ETHERNET ROLLER CONTROL MODULE User's Manual
Contents
1. 3 1 Ethernet RJ 45 A 3 3 Ethernet and Application Status LED Indicators 3 3 Right Link LEDS J LU 3 3 n en acorta 3 3 A e em EU CCE A 3 3 Power S ipp uu ua E 3 4 Power LED Indicator 3 4 Installation Push Button dua 3 4 Photosensor and Powered Roller Interfaces 3 4 Photosensor IHTErace MERE UU UT 3 5 Powered Roller 1 MACS ccs ias 3 6 Zone Status LED Indicators a a nennen nennen 3 6 sensor Zone Status LED Indica Sesma alas 3 6 Motor Zone Status LED Indicators a nenne nennen 3 6 ERCM SIZE AND MECHANICAL INSTALLATION 3 7 DIN Rail Version Sizes and Mechanical Installation 3 7 DEM Version SIZES dansa 3 8 ERCM TERMINALS colar iris idas 3 8 Photosensor Powered Roller Connectors 3 9 ERCM Power Connector aan 3 9 Purge Connector APS 3 10 INETNEL CONNECTOR ee eu 3 10 ERCM 82. 2 9 Regular Mode of Operation a a nennen nenn 2 9 ACCUMULI O 2 9 JO u 2 9 j ne ee E 2 9 A ze ISA 2 9 e e PA E 2 9 CONTROL MODULE CONVEYOR INTERFACE 2 9 Brushless Powered Roller Interface 2 10 PNOLIOSENSOr Mlerat 2 11 ERCM ZONES A 2 12 LOCAL REMOTE 20 5 2 12 ZONES 2 12 o 2 13 Ethernet Roller Control Module User s Manual 2 9 2 9 1 2 9 2 2 9 3 2 10 ZONE TO ZONE INFORMATION FLOW 2 13 Information Flow Between Two Adjacent 2 2 14 Information Flow Among ERCM Zones 2 14 Information Flow Between Two Adjacent Remote 2 2 15 GLOSSARY 2 15 CHAPTER 3 ETHERNET POWERED ROLLER CONTROL MODULE 3 1 3 1 1 3 1 2 3 1 3 3 1 4 3 1 5 3 1 6 3 1 7 3 1 8 3 1 9 3 1 9 1 3 1 9 2 3 1 10 3 1 10 1 3 1 10 2 3 2 3 2 1 3 2 2 3 3 3 3 1 3 3 2 3 3 3 3 3 4 3 4 GENERAL DESCRIPTION
3. 3 10 Ethernet Roller Control Module User s Manual CHAPTER 4 ERCM EXTERNAL WIRING 4 1 4 2 4 3 4 4 4 5 4 6 INTRODUCTION ias 4 1 ERCM POWER SUPPLY CONNECTOR 4 1 ERCM ETHERNET INTERFACE 4 3 PURGE INTERFACE 2 4 3 PHOTOSENSOR POWERED ROLLER INTERFACE CONNECTORS 4 4 COMPLETE SYSTEM WIRING 4 5 CHAPTER 5 ERCM PRINCIPLES OF OPERATION 5 1 5 1 1 5 1 2 5 1 3 5 1 4 5 1 5 5 1 6 5 1 7 5 1 8 5 1 9 5 1 10 5 1 11 5 1 12 5 1 13 5 1 14 5 1 15 INTRODUCTION 5 1 ras i tesa TE RE TE TM 5 1 Not Only Ethernet Ethernet IP and PROFInet 5 1 Principals of Operation of Each Zone 5 2 Using ERCM for Linear Transfer and Merge Operation 5 3 Using ERCM for Divert Operation 22 2 5 5 Barcode Tracking uuu uu uuu u I LIMIT 5 8 Working with ERCM through Ethernet IP amp PROFInet 5 8 Configuration Properties
4. TrackingOutC EE TrackingOutR zone From To Downstream A Network Module PR StateC gt StateR raton DivertCmd Trackingout TrackingOutC TrackingOutR 5 6 Fig 5 10 Left Lane Central Lane Right Lane Ethernet Roller Control Module User s Manual ZoneA object sends commands to Diverter actuator control PLC via DivertCmd DivertAck pair of properties Divert request can be placed by PLC via DivertAck properties by other devices via UpL UpR properties for example size sensor can be connected to other ERCM s sensor input and it State property can be used as request signal for divert zone or by barcode tracking algorithm see next chapter Note that command sequence and timing are configured in ConfigTimersDivert and Config1 properties of Zone A Each command 32 bit unsigned integer encapsulates inside also configured in ERCM operation timeouts So you don t need to configure your timings in 2 devices ERCM and PLC When ERCM sends a command it also sends timeout timing information for it For Example if your divert device is two way pusher when Zone D sends Prepositioning command it also sends configured in it timeout for this operation You may use schematics 5 10 to control both two way pusher or pop up diverter You have to simply configure Silent receive bit 1 in Configuration1 property for zone transfer from Zone A for pusher
5. menn 5 10 Configuring and Building Connections Between Objects through IP c uns 5 10 Configuring and Building Connections Between Objects through PROFInet 5 10 Mixing Protocols in Powered Roller Control System 5 10 Network Throughput1 a nennen nnn nnns 5 11 Timings with PROFInet and Ethernet IP Communication 5 11 Configuring ERCM Conveyor Control System with RollOn c 5 12 Older System Support and Investment 5 12 CHAPTER 6 ERCM ELECTRONIC DATA SHEET 6 1 6 2 6 3 6 4 GENERAL 6 1 ERCM EDS FILE ETHERNET IP ea 6 2 ERCM XML INTERFACE DESCRIPTION PROFINET 6 3 PROFILON GATEWAY XML INTERFACE DESCRIPTION PROFINET 6 4 Ethernet Roller Control Module User s Manual lii CHAPTER 7 CONFIGURING POWERED ROLLER CONVEYOR WITH SIMPLE APPLET USING ETHERNET ROLLER CONTROL MODULE CHAPTER 8 VERSIONS REVISIONS HISTORY Ethernet Roller Control Module User s Manual 5 1 DEFINITIONS SAFETY AND OPERATING INSTRUCTIONS 1 1 EXPLANATION OF SYMBOLS 1 2 DEFINITI
6. 3 1 6 Power Supply The power supply voltage of ERCM is 24 V DC 18 to 30 V The module current consumption is 100 mA For more details you may refer to Table 3 5 3 1 7 Power LED Indicator This LED is Red Power LED indicator is ON when 24 V DC power is connected properly to ERCM 3 1 8 Installation Push Button The Installation Push Button is used during the configuration procedures of ERCM 3 1 9 Photosensor and Powered Roller Interfaces Each ERCM provides four sets of Photosensor Powered Roller interfaces one set per zone The interface for one zone is shown in Fig 3 3 3 4 Ethernet Roller Control Module User s Manual CONVEYOR ZONE Powered Roller Interface Section Photosensor Section F c JE x 51218 di lt BRUSHLESS PHOTO POWERED ROLLER ili ER VERED ROLLER maw Ir INTERFACE ZONE A ZONE B Y ZO Sen Sen Sen ndustrial Ethernet Purge Er dustria Left Link y Software Right Link Tf LETE mignt Fig 3 3 You may refer also to subsection 2 6 3 1 9 1 Photosensor Interface CS First refer to subsection 2 6 2 CS The power supply pins for the photosensor are internally connected to the 24 V DC power input of ERCM CF it your photosensors do not have Sensor Error output leave the Sensor Error pin not connected CS Sensor error input can be pr
7. ETHERNET ROLLER CONTROL MODULE User s Manual Version Preliminary ZONE D e _ Sen Mo Mot Sen Mot ff nm Left Link 5 _ Ethernet 1 J Software 1 j Right Link Activity Revision March 2004 Industrial Software Ltd 45 Lokorska Str 1225 Sofia BULGARIA Phone Fax 359 2 975 11 80 1 2 3 4 E mail indsoft einet bg www indsoft bg Ethernet Roller Control Module User s Manual CONTENTS CAPTER 1 DEFINITIONS SAFETY AND OPERATING INSTRUCTIONS 1 1 1 2 1 3 1 4 EXPLANATION OF 5 1 1 DEFINITIONS AND 5 1 1 NUMERICAL DATA mean een 1 2 SAFETY AND OPERATING INSTRUCTIONS 1 2 CHAPTER 2 GENERAL INFORMATION 2 1 2 2 2 3 2 4 2 4 1 2 4 2 2 4 3 2 5 2 5 1 2 5 2 2 5 3 2 5 4 2 5 5 2 5 6 2 6 2 6 1 2 6 2 2 7 2 8 2 8 1 2 8 2 POWERED ROLLER CONVEYOR CONFIGURATION 2 1 CONVEYOR 2 3 UPSTREAM DOWNSTREAM CONVEYOR ZONES 2 4 CONVEYOR AREAS ree eee eee 2 5 Standard Linear Area scsi iria 2 5 Merge ARCA cometida 2 6 DIVE ATE A A A 2 8 CONVEYOR MODES OF
