Supplementary Document to the Interroll MultiControl User Manual Firmware version 2.1 ZPA

Transcription

1 Supplementary Document to the Interroll MultiControl User Manual Firmware version 2.1 ZPA o Single release o Train release o Transfer In o Transfer Out o HPD o Merge Semi-automatic Transfer HPD I/O device Teach In Plug&play This document is valid only in conjunction with the operating instructions Interroll MultiControl Version 2.3 (01/2017).

2 Table of contents Product description... 5 Use... 5 Settings in the web interface... 6 Motor settings... 6 Digital I/O settings... 7 Example: Start sensor... 8 Example: Stopping Zone Digital I/O states... 9 Control Program Selection Control Timer Error settings Network error Overvoltage error Undervoltage error Motor error Network settings Examples of network settings Example 1: Conveyor with three MultiControls Example 2: Conveyors and transfer with five MultiControls Up/download Saving the data Uploading the data ZPA program with stop function for straight sections and curves Single release Train release Handover (handshake ) ZPA -programs Transfer In /Transfer Out Transfer In Handover (handshake ) Transfer Out Handover (handshake ) HPD (High Performance Divert)

3 Handover (handshake ) Merge Handover (handshake ) Semi-automatic programs Transfer HPD I/O device Motor settings Specific parameters (only Transfer and HPD) in the I/O Device Transfer HPD Teach-in process Reading in the motors Assigning the slave RollerDrive Aborting the teach-in process Configuring the sensors Plug-and-play Plug-and-play semi-automatic Help in case of problems Appendix Overview of process images PAE PAA Inputs (observing and analyzing) PAE, process image Universal Full PAE, process image Universal Compact PAE, process image I/O Mode PAE, process image Control Mode PAE, process image I/O Mode Tiny Outputs (control) PAE, process image Universal Full PAA, process image Universal Compact PAA, process image I/O Mode

4 PAA, process image Control Mode PAA, process image I/O Mode Tiny Interface Box Signal flow Legal disclaimer

5 Product description The MultiControl can be operated in various operating modes: as an I/O device (fully SPScontrolled), semi-automatic (partially SPS-controlled), and fully automatic (without SPS). A MultiControl can control up to four RollerDrives with different rpm levels, acceleration rates, and deceleration rates. In addition to the four sensor inputs, four inputs or outputs can be configured freely. Depending on the ZPA program selected (zero pressure accumulation), the conveying process can be influenced by an SPS. When operated as an I/O device, an SPS controls the motors without influence by a ZPA program. Each MultiControl controls up to four zones. One zone corresponds to one conveyor section consisting of RollerDrive, rotating rollers, and the corresponding sensors and switches. Depending on the ZPA program selected, it is possible to assign up to three slave RollerDrives. The combination of a MultiControl and the associated zones, RollerDrive, and sensors is referred to as a module. To configure larger conveying systems, multiple modules can be linked together. For this purpose, different IP addresses are assigned to the MultiControl. The connection to additional conveying systems is done by means of configurable inputs/outputs. Data interchange with a master control system (SPS) is done via the field bus systems PROFINET, EtherNet/IP, or EtherCat. Note: EtherCat can be used only as an I/O device The MultiControl has an integrated web server, which generates a user interface for configuration of the MultiControl. On a computer connected to the MultiControl, this user interface can be called up in a web browser. Except for a web browser, no other software has to be installed on the computer. Use Control program with stop function for straight sections and curves o Single release o Train release Control program Transfer In/Transfer Out o Transfer In o Transfer Out o High Performance Divert (HPD) o Merge Semi-automatic programs 5

6 o Transfer o HPD I/O device without ZPA functions EtherCat can be used only as an I/O device Settings in the web interface Motor settings Deactivate motors that are not being used, in order to avoid errors. If a motor is activated but not connected, the LED RD1 4 lights up. Set roller diameter, gearing ratio, and normal speed in accordance with the RollerDrive used. In the I/O device control program, the speed setting in % is based on the value set here under normal speed. Use the parameter direction to adjust the turning direction of RollerDrive according to the installation position (turning direction viewed from the end of the cable of the RollerDrive). Acceleration and deceleration change the start/stop behavior of the RollerDrive. The parameter alternate speed currently has no function. Note: Altered parameters must be transferred to the MultiControl by hitting the Submit button. 6

7 Digital I/O settings Sensors 1 to 4 are always assigned to the zone sensors. In order to use the additional I/O, a Y-cable must be connected. I/O 1 to I/O 4 can be configured as inputs or outputs with the following functions: I/O functions 1 to 4: Function Description PLC input Input signal from SPS PLC output Output signal to SPS Sensor 5 Start sensor for Zone 1; polarity must be negative Control input 1 Stops Zone 1 Control input 2 Stops Zone 2 Control input 3 Stops Zone 3 Control input 4 Stops Zone 4 Control output 1 Output signal, Zone 1 blocked Control output 2 Output signal, Zone 2 blocked Control output 3 Output signal, Zone 3 blocked Control output 4 Output signal, Zone 4 blocked Handshake In Up Receive conveyed item in start zone Handshake In Down Discharge conveyed item from end zone Handshake Out Up Start zone is free Handshake Out Down End zone is blocked These functions have no effect on the I/O device control program. Depending on the control program selected, the functions vary; see description of control programs. 7

8 Note: Altered parameters must be transferred to the MultiControl by hitting the Submit button. Example: Start sensor I/O 1 Function = Sensor 5 Polarity = negative The sensor connected to I/O 1 is configured as the start sensor. 8

9 Example: Stopping Zone 3 I/O 2 Function = Control input 3 The third zone is stopped with a signal to I/O 2. I/O 4 Function = Control output 3 The status (zone sensor blocked) of the third zone is output at I/O 4. Digital I/O states Display of the switching states of the connected sensors and I/O. Status changes become visible only after refreshing the web browser (Key F5). 9

