23]
Speed * For PGD value is in RPM x 10
P: Byte 46 (Hi)
4:0507 bit 14: 1 = Set Speed is above motor’s
Byte 47 (L
(Lo)
o)
maximum speed capability
bit 15: 1 = Set Speed is below motor’s
minimum speed capability
Motor R
Rotation
otation Status
Bits 0 and 1 are used in combination to provide 4 possible states. The following chart defines
Page 253 of 329

the bit values for these states:
Bit 1 Bit 0 Description
0 0 Motor not running, Normal or Servo Braking Mode applied
0 1 Motor running in CCW Direction
1 0 Motor running in CW Direction
1 1 Motor not running and Free Braking Mode applied
Motor F
Frrequency
This contains the current value of the electrical frequency of the motor if it is running. For
Senergy motors, electrical frequency divided by 5 = mechanical frequency. The mechanical
frequency is the number of motor rotations per second. You can use this value along with the
mechanical gear ratio of the gearbox to calculate the actual running motor RPM. Please consult
your Pulseroller catalog for the gear ratio value for the particular part number you are using.
Motor R
Real
eal Speed
The Ai motor technology encodes the specific motor data into a memory chip inside the motor.
This data is read by the ConveyLinx Module. Included in this data are the mechanical
characteristics for the motor including the minimum and maximum speed settings. You can
enter values in the speed reference registers that are outside the allowable range for the
connected motor. If you enter a value greater than the maximum; the speed will be set to the
maximum. If you enter a value lower than the minimum, the speed will be set to the minimum.
For the Motor R

Real
eal Speed input registers, you can know if the value entered in the Speed
Reference register is outside the allowable range by monitoring bits 14 and 15 of these
registers.
Page 254 of 329

An Example
For example, let’s say we have an MDR whose maximum speed is 1.34 m/s. At this speed, the
value in the Real Speed input register will show a decimal value very close or equal to 1340
(which is the speed in mm/s).
If we enter a value of 2.0 m/s for the speed reference (value of 2000 in Speed R
Refer
eference
ence
register) and then run the motor, in the Real Speed input register for that motor you will see a
decimal value very close or equal to 17724. Analyzing this value at the bit level, you will see
that bit 14 is set indicating that the Speed R
Refer
eference
ence value is above the maximum value.
If you strip off bit 14 from this value, the remaining decimal value (i.e. the binary value of bits
Page 255 of 329

0 thru 13) will be very close or equal to 1340; which is the maximum speed allowed for the
MDR. Similarly, if the Speed R
Refer
eference
ence value entered is below the minimum value, bit 15 will be
set in the motor’s Real Speed register. Stripping out bit 15, the binary value of bits 0 thru 13
will indicate a value very close or equal to the motor’s minimum allowed speed.
Page 256 of 329

10.4.4.4. Right Motor Status

Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
M: 4:1708
Right Motor
E: I.Data [8] Integer Value in mA for the current the motor is drawing
Current
P: Byte 16 (Hi) Example: 1900 = 1.9 Amps
4:0079
Byte 17 (L
(Lo)
o)
M: 4:1709
Right Motor Integer value in Hz for the electrical frequency the motor
E: I.Data [9]
Frequency is running
P: Byte 18 (Hi)
4:0080 Example: 300 = 300 Hz
Byte 19 (L
(Lo)
o)
High Byte / Low Byte of temperatures in °C

M: 4:1710
Right Motor
E: I.Data [10]
Temperature High Byte = Calculated motor temperature
P: Byte 20 (Hi)
4:0081 Low Byte = Temperature reading from the on board
Byte 21 (L
(Lo)
o)
sensor

bit 2 = Port in Digital Mode
bit 3 = Reserved
bit 4 = Reserved
bit 5 = Board Overheat
M: 4:1711
Right Motor bit 6 = Over-voltage
E: O
O.Data
.Data [11]
Status bit 7 = Low Voltage
P: Byte 22 (Hi)
4:0082 bit 8 = Over-heated
Byte 23 (L
(Lo)
o)
bit 9 = Over-current
bit 10 = Short Circuit
bit 11 = Motor Not Connected
bit 12 = Overloaded
bit 13 = Stalled
bit 14 = Sensor Error
bit 15 = Motor Not Used
Motor R
Rotation
otation Status
Motor F
Frrequency
Motor R
Real
eal Speed
Page 257 of 329

10.4.4.5. Motor P
Ports
orts Digital Status
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
M: 4:1712
Left Motor Port
E: I.Data [12]
Digital I/O Status Bitwise Value – Read Only:
P: Byte 24 (Hi)
4:0060
Byte 25 (L
(Lo)
o)
bit 12 = Short Circuit Error on one or more outputs
M: 4:1713 bit 14 = Over Current – More than 1A detected on one
Right Motor Port
E: I.Data [13] or more outputs
Digital I/O Status
P: Byte 26 (Hi)
4:0084
Byte 27 (L
(Lo)
o)
How to Use Motor P

Ports
orts as Digital Outputs
Page 258 of 329

10.4.4.6. Upstr
Upstream
eam / Downstr
Downstream
eam Status &
Tracking
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
M: 4:1714 Interger Value of Low or High Byte:

Upstream Module
E: I.Data [14]
Status
P: Byte 28 (Hi) 0×01 = Zone sensor clear and motor stopped
4:0134
Byte 29 (L
(Lo)
o) 0×02 = Zone sensor clear, motor running, accepting
from upstream zone
M: 4:1715 0×04 = Zone sensor blocked, motor running,
Downstream discharging
E: I.Data [15]
Module Status to downstream zone
P: Byte 30 (Hi)
4:0232 0×05 = Zone sensor blocked and motor stopped
Byte 31 (L
(Lo)
o)
0×06 = Busy (state during ConveyStop active mode)
Current Tracking
M: 4:1716
Word 1 for Value = Tracking data word #1 (16-bit integer) for the
E: I.Data [16]
Adjacent Carton that has just discharged from the module adjacent
P: Byte 32 (Hi)
Upstream Module to this local module
Byte 33 (L
(Lo)
o)
4:0139
Current Tracking
M: 4:1717
Word 2 for Value = Tracking data word #2 (16-bit integer) for the
E: I.Data [17]
Adjacent Carton that has just discharged from the module adjacent
P: Byte 34 (Hi)
Upstream Module to this local module
Byte 35 (L
(Lo)
o)
4:0140
M: 4:1718
E: I.Data [18]
Reserved
P: Byte 36 (Hi)
Byte 37 (L
(Lo)
o)
Understanding A
Adjacent
djacent Modules
These registers only contain meaningful data if the ConveyLinx connections between upstream
and/or downstream modules are preserved when placing the local module into PLC I/O mode
from within EasyR
EasyRoll
oll. If connections are cleared in EasyR
EasyRoll
oll, these registers will not contain any
pertinent data and will not be updated by adjacent modules. Learn about clearing connections.
Page 259 of 329

10.4.4.7. Servo Contr

Control
ol Status
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
M: 4:1719
Left Motor Servo
E: I.Data [19] Signed integer value that indicates the current position of
Position
P: Byte 38 (Hi) the Left Motor in relation to its “0” position
4:0062
Byte 39 (L
(Lo)
o)
M: 4:1720
Right Motor Servo
E: I.Data [20] Signed integer value that indicates the current position of
Position
P: Byte 40 (Hi) the Right Motor in relation to its “0” position
4:0086
Byte 41 (L
(Lo)
o)
M: 4:1721 Bit 0: Servo Command Status

Left Motor Servo
E: I.Data [21] 1 = Last Servo Run Command Complete
Status
P: Byte 42 (Hi) 0 = Servo Command in Process
4:0011
Byte 43 (L
(Lo)
o)
Bit 1: Servo Reset Status
M: 4:1722 Echoes state of Motor Servo Command bit 0
Right Motor Servo
E: I.Data [22]
Status
P: Byte 44 (Hi) Bit 2: Servo Command Status
4:0016
Byte 45 (L
(Lo)
o) Echoes state of Motor Servo Command bit 1
See Servo Move example
Page 260 of 329

10.4.5. PLC Outputs for PLC I/O Mode
Page 261 of 329

10.4.5.1. ConveyStop Command & Clear

Motor Er
Errror
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Integer Value
M: 4:1800 0= No Command
ConveyStop
E: O
O.Data
.Data [0] 1 = Command local module’s Stop Group to
Command Word
P: Byte 0 (Hi) go to Stopped State
4:0020
Byte 1 (L
(Lo)
o) 2 = Command local module’s Stop Group to
Clear Stopped State
M: 4:1616
Logical 1 or 0:
Clear Motor Error E: O
O.Data
.Data [16]
1 = send reset command
4:0022 P: Byte 32 (Hi)
0 = clear reset command
Byte 33 (L
(Lo)
o)
Learn more about Clear Motor Error
Page 262 of 329

10.4.5.2. Motor & Contr

Control
ol P
Port
ort Digital
Output
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Bitwise values
bit 00 = Reserved
Set Left Motor M: 4:1801 bit 01 = Energize Motor Port Pin 4
Port Digital E: O
O.Data
.Data [1] bit 02 = Energize Motor Port Pin 3
Control P: Byte 2 (Hi) bit 03 thru bit 14 = Reserved
4:0060 Byte 3 (L
(Lo)
o) bit 15 = Digital Output Enable
0 = Use Port as Motor Control
1 = Use Port as Digital Outputs
Bitwise values
bit 00 = Reserved
Set Right Motor M: 4:1802 bit 01 = Energize Motor Port Pin 4
Port Digital E: O
O.Data
.Data [2] bit 02 = Energize Motor Port Pin 3
Control P: Byte 4 (Hi) bit 03 thru bit 14 = Reserved
4:0048 Byte 5 (L
(Lo)
o) bit 15 = Digital Output Enable
0 = Use Port as Motor Control
1 = Use Port as Digital Outputs
Bitwise Values
bit 00: 1 = Left Pin 2 ON, 0 = Left Pin 2 OFF
bit 01: 1 = Right Pin 2 ON, 0 = Right Pin 2 OFF
Control Port M: 4:1803
bit 02 thru bit 04 = Reserved
Digital Output E: O
O.Data
.Data [3]
bit 05: 1 = Enable Left Pin 2 as Output, 0 = Enable Left
Control P: Byte 6 (Hi)
Pin 2 as Input
4:0037 Byte 7 (L
(Lo)
o)
bit 06: 1 = Enable Right Pin 2 as Output, 0 = Enable
Right Pin 2 as Input
Learn more about using Motor Ports for Digital Outputs
Page 263 of 329

10.4.5.3. Lef
eftt Motor Contr
Control
ol
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Bit 0:
M: 4:1804 1= Run Command
Left Motor Run /
E: O
O.Data
.Data [4] 0= Stop Command
Reverse
P: Byte 8 (Hi) Bit 8:
4:0260
Byte 9 (L
(Lo)
o) 0= Run in Configured Direction
1= Run opposite of Configured Direction
Integer Value:
M: 4:1805
Left Motor Brake 1 = Use Standard Brake Method
E: O
O.Data
.Data [5]
Method 2 = Use Free Coast Brake Method
P: Byte 10 (Hi)
4:0261 3 = Use Servo Brake Method
Byte 11 (L
(Lo)
o)
0 = Remain at last configured or last value entered
Integer Value:
0 = Ignore
M: 4:1806 1 = Slave Mode OFF – Left motor independently
Left Motor Slave
E: O
O.Data
.Data [6] controlled from Right
Mode
P: Byte 12 (Hi) 2 = Slave Mode ON – Left motor mirrors Right motor
4:0262
Byte 13 (L
(Lo)
o) control
3 = Slave Mode ON – Left motor runs in opposite
direction of Right motor
M: 4:1810 Integer Value

Left Motor Speed
E: O
O.Data
.Data [10] For MDR value is in mm/s
Reference
P: Byte 20 (Hi) For PGD value is in RPM X 10
4:0040
Byte 21 (L
(Lo)
o) 0 = Remain at last non zero value entered
M: 4:1812
Left Motor Integer Value
E: O
O.Data
.Data [12]
Acceleration For MDR value is in mm
P: Byte 24 (Hi)
4:0043 For PGD value is in motor pulses
Byte 25 (L
(Lo)
o)
M: 4:1813 Deceleration Range: 0 to 10000 (Both MDR and PGD)