8. The examples are based on the assumption that a ERCM is controlling linear area zones Some particularities related to ERCMs controlling other conveyor areas will be discussed separately The module terminals are represented by male pin connectors assembled on the module PCB Fig 4 1 ZONE A ZONEB 24 ZONEC ZONE D Sen Mot Sen Mot Sen Mot Sen Mot Purge Left LinkO Ethernet Software Right LinkO ActivityO af ight Fig 4 1 The corresponding voltage ratings and polarity if required are shown on the front panel of the module Fig 4 1 Each module is supplied by Industrial Software with 6 female connectors with relevant pin number As a matter of fact when considering the external wiring we refer to wiring of these female connectors Therefore the electrician must follow the guidance extended in Tables 3 1 3 2 3 3 and 3 4 besides the considerations outlined below 4 2 ERCM POWER SUPPLY CONNECTOR A This connection is polarity sensitive The 24 V DC power supply female 2 pin connector must be wired in accordance with Table 3 2 The correct wiring will provide the electrical connection shown in Fig 4 2 A Please check twice to make sure that your wiring is Ethernet Roller Control Module User s Manual 4 1 ETHERNET ROLLER CONTROL MODULE ZONEA ZONEB ZONEC ZONED D POWER Sen Mot Sen Mot TN Ethern Purge RS232 E23 MI Software Fig
9. Both Dark operated and Light operated photosensors may be used From electronic point of view the conveyor zone may be regarded as a black box with two I O sections Powered Roller Interface Section and Photosensor Section Fig 2 3 The ERROR signal is generated when the DC motor is overloaded The ALARM signal is generated when the photosensor gain factor is improper The designations of the other terminals are self explanatory Ethernet Roller Control Module User s Manual 2 3 ERROR LLI gt 9 2 INVERSE 5 O c c RUN GO 1 COMMON gt 53 cz oe O gt 0 N O Y 2 x 2 5 5 TT DC O 9 SENSOR ALARM O x Fig 2 3 2 3 UPSTREAMIDOWNSTREAM CONVEYOR ZONES The above terms depend upon the direction of the conveyor packages movement For the left to right direction of the conveyor movement Fig 2 4 Zone N 1 is the downstream zone in relation to zone N Zone N 1 is the upstream zone in relation to zone N Zone N is the upstream zone in relation to zone 1 Zone is the downstream zone in relation to zone N 1 LEFT TO RIGHT DIRECTION OF CONVEYOR MOVEMENT Zone 1 Zone N O Zone N 1 Fig 2 4 T 2 4 Ethernet Roller Control Module User s Manual For the right to left direction of the conveyor movement Fig 2 5 Zone 1 is the upstream zone in relation to zone Zone N 1 is the downstream
10. StateR DivertCmd TrackingOutL TrackingOutC TrackingOutR From To Downstream Network Module Left Lane gt Zone B UpL UpC UpR DownL DownC DownR AccJog Configuration1 ConfigTimersRoller ConfigTimersDivert DivertACK TrackingL TrackingC TrackingR StateL StateC StateR DivertCmd TrackingOutL TrackingOutC TrackingOutR From To Downstream Network Module Central Lane gt Network Module lt q gt Right Lane From To Upstream Network Module i Zone C UpL UpC Ms UpR DownL DownC DownR AccJog Configuration ConfigTimersRoller ConfigTimersDivert DivertACK TrackingL TrackingC TrackingR StateL StateC StateR DivertCmd TrackingOutL TrackingOutC TrackingOutR From To Downstream Network Module Right Lane 5 1 6 Barcode Tracking Fig 5 12 has build in algorithm for distributed Barcode Tracking When a carton is scanned barcode information together with desired divert point IP address of diverter zone device is written by external PC or PLC in TrackingL or C or R property This information is tracked along with cartons When carton arrives at desired diverting point it s diverted by ERCM Carton continue downstream with it s tracking information and can be monitored for Successful Arrival on arrival points Using ERCM Barcode Tracking requires only 1 bar code scanner on the co
11. so zones C and A don t rotate rollers during receipt of cartons When use with pop up transfers you configure this bit to 0 so rollers are rotating when receiving cartons from divert area More complicated schematic for divert area is described on Fig 5 11 and 5 12 PA Y dl aat aao at sas am ow o te s 1 m Tres MEM s 5 955 TER 25 EE ee Left Lane a ze ul I a gt gt m u comune Central Lane hTP Was Right Lane Bee de 222213 eff PPS Ethernet Roller Control Module User s Manual 5 7 4 From To Upstream Left Lane Network Module lt From To Actuator Control PLC or Industrial Software Ethernet I O V Zone D UpL UpR mM DownL mM DownC M DownR AccJog Configuration ConfigTimersRoller From Upstream Network Module Central Lane ConfigTimersDivert o DivertACK TrackingL TrackingC TrackingR To Upstream StateL StateC StateR DivertCmd TrackingOutL TrackingOutC TrackingOutR E Zone A UpL UpC UpR DownL DownC DownR AccJog Configuration1 ConfigTimersRoller ConfigTimersDivert DivertACK TrackingL TrackingC TrackingR StateL StateC
12. 2 4 CONVEYOR AREAS 2 4 1 Standard Linear Area 2 4 2 Merge Area 2 4 3 Divert Area 2 5 CONVEYOR MODES OF OPERATION 2 5 1 Regular Mode of Operation 2 5 2 Accumulation 2 5 3 2 5 4 Train 2 5 5 Singulation 2 5 6 Purge 2 6 CONTROL MODULE TO CONVEYOR INTERFACE 2 6 1 Brushless Powered Roller Interface Ethernet Roller Control Module User s Manual 2 6 2 2 7 2 8 2 8 1 2 8 2 2 9 2 9 1 2 9 2 2 9 3 2 10 Photosensor Interface ERCM ZONES LOCAL REMOTE ZONES Local Zones Remote Zones ZONE TO ZONE INFORMATION FLOW Information Flow Between Two Adjacent Zones Information Flow Among ERCM Zones Information Flow Between Two Adjacent Remote Zones GLOSSARY Ethernet Roller Control Module User s Manual This document describes the principle of operation of the Ethernet Powered Roller Control Module ERCM as well as the principle of its communication with the other devices of the system Ethernet is multimaster compatible this means that several Ethernet stations are able to request the bus at the same time The messages with the highest priority will be transmitted immediately The data transfer is managed by build in ERCM Ethernet switch ERCM are designated for flexible motorized roller conveyor automation 2 1 POWERED ROLLER CONVEYOR CONFIGURATION A general view of a powered roller conveyor is shown in Fig 2 1 If a package also referred to as tray or packet is p
13. 5 7 Example of how to use ERCM for merge operation is described on Fig 5 8 and Fig 5 9 ZONE Sen Mot Purge RS232 ZONi o O 4 Sen Mo O MIT ZC NE 7 D fa Sen Mot Sen Mot Ethernet Left Link 2 Right Lir ityO Ethernet Roller Control Module User s Manual Left Lane Network Moue Zone gt StateL StateC m StateR Oren j 7 Tr TrackingOutC TrackingOutR m Central Lane From To Upstream Zone C Zone A Network Module UpL nm UpL mm gt Upc UpC To Downstream StateC StateC i aM TE StateR StateR TE a GonfTimesDer Trackngout ConfigrimersDven TraokngOut TrackingOutC TrackingOutC TrackingOutR TrackingOutR From Downstream Network Module Right Lane eye u UpC StateL StateC m StateR TrackingOutC TrackingOutR Fig 5 9 5 1 5 Using ERCM for Divert Operation The idea of using Zone object to control divert operations is to use ERCM to control zones before and after the divert area the divert area itself and use external control PLC or module to control diverter s actuator Communication between ERCM s diverter zone and Actuator control PLC us done via DivertCmd for Divert command and DivertAck for Divert Acknowledge Propertie
