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EN MultiControl Supplement Online
EN MultiControl Supplement Online
Supplement
Start-up and Programming
MultiControl AI/BI, RollerDrive EC5000 BI
Manufacturer details
Interroll Engineering GmbH
Höferhof 16
42929 Wermelskirchen
Germany
Tel.: +49 (0) 2193 23 0
Fax: +49 (0) 2193 2022
www.interroll.com
Content
We strive for the accuracy, timeliness and completeness of the information and have carefully prepared the contents
in this document. Regardless of this, errors and changes are expressly reserved.
Please direct any comments and suggestions regarding our manuals to manuals@interroll.com
Contents
7 Process data 32
7.1 Input process image 32
Sensors32
Digital I/O 33
Motor status 34
System status 35
Other signals 35
7.2 Output process image 38
Digital outputs 38
Motors38
EC31039
Other signals 40
8 Different process images 42
8.1 Process image “Universal Full” 43
IPI, Input process image “Universal Full” 43
OPI, Output process image “Universal Full” 46
8.2 Process image “Universal Compact” 48
IPI, Input process image “Universal Compact” 48
EC500052
OPI, Output process image “Universal Compact” 53
8.3 Process image “I/O Mode” 56
IPI, Input process image “I/O Mode” 56
OPI, Output process image “I/O Mode” 58
8.4 Process image “Control Mode” 59
IPI, Input process image “Control Mode” 59
OPI, Output process image “Control Mode” 62
8.5 Process image “I/O Tiny Mode” 64
IPI, Input process image “I/O Tiny Mode” 64
OPI, Output process image “I/O Tiny Mode” 66
8.6 Process image “CANopen” 67
IPI, Input process image “CANopen” 67
OPI, Output process image “CANopen” 69
9 I/O configuration 70
The manufacturer assumes no liability for damage and malfunctions that occur as a result of non-
compliance with these operating manuals.
Should you still have any unanswered questions after reading the operating manuals, please contact
Interroll customer service. Contact details for your region can be found online at www.interroll.com/contact/
Please direct any comments and suggestions regarding our operating manuals to manuals@interroll.com
1.2 Symbols
2 Description
The new DC platform comprising the
• Interroll High Performance power supply units DC5424 and DC5448
• Interroll MultiControl AI/BI
• Interroll RollerDrive EC5000 AI/BI
marks Interroll's first step towards Industry 4.0.
In addition to tried-and-tested options for component start-up and programming, Interroll now offers a CANopen
connection between the MultiControl BI and the connected RollerDrives EC5000 BI for the first time.
Among other benefits, this opens up new possibilities for monitoring the connected drives and therefore detecting
possible wear early on, resulting in a predictable replacement of the affected RollerDrives.
3 Configuration options
The MultiControl must be configured before it can be started up. There are various ways of doing this:
• All settings can be configured via a web-based user interface on a computer connected to the MultiControl (see
"Interroll MultiControl operating manual").
• Using the magnetic sensor, the sensors, bus type and LED displays can configured directly on the MultiControl and
the MultiControl can be tested, configured automatically or reset to factory settings (see „Magnetic sensor“ on
page 11).
• All settings except the bus type can be configured via service data objects (SDOs) written by a higher-level control
system (see „MultiControl service data objects (SDO)“ on page 15).
• The station name, the IP configuration and the connection settings can be modified via a PLC development
environment.
• The data is automatically transferred by the Plug&Play function when the MultiControl is replaced.
4 Magnetic sensor
An optional magnet (see Interroll MultiControl operating manual/Appendix/Accessories) is used to actuate the fitted
magnetic sensor.
The magnetic sensor is located on the top of the MultiControl, between the two Rs of "INTERROLL" directly in front of
the base plate (see Interroll MultiControl operating manual/Product information/Setup).
The magnetic sensor can be used to perform the following functions:
• Setting the sensors
• Setting the bus type
• Executing the teach-in process
• Switching LED displays on or off
• Resetting the MultiControl to the default settings
Selecting functions
¾ Hold the magnet up to the magnetic sensor.