Left Motor
E: O
O.Data
.Data [13] Acceleration Range: 30 to 10000 (Both MDR and PGD)
Deceleration
P: Byte 26 (Hi) 0 = Remain at last non-zero value entered
4:0044
Byte 27 (L
(Lo)
o)
Page 264 of 329

10.4.5.4. Right Motor Contr

Control
ol
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Bit 0:
M: 4:1807 1= Run Command
Right Motor Run /
E: O
O.Data
.Data [7] 0= Stop Command
Reverse
P: Byte 14 (Hi) Bit 8:
4:0270
Byte 15 (L
(Lo)
o) 0= Run in Configured Direction
1= Run opposite of Configured Direction
Integer Value:
M: 4:1808
Right Motor Brake 1 = Use Standard Brake Method
E: O
O.Data
.Data [8]
Method 2 = Use Free Coast Brake Method
P: Byte 16 (Hi)
4:0271 3 = Use Servo Brake Method
Byte 17 (L
(Lo)
o)
0 = Remain at last configured or last value entered
Integer Value:
0 = Ignore
M: 4:1809 1 = Slave Mode OFF – Right motor independently
Right Motor Slave
E: O
O.Data
.Data [9] controlled from Left
Mode
P: Byte 18 (Hi) 2 = Slave Mode ON – Right motor mirrors Left motor
4:0272
Byte 19 (L
(Lo)
o) control
3 = Slave Mode ON – Right motor runs in opposite
direction of Left motor
M: 4:1811 Integer Value

Right Motor
E: O
O.Data
.Data [11] For MDR value is in mm/s
Speed Reference
P: Byte 22 (Hi) For PGD value is in RPM X 10
4:0064
Byte 23 (L
(Lo)
o) 0 = Remain at last non zero value entered
M: 4:1814
Right Motor Integer Value
E: O
O.Data
.Data [14]
Acceleration For MDR value is in mm
P: Byte 28 (Hi)
4:0067 For PGD value is in motor pulses
Byte 29 (L
(Lo)
o)
M: 4:1815 Deceleration Range: 0 to 10000 (Both MDR and PGD)

Right Motor
E: O
O.Data
.Data [15] Acceleration Range: 30 to 10000 (Both MDR and PGD)
Deceleration
P: Byte 30 (Hi) 0 = Remain at last non-zero value entered
4:0068
Byte 31 (L
(Lo)
o)
Page 265 of 329

10.4.5.5. Set Status & T

Tracking
racking
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Used to write this module’s ZPA Status to its neighboring

Downstream module:
Set Status to M: 4:1817 4 = Instruct Downstream module to “wake-up” and

Downstream E: O
O.Data
.Data [17] run its most upstream zone
Module P: Byte 34 (Hi)
4:0196 Byte 35 (L
(Lo)
o) 1 = Instructs Downstream module that carton has
exited local zone and to accept any tracking data
written in Set Discharge Tracking Word 1 / Word 2
registers when carton arrives
Used to write this module’s ZPA Status to its neighboring

Upstream module:
M: 4:1818
Set Status to 5 = Instructs Upstream module’s discharge zone to
E: O
O.Data
.Data [18]
Upstream Module accumulate and hold any carton that arrives at its
P: Byte 36 (Hi)
4:0116 discharge zone.
Byte 37 (L
(Lo)
o)
1 = Instructs Upstream module’s discharge zone to
release any carton that arrives at its discharge zone
M: 4:1820
Set Discharge
E: O
O.Data
.Data [20]
Tracking Word 1
P: Byte 40 (Hi) Only used when local PLC I/O Mode module needs to pass
4:0201
Byte 41 (L
(Lo)
o) tracking data to a downstream connected ConveyLinx
M: 4:1821 Module. Used in conjunction with Set Status to
Set Discharge Downstream Module register
E: O
O.Data
.Data [21]
Tracking Word 2
P: Byte 42 (Hi)
4:0202
Byte 43 (L
(Lo)
o)
M: 4:1822
E: O
O.Data
.Data [22]
Reserved
P: Byte 44 (Hi)
Byte 45 (L
(Lo)
o)
* For registers involving status and tracking to upstream or downstream modules

that are in ZPA mode, the connections must NOT be cleared when placing this
module into PLC I/O mode from within EasyR
EasyRoll
oll. Learn more about Clearing
Connection Options
Page 266 of 329

10.4.5.6. Set Sensor P

Port
ort Input Mask
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
Bitwise Value:
Sensor Port Input M: 4:1819 bit 00 = Left Sensor Port – Aux I/O (M8 Pin 2)
Signal Condition E: O
O.Data
.Data [19] bit 02 = Right Sensor Port – Aux I/O (M8 Pin 2)
Mask P: Byte 38 (Hi) bit 04 = Left Sensor Port – Sensor Signal (M8 Pin 4)
4:0034 Byte 39 (L
(Lo)
o) bit 06 = Right Sensor Port – Sensor Signal (M8 Pin 4)
How Input signals ar

are
e conditioned in ZP
ZPA
A Mode
For a module in standard ZPA mode, the AutoAuto-Configuration

-Configuration procedure sets values in this
register to allow the module to correctly display the Sensor Port’s LEDs to facilitate diagnostics.
This is done, for example, to make visual LED diagnostics the same for “zone blocked”
regardless of the sensor type.
For example, suppose the zone photo sensors used are “Light Operate, Normally Open”. This
means that the sensor’s output is energizing the Sensor Port input pin 4 when the zone is clear.
The module’s Sensor Port LED indicator for pin 4 (green) should illuminate when the zone is
blocked; so the Auto
Auto-Configuration
-Configuration procedure sets a bit in the Sensor PPort
ort Input Signal
Condition Mask register to correspond to the pin 4 signal on the appropriate sensor port. If the
sensor is electrically opposite such that its output energizes pin 4 of the sensor port when the
zone is blocked, then the bit corresponding to pin 4 for this sensor port is clear such that the
sensor port’s LED illuminates green when pin 4 is energized.
How Input signals ar

are
e conditioned in PLC I/O Mode
When a module is placed in PLC I/O mode; the Sensor P Port

ort Input Signal Condition Mask register
is cleared of the values set during the Auto
Auto-Configur
-Configure
e procedure. The Sensor P Port
ort Input Signal
Condition Mask register is made available for PLC I/O mode Sensor Port inputs to give the PLC
programmer the same flexibility for configuring which electrical state (on or off) of the input
will cause a logical 1 to appear in the Sensor PPort
ort Inputs register and illuminate the pin’s
corresponding LED. By setting or clearing the corresponding bit for a given port’s pin 3 or 4
signal, the PLC programmer can determine which physical state (on or off) of the input signal
will cause its corresponding pin’s bit in the Sensor Port Inputs register to be set and its
corresponding LED to illuminate. The following are two examples that show the bit patterns
and signals for one of the module’s inputs. The same pattern applies to all available inputs:
Example: Right Sensor P

Port
ort – P
Pin
in 4 Signal
Sensor PPort
ort
Sensor P
Port
Electrical Signal Inputs Register LED State
Mask Register bit 6
bit 6
OFF 0 0 Green = OFF
ON 0 1 Green = ON
OFF 1 1 Green = ON
Page 267 of 329

ON 1 0 Green = OFF
Example: L
Lef
eftt Sensor P
Port
ort – P
Pin
in 2 Signal
Sensor PPort
ort
Sensor P
Port
Electrical Signal Inputs Register LED State
Mask Register bit 0
bit 0
OFF 0 0 Red = OFF
ON 0 1 Red = ON
OFF 1 1 Red = ON
ON 1 0 Red = OFF
! Be careful when changing the Sensor Port Input Signal Condition Mask in
your Ethernet I/P PLC program. The input bit values in the Sensor Port Inputs
register can show unexpected or opposite values from expected until the PLC
has updated the Sensor Port Input Signal Condition Mask data. This update
could take several program scans depending upon the Ethernet I/P RPI
settings. Take care to be sure that the Sensor Port Input Signal Condition
Mask data is written to the module before acting on any input values in the
Sensor Port Inputs register
Page 268 of 329

10.4.5.7. Servo Contr

Control
ol
Description
Module AAddr
ddress
ess Addr
ddress
ess for PLC
M: 4:1824
Left Motor Servo Bit 0: Reset Command
E: O
O.Data
.Data [24]
Command Word 1 = Set Current Pulse Count to “0”
P: Byte 48 (Hi)
4:0009
Byte 49 (L
(Lo)
o)
Bit 1: Servo Run Command
M: 4:1826 1 = Run in Motor from current pulse count to set
Right Motor Servo
E: O
O.Data
.Data [26] pulse count in Left Motor Servo Command
Command Word
P: Byte 52 (Hi) Pulses Register
4:0014
Byte 53 (L
(Lo)
o)
M: 4:1823
Left Motor Servo
E: O
O.Data
.Data [23]
Command Pulses
P: Byte 46 (Hi) Signed integer value in motor pulses of the position to
4:0008
Byte 47 (L
(Lo)
o) move to on the next Servo Run Command
M: 4:1825
Right Motor Servo Valid values are from -32767 to +32767
E: O
O.Data
.Data [25]
Command Pulses
P: Byte 50 (Hi)
4:0013
Byte 51 (L
(Lo)
o)
! For the ConveyLinx-Ai2 module, Servo Motor Control requires firmware 4.14 or
later
* The Servo Motor Control function utilizes the existing motor speed, acceleration,
and deceleration registers. The existing starting, stopping, and direction control
registers are not used and these functions are incorporated into the Servo
Control registers
Page 269 of 329

10.4.5.7.1. Servo Contr

Control
ol Example
For our example, we want to perform the following cycle using PLC control of the Left MDR on
an ConveyLinx Module:
• Establish a zero or home position by external input to the module form a PLC (sensor or
operator button)
• Rotate in the CCW direction for 7000 mm at a speed of 0.8 m/s with acceleration ramp of
100 mm and a deceleration ramp of 50 mm
• Rotate the CW direction for 9000 mm at a speed of 1.0 m/s with acceleration ramp of 50
mm and a deceleration ramp of 10 mm.
• Rotate CCW back to the zero or home position at a speed of 0.8 m/s with acceleration
ramp of 50 mm and a deceleration ramp of 10 mm.
• Wait for a cycle dwell time of 4 seconds and then repeat the rotation cycles
! Rotation from 0 to a positive value always causes rotation in CCW direction and
rotation from 0 to a negative value always causes rotation in CW direction. Servo
Motor Control ignores the CW/CCW direction setting in EasyRoll and/or any
configured or default direction that may exist in the ConveyLinx Module’s
configuration
Define PLC Tags
Tag Name Data T

Type
ype Assembly R
Register
egister (/bit)
ZERO Boolean Left Servo Command Word – bit 0
ZERO_ACK Boolean Left Motor Servo Status – bit 1
RUN Boolean Left Servo Command Word – bit 1
READY Boolean Left Motor Servo Status – bit 0
POSITION Integer Left Servo Command Pulses
SPEED Integer Left Motor Speed Reference
ACCEL Integer Left Motor Acceleration Ramp
DECEL Integer Left Motor Deceleration Ramp
Sequence of Operation
Step #1: Upon external signal from sensor or button, set ZERO bit to establish zero or “home”
position. When PLC sees that the ZERO_ACK bit is set, then the PLC resets the ZERO bit.
Page 270 of 329

Step #2: To make the first rotation, we need write the speed, ramp values, and distance to
rotate to the appropriate registers:
• Write 800 to SPEED

• Write 100 to ACCEL
• Write 50 to DECEL
• Write 7000 to POSITION
Step #3: If READY is reset, then the PLC can set the RUN bit to begin the rotation. When the
rotation is complete, the module sets the READY bit. This will be the signal to the PLC to reset
the RUN bit. Once the module sees that the RUN bit has been reset, it will reset the READY bit.
Step #4: For the second rotation, we need to write the speed and ramp values to the
appropriate registers:

• Write 50 to ACCEL
• Write 10 to DECEL
Because we want to rotate in the opposite direction, we need to determine the new location
based upon the zero or “home” position. In this case, we know we went 7000 mm “forward”
and we want to move 9000 mm “backward”. The position we want to end up is 7000-9000 =
-2000.
• Write -2000 to POSITION
Step #5: Repeat Step #4
Step #6: For the 3rd rotation, we keep the ramp values from the 2nd rotation, but we need to
set the speed and the position to rotate. In this case we want to go to the zero or “home
position.