14. LinkO Ethernet Software Right Linko fj instan Left Right ZONE STATUS LEDs PURGE INSTALL PUSH POWER INPUT BUTTON LED CONNECTOR CRT MODULE amp NETWORK ETHERNET STATUS LEDS CONNECTORS Fig 3 2 3 2 Ethernet Roller Control Module User s Manual 3 1 1 Ethernet RJ 45 Jacks Two RJ 45 connectors are used to connect to upstream and downstream modules 3 1 2 Ethernet and Application Status LED Indicators Each ERCM has following diagnostic LED s 2 Ethernet Module Status LED s These 2 LEDs are specific and report the state of the module and communication as described in Ethernet IP documentation Chapter 9 These two LEDs are labeled as Module Status and Network Status Module Status LED is bicolor Green Red Network Status LED is bicolor Green Red Module Status Off Power not present or Module is damaged Module Status Green Red Blinking Selftest in progress Module Status Green Blinking Module have not been configured Module Status Red Blinking Recoverable minor fault Module Status Steady Red Non recoverable major fault Module Status Steady Green Device operating correctly Network Status Off Power not present or does not have IP address Network Status Green Red Blinking Selftest in progress Network Status Green Blinking The device has not established connections Network Status Red Blinking At least one of the connections has timeou
15. Properties UpL UpC UpR for Upstream Left Upstream Central and Upstream Right are used to receive status information from upstream zones Properties DownL DownC DownR for Downstream Left Central Right are used to receive information from downstream zones Output properties StateL StateC StateR are used to propagate Zone s status to both upstream and downstream lanes Left Central and Right Functioning of the ERCM mainly depends on how it s zones are connected Note that connections between zones can be either local inside module or via Ethernet There is no difference in operation of zone object with both types of the connection Most easy way to use a zone object from ERCM for linear transfer is described on Fig 5 3 5 2 Ethernet Roller Control Module User s Manual From Upstream Zone Network Module UpL Downstream StateC Network Module DownL DownC DownR StateR AccJog Configuration1 DivertCmd ConfigTimersRoller ConfigTimersDivert TrackingOutL DivertACK TrackingL TrackingOutC TrackingC TrackingR TrackingOutR SA Network Module To Upstream 2 Network Module 4 Fig 5 3 5 1 4 Using for Linear Transfer Operation Example connections inside module for 2 3 4 zone linear transfer operations are described on Fig 5 4 Fig 5 5 Fig 5 6 and Fig 5 7 HERMET ROLLER COR TROL MODUL
16. the packages from two or three lanes are merged into one merge lane Package A separate usually wrapped or boxed object to be transported by the conveyor The term tray or the term tote is also used instead of the term package Photosensor A device mounted on the end of the conveyor zone to sense the presence of a package on the zone Powered Roller also referred to as DRIVE ROLLER or MOTORIZED ROLLER or MASTER ROLLER This is a roller driven by a motor The powered roller drives the slave rollers of the zone by means of belts or chains Purge Mode of operation when all zones are forced to move in order to clear the conveyor completely Remote Zones The zones belonging to different ERCMs Roller Interface The interface card of the brushless DC motor driving the Powered Roller Ethernet Roller Control Module User s Manual 2 15 Singulation Mode of operation when the zone establishes one zone gap between the adjacent packages and accumulating until the downstream zone is cleared Slave Rollers A set of rollers in a conveyor zone driven by the Powered Roller Standard Area Also referred to as LINEAR AREA set of linear and or curved conveyor zones Tote A term sometimes used instead of the term package Train Mode operation when the zone transfers the packages as they arrive without gap between the adjacent packages Tray A term frequently used instead of the term package Upstream Zone The p
17. zone in relation to zone N Zone N is the downstream zone in relation to zone 1 Zone N is the upstream zone in relation to zone N 1 RIGHT TO LEFT DIRECTION OF CONVEYOR MOVEMENT Zone N 1 Zone N Zone 1 a Fig 2 5 2 4 CONVEYOR AREAS Several typical areas may be identified on a conveyor refer to Fig 2 1 2 4 1 Standard Linear Area The standard or linear conveyor area consists of a set of linear or curved zones as shown in Fig 2 6 The packages are transferred along the conveyor in an ordinary way THIS SPACE IS LEFT INTENTIONALLY BLANK Ethernet Roller Control Module User s Manual 2 5 Fig 2 6 2 4 2 Merge Area This is the area where the packages from two or three conveyor lanes are merged onto one conveyor lane Fig 2 7 THIS SPACE IS LEFT INTENTIONALLY BLANK 2 6 Ethernet Roller Control Module User s Manual right and left zones are physically equal Therefore their denominations must not be necessarily associated with the left right denominations of the Control Module The Merge zone and the Central zone must be strictly connected with the respective zones of the Control Module 2 4 3 Divert Area This is the conveyor area where the package is transferred to the left divert lane or to the right divert lane Fig 2 8 and 2 9 This is example of Pusher divert area dam 7 Main Lane Main Lane 744424444440 Qa w
18. 1131 1 ISO 11898 x Size max dimensions 157mm 90mm 36 2mm DIN 159mm 107mm 37mm Weight without DIN Rail Weight without DIN Rail DIN Rail Approx 1709 170 g Housing Material Polyamide PA F fiber reinforced Face JFace polycarbonate Termination s Plug in direction vertical to conductor axis connection point towards the coded side of the header 3 81 mm step Recommended wire size AWG28 16 24 14 stranded or solid Zone Status Indicators One bicolor one green LED Jam Motor Fault Sensor Fault Direction Accumulation forced Sensor ON Off Roller On Off Power red Network Status bicolor Module Status bicolor Left Right Link green Activity red Additional Indicators Front Panel See Fig 3 2 3 2 1 Ethernet Roller Control Module User s Manual 3 11 750 91 7 A Wi CHAPTER 4 ERCM EXTERNAL WIRING 4 1 INTRODUCTION 4 2 ERCM POWER SUPPLY CONNECTOR 4 3 ERCM ETHERNET INTERFACE CONNECTOR 4 4 PURGE INTERFACE CONNECTOR 4 5 PHOTOSENSOR POWERED ROLLER INTERFACE CONNECTORS 4 6 COMPLETE SYSTEM WIRING Ethernet Roller Control Module User s Manual 4 1 INTRODUCTION The external wiring of ERCM although simple requires special attention in order to avoid commissioning troubles and or devices damage The instructions outlined below are designated to serve as guidance for the installation electricians
19. 2 8 1 Local Zones These are the zones that belong to one ERCM 2 13 Direction of Conveyor Movement m Fig 2 13 2 12 Ethernet Roller Control Module User s Manual The above zones are referred to as local zones Furthermore Zone D is the upstream zone in relation to zone C Zone C is the upstream zone in relation to zone B Zone is the upstream zone in relation to zone and vice versa Zone is the downstream zone in relation to zone B Zone B is the downstream zone in relation to zone C Zone C is the downstream zone in relation to zone D 2 8 2 Remote Zones These are the zones that belong to different ERCMs Fig 2 14 REMOTE ZONES IN RELATION TO ERCM 1 ERCM ERCM LOCAL ZONES ERCM 2 ForERCM 1 Fig 2 14 2 9 ZONE TO ZONE INFORMATION FLOW Two adjacent zones have to exchange information during the regular conveyor operation The downstream zone should inform the upstream zone about its state of operation for example Its powered roller is running or Its powered roller is stopped or Its powered roller is on inverse mode of operation or Its powered roller is overloaded or There is a package on the zone or photosensor gain is improper etc The upstream zone should inform the downstream zone about similar events Ethernet Roller Control Module User s Manual 2 13 2 9 1 Information Flow Between Two Adjacent Zones The information flow between two adj