10 Control Program Selection ZPA single release system ZPA train release system ZPA modul No ZPA Program ID Program ID Program ID Program ID ZPA Single Release 1 Zone ZPA Train Release 1 Zone ZPA Transfer In I/O device ZPA Single Release 2 Zone ZPA Train Release 2 Zone ZPA Transfer Out ZPA Single Release 3 Zone ZPA Train Release 3 Zone ZPA Merge ZPA Single Release 4 Zone ZPA Train Release 4 Zone ZPA HPD HPD semi-automatic Transfer semi-automatic Control Timer Timer 1: Timer 2: Timer 3: Timer 4: Single release: Transfer communication time Train release: time-delayed start of RollerDrive Internal conveyed item monitoring After-run of RollerDrive Fault reset The timer parameters apply for all zones. The default parameters can be adapted to the specific conveying system. Note: Depending on the control program selected, the functions and default settings of the timer vary; see descriptions of the control programs. Note: Altered parameters must be transferred to the MultiControl by hitting the Submit button. 10

11 Error settings Network error Monitoring the communication between MultiControl and SPS. Ignore Warning Immediate stop The default setting is Warning. Error is not displayed. Error is displayed by a 2x-blinking fault LED. The conveying process is not interrupted. Error is displayed by a 2x-blinking fault LED. The conveying process is interrupted. If the MultiControl is operated without SPS, the Ignore setting is recommended. If the MultiControl is operated with an SPS, the Immediate stop setting is recommended. Overvoltage error If the supply voltage is too high, it is indicated by the 6x-blinking fault LED. Ignore Warning Immediate stop The default setting is Warning. Undervoltage error Error is not displayed. Error is displayed by blinking fault LED. The conveying process is not interrupted. Error is displayed by a blinking fault LED. The conveying process is interrupted. If the supply voltage is too low, it is indicated by the 5x-blinking fault LED. Ignore Warning Immediate stop The default setting is Warning. Error is not displayed. Error is displayed by blinking fault LED. The conveying process is not interrupted. Error is displayed by a blinking fault LED. The conveying process is interrupted. 11

12 Motor error Monitoring the motors. Ignore: Immediate stop: Warning Error is not displayed. Error is displayed by a 3x-blinking fault LED. Other motors connected to the MultiControl stop. Error is displayed by a 3x-blinking fault LED. Other motors connected to the MultiControl turn. Once the error is no longer present, the LED goes out. Note: Altered parameters must be transferred to the MultiControl by hitting the Submit button. Changes take effect only after switching the system off/on. The control settings for errors 1 8 have no function. Immediate stop and normal stop behave in the same way. 12

13 Network settings If the MultiControl is to be connected to a master control system, the associated bus protocol must be selected. As delivered, the IP address of the MultiControl is ; the IP address can be changed in the field IP address. All MultiControls must be in the same sub-network; the default setting is This makes it theoretically possible to set up a conveyor with 253 MultiControls. For larger conveyors, the network mask can be adjusted accordingly. In the field Host name, a name is assigned to the MultiControl. The default name is MultiControl. When issuing the name, the Profinet naming conventions must be observed. The position in the conveying system is determined under neighbors. IP address upstream is the previous neighbor. IP address downstream is the next neighbor. Depending on the control program selected, it can be necessary to make other neighbors settings. (See Example 2: Conveyors and transfer.) For communication among multiple MultiControls, it is necessary to connect them together with a PROFINET network cable, even if no master control system is used. Note: Altered parameters must be transferred to the MultiControl by hitting the Submit button. 13

14 Examples of network settings Example 1: Conveyor with three MultiControls MultiControl 1: Control program ZPA Single Release 4 Zone MultiControl 2: Control program: ZPA Single Release 4 Zone 14

15 MultiControl 3: Control program: ZPA Single Release 4 Zone 15

16 Example 2: Conveyors and transfer with five MultiControls MultiControl 1: Control program: ZPA Single Release 4 Zone 16

17 MultiControl 2: Control program: ZPA Single Release 4 Zone MultiControl 3: Control program: ZPA Single Release 4 Zone 17

18 MultiControl 4: Control program: ZPA Single Release 4 Zone MultiControl 5: Control program: ZPA Transfer In/Out 18

19 Up/download The download function can be used to download configuration data from a MultiControl and store it on the PC. The upload function makes it possible to read data into a MultiControl. Bus config saves the data of the network settings. Application config saves the program data. Saving the data Place the mouse cursor on the Download button and open the menu with a right mouse click. Select the save location using Save target as. Uploading the data Click on the Upload button. Select the save file in the target directory. Clicking on the Upload button transfers the data to the MultiControl. After the files are uploaded, the MultiControl must be restarted, so that the settings can be activated. 19

20 ZPA program with stop function for straight sections and curves The programs single release and train release make conveying with zero pressure accumulation possible. The conveyed items are held back until the logic detects that the next zone is free. If the conveyed items accumulate, a signal is sent to the next upstream zone to hold back the conveyed items. There is always a gap between the goods being conveyed; there is no pressure accumulation. In single release, the removal occurs in individual zones; in train release the removal occurs in blocks, so that all the associated zones are free at nearly the same time. In the ZPA programs, one MultiControl can control up to four zones. Each zone can be stopped via an input signal or an SPS. The conveying process runs from upstream to downstream. The start zone is always Zone 1. It is not possible to define another zone as the start zone. If there is an active stop signal, the goods to be conveyed are still transported to the zone sensor. After deactivating the stop signal, the conveyed items are transported further, if the downstream zone is free. If the goods to be conveyed are removed from a stopped zone, and the stop signal is reset, the RollerDrive starts, and, after Timer 4 expires, the conveying process is continued. If the goods to be conveyed are placed in the zone sensor before Timer 4 expires, the conveying process starts immediately. As long as the conveyed items are stopped, the downstream zone always gets a free signal, not a blocked signal. After leaving the zone sensor, goods to be conveyed must reach the next zone sensor within the time for Timer 2. While Timer 2 is running, the upstream zone is stopped. After expiration of the Timer 2 time, the zone is interpreted as free, and the upstream zone can transfer goods in, because it is assumed that the conveyed items have been removed. If goods to be conveyed block the zone sensor, the RollerDrive stops after expiration of Timer 2 (internal conveyed items monitoring). After a pause, which is equivalent to Timer 2, the RollerDrive restarts. This process repeats itself until the goods to be conveyed have been removed from the zone sensor. As long as the zone sensor is blocked, the upstream zone is given a blocked signal. After the conveyed items have left the zone sensor, the RollerDrive continues to run as set for Timer 3 (run out delay). 20