• Write 0 to POSITION
Step #7: Repeat Step #4
PLC Ladder Diagram
Page 271 of 329

Page 272 of 329

Page 273 of 329

Page 274 of 329

10.4.6. Reduced Size PLC I/O Mode

Assemblies
For some PLC controllers, the data size footprint required for a given assembly can be a limiting
factor on how many devices can connect to a given controller. ConveyLinx includes input/
output assemblies with fewer registers that contain basic functions in applications where the
full functionality of the PLC I/O Mode Assemblies is not required. The Reduced Size Assemblies
provide basic I/O and motor control while removing the interfaces for servo moves, upstream/
downstream data, tracking data, etc.
PLC I/O Mode Inputs to PLC

Module
Addr
ddress
ess
Addr
ddress
ess Addr
ddress
ess Addr
ddress
ess
Byte 0 (Hi)
4:0035 Sensor & Control Port Inputs 4:2700 I.Data [0]
Byte 1 (L
(Lo)
o)
Byte 2 (Hi)
4:0036 Sensor Detect 4:2701 I.Data [1]
Byte 3 (L
(Lo)
o)
Byte 4 (Hi)
4:0057 Left Motor Temperature 4:2702 I.Data [2]
Byte 5 (L
(Lo)
o)
Byte 6 (Hi)
4:0058 Left Motor Status 4:2703 I.Data [3]
Byte 7 (L
(Lo)
o)
Byte 8 (Hi)
4:0081 Right Motor Temperature 4:2704 I.Data [4]
Byte 9 (L
(Lo)
o)
Byte 10 (Hi)
4:0082 Right Motor Status 4:2705 I.Data [5]
Byte 11 (L
(Lo)
o)
Byte 12 (Hi)
4:0060 Left Motor Port Digital I/O Status 4:2706 I.Data [6]
Byte 13 (L
(Lo)
o)
Byte 14 (Hi)
4:0084 Right Motor Port Digital I/O Status 4:2707 I.Data [7]
Byte 15 (L
(Lo)
o)
Byte 16 (Hi)
Reserved 4:2708 I.Data [8]
Byte 17 (L
(Lo)
o)
PLC I/O Mode Outputs fr

from
om PLC
Module
Addr
ddress
ess
Addr
ddress
ess Addr
ddress
ess Addr
ddress
ess
Page 275 of 329

Byte 0 (Hi)
4:0060 Set Left Motor Port Digital Control 4:2800 O.Data [0]
Byte 1 (L
(Lo)
o)
Byte 2 (Hi)
4:0084 Set Right Motor Port Digital Control 4:2801 O.Data [1]
Byte 3 (L
(Lo)
o)
Byte 4 (Hi)
4:0037 Control Port Digital Output Control 4:2802 O.Data [2]
Byte 5 (L
(Lo)
o)
Byte 6 (Hi)
4:0260 Left Motor Run / Reverse 4:2803 O.Data [3]
Byte 7 (L
(Lo)
o)
Byte 8 (Hi)
4:0270 Right Motor Run / Reverse 4:2804 O.Data [4]
Byte 9 (L
(Lo)
o)
Byte 10 (Hi)
4:0040 Left Motor Speed Reference 4:2805 O.Data [5]
Byte 11 (L
(Lo)
o)
Byte 12 (Hi)
4:0064 Right Motor Speed Reference 4:2806 O.Data [6]
Byte 13 (L
(Lo)
o)
Byte 14 (Hi)
4:0022 Clear Motor Error 4:2807 O.Data [7]
Byte 15 (L
(Lo)
o)
Byte 16 (Hi)
Reserved 4:2808 O.Data [8]
Byte 17 (L
(Lo)
o)
Page 276 of 329

10.5. ConveyL
ConveyLogix
ogix Interface
ConveyLinx Modules in PLC I/O mode allow for download of a user program generated with the
ConveyLogix programming tool. There may be instances when you would like for an external
PLC to be able to interface with an ConveyLinx Module that is running a ConveyLogix program.
* With ConveyLogix, because a custom user generated program is running in the

ConveyLinx Module, the previously defined existing Assemblies for ZPA and PLO
I/O modes are no longer valid and if used, could produce unexpected results
When using ConveyLogix programming software version 2.2 and later, the environment
provides predefined controlled input and output register tags that can be used by the
programmer to interface with an external PLC. The Assemblies described in this section are
those that the external PLC would connect and use to access the data in the ConveyLogix
program.
This data is divided into 16 Integer Input words and 16 Integer output words. It is left to the
ConveyLogix programmer and the PLC programmer to utilize as much or as little of these data
blocks as needed for their particular application.
Page 277 of 329

10.5.1. ConveyL
ConveyLogix
ogix Assembly Inputs to
PLC
ConveyL
ConveyLogix
ogix Modbus PLC
Ether
Ethernet
net I/P T
Tag
ag Profinet I/O Byte Offset
Contr
Controller
oller T
Tag
ag Holding R
Register
egister
ToPLCAr
oPLCArray
ray [0] E: I.Data [0] M: 4:13100 P: Byte 0 (Hi) Byte 1 (L
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
ToPLCAr
oPLCArray
(Lo)
o)
Page 278 of 329

10.5.2. ConveyL
ConveyLogix
ogix Assembly Outputs
fr
from
om PLC
ConveyL
ConveyLogix
ogix Modbus PLC
Ether
Ethernet
net I/P T
Tag
ag Profinet I/O Byte Offset
Contr
Controller
oller T
Tag
ag Holding R
Register
egister
FromPLCAr
omPLCArray
ray [0] E: O
O.Data
.Data [0] M: 4:13200 P: Byte 0 (Hi) Byte 1 (L
(Lo)
o)
FromPLCAr
omPLCArray
ray [1] E: O
O.Data
(Lo)
o)
FromPLCAr
omPLCArray
ray [2] E: O
O.Data
(Lo)
o)
FromPLCAr
omPLCArray
ray [3] E: O
O.Data
(Lo)
o)
FromPLCAr
omPLCArray
ray [4] E: O
O.Data
(Lo)
o)
FromPLCAr
omPLCArray
ray [5] E: O
O.Data
(Lo)
o)
FromPLCAr
omPLCArray
ray [6] E: O
O.Data
(Lo)
o)
FromPLCAr
omPLCArray
ray [7] E: O
O.Data
(Lo)
o)
FromPLCAr
omPLCArray
ray [8] E: O
O.Data
(Lo)
o)
FromPLCAr
omPLCArray
ray [9] E: O
O.Data
(Lo)
o)
FromPLCAr
omPLCArray
ray
E: O
O.Data
(Lo)
o)
[10]
FromPLCAr
omPLCArray
ray
E: O
O.Data
(Lo)
o)
[11]
FromPLCAr
omPLCArray
ray
E: O
O.Data
(Lo)
o)
[12]
FromPLCAr
omPLCArray
ray
E: O
O.Data
(Lo)
o)
[13]
FromPLCAr
omPLCArray
ray
E: O
O.Data
(Lo)
o)
[14]
FromPLCAr
omPLCArray
ray
E: O
O.Data
(Lo)
o)
[15]
Page 279 of 329

10.6. Assemblies with R

Reset
eset P
Prrotection
For control system applications where the Ethernet I/P PLC needs to take specific action to
recover from a loss of communications due to a module that has had its power cycled off and
on; there is an additional set of instances implemented that provides 2 new registers that
allows the PLC to manipulate the function of the module for recovery.
When a ConveyLinx Module in ZPA Mode has lost power and then is powered back up, due to
perhaps a system E-stop that disconnects control power, some of the module’s working register
values are reset to 0. Among these are the arrival counters, departure counters, and the
accumulate commands for each configured zone(s) on the module. Upon power cycle to the
ConveyLinx Module, if the PLC can establish its full Ethernet I/P connection prior to the ZPA task
becoming fully functional, the preceding PLC programming examples would still function as
expected. However, because PLC Ethernet I/P connection time is variable and not fixed; a
robust control system design cannot count on the PLC establishing Ethernet I/P connection prior
to the ConveyLinx Module’s ZPA task commanding the module as if no PLC was connected. A
consequence of this in the previous programming example is that if a load happens to be
accumulated in a PLC controlled zone at the time of power loss, upon powering back up, the
load can release without the PLC commanding it to do so. This release could be caused by the
PLC logic detecting a change in arrival count and thus incrementing the release or it could be
caused by the fact that the accumulate command is cleared in the ConveyLinx Module due to
power cycle and because the PLC has not established communications to set the accumulate
command bit, the module releases the zone because there is no command present to
accumulate.
For ConveyLinx Module’s in PLC I/O mode, Reset P

Prrotection may not be as much a concern,
however reset protection assemblies are available for PLC I/O mode. Some items such as
current servo position, etc. are reset upon restoration of power and thus the PLC programmer
may want to detect this condition and act accordingly.
* Reset P
Prrotection assemblies are used for applications where the ConveyLinx
Module remains in a “hold” state until the PLC has established communications.
Otherwise, the register mappings for these assemblies are the same as their
non-protected counterparts.
! Please note that the Modbus TCP starting addresses for each assembly with reset
protection is different from their non-protected counterparts.
Page 280 of 329

10.6.1. ZP
ZPAA Mode Assembly Inputs with
Reset P
Prrotection
Modbus PLC
Module
Register Name Ether
Ethernet
net I/P T
Tag
ag Holding
Addr
ddress
ess
Register
4:0116 Local Status Upstream Zone E: I.Data [0] M: 4:3500
4:0196 Local Status Downstream Zone E: I.Data [1] M: 4:3501
4:0106 Arrival Count Local Upstream Zone E: I.Data [2] M: 4:3502
4:0107 Departure Count Local Upstream Zone E: I.Data [3] M: 4:3503
4:0186 Arrival Count Local Downstream Zone E: I.Data [4] M: 4:3504
4:0187 Departure Count Local Downstream Zone E: I.Data [5] M: 4:3505
4:0088 Module Status Word 1 E: I.Data [6] M: 4:3506
4:0119 Current Upstream Zone Tracking Word 1 E: I.Data [8] M: 4:3508
4:0120 Current Upstream Zone Tracking Word 2 E: I.Data [9] M: 4:3509
4:0199 Current Downstream Zone Tracking Word 1 E: I.Data [10] M: 4:3510
4:0200 Current Downstream Zone Tracking Word 2 E: I.Data [11] M: 4:3511
4:0105 Current Release Count for Upstream Zone E: I.Data [12] M: 4:3512
4:0185 Current Release Count for Downstream Zone E: I.Data [13] M: 4:3513
4:0201 Get Tracking Forward Direction Word 1 E: I.Data [14] M: 4:3514
4:0202 Get Tracking Forward Direction Word 2 E: I.Data [15] M: 4:3515
4:0237 Get Tracking Reverse Direction Word 1 E: I.Data [16] M: 4:3516
4:0238 Get Tracking Reverse Direction Word 2 E: I.Data [17] M: 4:3517
4:0035 Sensor & Control Port Inputs E: I.Data [18] M: 4:3518
N/A Cur
Currrent Module R
Reset
eset Count E: I.Data [19] M: 4:3519
4:0019 ConveyStop Status E: I.Data [20] M: 4:3520
Page 281 of 329

10.6.2. ZP
ZPAA Mode Assembly Outputs with
Reset P
Prrotection
Modbus PLC
Module Ether
Ethernet
net I/P
Register Name Holding
Addr
ddress
ess Tag
Register
4:0132 Set Local Upstream Zone Tracking Word 1 E: I.Data [0] M: 4:3600
4:0133 Set Local Upstream Zone Tracking Word 2 E: I.Data [1] M: 4:3601
4:0212 Set Local Downstream Zone Tracking Word 1 E: I.Data [2] M: 4:3602
4:0213 Set Local Downstream Zone Tracking Word 2 E: I.Data [3] M: 4:3603
4:0104 Accumulation Control for Local Upstream Zone E: I.Data [4] M: 4:3604
4:0184 Accumulation Control for Local Downstream Zone E: I.Data [5] M: 4:3605
4:0040 Set Left MDR Speed E: I.Data [6] M: 4:3606
4:0064 Set Right MDR Speed E: I.Data [7] M: 4:3607
Release and Accumulate on Next Arrival for Local