20. 4 2 Left LinkO Right LinkO Left A The photosensor supply voltage is internally connected to ERCM Power Supply Fig 4 3 This must be taken into account during the system design AN The GROUND terminal of the Powered Roller section Photosensor Powered Roller Interface is internally connected to 24V DC ERCM Power Supply Fig 4 3 Ethernet RS232 Left LinkO Right LinkO Install Activity Fig 4 3 4 2 Ethernet Roller Control Module User s Manual 59 24 V DC power supply connector is of the same type as the connector Wrong connection 24 V DC power supply on Purge connector or Purge signal on power supply connector will not damage the module but may force the system into a not functioning mode until the wrong connection is removed 4 3 ERCM ETHERNET INTERFACE CONNECTOR ERCM has build in 3 port 10 100MB switch One of the ports is connected internally and other two ports are connected to two RJ 45 connectors With these two RJ 45 connectors ERCM is connected to nearest upstream and downstream modules It is not necessary that these two modules are logically upstream and downstream to the module ZONE A LA 24vpc ZONE D Sen Mot Sen Mot Sen Mot Sen Purge RS232 Left Link Ethernet pr Software Right 117 Activity Ler KIM J t Cross connect UTP Cross connect UTP Fig 4 4 4 4 PURGE INTERFACE CONNE
21. 5 10 Ethernet Roller Control Module User s Manual PROFInet PROF Inet Engineering Tool Z OS Ethernet Ethernet IP Ar SLC 5 05 ModBus TCP with Ethernet ool Fig 5 14 5 1 12 Network Throughput Conveyors are very suitable for using Ethernet for communication between devices in distributed control system Main reason is that network traffic is mainly between upstream and downstream device Fig 5 15 illustrates this ERCM1 ERCM2 ERCM3 ERCM4 Upstream Downstream 1 2 2 3 3 4 Fig 5 15 When a carton is released from ERCM2 messages are generated to ERCM1 and ERCMS Build in ERCM3 switch recognizes network packet and transfers it to ERCM3 but to ERCM4 So in this situation part of the network 3 4 and downstream it and upstream ERCM1 are silent and free of traffic Switches in ERCM can operate at 100MB s so system with very heavy traffic of cartons can be created 5 1 13 Timings with PROFInet and Ethernet IP Communication ERCM can support QoS Quality of Service down to 8 mS when PROF Inet is used and 10ms reaction time when Ethernet IP is used Although ERCM supports Ethernet IP cyclic I O connections with multicasting it s not good idea to use such connections for distributed conveyor applications The reason is that in this case build in ERCMs switches will retransmit multicast messages all over the subnet thus dramatically decrease
22. ACE RUN GO COMMON DC SENSOR DC INTERFACE ALARM INPUT SENSE INPUT CON O OIRA O N The connections between the module zone and the respective conveyor zone are shown already in Fig 3 3 3 3 2 ERCM Power Connector The connector pin out information related to the module power supply is outlined in Table 3 2 Table 3 2 Power Supply DIN rail version Power Supply OEM rail version Power Supply DIN rail version Power Supply OEM rail version Ethernet Roller Control Module User s Manual 3 9 3 3 3 Purge Connector The connector pin out information related to Purge input is outlined in Table 3 3 Table 3 3 urge Connection PmNo Function B 3 3 4 Ethernet Connector ERCM uses standard Ethernet cross connect UTP cables 3 4 ERCM SPECIFICATIONS The main technical ERCM specifications are described in Table 3 5 Table 3 4 Module Power Voltage 18 30 18 30VDCMainPowerSuply PA Main Power 18 30VDCMainPowerSuply PA Module Current Consumption Main Power Supply 100 mA excluding motor power and current drawn the photosensor Interface Capacity 4 4 sensors 4 brushless motors 4 brushless motors Galvanic insulation Ethernet to processor Power to processor Motor to motor Sensor to sensor motor amp sensor to processor Power to Ethernet LJ mmm o 3 10 Ethernet Roller Control Module User s Manual a EE 801 IEC
23. CTOR C This connection is not polarity sensitive The Purge signal female 2 pin connector must be wired in accordance with Table 3 3 The correct wiring will provide the electrical connection shown in Fig 4 5 Ethernet Roller Control Module User s Manual 4 3 ZONE 2 24 VDC EET ZONE D Sen Mot Sen Mot Sen Mot Sen Mot Purge Left LinkO Ethernet Software Right LinkO ActivityO IRignt 10 30 V DC PURGE SIGNAL NETWORK Fig 4 5 The 24 V DC power supply connector is of the same type as the Purge connector Wrong connection 24 V DC power supply on Purge connector or Purge signal on power supply will not damage the module but may force the system into functioning mode until the wrong connection is removed D The capacity of the System s Purge Signal power supply must be selected to meet the requirement for 4 ma per one ERCM For example in case of a 1000 module system configuration the required capacity is 1000x4mA 4A 4 5 PHOTOSENSOR POWERED ROLLER INTERFACE CONNECTORS A These connections are polarity sensitive The module is supplied with four 8 pin female connectors one per each zone The Photosensor Powered Roller Interface female 8 pin connectors must be wired in accordance with Table 3 1 The correct wiring will provide the electrical connections shown in Fig 3 3 A Please check it twice to make sure that your wiring is OK 4 4 Ether
24. E THERNE ER CONTROL ZONE A ZONEB ZONE ZONE D ZONE A ZONEB WA AODULE ZONED Sen Mot Sen Sen Sen Mot Sen Sen Sen Mat Purge R 232 kt Hor a Sen Mot Left Link Ethernet Right Lini Cert Left Link Ethernet Right Link 9 Purge 5232 Zone Zone From Upstream Network Module UpL UpC StateL StateL To Downstream UpR UpR Network Module StateC gt DownC gt DownC DownR StateR DownR StateR AccJog AccJog Configuration Pretend Configuration 1 Pive na ConfigTimersRoller ConfigTimersRoller ConfigTimersDivert I s ui ConfigTimersDivert DivertACK DivertACK Tal TrackingOutC TAG TrackingOutC TrackingC TrackingC Tracking TrackingOutR Tracking TrackingOutR To Upstream Network Module From Downstream A Network Module Two Zone Controller Fig 5 5 Ethernet Roller Control Module User s Manual 5 3 Zone C Zone B Zone A From Upstream Network Module UpL UpL UpL UpC StateL UpC StateL UpC StateL To Downstream UpR UpR UpR Network Module Down StateC DownL StateC DownL StateC gt m DownC DownC DownC R R R DownR State State DownR State A 2 DivertCmd Boney DivertCmd DivertCmd Configuration1 Configuration1 Configuration1 ConfigTimersRoller Confi
25. EWAY XML INTERFACE DESCRIPTION PROFINET Ethernet Roller Control Module User s Manual 6 1 GENERAL The usage of devices in a communication network requires configuration of the device parameters and communication facilities Ethernet IP defines a standardized way to access these parameters via the Objects described by Electronic Data Sheet PROFInet uses XML files to describe object interfaces Ethernet Roller Control Module User s Manual 6 1 6 2 ERCM EDS FILE ETHERNET 6 2 Ethernet Roller Control Module User s Manual 6 3 ERCM XML INTERFACE DESCRIPTION PROFINET Ethernet Roller Control Module User s Manual 6 3 6 4 PROFILON GATEWAY XML INTERFACE DESCRIPTION PROFINET 6 4 Ethernet Roller Control Module User s Manual CHAPTER 7 CONFIGURING POWERED ROLLER CONVEYOR WITH SIMPLE APPLET USING ETHERNET ROLLER CONTROL MODULE Ethernet Roller Control Module User s Manua Ethernet Roller Control Module User s Manual 7 1 CHAPTER 8 VERSIONS REVISIONS HISTORY Ethernet Roller Control Module User s Manua 1 Version Preliminary Rev March 2004 Ethernet Roller Control Module User s Manual 8 1