9 The "Fault" LED will light up permanently once the magnetic sensor detects the magnet. After one second,
chase lighting starts on the LED strip on the left side of the MultiControl.
Each LED corresponds to a specific function:
¾ To select a function, remove the magnet when the corresponding LED lights up.
9 The selection is confirmed two seconds after the magnet is removed. During this period, the "Ready" and "Net
Run" LEDs as well as the LED for the selected function flash. If a second selection is associated with this function,
the LED for the current selection flashes for approx. seven seconds.
¾ To select the second choice, hold the magnet up to the magnetic sensor again after two seconds.
9 Chase lighting starts on the LED strip on the right side of the MultiControl.
¾ To confirm the second selection, remove the magnet when the corresponding LED lights up. The selection is
confirmed five seconds after the magnet is removed.
If the EtherCAT bus type is selected, the user interface can no longer be used after restarting as it is not
supported by this bus type.
The "Ready" and "Net Run" LEDs flash with a frequency of 2 Hz together with the following displays. The "Fault" LED
is off.
CAN gateway
SDO index: 0x200
Version information
SDO index: 0x4000
Manufacturer information
SDO index: 0x4100
Diagnosis information
SDO index: 0x4200
Error information
SDO index: 0x4300
Bus parameters
SDO index: 0x4600
If the EtherCAT bus type is selected, the user interface can no longer be used after restarting as it is not
supported by this bus type.
In big-endian format, the higher-level byte is saved first for composite data.
Motor settings
SDO index: 0x4700
Application module
SDO index: 0x4900
Error behaviour
SDO index: 0x4A00
Once the teach-in process in complete, all modules will be in ZPA mode.
If a setting is changed in the first MultiControl prior to the process, the MultiControls will be in the selected control
program following teach-in.
Example:
Changed values in MultiControl 1
• Normal speed: 0.8 m/s
• IP address: 192.168.0.20
• Control program: I/O device
After the teach-in process, the system is in I/O device mode, all RollerDrives are set to the speed value 0.8 m/s, each
IP address has been counted up by one (192.168.0.21, 192.168.0.22, etc.).
The teach-in process always starts at the first MultiControl on the conveyor. All MultiControls are contacted when
transferring settings from one MultiControl to another. For this reason, the teach-in process is independent of the
physical bus cable layout (topology).
The following settings are determined or stipulated:
• The network settings (host name, IP address, bus protocol, neighbouring addresses, etc.)
• The application settings (motor settings, control program, sensor settings, digital I/O, etc.)
• The error settings
Prerequisites
• All MultiControls are either in the as-delivered condition or have been (re)set to factory settings.
• The sensor types are configured correctly (PNP/NPN types and normally open/closed switching logic).
• All sensors must be of the same type.
• There is no material to be conveyed on the conveyor.
Once all slave RollerDrives are assigned, the RollerDrive of the first zone starts rotating alternatingly.
Once the RollerDrive rotates in the required conveying direction, place material to be conveyed into the zone sensor
for the first zone. The teach-in process now occurs automatically. If the one RollerDrive's direction of rotation does not
correspond to the conveying direction, it is changed (material to be conveyed moves in place). Due to the required
data transfer, there are breaks when moving from one MultiControl to the next.
Once the material to be conveyed has reached the last zone sensor, the material to be conveyed can be removed as
it may otherwise be conveyed out of the last zone and fall.
The teach-in process is completed automatically and the conveyor is initialised again. The system is ready for
operation following restart.
6.2 Plug&Play
MultiControls can be easily replace via Plug&Play technology.
This method means that a MultiControl is configured without external access. The replaced MultiControl receives the
same settings as the removed module.
If several MultiControls need to be replaced at the same time, the semi-automatic Plug&Play method needs to be
selected.
If a MultiControl is set to factory settings, the Plug&Play technology is always activated.
