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Installation user manual

Title: Installation user manual


Type: Technical manual
Version: 1.1
Company: Pick To Light Systems, S.L.
Contents
1. Overview.............................................................................................................................. 1
1.1. Overview ...............................................................................................................................1
2. MWU Series Installation Limitation .................................................................................... 2
2.1. Limitation on Connectible Junction Box When Installing .................................................2
2.2. Limitation on Connectible Light Modules for Installation .................................................2
2.3. Limitation on the Ethernet Junction Box / Number of Connectible Junction Box when
Installing ........................................................................................................................................2
2.4. System Configuration .........................................................................................................3
3. List of Installation Related Material ................................................................................... 4
3.1. List of Installation Products ...............................................................................................4
3.2. Dimensions of Installation Material ....................................................................................6
3.2.1. Dimensions: MWUD2135 (total length1.35 m) ....................................................................... 6
3.2.2. Dimensions of MWUE2001 Duct end (R) .................................................................................. 7
3.2.3. Dimensions of MWUE2002 Duct End (L) ............................................................................... 7
3.2.4. Dimensions of MWUE2003 Cable Holder ................................................................................. 8
3.2.5. Dimensions of the Flat Base for MWU2000-03, MWU2000/L .................................................... 9
3.2.6. Dimensions of the Pipe Base for MWU 2000-04 and MWU 2000/L ........................................... 9
3.2.7. Dimensions of the Flat Base (with LS Guard) for MWU2000S-03, MWU2000/L ..................... 10
3.2.8. Dimensions of the Pipe Base (with LS Guard) for MWU2000S-04, MWU2000/L .................... 10
3.2.9. Dimensions of the Flat Base for MWU2040-03, MWU2040P................................................... 11
3.2.10. Dimensions of the Pipe Base for MWU2040-04, MWU2040P ................................................. 11
3.2.11. Dimensions of the Flat Base (with LS Guard) for MWU2040S-03, MWU2040P ...................... 12
3.2.12. Dimensions of the Pipe Base (with LS Guard) for MWU2040S-04, MWU2040P ..................... 12
3.3. Dimensions of Light Modules ...........................................................................................13
3.3.1. Dimensions of MWU2000LF, No Digit Light Module .............................................................. 13
3.3.2. Dimensions of MWU2000FE, No Digit Light Module with Sensor.......................................... 13
3.3.3. MWU2000LFS, No Digit Light Module with Limit Switch ....................................................... 14
3.3.4. Dimensions of MWU2040PF, 4-digit Light Module ................................................................. 14
3.3.5. Dimensions of MWU2401FE, Dot Module with Sensor .......................................................... 15
3.3.6. Dimensions of MWU2040PFS, 4-Digit Light Module with Limit Switch ................................. 15
3.3.7. Dimensions of MWU2040PRG-22, 2-2 Digit Dual Location Light Module .............................. 16
3.3.8. Dimensions of MWU2414, 12-digit Batch Display .................................................................. 16
3.4. Dimensions of the Junction Box ......................................................................................17
3.4.1. TW2209 Ethernet Junction Box .............................................................................................. 17
3.4.2. Dimensions of the TW2210..................................................................................................... 18
3.5. Dimensions of the Batch Display .....................................................................................19
3.5.1. TW2411, 6-digit Batch Display ................................................................................................ 19
3.5.2. TW2412 9-digit Batch Display ................................................................................................ 19
3.5.3. TW2413 12-digit Batch Display............................................................................................... 20
3.5.4. TW2415, 12-digit Mini Batch Display ...................................................................................... 20
3.6. Dimensions of Other Devices ...........................................................................................21
3.6.1. TW2911 Signal Tower Interface .............................................................................................. 21
3.6.2. TW2831 RS-232C Interface ..................................................................................................... 21
3.6.3. TW2832 RS232C Interface with 10-keys ................................................................................. 22
3.6.4. AW2821 Barcode Reader Interface ......................................................................................... 22
3.6.5. MWU2701 Address Writer ....................................................................................................... 23
3.6.6. MWU2706 Small Address Writer............................................................................................. 23
4. How to Connect................................................................................................................. 24
4.1. How to Connect the PC and Controller ............................................................................25
4.1.1. Connect the Ethernet Controller ............................................................................................ 25
4.2. How to Connect the Ethernet Junction Box and Junction Box with the Cable ..............27
4.2.1. How to Connect the Ethernet Junction Box and Junction Box ............................................. 27
4.2.2. Modular Cable Specification .................................................................................................. 29
4.3. AC Wiring Method .............................................................................................................30
4.3.1. AC Inlet and AC Switch .......................................................................................................... 30
4.4. How to Set Up the Junction Box ......................................................................................31
4.4.1. Mounting Base ....................................................................................................................... 31
4.5. How to Mount Duct and Light Modules ............................................................................32
4.5.1. Outline of How to Mount Ducts .............................................................................................. 32
4.5.2. Details of How to Mount Ducts ............................................................................................... 33
4.5.3. How to Install Ducts................................................................................................................ 34
4.5.4. How to Insert the AI Cable into the Duct ................................................................................ 35
4.6. How to Wire Light Modules and Junction Box ................................................................36
4.6.1. Light Module Connection Channels of TW2209/TW2210 ....................................................... 36
4.6.2. Installation on Medium Size Shelves ..................................................................................... 38
4.6.3. How to Mount Light Modules to the Duct............................................................................... 40
4.6.4. Install on to the Pipe Rack Using Pipe Base .......................................................................... 41
4.6.5. Cable Ties ............................................................................................................................... 46
4.7. How to Wire the Batch Display .........................................................................................47
4.7.1. DIGITAL OUT: Output Port for Batch Display and Signal Light ............................................. 47
4.8. Wiring of Signal Lights .....................................................................................................48
5. How to Set Up ................................................................................................................... 49
5.1. Network Setup (Ethernet type) .........................................................................................49
5.1.1. Startup Flowlight .................................................................................................................... 49
5.1.2. How to Set Up a Network........................................................................................................ 50
5.2. How to Set Up the Light Module Address ........................................................................52
5.2.1. Using the Address Setup Device............................................................................................ 52
5.2.2. Light Module Address Display Operation .............................................................................. 55
5.2.3. How to Set Up Using Flowlight .............................................................................................. 58
5.3. Checking the Operation of Devices..................................................................................59
5.3.1. Checking the Light Module Operation ................................................................................... 59
5.3.2. Checking the Operation of the TW2911 Signal Light Interface .............................................. 61
5.3.3. Checking the Operation of the AW2821 and RS232C I/F........................................................ 63
5.3.4. Maintenance Command .......................................................................................................... 65
6. Troubleshooting................................................................................................................ 67
6.1. Controller Junction Box ....................................................................................................67
6.2. Light Module .....................................................................................................................69
6.3. Interface and Other Devices .............................................................................................70
Installation user manual 1/ 76