26. FInet Mixing Protocols in Powered Roller Control System Network Throughput Timings with PROFInet and Ethernet IP Communication Ethernet Roller Control Module User s Manual 5 1 14 Configuring ERCM Conveyor Control System with RollOn Configuration Tool 5 1 15 Older System Support and Investment Protect Ethernet Roller Control Module User s Manual 5 1 INTRODUCTION 5 1 1 More Objects ERCM design is based on modern object oriented technology Object is main term in ERCM architecture Internally ERCM implements 4 objects of type Zone Zone A Zone B Zone C Zone D All four zones are absolutely equal in functionality Each zone is accessible via it s properties Below on Fig 5 1 is described object presentation of one zone All properties on left are inputs for the zone All properties on right are inputs for the zone and are driven by internal implementation of the zone s software Zone 025 StateL chi StateC StateR DivertCmd ConfigTimersDivert TrackingOutL TrackingOutC Tracking TrackingOut Fig 5 1 5 1 2 Not Only Ethernet Ethernet IP and PROFInet Ethernet is most popular media for communication in the business world TCP IP Transmission Control Protocol Internet Protocol which most people are familiar with is the network and transport layer protocols at the Internet The TCP IP protocol suite provides a set of services that two devices may use to communic
27. ONS AND ABBREVIATIONS 1 3 NUMERICAL DATA 1 4 SAFETY AND OPERATING INSTRUCTIONS Ethernet Roller Control Module User s Manua 1 1 EXPLANATION OF SYMBOLS 1 This symbol indicates important directions for the proper use of the Ethernet Roller Control Module This symbol provides important notes and or other useful information A This symbol indicates that special attention should be paid in order to ensure correct use as well as to avoid dangers 1 2 DEFINITIONS AND ABBREVIATIONS ERCM Ethernet Roller Control Module EDS Electronic Data Sheet EMC Electromagnetic Compatibility ESD Electrostatic Discharge Err Error HEX Hexadecimal number s ID d dentification Identification Number LED Light Emitting Diode OSI Open System Interconnection RO Read Only RW Read Write IP Internet Protocol TCP Transmit Control Protocol DCOM Distributed Component Object Model Ethernet Local Network Protocol ARP Address resolution Protocol HTTP Hipertext Transfer Protocol FTP File transfer Protocol SWITCH Device for switching Ethernet messages Ethernet IP Ethernet Industrial Protocol CIP Control and Information Protocol Ethernet Roller Control Module User s Manual 1 1 1 3 DATA Decimal values are represented as figures without additional features e g 1458 Binary values are marked b at the end the figures e g 1011b Hexadecimal values a
28. Status LED Indicators There is one bicolor LED for sensor section labeled Sen This LED is signaling the following information OFF No carton on zone sensing error Flashing Green Carton presents on the zone but accumulation is forced externally from external device via network or from internally programmed sensor error or motor error input Steady Green Carton presents on the zone and there is no externally forced accumulation Zone still can accumulate because of other conditions singulating or upstream damaged Flashing Red Jam error on the zone The sensor reports that a package is on the zone for a period of time longer than 2 s This time is configurable Steady Red Sensor Gain error in sensor error input programmed for this function 3 1 10 2 Motor Zone Status LED Indicator There is one Green LED for motor section labeled Mod This LED is signaling the following information 3 6 Ethernet Roller Control Module User s Manual Steady ON ERCM is driving the roller motor on RUN GO or on Purge mode operation Flashing ERCM receives a motor error signal Flickering The zone is forced on Inverse Direction mode of operation C This state cannot occur during normal operation of ERCM and can be forced only by the Installation Monitoring Tool or by PLC 3 2 ERCM SIZE AND MECHANICAL INSTALLATION ERCM is manufactured in two versions DIN rail mounting OEM rail mount versi
29. acent zones is illustrated in Fig 2 15 a UPSTREAM DOWNSTREAM LOCAL LOCAL ZONE ZONE SL Fig 2 15 2 9 2 Information Flow Among ERCM Zones The information flow among the four ERCM zones is shown in Fig 2 16 N C V CE All operations between these zones are organized locally i e inside the ERCM 5 ERCM A LOCAL ZONES Fig 2 16 2 14 Ethernet Roller Control Module User s Manual 2 9 3 Information Flow Between Two Adjacent Remote Zones The communication between two adjacent remote zones is illustrated in Fig 2 17 In fact this is the communication between two ERCMs D c B A p C B A D C B A ence CEP All operations between these adjacent remote zones are organized in the frame of the Ethernet Network Fig 2 17 2 10 GLOSSARY Accumulation A mode of operation when the zone contains package s and is holding Cross Transfer Area The area where a pusher transfers the packages from one to another lane Direction Main The normal operation direction of the conveyor Inverse The opposite of the main direction Downstream Zone The next zone in the main direction of the conveyor movement Jog Mode of operation when one or several specified zones are forced to jog unconditionally Linear Area Also referred to as STANDARD AREA A set of linear and or curved conveyor zones Local Zones The zones belonging to the same ERCM Merge Area The conveyor area where
30. ate with each other over Ethernet LAN or over a wide area network that spans the globe But this is not enough for industrial automation interoperability Standardization of upper layer protocols in needed so devices from different vendors can communicate each to other Two of the most popular and broad used protocols for Industrial Automation are Ethernet IP and PROFInet Ethernet Roller Control Module User s Manual 5 1 Application objects Conveyor zones Application object Library Device CIP Messaqin iis PDEV LDEV ACCO Automation Explicit Routing objects Encapsulation of CIP PROFInet object model Encapsulation EET Ethernet Data Link Layer Ethernet Physical Layer Fig 5 2 Both protocols are object oriented and well suited for use in conveyor controls Both protocols provide fundamental term Connection between object properties between modules PROFInet also provides term Local Connection between properties inside module and Constant Connection which puts constants on input properties of objects Ethernet IP provides same service via Parameter Object Further in this manual we will use term Object Connection Properties independently for the protocol used as both protocols provide services for those terms 5 1 3 Principals of Operation of Each Zone Each zone object inside ERCM has a set of input properties to receive data from up to 3 upstream zones and 3 downstream zones