4:0105 E: I.Data [8] M: 4:3608
Upstream Zone

4:0185 E: I.Data [9] M: 4:3609
Upstream Zone
E: I.Data
4:0134 Set Status for Upstream Induct M: 4:3610
[10]
E: I.Data
4:0232 Set Status for Downstream Discharge M: 4:3611
[11]
E: I.Data
4:0139 Set Induct Tracking Forward Direction Word 1 M: 4:3612
[12]
E: I.Data
4:0140 Set Induct Tracking Forward Direction Word 2 M: 4:3613
[13]
E: I.Data
4:0237 Set Induct Tracking Reverse Direction Word 1 M: 4:3614
[14]
E: I.Data
4:0238 Set Induct Tracking Reverse Direction Word 2 M: 4:3615
[15]
E: I.Data
4:0022 Clear Motor Error M: 4:3616
[16]
E: I.Data
4:0063 Set Control Port Outputs M: 4:3617
[17]
E: I.Data
N/A Set Module R
Reset
eset Count M: 4:3618
[18]
4:0020 ConveyStop Command E: I.Data M: 4:3619
Page 282 of 329

[19]
E: I.Data
4:0109 Clear Sensor Jam Command for Local Upstream Zone M: 4:3620
[20]
E: I.Data
4:0189 Clear Sensor Jam Command for Local Downstream Zone M: 4:3621
[21]
Direction & Accumulation Mode Control for Local E: I.Data

4:0365 M: 4:3622
Upstream Zone [22]
Direction & Accumulation Mode Control for Local E: I.Data

4:0375 M: 4:3623
Downstream Zone [23]
E: I.Data
4:0387 ConveyMerge Interface M: 4:3624
[24]
Page 283 of 329

10.6.3. Reduced Size ZPZPA

A Mode Assemblies
with R
Reset
eset P
Prrotection
Inputs to PLC
Modbus PLC
Module Ether
Ethernet
net I/P
Addr
ddress
ess Tag
Register
4:0116 Local Status Upstream Zone E: I.Data [0] M: 4:4900
4:0196 Local Status Downstream Zone E: I.Data [1] M: 4:4901
4:0106 Arrival Count Local Upstream Zone E: I.Data [2] M: 4:4902
4:0107 Departure Count Local Upstream Zone E: I.Data [3] M: 4:4903
4:0186 Arrival Count Local Downstream Zone E: I.Data [4] M: 4:4904
4:0187 Departure Count Local Downstream Zone E: I.Data [5] M: 4:4905
4:0105 Current Release Count for Upstream Zone E: I.Data [8] M: 4:4908
4:0185 Current Release Count for Downstream Zone E: I.Data [9] M: 4:4909
N/A Cur
Currrent Module R
Reset
Outputs fr
from
om PLC
Modbus PLC
Module Ether
Ethernet
net I/P
Addr
ddress
ess Tag
Register
4:0104 Accumulation Control for Local Upstream Zone E: O.Data [0] M: 4:5000
4:0184 Accumulation Control for Local Downstream Zone E: O.Data [0] M: 4:5001
4:0040 Set Left MDR Speed E: O.Data [2] M: 4:5002
4:0064 Set Right MDR Speed E: O.Data [3] M: 4:5003

4:0105 E: O.Data [4] M: 4:5004
Upstream Zone

4:0185 E: O.Data [5] M: 4:5005
Upstream Zone
4:0134 Set Status for Upstream Induct E: O.Data [6] M: 4:5006
Page 284 of 329

4:0232 Set Status for Downstream Discharge E: O.Data [7] M: 4:5007
4:0022 Clear Motor Error E: O.Data [8] M: 4:5008
4:0063 Set Control Port Outputs E: O.Data [9] M: 4:5009
N/A Set Module R

Reset
eset Count E: O
O.Data
.Data [10] M: 4:5010
4:0109 Clear Sensor Jam Command for Local Upstream Zone E: O.Data [11] M: 4:5011
Clear Sensor Jam Command for Local Downstream

4:0189 E: O.Data [12] M: 4:5012
Zone
Direction & Accumulation Mode Control for Local

4:0365 E: O.Data [13] M: 4:5013
Upstream Zone
Direction & Accumulation Mode Control for Local

4:0375 E: O.Data [14] M: 4:5014
Downstream Zone
Page 285 of 329

10.6.4. PLC I/O Mode Assembly Inputs with

Reset P
Prrotection
Modbus PLC
Module
Register Name Ether
Ethernet
net I/P T
Tag
ag Holding
Addr
ddress
ess
Register
4:0019 ConveyStop Status E: I.Data [0] M: 4:3700
4:0036 Sensor Detect E: I.Data [2] M: 4:3702
4:0024 Module Voltage E: I.Data [3] M: 4:3703
4:0055 Left Motor Current E: I.Data [4] M: 4:3704
4:0056 Left Motor Frequency E: I.Data [5] M: 4:3705
4:0057 Left Motor Temperature E: I.Data [6] M: 4:3706
4:0058 Left Motor Status E: I.Data [7] M: 4:3707
4:0079 Right Motor Current E: I.Data [8] M: 4:3708
4:0080 Right Motor Frequency E: I.Data [9] M: 4:3709
4:0081 Right Motor Temperature E: I.Data [10] M: 4:3710
4:0082 Right Motor Status E: I.Data [11] M: 4:3711
4:0060 Left Motor Port Digital I/O Status E: I.Data [12] M: 4:3712
4:0084 Right Motor Port Digital I/O Status E: I.Data [13] M: 4:3713
4:0134 Upstream Module Status E: I.Data [14] M: 4:3714
4:0232 Downstream Module Status E: I.Data [15] M: 4:3715
Current Tracking Word 1 for Adjacent

4:0139 E: I.Data [16] M: 4:3716
Upstream Module
Current Tracking Word 2 for Adjacent

4:0140 E: I.Data [17] M: 4:3717
Upstream Module
N/A Cur
Currrent Module R
Reset
eset Counter E: I.Data [18] M: 4:3718
4:0062 Left Motor Servo Position E: I.Data [19] M: 4:3719
4:0086 Right Motor Servo Position E: I.Data [20] M: 4:3720
4:0011 Left Motor Servo Status E: I.Data [21] M: 4:3721
4:0016 Right Motor Servo Status E: I.Data [22] M: 4:3722
Page 286 of 329

10.6.5. PLC I/O Mode Assembly Outputs

with R
Reset
eset P
Prrotection
Modbus PLC
Module
Register Name Ether
Ethernet
net I/P T
Tag
ag Holding
Addr
ddress
ess
Register
4:0020 ConveyStop Command E: O.Data [0] M: 4:3800
4:0060 Set Left Motor Port Digital Control E: O.Data [1] M: 4:3801
4:0084 Set Right Motor Port Digital Control E: O.Data [2] M: 4:3802
4:0037 Control Port Digital Output Control E: O.Data [3] M: 4:3803
4:0260 Left Motor Run / Reverse E: O.Data [4] M: 4:3804
4:0261 Left Motor Brake Method E: O.Data [5] M: 4:3805
4:0262 Left Motor Speed Control Method E: O.Data [6] M: 4:3806
4:0270 Right Motor Run / Reverse E: O.Data [7] M: 4:3807
4:0271 Right Motor Brake Method E: O.Data [8] M: 4:3808
4:0272 Right Motor Speed Control Method E: O.Data [9] M: 4:3809
4:0040 Left Motor Speed Reference E: O.Data [10] M: 4:3810
4:0064 Right Motor Speed Reference E: O.Data [11] M: 4:3811
4:0043 Left Motor Acceleration Ramp E: O.Data [12] M: 4:3812
4:0044 Left Motor Deceleration Ramp E: O.Data [13] M: 4:3813
4:0067 Right Motor Acceleration Ramp E: O.Data [14] M: 4:3814
4:0068 Right Motor Deceleration Ramp E: O.Data [15] M: 4:3815
4:0196 Set Status to Downstream Module E: O.Data [17] M: 4:3817
4:0116 Set Status to Upstream Module E: O.Data [18] M: 4:3818
4:0034 Sensor Port Input Signal Condition Mask E: O.Data [19] M: 4:3819
4:0201 Set Discharge Tracking Word 1 E: O.Data [20] M: 4:3820
4:0202 Set Discharge Tracking Word 2 E: O.Data [21] M: 4:3821
N/A Set Module R

Reset
eset Count E: O
O.Data
.Data [22] M: 4:3822
4:0008 Left Motor Servo Command Pulses E: O.Data [23] M: 4:3823
4:0009 Left Motor Servo Command Word E: O.Data [24] M: 4:3824
4:0013 Right Motor Servo Command Pulses E: O.Data [25] M: 4:3825
Page 287 of 329

4:0014 Right Motor Servo Command Word E: O.Data [26] M: 4:3826
Page 288 of 329

10.6.6. Reduced Size PLC I/O Mode

Assemblies with R
Reset
eset P
Prrotection
Inputs to PLC
Modbus PLC
Module Ether
Ethernet
net I/P
Addr
ddress
ess Tag
Register
4:0036 Sensor Detect E: I.Data [1] M: 4:4701
4:0057 Left Motor Temperature E: I.Data [2] M: 4:4702
4:0058 Left Motor Status E: I.Data [3] M: 4:4703
4:0081 Right Motor Temperature E: I.Data [4] M: 4:4704
4:0082 Right Motor Status E: I.Data [5] M: 4:4705
4:0060 Left Motor Port Digital I/O Status E: I.Data [6] M: 4:4706
4:0084 Right Motor Port Digital I/O Status E: I.Data [7] M: 4:4707
N/A Cur
Currrent Module R
Reset
Outputs fr
from
om PLC
Modbus PLC
Module Ether
Ethernet
net I/P
Addr
ddress
ess Tag
Register
4:0060 Set Left Motor Port Digital Control E: O.Data [0] M: 4:4800
4:0084 Set Right Motor Port Digital Control E: O.Data [1] M: 4:4801
4:0037 Control Port Digital Output Control E: O.Data [2] M: 4:4802
4:0260 Left Motor Run / Reverse E: O.Data [3] M: 4:4803
4:0270 Right Motor Run / Reverse E: O.Data [4] M: 4:4804
4:0040 Left Motor Speed Reference E: O.Data [5] M: 4:4805
4:0064 Right Motor Speed Reference E: O.Data [6] M: 4:4806
N/A Set Module R

Reset
eset Count E: O
O.Data
.Data [8] M: 4:4808
Page 289 of 329

10.6.7. How to use Assemblies with R

Reset
eset
Protection
When the PLC determines that it has a valid connection to the ConveyLinx Module in question
and is ready for it to respond to output data being written by the PLC:
• Your PLC program needs to move the value in the Cur

Currrent Module R
Reset
eset Counter register
into the Set Module R
Reset
• When the ConveyLinx Module detects that the value in Set Module R
Reset
is equal to the value in the Cur
Currrent Module R
Reset
eset Counter register; the module will
respond to data being written by the PLC to the remaining output assembly registers.
* Please note that when the value in Cur

equal to the value in the Set Module R
Currrent Module R
Reset
Reset
eset Counter register is not
eset Counter register; the values in the
Input registers will updated by the ConveyLinx Module and will be valid in your
PLC program. In this state, even though the PLC may be writing data to Output
registers, the module will ignor
ignoree it
* To make sure a given ZPA zone accumulates upon power up, use EasyRoll
configuration tool software to set the zone to “Accumulate”. When set from
EasyRoll, this setting will be retained in the flash memory of the module so that
the zone will initially accumulate if a load happens to be in the zone at the time
of power up. Learn about Accumulate control from EasyRoll
* When a ZPA zone is commanded to accumulate with a PLC and you happen to
connect to that module with EasyRoll; the “Accumulate” switch icon on the main
screen will visibly indicate that the zone is accumulated. This visible icon will
look the same as if it was clicked ON from EasyRoll.
Keep in mind that a PLC command to accumulate IS NOT retained upon power
loss to the module
module. Only if the “Accumulate” switch is toggled “ON” with EasyRoll
is the accumulate condition for the zone retained in flash memory for use upon
power-up
Page 290 of 329

10.7. Motor P
Port
ort as Digital I/O
! Motor port as digital I/O is only applicable for a ConveyLinx Module in PLC I/O
Mode
Each motor port can provide 1 or 2 independently controlled digital outputs and each of these
outputs can be energized simultaneously for a total of 4 outputs available per ConveyLinx-Ai
module. Each individual output has a 0.75A load capacity.
External controller must first set bit 15 = 1 in the Set L