1. Overview

1.1. Overview
This manual describes the MWU series light modules used in the L-PICK system. It explains how to connect
the system controller to the control PC, how power is supplied, and signals are provided from the junction box,
as well as restrictions on various ways light modules and cables are connected. It also explains how to install
MWU light modules.

※ The MWU series light modules are installed on shelves and pipes. The duct-related parts were
modified from the previous TW series. Because the upper-level system configuration is the same as
that of the TW, the MWU series light modules have similar functions as those of the TW series.
Except for light modules, other MWU devices remain the same as the TW devices.

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2. MWU Series Installation Limitation

2.1. Limitation on Connectible Junction Box When Installing


● The maximum number of junction boxes that can be connected to 1 controller is 32.

2.2. Limitation on Connectible Light Modules for Installation


● The maximum number of light modules that can be controlled from 1 controller is 5,120 units.
● The maximum number of units that can be connected to 1 TW2209 / TW2210 junction box is 250 (50
units per channel x 5 channels).

※ Power consumption of devices and cable length may reduce the number of maximum connectible
units.

※ The response will slow if a large number of light modules are connected and cause increased polling
time.

2.3. Limitation on the Ethernet Junction Box / Number of Connectible Junction Box when
Installing
● The IP address is set up for each TW2209 Ethernet controller. Because the control PC is able to control
the Ethernet junction box individually, the number of available IP addresses will depend on the network
of the TCP/IP protocol.