31. e B and Zone A Ethernet Roller Control Module User s Manual 2 9 The interconnections between a Control Module zone and a conveyor zone are shown in Fig 2 10 CONVEYOR ZONE Powered Roller Interface Section BRUSHLESS i POWERED D INTERFACE INVERSE ALARM ERROR COMMON PHOTO gt SENSOR INTERFACE ZONE A ZONE B zol Sen Mot Sen Sen x Ethernet Purge ndustrial Left Link A Software Right Link Activity eft Fig 2 10 2 6 1 Brushless Powered Roller Interface Four terminals are available for communication between the Control Module zone and the Powered Roller interface section of the conveyor zone namely COMMON self explanatory RUN GO normal forward drive of the powered roller hence normal operation of the conveyor zone INVERSE inverse operation of the conveyor zone ERROR an error signal is transmitted from the conveyor zone to the Control Module when the DC motor of the powered roller is overloaded 2 10 Ethernet Roller Control Module User s Manual 2 6 2 Photosensor Interface Four terminals are available for communication between the Control Module zone and the Photosensor section of the conveyor zone namely DC DC 24 V DC power supply for the photosensor is provided by the Control Module on these terminals SENSOR A signal for availability of packag
32. e downstream zone is available to receive the package The accumulation may be caused by the operator for maintenance or repair by a downstream zone fault condition signal by a merge operation signal etc This function overrides photosensor input 2 5 3 Jog One or several specified zones are forced to jog unconditionally during this mode of operation This function overrides all accumulation functions 2 5 4 Train This mode of operation defines the case when the zone transfers the packages as they come from the upstream zone without gaps between the adjacent packages 2 5 5 Singulation This mode of operation is relevant to the case when the zone establishes one zone gap between the adjacent packages accumulating until the downstream zone is cleared In other words the one zone gap is effected for the outgoing from the zone packages while the function accumulation is valid for the incoming into this zone packages 2 5 6 Purge All zones of the conveyor are forced to operate in order to clear the conveyor completely 2 6 CONTROL MODULE TO CONVEYOR INTERFACE The conveyor zone as described in subsection 2 2 is the basic conveyor cell to be controlled by the Control Module Therefore the respective section of the Control Module is referred to as control zone also One Control Module can control up to four conveyor zones i e the Control Module Incorporates four similar control zones Zone D Zone C Zon
33. e on the zone is transmitted to the Control Module via this terminal The type of the photosensor must be taken into account dark operated or light operated photosensor when configuring the respective ERCM ALARM In case the intensity of the photosensor beam is not satisfactory i e the photosensor gain factor is improper an alarm signal is transmitted to the Control Module An 8 pin connector is used for the above connections Fig 2 11 L Software POWER ZONE B e Sen Mot POWER j Left Link O Ethernet Software Right Link j Activity O Fig 2 11 Ethernet Roller Control Module User s Manual 2 11 2 7 ERCM ZONES Each Ethernet Roller Control Module ERCM incorporates up to four programmable zones Fig 2 11 hence one ERCM may control up to four conveyor zones The connection of several ERCMs to conveyor is illustrated in Fig 2 12 Direction of Conveyor Movement N N 1 N 2 N 3 N 4 N 5 N 6 N 7 N 8 N 9 N 10 N 11 71117 CONVEYOR ZONES GET 5505 GEL 1 ERCM ID No Fig 2 12 CS Based on the above ERCM zones will be considered henceforth taking into account that these ERCM zones rellect are related to the corresponding conveyor zones 2 8 LOCAL REMOTE ZONES The above terms reflect the fact that the zones belong to ERCM or belong to different ERCMs
34. et IP All run time properties of ERCM are mapped to instances of Assembly Object of implementation of CIP protocol All configuration properties Configuration1 Config TimersRoller ConfigTimersDivert are mapped to instances of Parameter Object and stored on internal flash memory when service Save service code 16hex is executed All internal local connections are also stored in Parameter Object Instances and stored to Flash Memory 5 1 10 Configuring and Building Connections Between Objects through PROFInet ERCM implements PROFInet ver 1 0 It uses PROFInet connection model with channel Configuration of module is done by adding Constant Connections to configuration properties Internal connections are done by adding Local Connections Intermodule connections are done by adding Connections All 3 type of connections are added using ICBAccoMgt AddConnection method All connections and configuration are stored on Flash on ICBAPersist Save method 5 1 11 Mixing Protocols in Powered Roller Control System When you use to build conveyor system you can mix devices with different network protocols On the Fig 5 14 ERCMs are configured with PROFInet tool but Allen Bradley PLC SLC5 05 is used to control diverter actuator SLC5 05 can make connection to Message Router object and Read Control Zone s object DivertCmd and DivertAck properties Also Modbus TCP monitoring tool can be used on same devices
35. gTimersRoller ConfigTimersRoller ConfigTimersDivert iri ConfigTimersDivert ConfigTimersDivert DivertACK DivertACK DivertACK TrackingOutC TrackingOutC TrackingOutC TrackingL TrackingL TrackingL TrackingC TrackingC TrackingC Trackin R Trackin R Trackin R TrackingR So TrackingR TrackingR From Downstream A Network Module To Upstream Network Module Zone D Zone C Zone B Zone A From Upstream Network Module UpL UpL UpL UpL UpC StateL UpC StateL UpC StateL UpC StateL To Downstream UpR UpR UpR UpR Network Module P Down StateC DownL StateC DUREE StateC DownL StateC r DownC r DownC DownC gt DownC DownR StateR DownR StateR DownR StateR DownR StateR AccJog AccJog AccJog Configuration1 Divenne Configuration1 sud Configuration1 Bud Configuration US ConfigTimersRoller ConfigTimersRoller ConfigTimersRoller I ConfigTimersRoller ConfigTimersDivert ConfigTimersDivert ConfigTimersDivert ConfigTimersDivert DivertACK DivertACK DivertACK DivertACK f TrackingL TrackingOutC TrackingL TrackingOutC TrackingL TrackingOutC TrackingL TrackingOutC TrackingC 2 TrackingC TrackingC TrackingC TrackingR TrackingOutR TrackingR TrackingOutR TrackingR TrackingOutR TrackingR TrackingOutR To Upstream From Downstream Network Module Network Module Four Zone Controller Fig
36. ink O Activity C Fig 3 1 i The Control Module may be configured as a POWERED ROLLER CONTROL MODULE or as a MERGER CONTROL MODULE or as DIVERT CONTROL MODULE Therefore the Control Module generally is referred to as ETHERNET POWERED ROLLER CONTROL MODULE or for short ERCM Ethernet Roller Control Module User s Manual 3 1 Each ERCM incorporates four equal zones Each of 4 zones can be used as linear merge or divert zones Each ERCM provides the following features Two Ethernet RJ 45 jacks internally connected with Ethernet switch Two bicolor Ethernet and Application Status LED indicators Two Ethernet Link LED indicators One Ethernet activity LED indicator 24V DC Purge input for clearing conveyor even without communication for 24V DC power supply Apr 100 mA sink current Power LED indicator Installation Push button Photosensor and Powered Roller interfaces per zone four zones altogether Two bicolor Zone Status LED indicators per zone four zones altogether The above features are illustrated in the respective group fields on the Front Panel shown in Fig 3 2 PHOTO SENSOR AND POWERED ROLLER INTERFACE CONNECTORS ERCM 24 V DC POWER SUPPLY CONNECTOR i T i B i F 1 4 FL Ti a T L AL L IL L ZONEA ZONE B Los ZONE D Sen Mot Sen Mot POWER Sen Mot Sen Mot Purge RS232 Left