21 Single release For single release the removal is done in individual zones. The parameter Timer 1 (connection monitoring) should not be changed. Free RollerDrive connections can be used as slave motors, as shown in the table (PAE Motor States). Control program Program ID ZPA Single Release 1 Zone ZPA Single Release 2 Zone ZPA Single Release 3 Zone ZPA Single Release 4 Zone Zones 1 Zone 2 Zones 3 Zones 4 Zones 21

22 SPS references as per process flow chart Universal Full (see attachment) PAE Sensors (Sensor 1 5) ID 1 Zone 2 Zones 3 Zones 4 Zones SPS reference (read) Byte B1 Sensor Zone 1 Sensor Zone 1 Sensor Zone 1 Sensor Zone 1 I: 0 0 B2 Not used Sensor Zone 2 Sensor Zone 2 Sensor Zone 2 I: 0 1 B3 Not used Not used Sensor Zone 3 Sensor Zone 3 I: 0 2 B4 Not used Not used Not used Sensor Zone 4 I: 0 3 B5 Start sensor Zone 1 Start sensor Zone 1 Start sensor Zone 1 Start sensor Zone 1 I: 0 4 Bit PAE Motor States (Speed 1 4) ID 1 Zone 2 Zones 3 Zones 4 Zones SPS reference (read) M1 Motor Zone 1 Motor Zone 1 Motor Zone 1 Motor Zone 1 I: 3 M2 Slave Zone 1 Motor Zone 2 Motor Zone 2 Motor Zone 2 I: 4 M3 Slave Zone 1 Slave Zone 1 Motor Zone 3 Motor Zone 3 I: 5 M4 Slave Zone 1 Slave Zone 2 - Motor Zone 4 I: 6 Byte PAA Control Inputs Overwrite (Control Input 1 4) ID 1 Zone 2 Zones 3 Zones 4 Zones SPS reference (write) Byte CI1 Stop Zone 1 Stop Zone 1 Stop Zone 1 Stop Zone 1 Q: 5 0 CI2 Not used Stop Zone 2 Stop Zone 2 Stop Zone 2 Q: 5 1 CI3 Not used Not used Stop Zone 3 Stop Zone 3 Q: 5 2 CI4 Not used Not used Not used Stop Zone 4 Q: 5 3 Bit PAE Control Outputs (Control Output 1 4) ID 1 Zone 2 Zones 3 Zones 4 Zones SPS reference (read) Byte CO1 Zone 1 blocked Zone 1 blocked Zone 1 blocked Zone 1 blocked I: 28 0 CO2 Not used Zone 2 blocked Zone 2 blocked Zone 2 blocked I: 28 1 CO3 Not used Not used Zone 3 blocked Zone 3 blocked I: 28 2 CO4 Not used Not used Not used Zone 4 blocked I: 28 3 Bit 22

23 Timer ID Description Default [ms] T1 Connection monitoring 200 T2 Internal conveyed items monitoring 4,000 T3 After-run of RollerDrive 5,000 T4 Fault reset 1,000 Train release In train release the removal always occurs in blocks, so that all the associated zones are free at nearly the same time. After a system restart or after a fault incident, initialization is done in the mode single release. Then it is changed to train release mode. Free RollerDrive connections can be used as slave motors, as shown in the table PAE Motor States. Control program Program ID ZPA Train Release 1 Zone ZPA Train Release 2 Zone ZPA Train Release 3 Zone ZPA Train Release 4 Zone Zones 1 Zone 2 Zones 3 Zones 4 Zones 23

24 SPS references as per process flow chart Universal Full PAE Sensors (Sensor 1 5) ID 1 Zone 2 Zones 3 Zones 4 Zones SPS reference (read) Byte B1 Sensor Zone 1 Sensor Zone 1 Sensor Zone 1 Sensor Zone 1 I: 0 0 B2 Not used Sensor Zone 2 Sensor Zone 2 Sensor Zone 2 I: 0 1 B3 Not used Not used Sensor Zone 3 Sensor Zone 3 I: 0 2 B4 Not used Not used Not used Sensor Zone 4 I: 0 3 B5 Start Sensor Zone 1 Start Sensor Zone 1 Start Sensor Zone 1 Start Sensor Zone 1 I: 0 4 Bit PAE Motor States (Speed 1 4) ID 1 Zone 2 Zones 3 Zones 4 Zones SPS reference (read) M1 Motor Zone 1 Motor Zone 1 Motor Zone 1 Motor Zone 1 I: 3 M2 Slave Zone 1 Motor Zone 2 Motor Zone 2 Motor Zone 2 I: 4 M3 Slave Zone 1 Slave Zone 1 Motor Zone 3 Motor Zone 3 I: 5 M4 Slave Zone 1 Slave Zone 2 - Motor Zone 4 I: 6 Byte PAA Control Inputs Overwrite (Control Input 1 4) ID 1 Zone 2 Zones 3 Zones 4 Zones SPS reference (write) Byte CI1 Stop Zone 1 Stop Zone 1 Stop Zone 1 Stop Zone 1 Q: 5 0 CI2 Not used Stop Zone 2 Stop Zone 2 Stop Zone 2 Q: 5 1 CI3 Not used Not used Stop Zone 3 Stop Zone 3 Q: 5 2 CI4 Not used Not used Not used Stop Zone 4 Q: 5 3 Bit PAE Control Outputs (Control Output 1 4) ID 1 Zone 2 Zones 3 Zones 4 Zones SPS reference (read) Byte CO1 Zone 1 blocked Zone 1 blocked Zone 1 blocked Zone 1 blocked I: 28 0 CO2 Not used Zone 2 blocked Zone 2 blocked Zone 2 blocked I: 28 1 CO3 Not used Not used Zone 3 blocked Zone 3 blocked I: 28 2 CO4 Not used Not used Not used Zone 4 blocked I: 28 3 Bit 24