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2.4. System Configuration

Control PC
TCP/IP

Modular Cable Controller Mounted


Junction Box

4-core round sealed cable

Junction Box

Batch Display
Signal Tower Interface, etc.

AI cable
Junction Box

Junction Box
32 units max.

Light Module
5,120 unis / system max.

Light Module

Installation Material
Maintenance Device

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3. List of Installation Related Material


3.1. List of Installation Products
External
Part No. Description Details Image
Dimensions (mm)

MWUD2135 Duct 1.35m For installing light 1350 x 14.5 x 43

modules, etc. (comes

with rail for signal/power

line).

Mount on shelves, etc.

Duct end (R)


MWUE2001 5 x 14.5 x 43
Mount at the end of the

duct base for protection.

If cable needs to be
thread through, peel off
Duct end (L)
MWUE2002 the cable cover. 5 x 14.5 x 43

Keeps the cable in

place and prevents it


MWUE2003 Cable holder 38.4 x 30 x 10.7
from coming out.

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External
Part No. Description Details Image
Dimensions (mm)

Base for mounting

Flat base for MWU2000/2000L on to


MWU2000-03 82 x 14.5 x 43
MWU2000/L flat or pipe frame

independently

Pipe base for


MWU2000-04 82 x 30 x 43
MWU2000/L

Flat base (with LS

MWU2000S-03 guard) for Base for mounting 82 x 14.5 x 53

MWU2000/L MWU2000FS/2000LFS

(with LS type) on to flat

Pipe base (with LS or pipe frame

MWU2000S-04 guard) for independently. 82 x 30 x 52

MWU2000/L

Flat base for


MWU2040-03 160.5 x 14.5 x 43
MWU2040P Base for mounting

MWU2040P on to flat or

pipe frame
Pipe base for independently.
MWU2040-04 160.5 x 30 x 43
MWU2040P

Base for mounting


Flat base (with LS
MWU2040PFS (with LS
MWU2040S-03 guard) for 160.5 x 14.5 x 43
type) on to flat or pipe
MWU2040P
frame independently.

Pipe base (with LS

MWU2040S-04 guard) for 160.5 x 30 x 52

MWU2040P

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3.2. Dimensions of Installation Material

3.2.1. Dimensions: MWUD2135 (total length1.35 m)


【mm】

1350

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3.2.2. Dimensions of MWUE2001 Duct end (R)


【mm】

3.2.3. Dimensions of MWUE2002 Duct End (L)


【mm】

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3.2.4. Dimensions of MWUE2003 Cable Holder


【mm】

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3.2.5. Dimensions of the Flat Base for MWU2000-03, MWU2000/L

【mm】

3.2.6. Dimensions of the Pipe Base for MWU 2000-04 and MWU 2000/L
【mm】

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3.2.7. Dimensions of the Flat Base (with LS Guard) for MWU2000S-03, MWU2000/L
【mm】

3.2.8. Dimensions of the Pipe Base (with LS Guard) for MWU2000S-04, MWU2000/L
【mm】

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3.2.9. Dimensions of the Flat Base for MWU2040-03, MWU2040P


【mm】

3.2.10. Dimensions of the Pipe Base for MWU2040-04, MWU2040P


【mm】

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3.2.11. Dimensions of the Flat Base (with LS Guard) for MWU2040S-03, MWU2040P
【mm】

3.2.12. Dimensions of the Pipe Base (with LS Guard) for MWU2040S-04, MWU2040P
【mm】

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3.3. Dimensions of Light Modules


3.3.1. Dimensions of MWU2000LF, No Digit Light Module
【mm】

3.3.2. Dimensions of MWU2000FE, No Digit Light Module with Sensor


【mm】

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3.3.3. MWU2000LFS, No Digit Light Module with Limit Switch


【mm】

3.3.4. Dimensions of MWU2040PF, 4-digit Light Module


【mm】

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3.3.5. Dimensions of MWU2401FE, Dot Module with Sensor