37. laced on the conveyor it will be transported transferred along the conveyor due to the rotation of the conveyor rollers The conveyor provides one Main Direction of package transportation this is the case when the conveyor is on RUN GO mode of operation The opposite direction is referred to as INVERSE or also referred to as REVERSE THIS SPACE IS LEFT INTENTIONALLY BLANK Ethernet Roller Control Module User s Manual 2 1 LNSWSAOW dO NOILLO3YI0 NIVIN 5 Ethernet Roller Control Module User s Manual 2 2 2 2 CONVEYOR ZONE Basic cells referred to as zones Fig 2 2 assemble the conveyor zone consists of a set of slave rollers driven by means belts or chains by one Powered Roller The zones are well recognized in Fig 2 1 gt Slave Powered Rollers Roller As shown in Fig 2 2 a zone consists of One motorized master roller referred to as Powered Roller A DC brushless motor usually incorporated with the roller itself for example ITOH Powered rollers drives the powered roller An interface electronic card is used as an indispensable part to serve as DC motor I O interface referred to as Roller brushless interface set of slave rollers driven by the powered roller One photosensor used to sense the presence of the package on the zone
38. maximum traffic throughput of the system If cyclic connections are used it s better to configure them with unicast addresses Ethernet Roller Control Module User s Manual 5 11 5 1 14 Configuring ERCM Conveyor Control System with RollOn M Configuration Tool Although ERCM can be configured with Ethernet IP configuration tools or PROFInet Map configuration tool easiest way to build conveyor system is RollOn configuration tool Engineering of the system is like LEGO play with easy drag amp drop interface Commissioning is few minutes process with Walk and press functionality RollOn takes care about all internal connections configuration inter module connections Additionally each ERCM has simple web server with configuration Java Applet so you may configure simple systems without any configuration tool Build in ftp server takes care for firmware upgrade web page upgrade eds files and XML Interface description 5 1 15 Older System Support and Investment Protect Industrial Software manufactures Ethernet LonWorks Gateway module and RollOn plug in for it to enable building upgrading older LonWorks based conveyor control systems with ERCM Devices ndustrial oftware 5 12 Ethernet Roller Control Module User s Manual CHAPTER 6 ERCM AND QATEWAY ELECTRONIC DATA SHEETS 6 1 6 2 6 3 6 4 GENERAL ERCM EDS FILE ETHERNET IP ERCM XML INTERFACE DESCRIPTION PROFINET PROFILON GAT
39. mmon lane Diverting points amp arrival points doesn t require additional barcode scanners 5 1 7 Working with ERCM through Ethernet IP amp PROFInet Ethernet IP PROFInet and Modbus TCP protocols are running concurrently at same time in ERCM so you may use any of them to Read Write Properties of Zone objects in ERCM and monitor it s state Only Ethernet IP or PROFInet can be used to configure devices or build connections both local or between devices 5 8 Ethernet Roller Control Module User s Manual lUnknown Phisical Device PDev_RollerControl Industrial Software IUnknown IUnknown 9 E O Logical Device U RT Auto In LDev RollerControl RollerZoneA E NEM Q to O RollerZoneB eri IUnkmown to RollerZoneC O O RollerZoneD A ACCO Zone A UpL Upc Zone B UpR UpL DownL UpC Zone C DownC UpR UpL DownR DownL UpC AccJog DownC UpR Configuratic DownR DownL ConfigTime AccJog DownC ConfigTime Configuratic DownR DivertACK AccJog TrackingL ConfigTime Configuratic ModBus TCP TrackingC DivertACK TrackingR TrackingL ConfigTime TrackingC DivertACK TrackingR TrackingL Holding Registers TrackingR Roller Control Unconnected Message Manager CIP Ethernet IP Object Model Industrial Software Connection Manager Message Router Fig 5 13 Ether
40. net Roller Control Module User s Manual 4 6 COMPLETE SYSTEM WIRING The complete system wiring is illustrated in Fig 4 6 2d 10 YIUMS OL dlif 1299uuo 55012 Alddns 3d A vc St 3464 ya7 3OVJM3LNI s m 19413413 N 300N 53091 11 S3NOZ s s m 10 emajes YIUMS anhH OL din P3uuos 55013 dl 2290002 855012 AlddNS AlddNS A v A vc Sy Sy TT Jybiy wy 3OV4M3LNI JOVAYSLNI 39419433 0 3I00N S3NOZ S39Vd3331NI S3NOZ ANITIVNSIS 390 A 05 01 4 5 Ethernet Roller Control Module User s Manual 5 1 5 1 1 5 1 2 5 1 3 5 1 4 5 1 5 5 1 6 5 1 7 5 1 8 5 1 9 5 1 10 5 1 11 5 1 12 5 1 13 CHAPTER 5 ERCM PRINCIPLES OF OPERATION INTRODUCTON More Objects Not Only Ethernet Ethernet IP and PROFInet Principals of Operation of Each Zone Using ERCM for Linear Transfer and Merge Operation Using ERCM for Divert Operation Barcode Tracking Working with ERCM through Ethernet IP amp PROFInet Configuration Properties Configuring and Building Connections Between Objects through Ethernet IP Configuring and Building Connections Between Objects through PRO
41. net Roller Control Module User s Manual Zone D UpL UpG UpR DownL DownC DownR AccJog Configuration ConfigTimersRoller ConfigTimersDivert DivertACK TrackingL TrackingC TrackingR Application Data Transports StateL StateC StateR DivertCmd TrackingOutL TrackingOutC TrackingOutR 9 9 5 1 8 Configuration Properties Each zone has few configuration properties Each property is divided in fields which configure different functionality of the device For example Configuration1 Property has following fields Sensor Type Field Light Dark operated Zone Mode Field train singulation Sensor Error Usage Field Sensor Error or External Infeed Input or External Accumulation Field force or Push Request Motor Error Usage Field Motor Error or External Accumulation Field force or Push Request Inverse Output Usage Field Field Inverse Infeed End Output Discharge End Output Silent Receive Field can configure Silent rollers not rotating receive of cartons for any of upstream incoming lanes Purge Input Usage Purge Change Direction Input Divert Command Set Field developer can choose between 8 different command sets send to acknowledged from Actuator Control PLC All configuration properties are saved on flash when appropriate service is invoked from Ethernet IP or PROF Inet 5 1 9 Configuring and Building Connections Between Objects through Ethern
42. ogrammed for different functions during ERCM configuration Ethernet Roller Control Module User s Manual 3 5 L 1 A Both Sensors Input and Sensors Error inputs are intended for use with 24V DC open collector transistor outputs from sensors For different type of sensors please call Industrial Software CS ERCM can be configured to work with Light Operated or Dark Operated sensors individually on each zone 3 1 9 2 Powered Roller Interface 4 pins are available for Roller Interface connections This interface can be directly connected to ITON Brushless power drive cards Common pin this pin have to be connected to common pin of Roller Driver card Run output pin open collector 20 mA sink output connected to Run input of Roller Driver card Direction Inverse output pin Open collector 20 mA sink output connected to Direction input of Roller Driver card If reversing feature of ERCM is not used this pin may be left not connected Motor Error Input pin this pin is input for ERCM to receive motor error signal CS Motor error input and Direction output pin can be programmed for different functions during ERCM configuration A Run and Direction outputs are open collector outputs so direct connection of 24V DC to these pins may damage them 3 1 10 Zone Status LED Indicators The zone status LED indicators are grouped in two separate field sections motor section and sensor section 3 1 10 1 Sensor Zone