Lef
eft/Right
t/Right Motor P
Port
ort Digital Contr
Control
ol
register for the motor port (Left or Right) that is to be used as digital output. If bit 15 = 0, then
the ConveyLinx Module ignores the bit 0 thru bit 2 commands and will not provide meaningful
status on bits 12 and 14 in the corresponding Lef
eft/Right
t/Right Motor P
Port
ort Digital I/O Status register
for the port in question
! Please note that for both the Left and Right Motor Ports, the each digital output
switches to GND to complete the circuit
See W
Wiring
iring Diagrams for Motor P
Port
ort Digital Outputs
! Short Cir
Circuit
cuit Er
Errror on bit 12 in the Lef
eft/Right
t/Right Motor P
Port
ort Digital I/O Status register
is classified as a “fatal” error that will require interaction. You can (1) cycle of
power on the ConveyLinx Module, (2) Send Reset command from EasyRoll, or (3)
Send a Motor Fault Reset command from the PLC
Page 291 of 329

11. Setting Up Dual Motor Zones

This section describes how to set up conveyor zones with two motor rollers in scenarios
involving ZPA Mode, PLC I/O Mode, and ConveyLogix program control. The details of the set up
are also governed by the mechanical construction of the conveyor zone.
Solution Matrix for ConveyLinx-Ai F

Family
amily Modules
Zone T
Type
ype Operational Mode Solution
ZPA Automatic – No Adjustments required
Requires program code to set up proper PLC Output

PLC I/O
2 MDRs – Coupled Assembly values
Requires program code to set up proper internal register

ConveyLogix
values
ZPA Will Not W

Work
ork P
Prroperly
No special adjustments required – Use program code to

2 MDRs – Non- PLC I/O
run independently or together as desired
Coupled
No special adjustments required – Use program code to
ConveyLogix
run independently or together as desired
ZPA Not P
Possible
ossible
Requires program code to set up proper PLC Output

2 Motors in 1 PLC I/O
Assembly values
MDR Tube
Requires program code to set up proper internal register
ConveyLogix
values
Page 292 of 329

11.1. Two Ai MDRs Mechanically Coupled

This scenario is perhaps the most common in that this would be the case for a two-motor roller
used in an incline or decline application as shown. Please note that mechanically the two motor
rollers can be coupled with just O-bands and with a full width belt. The concept is that the
upstream motor roller is there to assist the downstream motor roller.
Page 293 of 329

11.1.1. ZP
ZPA
A Mode
In general, when you perform an Auto
Auto-Configur
-Configure
e procedure, ConveyLinx-Ai2 modules will
configure in ZPA mode. If one sensor is connected (either Left or Right) and two motors are
connected, the module is automatically configured as a single logical zone and will run both
motors at the same time. The side (Left or Right) that the sensor is connected will
automatically configure that side’s motor as the master and the other motor is the slave. The
master motor’s PI regulation and PWM output is applied to the “slave” motor.
* Please note that any settings for the slave motor that may have been in place in
EasyRoll are ignored and only the master motor settings are recognized for both
motors
Page 294 of 329

11.1.2. PLC I/O Mode

In PLC I/O mode there is no ZP
ZPA
A logic operating in the module, so the motors are independently
controlled by default when the module is placed in PLC I/O mode. With a remote PLC you can
connect to the PLC I/O Assemblies and configure either the Left or the Right motor to be the
master and command only the master and the slave motor will operate along with the master.
In the PLC I/O Output Assembly, there is a Lef

eftt Motor Slave Mode (4:0262) register and a Right
Motor Slave Mode (4:0272) register. Depending on which single motor (L
Lef
eftt or Right
Right) you want
to command, you select the opposite motor’s cor
corrresponding Slave Mode rregister
egister to instruct the
opposite motor to follow the master motor’s commands. Also, when you do this, the Slave
Motor takes on the Master Motor’s speed and settings.
PLC I/O Mode Example

In this example, let’s say you want to use the Lef
eftt Motor as the Master and the Right Motor as
the Slave. In this case you populate the Right Motor Slave Mode register with a value of 2 to
tell the Right Motor to use the settings of the Lef
eftt Motor and operate when the Lef
eftt Motor is
instructed to operate by the PLC program logic.
Page 295 of 329

11.1.3. ConveyL
ConveyLogix
ogix P
Prrogram
Similar to PLC I/O Mode example, you populate either the Lef
eftt Motor Slave Mode (4:0262)
register or the Right Motor Slave Mode (4:0272) register according to the desired control. It is
recommended you use the FirstLadderEx
irstLadderExec
ec controller tag Boolean in a rung that executes a
WR
WRC
C block that writes the desired data to Register 262 or 272. By using the FirstLadderEx
irstLadderExec
ec
N.O. contact in this rung makes sure the data is written upon any power up or re-boot of the
ConveyLinx-Ai2 module and that it is not continuously writing the data every program scan and
using up unnecessary module resources.
Page 296 of 329

11.2. Two Ai Motors in One R

Roller
oller T
Tube
ube
(Dual Drive)
Some Pulseroller-Ai models are available with two motors in one tube as shown.
ZP
ZPA
A Mode
This mechanical configuration is not supported with ConveyLinx-Ai Family controls.
! Attempting to use a Dual Drive MDR in ZPA Mode with a ConveyLinx-Ai Family
controller could result in damage to the roller assembly
Page 297 of 329

PLC I/O Mode

During the Auto
Auto-Configur
-Configure
e
Procedur
ocedure e, all zones
become ZPZPA A mode and
motors will run. The
ConveyLinx Module does
not know the opposite
motor is in the same tube
and will try to rotate the
motors in the same
direction and they will be
in a mechanical bind.
Unplugging the opposite
motor will keep this from
happening. Once the Auto-
Configuration is complete,
place the module in PLC I/
O mode and you can
reconnect the motor to the
module.
Example
In this example, the Right
Motor is the Master and
the Left Motor is the Slave.
After ytou have performed
Auto-Configuration and
then placed the module in
PLC I/O Mode and
reconnected the motor,
you write a value of 3 set
up the Lef
eftt Motor Slave
Mode (4:0262) register.
This value tells the Left
Motor to be in Slave Mode
to the Right Motor and
always run in the opposite
direction of the Right
Motor.
ConveyL
ConveyLogix
ogix P
Prrogram
Follow the same procedure as in this PLC I/O Mode example as far as unplugging the Slave
motor prior to Auto-Configuration. The follow the procedure described for the Two Ai MDR
MDRss
Mechanically Coupled – ConveyL
ConveyLogix
ogix P
Prrogram section.
Page 298 of 329

! Be sure to remember to write the proper value in the proper Motor Slave Mode
register so that the Slave Motor always runs in the opposite direction to the
Master Motor
Page 299 of 329

11.3. Two Motor R

Rollers
ollers in One L
Logical
ogical Zone
Not Coupled
In this mechanical scenario, the motor rollers are not coupled together as shown.
ZP
ZPA
A Mode
In ZP
ZPA
A Mode with this mechanical configuration, it will not work properly because the module
will never monitor and adjust the Slave Motor’s speed. Because they are un-coupled; both
motors will vary their speed based upon their respective loads while the module is only paying
attention to the load on the master.
! Even though this configuration is logically allowed, it is recommended that you

do not use ZPA mode for this mechanical configuration
PLC I/O Mode and ConveyL

ConveyLogix
ogix P
Prrogram
You can set the motors to the same settings in EasyR
EasyRoll
oll and logically run both motors at the
same time in your PLC logic program or ConveyLogix program. Even though you can attempt to
Page 300 of 329

use the Master/Slave functionality as previously described, you will have the same situation as
just described for ZPA mode where uncoupled motors will vary their speed.
! It is not recommended to use Master/Slave motor control for this mechanical

configuration
Page 301 of 329

12. Connecting to R
Rockwell
ockwell PLCs with
Ether
Ethernet
net I/P
This manual will provide instructions on how to connect your Rockwell Ethernet I/P capable PLC
to a network of ConveyLinx modules. There are three basic methods for connecting ConveyLinx
to Rockwell PLCs:
• Use Generic Ether

Ethernet
net Device
• Import EDS and optionally import and use AOI
OIss
• Use MSG Instruction
All three methods can be used for ConveyLinx modules in ZPA mode and in PLC I/O mode.
However, the MSG Instruction method does not maintain a constant connection to a
ConveyLinx module and should not be used for “time critical” operations.
Ether
Ethernet
net I/P Guidelines
Each Allen-Bradley PLC has 2 metrics for limiting maintained Ethernet I/P communications to
remote devices:
• Fixed quantity of TCP connections available on its Ethernet Port

• Fixed quantity of I/O data table memory available for connected devices
If the limit of either of these quantities is reached, the PLC processor will indicate I/O
communications fault on one or more instances of device declaration. For ConveyLinx device
declarations utilizing either ZPA or PLC I/O Mode instances, in general the PLC limitation on TCP
connections will be reached before I/O data table memory limit is realized.
For example, for a CompactLogix L3x series processor, the documented quantity of TCP
connections available on its Ethernet Port is 32. The processor always keeps one TCP
connection in reserve for programming terminal access, etc. An L3x series processor can
accept 31 full-time ConveyLinx Connections as generic I/O modules utilizing any combination of
ZPA mode and PLC I/O Mode instances.
When a ConveyLinx module is attached as a “full-time generic I/O module” to the PLC, the
connection is continually maintained and data is exchanged at a minimum RPI value (referred
to as an implicit connection ). If the PLC cannot communicate with the ConveyLinx module for
any reason, the PLC’s I/O tree will register a fault. It is possible for the PLC to communicate via
Ethernet I/P with any ConveyLinx module it can physically reach over its Ethernet port without
the module being “full-time connected as a generic I/O module”. This is accomplished with a
Logix5000 MSG instruction (referred to as explicit connection ).
Page 302 of 329

* Reserve Ethernet I/P TCP connections for ConveyLinx modules in PLC I/O Mode
and for key ZPA Mode modules where permanent accumulate/query/release
functionality is required
* Use MSG Instruction to gather less time-critical data for things such as status
and diagnostics
test to see if all manuals get this
Page 303 of 329

12.1. Selecting Y
Your
our Connection Method
based upon Assembly
As described in the PLC Developer’s Guide section, the data that you exchange with your PLC
and a given ConveyLinx Module depends on the mode of the module and how you want to use
it. The I/O data to be exchanged are arranged in register Assemblies and depending on the
assembly, will dictate whether you can connect using the EDS file method or the Generic
Ethernet Module method.
* All available assemblies can be connected utilizing the Generic Ethernet Module
method and only selected assemblies are available from the EDS file installation
Available as
Available
Generic
Assembly P
Pair
air fr
from
om EDS File
Ether
Ethernet
net
Installation
Module
ZPA Mode Assembly Inputs

✔ ✔
ZPA Mode Assembly Outputs
ZPA Mode Assembly Inputs with Reset Protection

✔ ✔
ZPA Mode Assembly Outputs with Reset Protection
Reduced Size ZPA Mode Assembly Inputs

✔
Reduced Size ZPA Mode Assembly Outputs
Reduced Size ZPA Mode Assembly Inputs with Reset Protection

✔
Reduced Size ZPA Mode Assembly Outputs with Reset Protection
PLC I/O Mode Assembly Inputs

✔ ✔
PLC I/O Mode Assembly Outputs
PLC I/O Mode Assembly Inputs with Reset Protection

✔ ✔
PLC I/O Mode Assembly Outputs with Reset Protection
Reduced Size PLC I/O Mode Assembly Inputs

✔
Reduced Size PLC I/O Mode Assembly Outputs
Reduced Size PLC I/O Mode Assembly Inputs with Reset Protection
✔
Reduced Size PLC I/O Mode Assembly Outputs with Reset Protection
ConveyLogix Assembly Inputs

✔ ✔
ConveyLogix Assembly Outputs
Page 304 of 329

12.2. Using Generic Ether

Ethernet
net Module
Method
When using the Generic Ether
Ethernet
net Module construct in RSLogix 5000, you must supply
configuration information about the device you are trying to connect. The following sections
show the step by step procedure to connect a ConveyLinx Module for each set of Input and
Output Assemblies described in the PLC Developers Guide section.
Assembly Recognized Instance V

Values
alues
ZPA Mode Assembly Inputs 105
ZPA Mode Assembly Outputs 106
ZPA Mode Assembly Inputs with Reset Protection 305
ZPA Mode Assembly Outputs with Reset Protection 306
Reduced Size ZPA Mode Assembly Inputs 119
Reduced Size ZPA Mode Assembly Outputs 120
Reduced Size ZPA Mode Assembly Inputs with Reset