25 Timer ID Description Default [ms] T1 Train release time delay 100 T2 Internal conveyed items monitoring 4,000 T3 After-run of RollerDrive 5,000 T4 Fault reset 100 The parameter Timer 1 (train release delay time) influences the time-delayed starting of the RollerDrive in train release. Handover (handshake ) The exchange of the required information for the transport of conveyed items between the MultiControl and the external control system is carried out by means of handshake. Out Up = Signal from MultiControl Zone 1 is free In up = Signal to MultiControl Receive conveyed items in Zone 1 Out down = Signal from MultiControl Zone 4 is blocked In down = Signal to MultiControl Discharge conveyed items from Zone 4 SPS references as per process flow chart Universal Full PAE Handshake ID Zone Digital I/O settings SPS reference (read) Byte Bit Out Up Signal first zone free Handshake Out Up I: 29 4 Out Down Signal last zone blocked Handshake Out Down I:

26 PAA Handshake ID Zone Digital I/O settings SPS reference (write) Byte Bit In Up Signal transfer in to first zone Handshake In Up Q: 8 0 In Down Signal transfer out of last zone Handshake In Down Q: 8 1 Note: The signal for transferring the goods out must remain active until the conveyed items no longer block the zone sensor. If the signal is deactivated beforehand, the conveyed items remain in the blocked zone sensor. In train release, when the transfer out signal is reset, initialization is carried out in single release mode. The mode is then switched to train release. The signal for transferring goods in is an adequate impulse. The conveyed items are conveyed to the zone sensor. The length of the impulse must be at least 100 ms. ZPA -programs Transfer In /Transfer Out Note: These programs are possible only in single release. Transfer In With the control program Transfer In, it is possible to transfer conveyed items into the conveyor line from up to 2 additional infeeds. In accordance with the selected direction, the conveyed items are moved from upstream to the left or right, in each case downstream. The for selection of direction are set by an SPS. If an infeed is free in the setting Automatic merge, then the remaining infeeds are automatically handled alternately, in order to avoid a jam; see table merge prioritization. 26

27 SPS references as per process flow chart Universal Full PAE Sensors (Sensor 1 4) ID Description Connection MultiControl Type SPS reference (read) Byte B1 Sensor vertical zero position Sensor 1 PNP/positive I: 0 0 B2 Sensor infeed left Sensor 2 PNP/positive I: 0 1 (gap control) B3 Sensor infeed right Sensor 3 PNP/positive I: 0 2 (gap control) B4 Not used - - Bit Settings for transfer variants Transfer variant Connection MultiControl Type Up/Left/Right to Down - - Up/Left to Down Sensor 3 (B3) PNP/negative * Up/Right to Down Sensor 2 (B2) PNP/negative * Left to Down Sensor 3 (B3) PNP/negative * Right to Down Sensor 2 (B2) PNP/negative * Left/Right to Down - - *Setting in web server or via SDO, no sensor connected 27

28 PAE Motor States (Speed 1 4) ID Description Connection MultiControl Connection Interface Box M1 Motor lift drive - Motor 1 I: 3 M2 Motor belt drive - Motor 2 I: 4 M3 Motor conveyor roller RD 3 - I: 5 M4 Motor conveyor roller RD 4 - I: 6 SPS reference (read) Byte PAA Control Inputs Overwrite (Control Input 1 4) ID Description SPS reference (write) Byte CI1 Direction selection 1 Q: 5 0 CI2 Direction selection 2 Q: 5 1 CI3 Not used Not used CI4 Not used Not used Bit Direction selection CI2 CI1 Description 0 0 From Up to Down 0 1 From Left to Down 1 0 From Right to Down 1 1 Automatic merge 28

29 Merge prioritization Direction selection Up Left Right Decision From Up to Down Free Free Free No transport Free Free Blocked No transport Free Blocked Free No transport Free Blocked Blocked No transport Blocked Free Free From Up to Down Blocked Free Blocked From Up to Down Blocked Blocked Free From Up to Down Blocked Blocked Blocked From Up to Down From Left to Down Free Free Free No transport Free Free Blocked No transport Free Blocked Free From Left to Down Free Blocked Blocked From Left to Down Blocked Free Free No transport Blocked Free Blocked No transport Blocked Blocked Free From Left to Down Blocked Blocked Blocked From Left to Down From Right to Down Free Free Free No transport Free Free Blocked From Right to Down Free Blocked Free No transport Free Blocked Blocked From Right to Down Blocked Free Free No transport Blocked Free Blocked From Right to Down Blocked Blocked Free No transport Blocked Blocked Blocked From Right to Down Automatic merge Free Free Free No transport Free Free Blocked From Right to Down Free Blocked Free From Left to Down Free Blocked Blocked In order from Left/Right to Down Blocked Free Free From Up to Down Blocked Free Blocked In order from Up/Right to Down Blocked Blocked Free In order from Up/Left to Down Blocked Blocked Blocked In order from Up/Left/Right to Down 29

30 Handover (handshake ) The exchange of the required information for the transport of conveyed items between the MultiControl and an external control system is carried out by means of handshake. Out Left: Signal from MultiControl Transfer is free In Left: Signal to MultiControl Receive conveyed items from the left to transfer Out Right: Signal from MultiControl Transfer is free In Right: Signal to MultiControl Receive conveyed items from right to transfer PAE Handshake ID Zone SPS reference (read) Byte Out Left Signal: Transfer free I: 29 6 Out Right Signal: Transfer free I: 29 7 Bit PAA Handshake ID Zone SPS reference (write) Byte In Left Signal: Transfer in from left Q: 8 2 In Right Signal: Transfer in from right Q: 8 3 Bit Timer ID Description Basic setting [ms] T1 Connection monitoring 100 T2 Not used 2,000 T3 Fault reset 1,000 T4 Internal conveyed items monitoring 4,000 The parameter Timer 1 (connection monitoring) should not be changed. 30

31 Transfer Out With the Transfer Out program, it is possible to distribute conveyed items to a maximum of 2 additional outfeeds. The decision as to where goods are to be conveyed is queried when they are transferred in, meaning that the sensors must be arranged so that the information can be given to them in a timely fashion. If there is not enough time to ensure this, it is recommended that a stop function be set up on the MultiControl of the upstream conveyor, in order to avoid errors in reading and transferring out. If the downstream lateral conveyor is blocked, the transfer belt is run at a reduced speed. As soon as the downstream unit is free, normal speed is resumed. If an outfeed is blocked in the setting Automatic distribution, then the remaining outfeeds are automatically handled alternately, in order to avoid a jam; see table Distribution prioritization. 31