43. on 3 2 1 DIN Rail Version Sizes and Mechanical Installation The respective sizes of ERCM are shown in Fig 3 4 The mechanical installation of ERCM is executed in the following order a Drill two clearance holes for mounting DIN rail b Mount the rail c Mount the module on the rail ZONE A 20 24 VDC ZONE D Sen Mot Sen Sen Mot Sen Mot Purge RS232 Left LinkO Software Rig ht Link ES Po Left Ethernet Roller Control Module User s Manual 3 7 3 2 2 Rail Version Sizes The respective sizes of ERCM are shown in Fig 3 4 1 lt 159 gt A Zone A Zone B Zone C o 0 Mot Mot Mot Mot gt ndustrial Left Link Right Link Software amp e Activity POWER Y Fig 3 4 1 3 3 ERCM TERMINALS The connectors layout is shown in Fig 3 5 PHOTO SENSOR AND POWERED ROLLER INTERFACE CONNECTORS ERCM 24 V DC POWER SUPPLY ZONEA ZONE B ZONE C ZONE D Sen Sen Sen Sen LIP Ethernet Purge ads Lert Mf Software Right Link ActivityO PURGE INPUT CONNECTOR RJ 45 ETHERNET CONNECTORS Fig 3 5 3 8 Ethernet Roller Control Module User s Manual 3 3 1 Photosensor Powered Roller Connectors The connector pin out information related to Photosensor Powered Roller interface is outlined in Table 3 1 Table 3 1 INPUT ERROR ROLLER INVERSE INTERF
44. re represented in two manners The figures are preceded by e g 0x5FA3 Using a mark h at the end of the figures e g 5FA3h 1 4 SAFETY AND OPERATING INSTRUCTIONS The Ethernet Roller Control Modules ERCM are quality products which have been manufactured according to recognized electrical engineering regulations The modules have left the manufacturing company s premises meeting all relevant safety requirements In order to preserve this condition and to ensure an interference free operation of the modules the technical specifications outlined in this documentation must be observed C Field of application material handling systems A Skilled electricians may only install the modules The modules may only be operated within the limits defined in the technical data The maximum operating voltages must not be exceeded The neighboring parts as well as the installation of the cable system may produce a significant influence on the EMC of the modules Therefore the electrician has to ensure the EMC of the entire system gt In regions endangered by electrostatic discharges a good ESD protection for the plugs and the cables to be connected should be provided 1 2 Ethernet Roller Control Module User s Manual 91 7 2 GENERAL INFORMATION 2 1 POWERED ROLLER CONVEYOR CONFIGURATION 2 2 CONVEYOR ZONE 2 9 UPSTREAM DOWNSTREAM CONVEYOR ZONES
45. receding zone Zone A basic linear or curved cell of the conveyor consisting of a set of slave rollers driven by one Powered Roller The similar basic cell of the ERCM dedicated to a conveyor zone 2 16 Ethernet Roller Control Module User s Manual CHAPTER 3 ETHERNET POWERED ROLLER CONTROL MODULE 3 1 3 1 1 3 1 2 3 1 3 3 1 4 3 1 5 3 1 6 3 1 7 3 1 8 3 1 9 3 1 9 1 3 1 9 2 GENERAL DESCRIPTION Ethernet RJ 45 Jacks Ethernet and Application Status LED Indicators Left Right Link LEDs Activity LED Purge Input Power Supply Power LED Indicator Installation Push Button Photosensor and Powered Roller Interfaces Photosensor Interface Powered Roller Interface Ethernet Roller Control Module User s Manual 3 1 10 Zone Status LED Indicators 3 1 10 1 Sensor Zone Status LED Indicators 3 1 10 2 Motor Zone Status LED Indicators 3 2 ERCM SIZE AND MECHANICAL INSTALLATION 3 2 1 DIN Rail Version Sizes Mechanical Installation 3 2 2 OEM Rail Version Sizes 3 3 ERCM TERMINALS 3 3 1 Photosensor Powered Roller Connectors 3 3 2 ERCM Power Connector 3 3 3 Purge Connector 3 3 4 Ethernet Connector 3 4 ERCM SPECIFICATIONS Ethernet Roller Control Module User s Manual 3 1 GENERAL DESCRIPTION The Ethernet Control Module is shown in Fig 3 1 ndustrial Software POWER POWER ort tink Ethernet _ Soltware fF right L
46. s ERCM sends commands and receives acknowledges to from actuator control This is very flexible mechanism as you may use same design for different type of diverter devices only changing PLC program for actuator control and few settings of ERCM Example how to use ERCM for divert operations is shown on Fig 5 10 It can be both two way pusher or pop up diverter Here Zone is a divert zone with downstream zones Zone B is zone without diverting of cartons and Zones A and C on which cartons are diverted Ethernet Roller Control Module User s Manual 5 5 Main Lane Central Lane From To Actuator Control PLC or Industrial Software Ethernet I O Divert zone Divert Lane Main Lane Central Lane i Zone D From Upstream UpL Network Module ua UPC UpR DownL StateC mM EP DownR StateR AccJog Configuration1 ConfigTimersRoller ConfigTimersDivert Vereine DivertACK TrackingOutC TrackingG I TrackingR TrackingOutR To Upstream Network Module lt From To Downstream StateL Network Module m StateC gt StateR DivertCmd ConfgTimersRoler Trasingout TrackingOutC w TrackingOutR lt From To Downstream StateL Network Module boa StateC 7 gt StateR a
47. t EE T PEL PU P EE Rue EE NE I HE py LEM H 25 z HE PR Fa THE 022020200 HH OO HERE um JOSEP lt i utu EE Divert Lane ug ass Fig 2 8 This is example pop up divert area Divert Lane stet i tst ns c PORO OA oe Pon nr ot ee oe PSA gt p D M y PAE IR ea ee Main Lane Main Lane Gs 72 tt a ta epre 4 Divert zone N MS 2 M LJ s Fig 2 9 2 8 Ethernet Roller Control Module User s Manual 2 5 CONVEYOR MODES OF OPERATION Several typical conveyor modes operation must be explained in order to facilitate the appreciation of the description to follow 2 5 1 Regular Mode of Operation The conveyor is transferring the packages in a ordinary way during this mode of operation 2 5 2 Accumulation This mode operation is pertinent to the zone condition when the conveyor zone contains package s and is holding i e Full and stopped the package until th
48. ted Network Status Steady Hed The device has detected that its IP address already is used Network Status Steady Green The device has at least one established connection and all connections are OK 3 1 3 Left Right Link LEDs Two Green Left Right Link LEDs indicate that appropriate RJ 45 port is connected to a valid Ethernet node other ERCM PC HUB Switch Gateway Router On Connected Off Not connected Flickering Data transfer on appropriate port 3 1 4 Activity LED This Red LED indicates activity receive or transmit on third internal switch port On Receive or transmit in progress Off No activity 3 1 5 Purge Input This is polarity insensitive input for clearing the conveyor 24V DC on this pin will run all four Rollers i e the four conveyor zones connected to ERCM Ethernet Roller Control Module User s Manual 3 3 L 1 The 24V DC and Purge connectors of ERCM are of the same type Error connection 24V DC on Purge connector or the Purge signal on 24V DC connector will NOT damage the device but may force the system into a not functioning mode until the error connection is removed C The Purge mode of operation may be not required and is not used by the customer In this case the module may be configured in such a way that to use the Purge input for other functions such as Inverse direction of conveyor s movement Accumulation mode of operation of specific ERCM zone etc
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