Activation/deactivation:
1. Via the web browser user interface in the Service/Plug&Play menu
2. Using the magnetic key:
¾ Activate the magnetic sensor to start the Plug&Play function. The "Fault" LED will light up permanently once the
magnetic sensor detects the magnet.
¾ After one second, chase lighting starts on the LED strip on the left side of the MultiControl.
¾ Once the "Sensor 1" LED lights up, remove the magnetic key and wait until chase lighting starts on the right
LED strip.
¾ Activate the magnetic sensor again.
¾ Remove the magnetic key once the "I/O 1" LED lights up.
"Sensor 3" LED flashes – deactivated
"I/O 3" LED flashes – activated
To change the setting, hold the magnetic key in position until the required option is selected.
This option can be changed on each MultiControl and triggers a signal to all MultiControls in the same
subnetwork so that all Plug&Play settings are changed accordingly.
Once a new MultiControl has been restarted twice, the same configuration as before the replacement is set
and the unit is ready for operation.
Only prepare one MultiControl for configuration at a time! Otherwise all prepared units will receive the
same configuration.
Plug&Play is not available with network configuration „EtherCAT”!
2. Switch the upstream or downstream device to semi-automatic mode in the same way (if one MultiControl
measures several neighbouring devices, take into account that the upstream device has the highest priority
and Transfer 4 has the lowest priority).
¾ Select function 7 ("Sensor 1" + "I/O 1" LED)
¾ Select function 3 ("RD 3" LED)
This MultiControl sends the configuration to the unit awaiting configuration. The data transfer can be
repeated several times, if the transmission/receipt failed the first time. The new device is configured and
ready for operation after two restarts.
The teach-in process for a new MultiControl can only be performed via the upstream or downstream
MultiControl. It is not possible to teach-in a Transfer partner.
Restore the settings on all other unconfigured MultiControls in the same way.
Plug&Play does not work if the IP address does not come from the static address allocation.
If an error occurs during Plug&Play, the "I/O 3" LED lights up and the "Sensor 1", "I/O 1", "I/O 2" and
"Sensor 2" LEDs start flashing.
Select functions 7 ("Sensor 1" and "I/O 1" LED) and 4 ("RD 4" LED) with the magnetic key to acknowledge
the error.
Then carry out a factory reset using function 6 ("I/O 2" LED and function 6 LED "I/O 4").
7 Process data
The process data is split into two parts, the input process image and the output process image.
The addresses listed in this chapter should be regarded as an offset to the start addresses specified in the PLC
configuration.
7.1 Input process image
The input process image is divided into four parts:
• Sensors
• Digital I/O
• Motor status
• Other
Sensors
The information about the sensor switching states can be found in the first byte of the process image. The first four bits
contain the physical states of the "Sensor 1" to "Sensor 4" inputs, depending on the set PNP/NPN configuration and
the positive or negative polarity.
The "Sensor 5" to "Sensor 8" inputs are only shown here if I/O 1 to 4 are configured as additional sensors.
Digital I/O
The second byte contains the states of the digital I/Os. The value of the variable depends on the PNP/NPN
configuration and the positive or negative polarity. When using the I/Os as outputs, the specified switching status is
also displayed.
Motor status
Starting at the third byte, the status values for the connected motors are provided.
The error outputs of the connected motors are represented first. A logical "1" at the input means "The motor is faulty"
here. To ensure that unused motor connections do not cause any errors, the connections should be deactivated even
when using the MultiControl as an I/O device.
The set target values of the motors are output second.
The current consumption of the motors is specified third.
System status
The fourth area of the input process image represents the following system status information:
• The current level of the two supply voltages
• The temperature
• The runtime since the last restart
Other signals
The last part of the input process image is divided into five subsections:
• Control inputs
• Control outputs
• Handshake signals
• Zone status
• Global signals
These input signals are not relevant when using the MultiControl as an I/O device.