32 SPS references as per process flow chart Universal Full PAE Sensors (Sensor 1 4) ID Description Connection MultiControl Type SPS reference (read) Byte B1 Sensor vertical zero position Sensor 1 PNP/positive I: 0 0 B2 Sensor outfeed left Sensor 2 PNP/positive I: 0 1 B3 Sensor outfeed right Sensor 3 PNP/positive I: 0 2 B4 Sensor trailing edge query Sensor 4 PNP/positive I: 0 3 Bit Settings for transfer variants Transfer variant Connection MultiControl Type Up to Left/Right/Down - - Up to Left/Down Sensor 3 (B3) PNP/negative * Up to Right/Down Sensor 2 (B2) PNP/negative * Up to Left Sensor 3 (B3) PNP/negative * Up to Right Sensor 2 (B2) PNP/negative * Up to Left/Right - - *Setting in web server or via SDO, no sensor connected PAE Motor States (Speed 1 4) ID Description Connection MultiControl Connection Interface Box M1 Motor lift drive - Motor 1 I: 3 M2 Motor belt drive - Motor 2 I: 4 M3 Motor conveyor roller RD 3 - I: 5 M4 Motor conveyor roller RD 4 - I: 6 SPS reference (read) Byte PAA Control Inputs Overwrite (Control Input 1 4) ID Description SPS reference (write) Byte CI1 Direction selection 1 Q: 5 0 CI2 Direction selection 2 Q: 5 1 CI3 Not used Not used CI4 Not used Not used Bit 32

33 Direction selection CI2 CI1 Description 0 0 From Up to Down 0 1 From Up to Left 1 0 From Up to Right 1 1 Automatic distribution Distribution prioritization Direction selection Down Left Right Decision From Up to Down Free Free Free From Up to Down Free Free Blocked From Up to Down Free Blocked Free From Up to Down Free Blocked Blocked From Up to Down Blocked Free Free No transport Blocked Free Blocked No transport Blocked Blocked Free No transport Blocked Blocked Blocked No transport From Up to Left Free Free Free From Up to Left Free Free Blocked From Up to Left Free Blocked Free No transport Free Blocked Blocked No transport Blocked Free Free From Up to Left Blocked Free Blocked From Up to Left Blocked Blocked Free No transport Blocked Blocked Blocked No transport From Up to Right Free Free Free From Up to Right Free Free Blocked No transport Free Blocked Free From Up to Right Free Blocked Blocked No transport Blocked Free Free From Up to Right Blocked Free Blocked No transport Blocked Blocked Free From Up to Right Blocked Blocked Blocked No transport Automatic distribution Free Free Free In order to Left/Right/Down Free Free Blocked In order from Left/Down Free Blocked Free In order from Right/Down Free Blocked Blocked From Up to Down Blocked Free Free In order to Left/Right Blocked Free Blocked From Up to Left Blocked Blocked Free From Up to Right Blocked Blocked Blocked No transport 33

34 Handover (handshake ) The exchange of the required information for the transport of conveyed items between the MultiControl and an external control system is carried out by means of handshake. Out Left = Signal from MultiControl Conveyed items for left set to transfer In Left = Signal to MultiControl Conveyed items are to be transferred to the left Out Right = Signal from MultiControl Conveyed items for right set to transfer In Right = Signal to MultiControl Conveyed items are to be transferred to the right PAE Handshake ID Zone SPS reference (read) Byte Out Left Signal: Transfer blocked I: 29 6 Out Right Signal: Transfer blocked I: 29 7 Bit PAA Handshake ID Zone SPS reference (write) Byte In Left Signal: Transfer out to the left Q: 8 2 In Right Signal: Transfer out to the right Q: 8 3 Bit Timer ID Description Basic setting [ms] T1 Connection monitoring 100 T2 Not used 2,000 T3 Fault reset 1,000 T4 Internal conveyed items monitoring 5,000 The parameter Timer 1 (connection monitoring) should not be changed. 34

35 HPD (High Performance Divert) With the HPD program, it is possible to distribute conveyed items to a maximum of 2 additional outfeeds. The decision as to where goods are to be conveyed is queried when they are transferred in, meaning that the sensors must be arranged so that the information can be given to them in a timely fashion. If there is not enough time to ensure this, it is recommended that a stop function be set up on the MultiControl of the upstream conveyor, in order to avoid errors in reading and transferring out. If an outfeed is blocked in the setting Automatic distribution, then the remaining outfeeds are automatically handled alternately, in order to avoid a jam; see table Distribution prioritization. At a maximum, the HPD can rotate from +45 to

36 SPS references as per process flow chart Universal Full PAE Sensors (Sensor 1 4) ID Description Connection MultiControl Type SPS reference (read) Byte B1 0-position rotary actuator Sensor 1 PNP/negative I: 0 0 B2 Sensor outfeed left Sensor 2 PNP/positive I: 0 1 B3 Sensor outfeed right Sensor 3 PNP/positive I: 0 2 B4 Not used Bit Settings for HPD variants HPD variant Connection MultiControl Type Up to Left/Right/Down - - Up to Left/Down Sensor 3 (B3) PNP/negative * Up to Right/Down Sensor 2 (B2) PNP/negative * Up to Left Sensor 3 (B3) PNP/negative * Up to Right Sensor 2 (B2) PNP/negative * Up to Left/Right - - *Setting in web server or via SDO, no sensor connected PAE Motor States (Speed 1 4) ID Description Connection MultiControl Connection Interface Box M1 Motor rotary actuator drive - Motor 1 I: 3 M2 Motor conveyor roller drive - Motor 2 I: 4 M3 Motor outfeed left RD 3 - I: 5 M4 Motor outfeed right RD 4 - I: 6 SPS reference (read) Byte PAA Control Inputs Overwrite (Control Input 1 4) ID Description SPS reference (write) Byte CI1 Direction selection 1 Q: 5 0 CI2 Direction selection 2 Q: 5 1 CI3 Direction selection 3 Q: 5 2 CI4 Direction selection 4 Q: 5 3 Bit 36