【mm】

3.3.6. Dimensions of MWU2040PFS, 4-Digit Light Module with Limit Switch


【mm】

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3.3.7. Dimensions of MWU2040PRG-22, 2-2 Digit Dual Location Light Module


【mm】

3.3.8. Dimensions of MWU2414, 12-digit Batch Display


【mm】

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3.4. Dimensions of the Junction Box


3.4.1. TW2209 Ethernet Junction Box

【mm】

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3.4.2. Dimensions of the TW2210


【mm】

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3.5. Dimensions of the Batch Display


3.5.1. TW2411, 6-digit Batch Display
【mm】

3.5.2. TW2412 9-digit Batch Display

【mm】

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3.5.3. TW2413 12-digit Batch Display


【mm】

3.5.4. TW2415, 12-digit Mini Batch Display

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3.6. Dimensions of Other Devices


3.6.1. TW2911 Signal Tower Interface
115
【mm】

+12V

GND
F・G

Vin
S-
S+
L5
L4
L3
L2
L1
4 .5
2- φ

OUTPUT INPUT

Signal Light Interface TW2911

100 70
28.6

ON
21

64
32
16
8
4
2
1

ADDRESS SW
1

LAMP LED

130

3.6.2. TW2831 RS-232C Interface

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3.6.3. TW2832 RS232C Interface with 10-keys

【mm】

3.6.4. AW2821 Barcode Reader Interface


【mm】

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3.6.5. MWU2701 Address Writer


【mm】

3.6.6. MWU2706 Small Address Writer


【mm】

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4. How to Connect

This section explains the installation method of the MWU series and things to watch for when setting up and
installing.

Example of System Connection

Control PC

Cable between PC and


Junction Box Junction Box
Interface Device
AC
Wiring Ethernet Junction Box

Wiring
between JBs Wiring batch display

CH wiring
(AI-NET)

Branch
Connector Light Module

FG

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4.1. How to Connect the PC and Controller

4.1.1. Connect the Ethernet Controller


It is important to have the PC and network that are compatible with the Ethernet controller.
We recommend setting up the network first and then connecting the Ethernet controller.
For details of the network setup, check with the network administrators.

(1) How to connect the Ethernet controller (Ethernet junction box)


Use the LAN cable, category 5, to connect with the Ethernet controller.
In order to connect with the control PC, it is necessary to select cross cables and straight cables.

If you accidently connect the MJ to the 10/100BASE-T connector, the junction


Caution box or Ethernet interface can get damaged. Be careful.

[TW2209] Ethernet Junction Box LAN Connection Port

LAN Connection Port, LAN 10/100 BASE-T


This is the Ethernet Connection port. Connecting shape: RJ-45 standard.

Use the LAN cable to connect to the control PC or a HUB on the same network with the control PC, etc.

Do not connect the modular connector from the junction box because it may cause damage.
*Devices with POE (Power of Ethernet) standard must be turned OFF or do not use.

Connection via HUB (Recommended)



LAN Straight Cable PIN number
HUB
1 White Orange 1 White Orange
2 Orange 2 Orange
3 White Green 3 White Green
4 Blue 4 Blue
Control PC
5 White Blue 5 White Blue
6 Green 6 Green
7 White Brown 7 White Brown
Controller 8 Brown 8 Brown
1 ― 8

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Connect Directly to the PC※

LAN Cross Cable PIN Number


1 White Orange 1 White Green
2 Orange 2 Green
3 White Green 3 White Orange
4 Blue 4 Blue
Control PC
5 White Blue 5 White Blue
6 Green 6 Orange
7 White Brown 7 White Brown
Controller 8 Brown 8 Brown
1 ― 8

※When connecting with cross cable, the network control may be restricted by OS. Unless you are setting up
the controller, it is recommended that you use the above method via Hub.

Notes on Setting up the Network that Includes the Ethernet Controller.


The controller must operate in real time. For this reason, communication of devices that are not related to
the operation of the controller can load up the network causing response delays from the controller.
Depending on the degree of the network load, it may be necessary to have the controller on a separate,
independent network from the host PC and PC server with concentration of high traffic.

Also, when building a network, make sure to select LAN boards, HUB, and router that are highly reliable and
designed for business or industrial use.