Digital outputs
The digital outputs can be found in the first part of the process image. The outputs can only be switched directly with
a PLC if the I/O is set to "2: PLC output". The physical state at the output also depends on the configuration of the
output (PNP/NPN, positive or negative polarity).
Motors
The outputs for the connected motor target values can be found in the second part of the process image.
EC310
EC5000
Other signals
The last part of the output process image is divided into three subsections:
• Control inputs overwrite
• Control outputs overwrite
• Handshake signal overwrite
1)
Attention! Speed presets >100 % can lead to a malfunction of the connected RollerDrive!
5 .0 Control inputs overwrite Control input 1 BOOL Meaning depends on selected state
table (e.g. "stop zone" for zone
5 .1 Control inputs overwrite Control input 2 BOOL
control state table)
5 .2 Control inputs overwrite Control input 3 BOOL
5 .3 Control inputs overwrite Control input 4 BOOL
5 .4 Control inputs overwrite Control input 5 BOOL
5 .5 Control inputs overwrite Control input 6 BOOL
5 .6 Control inputs overwrite Control input 7 BOOL
5 .7 Control inputs overwrite Control input 8 BOOL
1)
Attention! Speed presets >100 % can lead to a malfunction of the connected RollerDrive!
1)
Attention! Speed presets >100 % can lead to a malfunction of the connected RollerDrive!
For positioning mode, the direction of rotation „clockwise” (factory setting) must be selected in the
presettings!
9 I/O configuration
No. Value Designation Comments
1 0 None I/O not in use
2 1 PLC input Input signal to PLC
3 2 PLC output Output signal from PLC
4 15 Sensor 5 Additional inputs can also be found in the
corresponding place in the process image.
5 16 Sensor 6
6 17 Sensor 7
7 18 Sensor 8
8 19 Dirt detect sensor Use Aux-Input near sensor
9 20 Output error Output state "Severe error"
10 21 Control input 1 Input 1
11 22 Control input 2 Input 2
12 23 Control input 3 Input 3
13 24 Control input 4 Input 4
14 25 Control input 5 Input 5
15 26 Control input 6 Input 6
16 27 Control input 7 Input 7
17 28 Control input 8 Input 8
18 31 Control output 1 Output 1 state
19 32 Control output 2 Output 2 state
20 33 Control output 3 Output 3 state
21 34 Control output 4 Output 4 state
22 35 Control output 5 Output 5 state
23 36 Control output 6 Output 6 state
24 37 Control output 7 Output 7 state
25 38 Control output 8 Output 8 state
26 41 Handshake InUp Handshake from upstream module
27 42 Handshake InDown Handshake from downstream module
B5 M1 B1 M2 B2 M3 B3 M4 B4
1 2 3 4
4 zone single release
1-4 Zone
M1 - M4 Motor 1 - 4
B1 - B4 Sensor
B5 Start sensor
Timers
For settings of polarity and function of the connected sensors see „Inputs and outputs“ on page 23.
B5 M1 B1 M2 B2 M3 B3 M4 B4
1 2 3 4
4 zone train release
1-4 Zone
M1 - M4 Motor 1 - 4
B1 - B4 Sensor
B5 Start sensor
Timers
The timer 1 parameter affects the delayed start of the RollerDrive for train release.
For settings of polarity and function of the connected sensors see „Inputs and outputs“ on page 23.
B5 M1 B1 M2 B2 M3 B3 M4 B4
1 2 3 4
4 zone train release
1-4 Zone
M1 - M4 Motor 1 - 4
B1 - B4 Sensor
B5 Start sensor
The signal to transport the material to be conveyed out of a zone must be active until the material to
be conveyed no longer occupies the zone sensor. If the signal is deactivated sooner, the material to be
conveyed remains in the occupied zone sensor.
If the signal to convey material out is set again in train release mode, the system initialises in single release
mode. It then switches to train release mode.
A pulse is sufficient for the signal to convey in. The material to be conveyed is conveyed up to the zone
sensor. The pulse must be at least 100 ms long.