37 Direction selection CI4 CI3 CI2 CI1 Description X X 0 0 From Up to Down X From Up to Left 45 0 X 1 0 From Up to Right 45 X From Up to Left 30 1 X 1 0 To right Automatic distribution right 45/left Automatic distribution right 30/left Automatic distribution right 30/left Automatic distribution right 45/left 30 Distribution prioritization Direction selection Down Left Right Decision From Up to Down Free Free Free From Up to Down Free Free Blocked From Up to Down Free Blocked Free From Up to Down Free Blocked Blocked From Up to Down Blocked Free Free No transport Blocked Free Blocked No transport Blocked Blocked Free No transport Blocked Blocked Blocked No transport From Up to Left Free Free Free From Up to Left Free Free Blocked From Up to Left Free Blocked Free No transport Free Blocked Blocked No transport Blocked Free Free From Up to Left Blocked Free Blocked From Up to Left Blocked Blocked Free No transport Blocked Blocked Blocked No transport From Up to Right Free Free Free From Up to Right Free Free Blocked No transport Free Blocked Free From Up to Right Free Blocked Blocked No transport Blocked Free Free From Up to Right Blocked Free Blocked No transport Blocked Blocked Free From Up to Right Blocked Blocked Blocked No transport Automatic distribution Free Free Free In order to Left/Right/Down Free Free Blocked In order from Left/Down Free Blocked Free In order from Right/Down 37

38 Free Blocked Blocked From Up to Down Blocked Free Free In order to Left/Right Blocked Free Blocked From Up to Left Blocked Blocked Free From Up to Right Blocked Blocked Blocked No transport Handover (handshake ) The exchange of the required information for the transport of conveyed items between the MultiControl and an external control system is carried out by means of handshake. Out Left = Signal from MultiControl Conveyed items for left are ready In Left = Signal to MultiControl Conveyed items are to be transferred to the left Out Right = Signal from MultiControl Conveyed items for right are ready In Right = Signal to MultiControl Conveyed items are to be transferred to the right PAE Handshake ID Zone SPS reference (read) Byte Out Left Signal: HPD blocked I: 29 6 Out Right Signal: HPD blocked I: 29 7 Bit PAA Handshake ID Zone SPS reference (write) Byte In Left Signal: Transfer out to the left Q: 8 2 In Right Signal: Transfer out to the right Q: 8 3 Bit Timer ID Description Basic setting [ms] T1 Connection monitoring 100 T2 Internal conveyed items monitoring 9,500 T3 Fault reset 1,000 T4 Step pulse 50 Note: The parameters Timer 1 to Timer 4 should not be changed. 38

39 Merge With the control program Merge, it is possible to transfer conveyed items into the conveyor line from up to 2 additional infeeds. If an infeed is free in the setting Automatic merge, then the remaining infeeds are automatically handled alternately, in order to avoid a jam; see table Merge prioritization. The parameter Timer 1 (connection monitoring) should not be changed. SPS references as per process flow chart Universal Full PAE Motor States (Speed 1 4) ID Description Connection MultiControl Connection Interface Box M1 Motor not used - - I: 3 M2 Motor not used - - I: 4 M3 Motor infeed left RD 3 - I: 5 M4 Motor infeed right RD 4 - I: 6 SPS reference (read) Byte 39

40 PAA Control Inputs Overwrite (Control Input 1 4) ID Description SPS reference (write) Byte CI1 Direction selection 1 Q: 5 0 CI2 Direction selection 2 Q: 5 1 CI3 Not used Not used CI4 Not used Not used Bit Direction selection CI2 CI1 Description 0 0 From Up to Down 0 1 From Left to Down 1 0 From Right to Down 1 1 Automatic merge Handover (handshake ) The exchange of the required information for the transport of conveyed items between the MultiControl and an external control system is carried out by means of handshake. Out Left = Signal from MultiControl Merge is free In Left = Signal to MultiControl Transfer conveyed items from the left Out Right = Signal from MultiControl Merge is free In Right = Signal to MultiControl Transfer conveyed items from the right PAE Handshake ID Zone SPS reference (read) Byte Out Left Signal: Merge free I: 29 6 Out Right Signal: Merge free I: 29 7 Bit PAA Handshake ID Zone SPS reference (write) Byte In Left Signal: Transfer in from left Q: 8 2 In Right Signal: Transfer in from right Q: 8 3 Bit 40

41 Merge prioritization Direction selection Up Left Right Decision From Up to Down Free Free Free No transport Free Free Blocked No transport Free Blocked Free No transport Free Blocked Blocked No transport Blocked Free Free From Up to Down Blocked Free Blocked From Up to Down Blocked Blocked Free From Up to Down Blocked Blocked Blocked From Up to Down From Left to Down Free Free Free No transport Free Free Blocked No transport Free Blocked Free From Left to Down Free Blocked Blocked From Left to Down Blocked Free Free No transport Blocked Free Blocked No transport Blocked Blocked Free From Left to Down Blocked Blocked Blocked From Left to Down From Right to Down Free Free Free No transport Free Free Blocked From Right to Down Free Blocked Free No transport Free Blocked Blocked From Right to Down Blocked Free Free No transport Blocked Free Blocked From Right to Down Blocked Blocked Free No transport Blocked Blocked Blocked From Right to Down Automatic merge Free Free Free No transport Free Free Blocked From Right to Down Free Blocked Free From Left to Down Free Blocked Blocked In order from Left/Right to Down Blocked Free Free From Up to Down Blocked Free Blocked In order from Up/Right to Down Blocked Blocked Free In order from Up/Left to Down Blocked Blocked Blocked In order from Up/Left/Right to Down Timer ID Description Basic setting [ms] T1 Connection monitoring 100 T2 Not used 2,000 T3 Fault reset 1,000 T4 Internal conveyed items monitoring 4,000 41

42 Semi-automatic programs In the semi-automatic program, it is possible to access the drives of the transfer with digital. Transfer SPS references as per process flow chart Universal Full PAE Sensors (Sensor 1 4) ID Description Connection MultiControl Type SPS reference (read) Byte B1 Sensor vertical zero position Sensor 1 PNP/positive I: 0 0 B2 Sensor outfeed links (gap Sensor 2 PNP/positive I: 0 1 control*) B3 Sensor outfeed right (gap Sensor 3 PNP/positive I: 0 2 control*) B4 Sensor trailing edge query Sensor 4 PNP/positive I: 0 3 * optional Bit 42