Ethernet Independent
Ethernet Network
Network Network

Controller Controller
PC PC

Controller Control
PC PC Controller
Control PC PC

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4.2. How to Connect the Ethernet Junction Box and Junction Box with the Cable

4.2.1. How to Connect the Ethernet Junction Box and Junction Box
(1) TW2209 Ethernet Junction Box

MJ OUT Port

MJ OUT: Output Port for Adding Junction Boxes

Connect the modular cable (RJ-45 connector).


● Modular cables have a different specification than LAN cables. Therefore, do not use LAN cables.
● Do not use the LAN cable connected to the HUB. The connected devices may get damaged.

(2) TW2210 Junction Box


MJ OUT Port
MJ IN Port

MJ IN: The input port for the upstream Junction Box

MJ OUT: Output port for Junction Box Expansion


This is the output port to connect to the downstream Junction Box.

Connect with the modular cable (RJ-45 Connector).


● Modular cables have a different specification than LAN cables. Therefore, do not use LAN cables.
● Do not use the LAN cable to connect to the HUB. Connected devices may get damaged.

The 8-core twisted cable is used to connect between the Ethernet junction box and junction box. Up to 32
junction boxes can be connected to 1 controller.

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(3) Example of Modular Wiring

【TW2209】
OUT

【TW2210】
OUT IN

【TW2210】
IN 【TW2210】
IN

32 units max.

[TW2209] Ethernet Junction Box


Channel Standard Connection Details
Name Terminal Shape
MJ OUT RJ45 Modular output to increase junction boxes ※1
※ 1: When connecting multiple junction boxes, connect MJ OUT with the MJ IN of the downstream
TW2210.

[TW2210] Junction Box


Channel Standard Connection Detail
Name Terminal Shape
MJ IN RJ45 Connect the modular connector from the controller ※1
MJ OUT1 RJ45 Modular Output 1 to the junction box to be expanded. ※2
MJ OUT2 RJ45 Modular Output 2 to the junction box to be expanded
※ 1: When connection multiple junction boxes, connect MJ OUT of the upstream junction box to the
MJ IN.
※ 2: The OUT of the junction box can be output to 2 systems by connecting to the MJ IN of the
downstream junction boxes.

Specification of the Connectors


Item Standard
Connector shape Modular Connector 8 pin
Recommended plug MP588-C (Panduit)

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4.2.2. Modular Cable Specification

From the cable length shown below, select the cable.

Length Type
TPCC5 (twist pair cable CAT5E)
0~200m
Note: Different from the LAN connection*
200~1200m MVVS・0.75SQ (Vinyl cab tire cable with shield)*

*Use the cable with the shield when you are concerned about an impact from the power-supply noise or static
electricity noise, etc.
*If you are using the MVVS・0.75SQ cable, use the modular rosette (MJ-8S made by Kameda Denki Co.)

If you are using the twisted pair cable, note that it is not compatible with the LAN cable.
The connection should be done as follows. (When the clasp is up, the pin number is 1 from the left.)

TW Series Modular Cable LAN Straight Cable


PIN number
L Brown 1White orange
2 White green 2 Orange
3 Green 3 White green
4 White orange 4 Blue
5 Orange 5 White blue Clasp
6 White blue 6 Green
7 Blue 7 White brown
8 White brown 8 Brown 1- 8

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4.3. AC Wiring Method

4.3.1. AC Inlet and AC Switch


The inlet consists of both power supply switch and AC input.
Connect the power supply cord.*
The input is wide - - AC100V ~ 240V.
*The power supply cord is an option and normally not included.
Please order separately based on the specification.

Before you supply power to the device, always verify the voltage so that
the device’s power supply voltage is compatible with the power voltage
Caution being supplied.
When supplying power to the device, connect the device after taking
protective steps, such as with the switch breaker and earth leakage circuit
breaker.

The maximum power consumption of the junction box is 360W [400VA/432VA


(100/200VAC)].
It may be lower based on the number of connected devices, but when selecting breakers,
base it on the maximum power consumption.

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4.4. How to Set Up the Junction Box


4.4.1. Mounting Base

The base is used to firmly place the junction box case.