LEFT
B2
M2
UP DOWN
M1
B1
B3
M1, M2 Motor
B1 - B3 Sensor
RIGHT
Timers
Choice of direction
CI 1 CI 2 Description
0 0 From up to down
1 0 From left to down
0 1 From right to down
1 1 Automatic merge
Merge prioritisation
LEFT
B2
M2
UP DOWN
M1
B1
B4
B3
M1, M2 Motor
B1 - B4 Sensor
RIGHT
Timers
Choice of direction
CI 1 CI 2 Description
0 0 From up to down
1 0 From up to left
0 1 From up to right
1 1 Automatic distribution
Distribution prioritisation
LEFT
M3
UP DOWN
M4
Timers
Choice of direction
CI 1 CI 2 Description
0 0 From up to down
1 0 From left to down
0 1 From right to down
1 1 Automatic merge
Merge prioritisation
M1
UP B1 DOWN
Timers
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 - -
* Set in web server or via SDOs, no sensor connected
Choice of direction
CI 1 CI 2 CI 3 CI 4 Description
0 0 X X From up to down
1 0 0 X From up to left 45°
0 1 X 0 From up to right 45°
1 0 1 X From up to left 30°
0 1 X 1 To right 30°
1 1 0 0 Automatic distribution right 45°/left 45°
1 1 1 1 Automatic distribution right 30°/left 30°
1 1 0 1 Automatic distribution right 30°/left 45°
1 1 1 0 Automatic distribution right 45°/left 30°
Distribution prioritisation
M1
UP B1 DOWN
Timers
CI 1 CI 2 CI 3 Angle setting
0 0 0 0°
1 0 1 -30° (left)
1 1 0 -45° (left)
1 1 1 -90° (left)
0 0 1 +30° (right)
0 1 0 +45° (right)
0 1 1 +90° (right)
1 0 0 Homing
M2
UP DOWN
M1
B1
M1, M2 Motor
B1 Sensor
RIGHT
Timers
Motor Settings
Motor 1 Motor 2 Motor 3 Motor 4
Motor Type EC5000 EC5000 Disabled Disabled
Roller Diameter [mm] 50.0 50.0 50.0 50.0
Gearing Ratio 49:1 49:1 none none
Direction CW CCW CW CCW CW CCW CW CCW
Normal Speed [m/s] 1.00 1.00 1.00 1.00
Alternate Speed [m/s] 0.50 0.50 0.50 0.50
Acceleration [m/s2] 0.00 0.00 0.00 0.00
Decceleration [m/s2] 0.00 0.00 0.00 0.00
Submit Reset
Set "Roller diameter", "Gearing ratio" and "Normal speed" according to the RollerDrive used.
The "Direction" parameter is used to adapt the rotational direction of the RollerDrive to the installation location
(rotational direction as viewed from the cable end of the RollerDrive).
"Acceleration" and "Deceleration" adapt the start/stop behaviour of the RollerDrive.
The "Alternate speed" parameter is only used in the "I/O mode tiny" process image.
Press the "Submit" button to transfer the modified parameters to the MultiControl.
Transfer
The MultiControl is the interface to the two motors in the Transfer.
Motor Settings
Motor 1 Motor 2 Motor 3 Motor 4
Motor Type VDC Speed VDC Speed Disabled Disabled
Roller Diameter [mm] 50.0 50.0 50.0 50.0
Gearing Ratio none none none none
Direction CW CCW CW CCW CW CCW CW CCW
Normal Speed [m/s] 1.00 1.00 1.00 1.00
Alternate Speed [m/s] 0.50 0.50 0.50 0.50
Acceleration [m/s2] 0.00 0.00 0.00 0.00
Decceleration [m/s2] 0.00 0.00 0.00 0.00
Submit Reset
HPD
The MultiControl is the interface to the two motors in the HPD.