43 PAE Motor States (Speed 1 4) ID Description Connection MultiControl Connection Interface Box M1 Motor lift drive - Motor 1 I: 3 M2 Motor belt drive - Motor 2 I: 4 M3 Optional RD 3 - I: 5 M4 Optional RD 4 - I: 6 SPS reference (read) Byte PAA Control Inputs Overwrite (Control Input 1 4) ID High Low SPS reference (write) Byte Bit CI1 M1 release lift M1 lift off Q: 5 0 CI2 M1 lift up M1 lift down Q: 5 1 CI3 M2 belt drive to the right - Q: 5 2 CI4 M2 belt drive to the left - Q: 5 3 PAE Control Outputs (Control Output 1 4) ID High Low SPS reference (read) Byte Bit CO1 Stop Normal operations I: 28 0 CO2 Lift up Lift down I: 28 1 CO3 Operational Not used I: 28 2 CO4 Not operational Not used I: 28 3 Timer ID Description Basic setting [ms] T1 Fault reset (restart of the program after timeout) 2,000 T2 Not used 2,000 T3 Not used 2,000 T4 Monitoring time (Movement not ended within the time period, vertical zero position not reached) 2,000 43

44 HPD At a maximum, the HPD can rotate from +90 to 90. SPS references as per process flow chart Universal Full PAE Sensors (Sensor 1 4) ID Description Connection MultiControl Type SPS reference (read) Byte B1 Sensor 0-position rotary Sensor 1 PNP/negative I: 0 0 actuator B2 Sensor outfeed left Sensor 2 PNP/positive I: 0 1 B3 Sensor outfeed right Sensor 3 PNP/positive I: 0 2 B4 Not used Bit 44

45 PAE Motor States (Speed 1 4) ID Description Connection MultiControl Connection Interface Box M1 Motor rotary actuator drive - M1 I: 3 M2 Motor conveyor drive - M2 I: 4 M3 Motor outfeed left RD 3 - I: 5 M4 Motor outfeed right RD 4 - I: 6 SPS reference (read) Byte PAA Control Inputs Overwrite (Control Input 1 4) ID High Low SPS reference (write) Byte Bit CI1 Swivel to left Swivel to right Q: 5 0 CI2 Angle setting (see table) Angle setting (see table) Q: 5 1 CI3 Angle setting (see table) Angle setting (see table) Q: 5 2 CI4 Start M2, M3, M4 Stop M2, M3, M4 Q: 5 3 Select angle setting CI1 CI2 CI3 Angle setting (left) (left) (left) (right) (right) (right) Homing PAE Control Outputs (Control Output 1 4) ID H SPS reference (read) Byte Bit CO1 Homing I: 28 0 CO2 Not used I: 28 1 CO3 Operational I: 28 2 CO4 Not operational I:

46 Timer ID Description Basic setting [ms] T1 0-Positioning (homing) 1,000 T2 Internal conveyed items monitoring 9,500 T3 Fault reset 5,000 T4 Step pulse 50 Timer 1: Timer 2: Timer 3: Timer 4: Homing delay Start homing after T1 inactivity Homing timeout Sensor 1 was not found Error recovery Restart of program after timeout Step pulse Executes one step for all T4 during homing Note: The parameters Timer 1 to Timer 4 should not be changed. 46

47 I/O device In the I/O Device program, the motors and the inputs/outputs are controlled by a program created in the higher-level control system. The speed settings of the motors are made using positive or negative percentage target settings in the corresponding output bytes. In the master controller, the Move command is used for this purpose. The percentage target setting refers to the value normal speed that was set in the web server. Motor settings Motors not used must be deactivated, in order to avoid errors. Roller diameter, gearing ratio, and normal speed must be set in accordance with the RollerDrive used. Use the parameter direction to adjust the turning direction of RollerDrive according to the installation position (turning direction viewed from the end of the cable of the RollerDrive). Acceleration and deceleration change the start/stop behavior of the RollerDrive. The parameter alternate speed currently has no function. In the I/O Drive program, the speed setting in % is based on the value set here under normal speed". Note: Altered parameters must be transferred to the MultiControl by hitting the Submit button. 47

48 Specific parameters (only Transfer and HPD) in the I/O Device The MultiControl offers the use of Transfer or HPD as completely SPC-controlled device. All functions must be implemented by SPS. The MultiControl is a bus-slave device. Transfer The MultiControl is the interface to the two motors in transfer. SPS references as per process flow chart Universal Full PAE Sensors (Sensor 1 4) ID Description Connection MultiControl B1 Sensor lift drive 0=up, 1=down Type SPS reference (read) Byte Sensor 1 PNP/positive I: 0 0 Bit PAA Motor (speed 1 4) ID Description Connection MultiControl Connection Interface Box SPS reference (write) Byte M1 Motor lift drive - M1 Q: 1 M2 Motor belt drive - M2 Q: 2 PAE Motor States (Speed 1 4) ID Description Connection MultiControl Connection Interface Box M1 Motor lift drive - M1 I: 3 M2 Motor belt drive - M2 I: 4 SPS reference (read) Byte Motor 1 is controlled by the output byte Motor-Speed 1. Value 30 to 100 = The motor turns clockwise at a constant speed. As a result, the cam turns and lifts and lowers the Transfer. Motor 2 is controlled by the output byte Motor-Speed 2. Value 0 to +100 speed forward. Value 0 to 100 speed reverse. 48

49 HPD The MultiControl is the interface to the two motors in HPD. SPS references as per process flow chart Universal Full PAE Sensors (Sensor 1 4) ID Description Connection MultiControl B1 Sensor rotary actuator drive 0 position Type SPS reference (read) Byte Sensor 1 PNP/negative I: 0 0 Bit PAA Motor (speed 1 4) ID Description Connection MultiControl Connection Interface Box SPS reference (write) Byte M1 Motor rotary actuator drive - M1 Q: 1 M2 Motor conveyor roller drive - M2 Q: 2 PAE Motor States (Speed 1 4) ID Description Connection MultiControl Connection Interface Box M1 Motor rotary actuator drive - M1 I: 3 M2 Motor conveyor roller drive - M2 I: 4 SPS reference (read) Byte Motor 1 is controlled via the output byte Motor-Speed 1. Value 0 to 90 = Motor angle in right-to-left direction. Value 0 to 90 = Motor angle in left-to-right direction. The current position is shown in the input byte. Motor 2 is controlled by the output byte Motor-Speed 2. Value 0 to 100 speed forward. Value 0 to 100 speed reverse. Homing: When operating the HPD, it is possible that the conveyor rollers can turn out of the zero position. The HPD must therefore reference from time to time and correct the position of the conveyor rollers if necessary (homing). During this process the input byte Motor-Speed 1 displays the value 127. Once the zero position is reached, the value 0 is displayed. Value 127 = HPD adjusting to zero position (homing - straight, 0 ) 49