After mounting the junction box to the base, tighten the side screws of the TW2209/TW2210. Mount it to fit
right into the base. Then tighten the screws.

※ Do not pile the TW2209/2210 on top of each other because this prevents ventilation of heat and may
cause a malfunction.

How to Mount

Horizontal Mounting

Vertical Mounting Vertical Mounting


Not Allowed on the Wall on the Wall

Upside Down Mounting

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4.5. How to Mount Duct and Light Modules


4.5.1. Outline of How to Mount Ducts
(1) Use the double-sided tape to mount the duct. (Do not let the duct protrude beyond the shelf top)

Recommended Incorrect Example

Caution when mounting the guard and angle


Leave at least 3mm of space from the top of the duct base, leave the bottom portion unmounted
so that you can press the hook. Do not mount the guard.

Leave at least 3mm of space

(2) It is recommended that you fasten the duct by using flat 4x13 screws in the center and both sides. Other
screw lengths may be used according to your need. Screw in 3 places -- middle and both sides -- but
use more screws if necessary. If you over tighten the screws, the duct may bend, so be careful. Finally,
check to see that there are no duct particles on the duct.

● Recommended screws for mounting the duct base


Flat screw 4×13 trivalent white (drill screw)
※ Depending on the shelf on which the duct is going to be mounted, you may need to use longer
screws. In that case, use the appropriate length of screw.

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4.5.2. Details of How to Mount Ducts

① ② ② Attach the duct lower than


the side of the frame/shelf.
③ ④

※Attach the duct end.


(See next page)

Make a countersunk Attach the duct to the shelf Attach the duct to the shelf Prepare a
Cut the aluminum
screw hole. with the adhesive tape. with the adhesive tape. countersunk
duct to meet the ※Make a hole not to ※ The duct top should be
※The duct top should be screw.
width of the location. protrude from the head of lower than the top of the
the screw. lower than top of the shelf.
shelf.

⑤ ⑥ ⑥

Installation is
Screw the duct Mount the light module
Duct installation is completed. Place the AI cable. completed.

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4.5.3. How to Install Ducts

The reverse side is also installed in the same way.

① ② Cable stops at the end.

※Tap the end. Do not


break the cable cover.

Make the end guides and the channel of the duct The duct end is now attached. Put the cable end into the cable cover.
meet. Then insert the ends into the channel by
tapping with a plastic hummer.

The cable goes through the cover


Remove the cable cover with pliers. Check the channel for the cable to go Make the cable go through.
through.

(Do the same on the other end.)

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4.5.4. How to Insert the AI Cable into the Duct

Correct way to insert a cable

① ② ③ ④ ⑤ ⑥

Push the bottom side of Push it into Push it into Completed when the
Insert a cable from the Push the cable up cable is pushed all the
the cable into the channel the channel. the channel.
bottom up. toward the top side. way in.

Wrong way to insert a cable:

Will not go in even when


Do not insert from top Insert to the edge in
the corner is pushed in.
to bottom. an angle.

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4.6. How to Wire Light Modules and Junction Box


4.6.1. Light Module Connection Channels of TW2209/TW2210
(1) TW2209 Ethernet Junction Box

Light Module Port

(2) TW2210 Junction Box

Light Module Port

Channels: CH1 ~ CH5 -- Light Module Connection Terminal

The terminal for connecting the wire to the light module


Up to 50 light modules can be connected per channel (250 units max. for 5 channels*).
* The maximum number of light modules you can connect may be fewer due to the light module power
consumption and the length of wiring.
* If wire shorts or a malfunction occurs, the protection circuit of the corresponding channel is activated,
power will be disconnected, and LED will turn off.
Keep the unused channels connected.
The channels are non-polar; however, match the connecting colors to make it easy to manage wiring.
Common wiring cannot be made with different channels.

Channel status
LED

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● Connector
Product Name ML-4500-CP Yellow white: (Sato Parts)
Polarity 2
2
Wiring range Recommended cable: AI cable 1.5mm ×2
2 2
Twisted wire: 1.25mm ~2.0mm (AWG24~ AWG14)
*1
Standard stripping length 10mm
Removal holding force 1.53N
*1: If the wire is narrow, the maximum distance will be shorter.