319
Protection
Reduced Size ZPA Mode Assembly Outputs with Reset

320
Protection
PLC I/O Mode Assembly Inputs 107
PLC I/O Mode Assembly Outputs 108
PLC I/O Mode Assembly Inputs with Reset Protection 307
PLC I/O Mode Assembly Outputs with Reset Protection 308
Reduced Size PLC I/O Mode Assembly Inputs 117
Reduced Size PLC I/O Mode Assembly Outputs 118
Reduced Size PLC I/O Mode Assembly Inputs with Reset

317
Protection
Reduced Size PLC I/O Mode Assembly Outputs with Reset

318
Protection
ConveyLogix Assembly Inputs 121
ConveyLogix Assembly Outputs 122
Page 305 of 329

12.3. Procedur
oceduree for Connecting using
Generic Ether
Ethernet
net Module
All assembly pairs can be connected to a single ConveyLinx Module using the same procedure
within RSLogix 5000 environment:
1. Create a New Module in your Ethernet Tree

2. Select Generic Ethernet Module from the list of devices
3. Enter name and I.P. Address
4. Select the correct Comm Data type
5. Enter Input Assembly Instance Value and Size
6. Enter Output Assembly Instance Value and Size
7. Enter desired RPI value
For example if you need to attach to 5 ConveyLinx Modules that are in ZPA Mode, each module
will have to have a unique name and I.P. address (step 3) and steps 4, 5, 6, and 7 will use the
same values for each ConveyLinx Module.
Page 306 of 329

12.3.1. Parameters for Each Assembly
* Please note that for all Assemblies and all versions of firmware the Instance
value for the “Configuration” parameter is always “1” and its size is always “0”
Assembly Type Instance V

Value
alue Size V
Value
alue
Input 105 21
ZP
ZPA
A Mode Assembly
Output 106 25
Input 305 21
ZP
ZPA
A Mode Assembly with R
Reset
eset P
Prrotection
Output 306 25
Input 119 12
Reduced Size ZP
ZPA
A Mode Assembly
Output 120 15
Reduced Size ZP
ZPA
A Mode Assembly with R
Reset
eset Input 319 12
Protection Output 320 15
Input 107 23
PLC I/O Mode Assembly
Output 108 27
Input 307 23
PLC I/O Mode Assembly with R
Reset
eset P
Prrotection
Output 308 27
Input 117 9
Reduced Size PLC I/O Mode Assembly
Output 118 9
Reduced Size PLC I/O Mode Assembly with Input 317 9

Reset P
Prrotection Output 318 9
Input 121 16
ConveyL
ConveyLogix
ogix Assembly
Output 122 16
Page 307 of 329

12.4. Procedur
oceduree for using EDS Method
Pulseroller.com website contains all EDS files for download including older versions. Please visit
the Downloads section of Pulseroller.com to get the latest EDS file for the ConveyLinx-Ai Family
of modules
! For best results, you should remove any previous ConveyLinx-Ai Family EDS
file(s) you may have installed in your RSLogix 5000 environment before installing
a new version
! Delete all unused module data types from your program especially if you are
modifying or starting with an existing program
Installing the EDS file provided by Pulseroller into your RSLogix 5000 environment will allow
you to select the ConveyLinx Module module from your list of known devices without having to
use the Generic Ethernet Module method. The EDS file contains the Instance and size
parameters so you do not have to fill in this information. When you connect to a ConveyLinx
Module, the data is arranged in assembled registers with the data appearing in your Controller
Tags similarly to how the data appears when you connect using the Generic Ether
Ethernet
net Module
method.
Page 308 of 329

12.5. Using A
Add
dd On Instructions (A
(AOI)
OI) with
RSL
RSLogix
ogix 5000
Pulseroller has authored and made available Add On Instructions ((A
AOI
OI)) in order to make your
programming easier to follow. In this document up until this section, when connecting to a
ConveyLinx Module regardless of mode; your PLC program needs to directly access the register
data array tags created when you created the ConveyLinx Module instance. The AOI
OIss attach to
the created ConveyLinx Module’s register data arrays and maps the data into user tags and
functions with meaningful names. There are two separate AOI
OIss for use depending on the mode
of the ConveyLinx Module you want to connect: a ZP
ZPA
A mode AOI and a PLC I/O mode AOI
* Please note that the use of AOI is pur

purely
ely optional
optional. However, you must install the
EDS file as previously described before you can use any AOI
Selecting the P
Prroper AOI Instruction
AOI files are imported to your specific PLC program file and not into the RSLogix 5000
environment like an EDS file. The following chart provides a cross-reference for selecting the
proper AOI file based upon the mode of operation
ConveyLinx Module
EDS File AOI File
Mode
ZP
ZPA
A Mode ConveyLinxAi_V5_1.eds Ai2_ZP
Ai2_ZPA_A
A_AOI_4_5.L5X
OI_4_5.L5X
PLC I/O Mode ConveyLinxAi_V5_1.eds Ai2_PLCIO_A

Ai2_PLCIO_AOI_4_5.L5X
OI_4_5.L5X
* Please refer to the downloads section of Pulseroller.com for the latest updates to
EDS and/or AOI files
Page 309 of 329

12.5.1. AOI T
Tag
ag Descriptions
The following links take you to the listings for each tag made available in the both the
ERSC-ZPA AOI and the PLC I/O AOI.
ZPA Mode Inputs

ZPA Mode Outputs
PLC I/O Inputs
PLC I/O Outputs
Page 310 of 329

12.5.1.1. ZP
ZPA
A Mode Inputs
Data Module
Tag Name Bit Description
Type Register
Accumulated Arrival Downstream –

AOI
I_Ar
I_Arrival_DnZone
rival_DnZone BOOL 4:0116 Only Active When Local
Logic
Accumulate Bit is Set
Accumulated Arrival Upstream –

AOI
I_Ar
I_Arrival_UpZone
rival_UpZone BOOL 4:0196 Only Active When Local
Logic
Accumulate Bit is Set
ConveyStop Activated Because Of

I_ConveyStopByL
I_ConveyStopByLostConnection
ostConnection BOOL 4:0019 6
Lost Connection

I_ConveyStopByPLCCmd BOOL 4:0019 10
PLC Command

I_ConveyStopByPLCDisconnect BOOL 4:0019 7
Lost PLC Connection
ConveyStop Activated By Another

I_ConveyStopByR
I_ConveyStopByRemoteModule
emoteModule BOOL 4:0019 5
Module in ConveyStop Group
4:0201
(MSW) AOI Get Forward Tracking Value at
I_Get_T
I_Get_Tracking_FWD
racking_FWD DINT
4:0202 Logic Induct to Local Upstream Zone
(LSW)
4:0121
(MSW) AOI Get Reverse Tracking Value at
I_Get_T
I_Get_Tracking_REV
racking_REV DINT
4:0122 Logic Induct to Local Downstream Zone
(LSW)
I_Heartbeat BOOL 4:0035 15 Module Heartbeat, 2s On / 2s Off
Sensor Jam Local Downstream

I_Jam_at_DnZone BOOL 4:0089 5
Zone
I_Jam_at_UpZone BOOL 4:0088 5 Sensor Jam Local Upstream Zone
AOI Local Outputs are Enabled (Reset

I_Module_Enabled BOOL -
Logic Protection Mode)
I_Module_F
I_Module_Fault_L
ault_Lef
eftt BOOL 4:0088 3 Left Motor Error Active
I_Module_F
I_Module_Fault_Right
ault_Right BOOL 4:0089 3 Right Motor Error Active
I_Module_Sts_L
I_Module_Sts_Lef
eftt INT 4:0088 - Left Module Status
I_Module_Sts_Right INT 4:0089 - Right Module Status
Left Sensor Port Pin 2 Energized ( if

I_Sensor_P
I_Sensor_Port_L
ort_Lef
eft_P
t_Pin2
in2 BOOL 4:0035 0
used as input )
I_Sensor_P
I_Sensor_Port_L
ort_Lef
eft_P
t_Pin4
in4 BOOL 4:0035 4 Left Sensor Port Pin 4 Energized
Page 311 of 329

Right Sensor Port Pin 2 Energized (

I_Sensor_P
I_Sensor_Port_Right_P
ort_Right_Pin2
in2 BOOL 4:0035 2
if used as input )
I_Sensor_P
ort_Right_Pin4
in4 BOOL 4:0035 6 Right Sensor Port Pin 4 Energized
4:0199
(MSW) AOI For Load Accumulated in
I_T
I_Tracking_DnZn
racking_DnZn DINT
4:0200 Logic Downstream Zone
(LSW)
4:0119
(MSW) AOI For Load Accumulated in Upstream
I_T
I_Tracking_UpZn
racking_UpZn DINT
4:0120 Logic Zone
(LSW)
Local Downstream Status Forward

I_Zone_Status_DnZn_FWD SINT 4:0196 Lo Byte
Direction
Local Downstream Status Reverse

I_Zone_Status_DnZn_REV SINT 4:0196 Hi Byte
Direction
Local Upstream Status Forward

I_Zone_Status_UpZn_FWD SINT 4:0116 Lo Byte
Direction
Local Upstream Status Reverse

I_Zone_Status_UpZn_REV SINT 4:0116 Hi Byte
Direction
Page 312 of 329

12.5.1.2. ZP
ZPA
A Mode Outputs
Data Module
Type Register
Accumulate Adlacent
O_A
O_Acc_A
cc_Adj_UpStr_to_DnZn
dj_UpStr_to_DnZn BOOL 4:0184 8 Upstream to Local Upstream
Zone
Accumulate Adlacent
O_A
O_Acc_A
cc_Adj_UpStr_to_UpZn
dj_UpStr_to_UpZn BOOL 4:0104 8 Upstream to Local
Downstream Zone
Set Local Downstream Zone

O_A
O_Acc_Ar
cc_Arr_DnZn
r_DnZn BOOL 4:0184 0
to Accumulate
Set Local Upstream Zone to

O_A
O_Acc_Ar
cc_Arr_UpZn
r_UpZn BOOL 4:0104 0
Accumulate
Clear Jam at local

O_Clear_Jam_DnZn BOOL 4:0189 0
Downstream Zone
Clear Jam at local Upstream

O_Clear_Jam_UpZn BOOL 4:0109 0
Zone
O_Clear_Motor_Er
O_Clear_Motor_Errror BOOL 4:0022 0 Clear Motor Error Left & Right
Confirm Downstream Arrival

O_ConfAr
O_ConfArrivalA
rivalAdjDownstr
djDownstreamT
eamToDnZn
oDnZn BOOL 4:0184 9 for Adjacent Downstream
Zone
Confirm Downstream Arrival

O_ConfAr
O_ConfArrivalA
rivalAdjDownstr
djDownstreamT
eamToUpZn
oUpZn BOOL 4:0104 9 for Adjacent Downstream
Zone
ConveyMerge: Disable Center

O_ConveyMer
O_ConveyMerge_Disable_Center
ge_Disable_Center BOOL 4:0387 4
Line from Releasing
ConveyMerge: Disable Left

O_ConveyMer
O_ConveyMerge_Disable_L
ge_Disable_Lef
eftt BOOL 4:0387 5
Line from Releasing
ConveyMerge: Disable Right

O_ConveyMer
O_ConveyMerge_Disable_Right
ge_Disable_Right BOOL 4:0387 6
Line from Releasing
Enable PLC to Control

O_ConveyMer
O_ConveyMerge_Enable_PLC_Cntrl
ge_Enable_PLC_Cntrl BOOL 4:0387 15 ConveyMerge Priorty &
Release
0 = First come first served, 1

= Center line has priority, 2
O_ConveyMer
O_ConveyMerge_P
ge_Priority
riority SINT 4:0387 -
= Left line has priority, 3 =
Right line has priority
Set Local ConveyStop

O_ConveyStop_Command INT 4:0020 -
Command
O_D
O_DA_Mode_Cmd_DnZn
A_Mode_Cmd_DnZn SINT 4:0375 Lo Direction & Accumulation
Page 313 of 329

Mode Command Byte for

Byte
Downstream Zone
Direction & Accumulation

Lo
O_D
O_DA_Mode_Cmd_UpZn
A_Mode_Cmd_UpZn SINT 4:0365 Mode Command Byte for
Byte
Upstream Zone
Hi Direction & Accumulation