50 Note: We recommend doing the initialization regularly (such as once a minute), if the HPD is on or near the zero position and there is no conveying for about two seconds, because the process then takes less than 200 ms. If homing is started at another position, the process can take seconds. It is only possible to start a reference run every 30 seconds. Homing may be started only when the HPD is between +80 and 80, because otherwise it is not possible to do a correct reference run. What happens during homing? 1. If Sensor 1 = 0: Motor turns to the left, until Sensor 1 = 1. (finished) 2. If Sensor 1 = 1: Motor turns to the right, until Sensor 1 = 0. Then back to the left, until Sensor 1 = 1. (finished) 50

51 Teach-in process The teach-in process provides a way to address multiple MultiControls automatically; furthermore, the configuration of one MultiControl can be transferred to another MultiControl. The process can be initiated by using the magnetic key or by a function in the web server. After the teach-in is completed, all modules are in ZPA mode. If a setting in the first MultiControl is changed before the process, then the MultiControls are in the selected Control Program after the teach-in process. Example: Changed value MultiControl 1 Normal speed: 0.8 m/s IP address: Control program: I/O device After the teach-in, the system is in I/O Device; all RollerDrives are set to the speed 0.8 m/s; each IP address has been raised by the value of 1 ( , ,... ). The teach-in process is always started on the first MultiControl. At the handover point from one MultiControl to the next, all MultiControls are addressed. For this reason, the teach-in depends on the physical structure of the bus line (topology). In this process, the following settings are determined or specified: The network settings (host name, IP address, bus protocol, neighborhood addresses, etc.) The application settings (motor settings, control program, sensor settings, digital I/Os, etc.) The fault settings Prerequisites All MultiControls are in the delivery state or factory settings. Correct configuration of sensor types (type PNP/NPN and switching logic normally open/closed) All sensors must be of the same type. No items are on the conveyor. The process goes through multiple steps: Step 1: Reading in the motor configuration Step 2: Assigning the slave RollerDrive 51

52 Basic setting of the MultiControl All network, application, and fault settings of the first MultiControl can be changed before the teach-in process. The names (host name) and IP addresses of the additional connected MultiControls are each increased by 1 during the teach-in process. The settings of the first MultiControl are transferred to the following ones. Reading in the motors 1. Via web browser in the menu Service/Teach-In/Init 2. With the magnetic key: To start the teach-in process, the magnetic sensor must be actuated. When the magnetic sensor detects the magnet, the Fault LED lights up continuously. After one second, running lights start on the LED bar on the left side of the MultiControl. As soon as LED RD2 lights up, remove the magnet and wait until the running lights start in the right LED bar. Re-actuate the magnetic sensor. When LED I/O3 lights up, remove the magnet. The RollerDrives connected to the first MultiControl turn; with a slight delay, all the RollerDrives of the conveyor system also begin to turn. If a RollerDrive turns in a pulsing manner, another RollerDrive connected to the same MultiControl is inserted incorrectly or improperly. Assigning the slave RollerDrive 1. Via web browser in the menu Service/Teach-In/Start 2. With the magnet: With the magnet, again select the LED RD2 on the left side, remove the magnet, and wait until the running light lights up in the right LED bar. Re-actuate the magnetic sensor. When LED RD4 lights up, remove the magnet. If RollerDrives are connected to a MultiControl, but no corresponding zone sensors, they are detected as slave RollerDrives. The slave RollerDrives of a zone turn in a pulsing fashion. The slave RollerDrives are assigned by activating the corresponding zone sensor. Program: Assigned sensors and motors 4x accumulation area B1 (for M1), B2 (for M2), B3 (for M3), B4 (for M4) 3x accumulation area B1 (for M1), B2 (for M2), B3 (for M3) 2x accumulation area B1 (for M1 + M3), B2 (for M2 + M4) 1x accumulation area B1 (for M1+M2+M3+M4) 52

53 After all the slave RollerDrives have been assigned, the RollerDrive of the first zone begins to turn in an alternating fashion. As soon as the RollerDrive is turning in the desired conveying direction, place an item to be conveyed into the zone sensor of the first zone. The teach-in process now runs automatically. If the turning direction of a RollerDrive does not match the conveying direction, it is changed (conveyed items oscillate). Due to the necessary data transfer, there are pauses in the transitions from one MultiControl to the next. After the conveyed item has reached the last zone sensor, the conveyed item can be removed, because otherwise it will be transferred out of the last zone and fall down. The teach-in is completed automatically, and the conveyor is re-initialized. After the re-start, the system is operational. Note: After completion of the teach-in, it is possible to repeat the process to change settings (such as the speed of the RollerDrive). Aborting the teach-in process 1. Via web browser in the menu Service/Teach-In/Abort 2. With the magnet: In order to abort the teach-in process, the magnetic sensor must be actuated. When the magnetic sensor detects the magnet, the Fault LED lights up continuously. After one second, running lights start on the LED bar on the left side of MultiControl. As soon as LED RD2 lights up, remove the magnet and wait until the running light in the right LED bar lights up. Re-actuate the magnetic sensor. When LED Sensor 3 lights up, remove the magnet. Configuring the sensors If the sensor settings are changed and the ZPA program is desired, that must be set via the web browser. If the sensors do not match the factory settings of the MultiControl, it is possible to change them using the magnet. To do so, actuate the magnetic sensor. When the magnetic sensor detects the magnet, the Fault LED lights up continuously. After one second, a running light lights up on the LED bar on the left side of MultiControl. As soon as LED I/O1 lights up, remove the magnet and wait until the running light lights up in the right LED bar. Re-actuate the magnetic sensor. When LED of the desired sensor type lights up, remove the magnet. 53