Motor Settings
Motor 1 Motor 2 Motor 3 Motor 4
Motor Type VDC Position VDC Speed Disabled Disabled
Roller Diameter [mm] 50.0 50.0 50.0 50.0
Gearing Ratio none none none none
Direction CW CCW CW CCW CW CCW CW CCW
Normal Speed [m/s] 1.00 1.00 1.00 1.00
Alternate Speed [m/s] 0.50 0.50 0.50 0.50
Acceleration [m/s2] 0.00 0.00 0.00 0.00
Decceleration [m/s2] 0.00 0.00 0.00 0.00
Submit Reset
Homing
When operating the HPD, the idler rollers may become twisted compared to the zero position. For this reason, the
HPD has to be referenced from time to time and the position of the idler rollers corrected as needed (homing).
During this process, the "Motor speed 1" input byte shows the value 127. Once the zero position is reached, the value
0 is shown.
Value 127 = HPD resetting to zero position (homing straight, 0°)
We recommend carrying out the initialisation regularly (e.g. every minute) when the HPD is at or near the
zero position and there is no material flow for about two seconds, as the process takes less than 200 ms in
this case. If the homing process is started in a different position, it may take several seconds.
A new referencing process can only be started every 30 seconds.
Homing may only be started when the HPD is between +80° and -80° as referencing cannot be performed
correctly otherwise.
11 Application examples
11.1 Application example 1: Conveyor with three MultiControls
MultiControl 1
Control program selection: "ZPA single release 4 zone"
MultiControl 2
Control program selection: "ZPA single release 4 zone"
MultiControl 3
Control program selection: "ZPA single release 4 zone"
MultiControl 1
Control program selection: "ZPA single release 4 zone"
MultiControl 2
Control program selection: "ZPA single release 4 zone"
MultiControl 3
Control program selection: "ZPA single release 4 zone"
MultiControl 4
Control program selection: "ZPA single release 4 zone"
MultiControl 5
Control program selection: "ZPA Transfer In/Out"
I/O 1
Function = sensor 5
Polarity = negative
The sensor connected to I/O 1 is now configured as the start sensor
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 "Zone sensor occupied" state of the third zone is output at I/O 4.
Bootloader objects
Monitoring
Object Sub Name Unit Data Acc Min. Max. Default Mapp-
ID index type able
2200h 00h Monitoring values UINT8 ro 9 x
01h Start stops UINT32 ro 0 COS TM
Runtime Objects
Thresholds
Application parameters
General objects
Velocity mode
For the positioning mode, the direction of rotation „clockwise” (factory setting) must be selected in the
default settings!
General objects
Factor Group
For HPD, a homing process must be performed each time "Power RollerDrive" is switched on.
Different settings of the DIP switch on the interface box are used to transfer different parameters to the motors, see
table.
1 2 3 4 5
HPD L L L L L
Transfer 28 A H L L L L
Transfer 20 A H H L L L
Transfer 12 A L L H L L
Reclaim unit 28 A L H L L L
For HPD, a homing process must be performed each time “Power RollerDrive” is switched on.
Different settings of the DIP switch on the interface box 48 are used to transfer different parameters to the motors,
see table.
1 2 3 4 5 6 7 8
HPD L L L L L
L = 24 V, H = 48 V
H = Motor 1
H = Motor 2
Transfer 28 A* / 14 A** H L L L L
deactivated
deactivated
Transfer 20 A* / 10 A** H H L L L
Transfer 12 A* / 6 A** L L H L L
Reclaim unit 28 A / 14 A L H L L L
*24 V **48 V
Control
Outputs
Handshake
Control Inputs
Overwrite
>= >=
Handshake
Inputs
Overwrite
Logical Logical
Sensors Control Handshake
Sensors
Inputs Outputs
Control
Inputs
Handshake
State Table State Table Inputs
(Control Interpreter
„Overwrite“ Signals have higher priority than internal signals
Program) Handshake
Outputs
Overwrite
135 of 136
Signal flow
INSPIRED BY
EFFICIENCY EN | 04/2020 | Version 2.1
© 2020 INTERROLL