O_D
O_DA_Mode_V
A_Mode_Value_DnZn
alue_DnZn SINT 4:0375
Byte Mode Number of Zones
Hi Direction & Accumulation

O_D
O_DA_Mode_V
A_Mode_Value_UpZn
alue_UpZn SINT 4:0365
Byte Mode Number of Zones
AOI Enable Output to Module

O_Enable_Module BOOL -
Logic (Reset Protection Mode)
Jog Forward for Local

O_Jog_FWD_DnZn BOOL 4:0184 10
Downstream Zone
Jog Forward for Local

O_Jog_FWD_UpZn BOOL 4:0104 10
Upstream Zone
Jog Reverse for Local

O_Jog_REV_DnZn BOOL 4:0184 11
Downstream Zone
Jog Reverse for Local

O_Jog_REV_UpZn BOOL 4:0104 11
Upstream Zone
Force Stop Local Downstream

O_Maintenance_Stop_DnZn BOOL 4:0184 13
Zone
Force Stop Local Upstream

O_Maintenance_Stop_UpZn BOOL 4:0104 13
Zone
AOI Release and Accumulate on

O_R
O_Release_DnZn
elease_DnZn BOOL 4:0185
Logic Next at Downstream Zone
AOI Release and Accumulate on

O_R
O_Release_UpZn
elease_UpZn BOOL 4:0105
Logic Next at Upstream Zone
Enable Sensor Port Pin 2 Left

O_Sensor_P
O_Sensor_Prt_P2_L
rt_P2_Lef
eft_Output_Enable
t_Output_Enable BOOL 4:0063 12
to be an Output
Energize Sensor Port Pin 2

O_Sensor_P
O_Sensor_Prt_P2_L
rt_P2_Lef
eft_Output_Ener
t_Output_Energize
gize BOOL 4:0063 8 Left, Output Enable must be
Energized
Enable Sensor Port Pin 2

O_Sensor_P
O_Sensor_Prt_P2_Right_Output_Enable
rt_P2_Right_Output_Enable BOOL 4:0063 13
Right to be an Output

O_Sensor_P
O_Sensor_Prt_P2_Right_Output_Ener
rt_P2_Right_Output_Energize
gize BOOL 4:0063 9 Right, Output Enable must be
Energized
Value in mm/sec for MDR or

O_Speed_Motor_L
O_Speed_Motor_Lef
eftt INT 4:0040 -
RPM x 10 for PGD

O_Speed_Motor_Right INT 4:0064 -
RPM x 10 for PGD
Page 314 of 329

AOI Set Downstream Discharge

O_Sts_DnZn_Dischar
O_Sts_DnZn_Discharge_FWD
ge_FWD SINT 4:0232
Logic Zone Forward Status Value
AOI Set Downstream Discharge

O_Sts_DnZn_Dischar
O_Sts_DnZn_Discharge_REV
ge_REV SINT 4:0232
Logic Zone Reverse Status Value
AOI Set Upstream Induct Zone

O_Sts_UpZn_Induct_FWD SINT 4:0134
Logic Forward Status Value
AOI Set Upstream Induct Zone

O_Sts_UpZn_Induct_REV SINT 4:0134
Logic Reverse Status Value
4:0212
(MSW) AOI Write 32 Bit Tracking Data for
O_T
O_Tracking_DnZn
racking_DnZn DINT
4:0213 Logic Local DnZn When Accum.
(LSW)
4:0139
(MSW) AOI Set Forward Induct Tracking
O_T
O_Tracking_Induct_FWD
racking_Induct_FWD DINT
4:0140 Logic Value
(LSW)
4:0237
(MSW) AOI Set Reverse Induct Tracking
O_T
O_Tracking_Induct_REV
racking_Induct_REV DINT
4:0238 Logic Value
(LSW)
4:0132
(MSW) AOI Write 32 Bit Tracking Data for
O_T
O_Tracking_UpZn
racking_UpZn DINT
4:0133 Logic Local UpZn When Accum.
(LSW)
WakeUp Local Downstream

O_W
O_Wak
akeUp_DnZn
eUp_DnZn BOOL 4:0184 12
Zone
O_W
O_Wak
akeUp_UpZn
eUp_UpZn BOOL 4:0104 12 WakeUp Local Upstream Zone
Page 315 of 329

12.5.1.3. PLC I/O Mode Inputs

Data Module
Type Register
Stop active due to lost

I_ConveyStopByL
I_ConveyStopByLostConnection
ostConnection BOOL 4:0019 6
communication connection
Stop active due to Stop Command

I_ConveyStopByPLCCmd BOOL 4:0019 10
from PLC
Stop active due to lost PLC

I_ConveyStopByPLCDisconnect BOOL 4:0019 7
connection
Stop active on other module in

I_ConveyStopByR
I_ConveyStopByRemoteModule
emoteModule BOOL 4:0019 5
Stop Group
I_Cur
I_Currrent_L
ent_Lef
eft_MDR
t_MDR REAL 4:0055 - Current Draw of Left MDR in Amps
I_Cur
I_Currrent_Right_MDR REAL 4:0079 - Current Draw of Right MDR in Amps
Left: More than 1A detected on one

I_Dig_Mtr_Over_Cur_L
I_Dig_Mtr_Over_Cur_Lef
eftt BOOL 4:0060 14
or more outputs
Right: More than 1A detected on

I_Dig_Mtr_Over_Cur_Right BOOL 4:0084 14
one or more outputs
Left: Short Circuit Error on one or

I_Dig_Mtr_Short_Cir_L
I_Dig_Mtr_Short_Cir_Lef
eftt BOOL 4:0060 12
more outputs
Right: Short Circuit Error on one or

I_Dig_Mtr_Short_Cir_Right BOOL 4:0084 12
more outputs
I_F
I_Frrequency_L
equency_Lef
eft_MDR
t_MDR INT 4:0056 - Frequency of Left MDR in Hz
I_F
I_Frrequency_Right_MDR INT 4:0080 - Frequency of Right MDR in Hz
I_Heartbeat BOOL 4:0035 15 Module Heartbeat, 2s On / 2s Off
AOI Local Outputs are Enabled (Reset

I_Module_Enabled BOOL -
Logic Protection Mode)
I_Motor_Sts_L
I_Motor_Sts_Lef
eftt INT 4:0058 - Left Module Status
I_Motor_Sts_Right INT 4:0082 - Right Module Status
I_Sensor_Detect_L
I_Sensor_Detect_Lef
eft_P
t_Port
ort BOOL 4:0036 1 Sensor Detected on Left Pin 4
I_Sensor_Detect_Right_P
I_Sensor_Detect_Right_Port
ort BOOL 4:0036 0 Sensor Detected on Right Pin 4
Left Sensor Port Pin 2 Energized ( if

I_Sensor_P
I_Sensor_Port_L
ort_Lef
eft_P
t_Pin2
in2 BOOL 4:0035 0
used as input )
I_Sensor_P
I_Sensor_Port_L
ort_Lef
eft_P
t_Pin4
in4 BOOL 4:0035 4 Left Sensor Port Pin 4 Energized
Right Sensor Port Pin 2 Energized (

I_Sensor_P
ort_Right_Pin2
in2 BOOL 4:0035 2
if used as input )
Page 316 of 329

I_Sensor_P
ort_Right_Pin4
in4 BOOL 4:0035 6 Right Sensor Port Pin 4 Energized
1 = Last Servo Run Command

I_Servo_CmdComplete_L
I_Servo_CmdComplete_Lef
eftt BOOL 4:0011 0
Complete
1 = Last Servo Run Command

I_Servo_CmdComplete_Right BOOL 4:0016 0
Complete
1 = Running to Pulse Command

I_Servo_CmdStatus_L
I_Servo_CmdStatus_Lef
eftt BOOL 4:0011 2
Position
1 = Running to Pulse Command

I_Servo_CmdStatus_Right BOOL 4:0016 2
Position
Signed Integer Value for Position

I_Servo_P
I_Servo_Position_L
osition_Lef
eftt INT 4:0062 -
from Position “0”
Signed Integer Value for Position

I_Servo_P
I_Servo_Position_Right
osition_Right INT 4:0086 -
Value in mm/sec for MDR or RPM x

10 for PGD Range: depends upon
the Ai MDR or PGD connected MDR
I_Speed_L
I_Speed_Lef
eftt INT 4:0507 - Example: 400 = 0.40 m/s PGD
Example : 400 = 40 RPM 0 =
Remain at last non zero value
entered
Left Motor Set Speed is Greater

I_Speed_L
I_Speed_Lef
eft_Max
t_Max BOOL 4:0507 14
Than Motor Maximum
Left Motor Set Speed is Less Than

I_Speed_L
I_Speed_Lef
eft_Min
t_Min BOOL 4:0507 15
Motor Minimum
Value in mm/sec for MDR or RPM x

10 for PGD Range: depends upon
the Ai MDR or PGD connected MDR
I_Speed_Right INT 4:0508 - Example: 400 = 0.40 m/s PGD
Example : 400 = 40 RPM 0 =
Remain at last non zero value
entered
Right Motor Set Speed is Greater

I_Speed_Right_Max BOOL 4:0508 14
Than Motor Maximum
Right Motor Set Speed is Less Than

I_Speed_Right_Min BOOL 4:0508 15
Motor Minimum
I_T
I_Temp_MDR_L
emp_MDR_Lef
eftt INT 4:0057 Hi Byte Left Motor Temperature Reading
I_T
I_Temp_MDR_Right
emp_MDR_Right INT 4:0081 Hi Byte Right Motor Temperature Reading
I_T
I_Temp_On_Boar
emp_On_Board_L
d_Lef
eftt INT 4:0057 Lo Byte Left On Board Temperature Reading
Right On Board Temperature

I_T
I_Temp_On_Boar
emp_On_Board_Right
d_Right INT 4:0081 Lo Byte
Reading
I_T
I_Tracking_UpZn
racking_UpZn DINT 4:0139 AOI Tracking for Load Discharged from
Page 317 of 329

(MSW)
4:0140 Logic Adjacent Upstream Module
(LSW)
Voltage Measured on MDR Power

I_V
I_Voltage_MDR
oltage_MDR REAL 4:0024 -
Connection
I_Zone_Status_DnModule INT 4:0232 - Local Downstream Status
I_Zone_Status_UpModule INT 4:0134 - Local Upstream Status
Page 318 of 329

12.5.1.4. PLC I/O Mode Outputs

Data Module
Type Register
O_Clear_Motor_Er
O_Clear_Motor_Errror BOOL 4:0022 0 Clear Motor Error Left & Right
Set Local ConveyStop

O_ConveyStop_Command INT 4:0020 -
Command
Enable Digital Output Mode

O_Digital_Mode_Enable_L
O_Digital_Mode_Enable_Lef
eftt BOOL 4:0060 15
for Left Motor Port
Enable Digital Output Mode

O_Digital_Mode_Enable_Right BOOL 4:0084 15
for Right Motor Port
Energize Digital Output Pin 3

O_Digital_Out_L
O_Digital_Out_Lef
eft_P3_Ener
t_P3_Energize
gize BOOL 4:0060 2
Left Motor Port

O_Digital_Out_L
O_Digital_Out_Lef
eft_P4_Ener
t_P4_Energize
gize BOOL 4:0060 1
Left Motor Port

O_Digital_Out_Right_P2_Ener
O_Digital_Out_Right_P2_Energize
gize BOOL 4:0084 2
Right Motor Port

O_Digital_Out_Right_P3_Ener
O_Digital_Out_Right_P3_Energize
gize BOOL 4:0084 1
Right Motor Port
AOI Enable Output to Module

O_Enable_Module BOOL -
Logic (Reset Protection Mode)
Value in mm for MDR or

O_Mtr_A
O_Mtr_Accel_R
ccel_Ramp_L
amp_Lef
eftt INT 4:0043 -
Pulses for PGD

O_Mtr_A
O_Mtr_Accel_R
ccel_Ramp_Right
amp_Right INT 4:0067 -
Pulses for PGD
O_Mtr_Brak
O_Mtr_Brake_Method_L
e_Method_Lef
eftt INT 4:0261 - Left Motor Control
O_Mtr_Brak
O_Mtr_Brake_Method_Right
e_Method_Right INT 4:0271 - Right Motor Control

O_Mtr_Decel_R
O_Mtr_Decel_Ramp_L
amp_Lef
eftt INT 4:0044 -
Pulses for PGD

O_Mtr_Decel_R
O_Mtr_Decel_Ramp_Right
amp_Right INT 4:0068 -
Pulses for PGD
On = Run in Opposite of
O_Mtr_Dir_L
O_Mtr_Dir_Lef
eftt BOOL 4:0260 8
Config. Dir.
On = Run in Opposite of
O_Mtr_Dir_Right BOOL 4:0270 8
Config. Dir.
O_Mtr_R
O_Mtr_Run_L
un_Lef
eftt BOOL 4:0260 0 On = Run
O_Mtr_R
O_Mtr_Run_Right
un_Right BOOL 4:0270 0 On = Run
O_Mtr_Slave_Mode_L
O_Mtr_Slave_Mode_Lef
eftt INT 4:0262 - 0 = Ignore 1 = OFF: Left
Page 319 of 329

motor independently
controlled 2 = ON: Left motor
mirrors Right motor control
0 = Ignore 1 = OFF: Right

motor independently
O_Mtr_Slave_Mode_Right INT 4:0272 - controlled 2 = ON: Right
motor mirrors Left motor
control

O_Mtr_Speed_L
O_Mtr_Speed_Lef
eftt INT 4:0040 -
RPM x 10 for PGD

O_Mtr_Speed_Right INT 4:0064 -
RPM x 10 for PGD
Invert the Active State for the

O_Sensor_P
O_Sensor_Prt_Mask_P2_L
rt_Mask_P2_Lef
eftt BOOL 4:0034 0
Pin

O_Sensor_P
O_Sensor_Prt_Mask_P2_Right
rt_Mask_P2_Right BOOL 4:0034 2
Pin

O_Sensor_P
O_Sensor_Prt_Mask_P4_L
rt_Mask_P4_Lef
eftt BOOL 4:0034 4
Pin

O_Sensor_P
O_Sensor_Prt_Mask_P4_Right
rt_Mask_P4_Right BOOL 4:0034 6
Pin
Enable Sensor Port Pin 2 Left

O_Sensor_P
O_Sensor_Prt_P2_L
rt_P2_Lef
eft_Output_Enable
t_Output_Enable BOOL 4:0037 5
to be an Output

O_Sensor_P
O_Sensor_Prt_P2_L
rt_P2_Lef
eft_Output_Ener
t_Output_Energize
gize BOOL 4:0037 0 Left, Output Enable must be
Energized
Enable Sensor Port Pin 2

O_Sensor_P
O_Sensor_Prt_P2_Right_Output_Enable
rt_P2_Right_Output_Enable BOOL 4:0037 6
Right to be an Output

O_Sensor_P
O_Sensor_Prt_P2_Right_Output_Ener
rt_P2_Right_Output_Energize
gize BOOL 4:0037 1 Right, Output Enable must be
Energized

O_Servo_CmdP
O_Servo_CmdPosition_L
osition_Lef
eftt INT 4:0008 -
Pulses for PGD

O_Servo_CmdP
O_Servo_CmdPosition_Right
osition_Right INT 4:0013 -
Pulses for PGD
Go to Commanded Position
O_Servo_GoCmd_L
O_Servo_GoCmd_Lef
eftt BOOL 4:0009 1
Go to Commanded Position
O_Servo_GoCmd_Right BOOL 4:0014 1
Set Current Pulse Count as

O_Servo_Zer
O_Servo_Zero_L
o_Lef
eftt BOOL 4:0009 0
“0”
O_Servo_Zer
O_Servo_Zero_Right
o_Right BOOL 4:0014 0 Set Current Pulse Count as
Page 320 of 329

“0”
4:0201
(MSW) AOI Tracking for Load Being
O_T
O_Tracking_Dischar
racking_Discharge
ge DINT
4:0202 Logic Discharged
(LSW)
Zone Status to Downstream

O_Zone_Sts_DnZn INT 4:0196 -
Module
Zone Status to Upstream

O_Zone_Sts_UpZn INT 4:0116 -
Module
Page 321 of 329

12.6. Using L
Logix
ogix 5000 MSG Instruction
Access to ConveyLinx Modules is also available utilizing the Logix 5000 MSG instruction. The
MSG instruction utilizes CIP Explicit Messaging . This means that the connection is not
maintained as an implicit connection. Generic Ether
Ethernet
net Module and EDS connections are
implicit and thus must be maintained at all times or there will be a communication fault.
Explicit Messaging opens the connection, reads/writes data, and then closes the connection
thus freeing up communications resources for the PLC.
When to use MSG Instructions
Because the MSG instruction is executed asynchronous to program scan and is not subject to
implicit messaging RPI restrictions; the response time between requesting data and receiving
data is not deterministic and can vary between separate requests for the same data from the
ecommend that MSG instructions should not be used for dedicated
same device. Therefore, we rrecommend
“real time” contr
control equipment. For ConveyLinx Modules, MSG instructions are intended to
ol of equipment
gather “low priority” status information and/or to send infrequent parameter changes. Please
note that this is only a recommendation. Your particular application’s specifics, PLC’s capacity,
available network bandwidth, etc. may allow you to get expected results with “real time”
control utilizing MSG instructions to interface with ConveyLinx Modules.
Module VS. Assembly A

Addr
ddresses
esses with MSG Instruction
Module Addresses are the 512 “actual” registers in the module and Assemblies are “virtual”
registers grouped based upon function. There are certain restrictions on what you can do with a
MSG Instruction:
• You can us a single MSG instruction to read one and up to 30 consecutive ConveyLinx
Module registers
• You can use a single MSG instruction to write to one (an only one) of the ConveyLinx
Module registers
• You can use a single MSG instruction to read any of the available Input Assembly registers
in their entirety
• You CANNOT use a MSG instruction to write to an Output Assembly array of registers.
Page 322 of 329

12.6.1. Read MSG Instruction

For this example, we have created a ConveyLinx Module in our Ethernet Tree and added a MSG
Instruction to a ladder rung. We named this MSG block “ReadStatus” and created the Controller
Tag for it. With this MSG Instruction we are going to read Module Address 4:0088 and 4:0089
which are Module Status Word 1 and 2. We also created a Controller Tag of data type DINT we
named “TempDiagStatus” to hold this data. Data from 4:0088 will be in the High Word of the
DINT and 4:0089 will be in the low word of the DINT.
From the Message Type drop down, select CIP Generic
From the Service Type drop down, select Get Attribute Single
For the Instance Field, enter “88”
Page 323 of 329

For the Class Field, enter “64”
For the Attribute Field, enter “2” because we want to read 4:0088 and 4:0089
For the Destination Element, use the Tag Browser drop down to select TempDiagStatus
Page 324 of 329

12.6.2. Write MSG Instruction

Instruction to a ladder rung. We named this MSG block “WriteSpeed” and created the Controller
Tag for it. With this MSG Instruction we are going to write a value for the Left Motor Speed at
Module Address 4:0040. We also created a Controller Tag of data type INT we named
“NewSpeed” which will hold the speed value we want to write to the module when we execute
the MSG Instruction.
From the Service Type drop down, select Set Attribute Single
For the Instance Field, enter “40”
Page 325 of 329

For the Attribute Field, enter “1”
For the Source Element, use the Tag Browser drop down to select NewSpeed
For the Source Length, enter “2” (2 bytes = 1 INT)
Page 326 of 329

12.6.3. Reading an Input Assembly with

MSG Instruction
Instruction to a ladder rung. We named this MSG block “ReadZPA” and created the Controller
Tag for it. With this MSG Instruction we are going to read all 21 registers from PLC Inputs for
ZPA Mode. We also created a Controller Tag called “ZPA_Inputs” which is an INT array of 21
elements in order to hold the data.
* When reading any input Assembly with a MSG Instruction, be sure you create the
Destination Element Controller Tag an array of INT with the number of elements
that match the number of registers in the Assembly
Page 327 of 329

From the Service Type drop down, select Get Attribute Single
For the Instance Field, enter “105” which is the Assembly vale for the ZPA Mode inputs
For the Attribute Field, enter “3”
For the Destination Element, use the Tag Browser drop down to select ZPA_Inputs and
expand to select the [0] element
Page 328 of 329

12.7. EDS Module Data T

Type
ype Cr
Cross
oss
Refer
eference
ence
When you create an instance of a device from an EDS file in your RSLogix 5000 environment;
the EDS file provides a Module Defined Data T
Type
ype for the inputs and outputs of the device. This
Module Defined Data T
Type’s
ype’s name is automatically generated by the EDS file creation’s
software and is based upon (among other things) a checksum of the items in the file. This often
creates a somewhat cryptic alpha-numeric string for the name.
In situations where you may inherit an existing program and your RSLogix 5000 environment is
missing the EDS file used for this program; you will need to determine which version of EDS file
was used and then go find it on our Pulseroller.com web site. Similarly, you may also have the
situation where you need to be able to match your AOI version to its correct EDS file. The
following chart cross references the most common EDS files, AOI files, and Module Data Types
EDS File AOI File Module Data T

Type
ype
_055C:Ai2_84EED4D3:I:0
Ai2_ZPA_AOI_4_5.L5X
_055C:Ai2_3015BAF1:O:0
ConveyLinxAi_V5_1.eds
_055C:Ai2_1F7F96C5:I:0
Ai2_PLCIO_AOI_4_5.L5X
_055C:Ai2_7DDD1BFA:O:0
* For versions or Module Data Types not shown, please contact

[email protected]
Page 329 of 329

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ConveyLinx-Ai Family

Copyright © 2021 PULSEROLLER

2. Glossary of Terms .................................................................................................................................. 9

3. Getting Started ..................................................................................................................................... 13

7. EasyRoll Software ................................................................................................................................ 88

8. ConveyMerge ...................................................................................................................................... 164

9. IOX Interface Module .......................................................................................................................... 190

10. PLC Developers Guide ..................................................................................................................... 199

11. Setting Up Dual Motor Zones ........................................................................................................... 292

12. Connecting to Rockwell PLCs with Ethernet I/P ............................................................................. 302

1. About This Manual

ConveyLinx-Ai2 – All Article Numbers 3022-xxxx

ConveyLinx-Ai3-24-FC – Article Number 3023-0001

Important User Infor

! Modules contain ESD (Electrostatic Discharge) sensitive parts and components.

• Touch a grounded object to discharge potential static

! Reproduction of the contents of this manual, in whole or in part, without written

Not Included in this Manual

A separate (usually wrapped or boxed) object to be transported by the

Conveyor controls architecture based upon modular distributed devices

Dynamic Host Configuration Protocol A protocol for assigning IP addresses to

Designed to “break-out” the RJ11 connection for easy installation. The

Special sensor embedded within the brushless DC motor of an MDR used to

The IP Code (International Protection Marking) specifies the device’s degree

This is the name of a particular connector manufacturer that produces a

Term used to describe how the signaling output circuit of a photo-sensor is

Motorized Drive Roller or Motor Driven Roller – Brushless DC motor and

Programmable Logic Controller – A wide variety of industrial computing

Term used to describe the two basic types of photo-sensors. Retro-reflective

Registered Jack Style 11 / 12 – Standard connector / receptacle format

Registered Jack Style 45 – Standard connector / receptacle format utilizing 8

PulseRoller brand proprietary motor control platform that provides electronic

A set of non-motorized conveyor rollers mechanically linked to an MDR. The

Transport Control Protocol / Internet Protocol – IP is the protocol which

A basic (linear or curved) cell of the conveyor consisting of a set of slave

The purpose of this manual is to:

• Identify the components and ports available on a module

Who Should Use this Manual?

What do you want to do?

Learn about module hardware ports

Basic things you can do with EasyR

Learn about basic navigation through EasyRoll

Some advanced things you can do with EasyR

Learn how to discover modules on your network and change IP addresses

Left Sensor & Right Sensor Status LED Indicators

Module Status LED Indicator

Module Power LED Indicator

Removable IP54 Power Compartment Cover

Module Replacement Button

modules including LED Indicators

IP54 Protection Shrouds for Ethernet cabling and power wiring

Mounting Bracket with FC cable routing channels

Left Sensor & Right Sensor Status LED Indicators

Module Status LED Indicator

Module Power LED Indicator

Module Clamping brackets

Module Replacement Button

IP54 Protection Shrouds for Ethernet cabling and power wiring

Mounting Bracket with RC wire routing channels