How to Connect the Connector

Step 1: Peel about 10mm of the outer layer of the AI cable with a stripper to expose the inner cable.

Stripped area: 10mm * Connection may fail if the stripped portion is too short.

Step 2: Press the release button using a tool such as a minus screw driver.

* You can use any tool to press the button.


* The button will stay pressed.

Step 3: Insert the cable and bring back the release button.

* Make sure the cable is locked.

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4.6.2. Installation on Medium Size Shelves


Connect the AI cable from the duct end with the AI cable of the junction box.

Branch connector
Ground the shelf

(1) Both ends of the cables from the duct ends are crimped into connectors.
• Recommended branching connector: AI-J01.
※The explanation on wiring is based on the use of this connector.
(2) The branching AI cable is placed to the edge of the stopper section; the main AI cable is placed on the
crimping portion. Use pliers to crimp the connector.
※No special tools are required.

Stopper

AI cable section

Place the AI cable

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Picture showing
completion

Make sure the connector is


firmly locked

(3) The cable should not protrude in front or back of the rack.
(As needed, use an Insulock-tie, a plastic tie with a camp lock mechanism and base.)
(4) Ground the shelf to prevent damage caused by static electricity or external noise. This is especially
important if the shelf mounted with light modules has insulated coating. In that case, drill in a small screw
and use a grounding wire to connect the shelf to maintain conduction with the main shelf.

 Before wiring, make sure there is no electric malfunction, such as leakage


in the main current.
Caution
 Before connecting to the junction box, make sure there is no shorting,
between the 2 wires or FG “frame grounding”.
Not taking these steps may cause damage to the system devices, so use
caution.

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4.6.3. How to Mount Light Modules to the Duct


The light module addresses must be set up.

Set up addresses using the address setup device.


Refer to Section 5.2.1 Using the Address Setup Device

Send the address setup command through the application.

Refer to Section 5.2.3 How to Set Up Addresses


Using Flowlight
(1) Make sure there are no dirt particles or debris on the duct base area.

(2) After making sure that light module addresses match the location, install the light modules.

① ② ③ ④
Match the
convexity to
the concavity.

Prepare to mount the Make the convexity of the module and As indicated by an arrow, push Push in further so that the
the concavity of the duct match. the lower portion of the module. guide potion of the module
light module. Check the
goes into the duct channel.
light module plugs.

⑤ ⑥

Push the module lever


into the duct channel.

Enlarge to

Push in further so that the


module pins pierce into the
cable. Push until the module pins pierce into the
cable, and the module hooks are engaged It shows that the module
completely with the duct’s lower channel. lever corner edge is
※ Make sure the 2 corner edges are caught by the duct
completely caught by the duct edge. channel completely.

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4.6.4. Install on to the Pipe Rack Using Pipe Base


(1) Mount the Insulok tie on to the pipe base.

① From the lower back, pass through the ② Thread the Insulok tie to the back through the
Insulok tie. other hole.

③ Shows Insulok from back to front, front to back. ④ Do the same for both ends.

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(2) Mount the Pipe Base to Pipe Rack

① Place pipe base in the ② Firmly tie the Insulok around ③Firmly tighten the Insulok ties.
mounting position the pipe.

④ Firmly tightening the Insulok tie to make sure the base does not ⑤ All the bases are installed for
rotate. pipe wiring.

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(3) Wiring the AI cable to the Pipe Rack


Place the AI cable to the base for wiring.

① Put the AI cable into the base groove. ② Make sure the wire does not float.

③ Hook the wire to the cable of the base. ④ Fasten the wire firmly to the hooks on both sides.

Wiring the AI Cable to the Pipe Rack with Insulok Ties

① Put the AI cable into the base groove. ② Make sure there is no slack in AI cable wiring.

③ Cut the unnecessary wire inside the pipe base. ④ Cut the extra Insulok ties. Pipe bases
are now attached with wiring.

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(4) How to Install a Light Module

① Place the light module inside the ② Press the upper part of the light module into inside the base. The bottom
base. portion is still unmounted.

③ Insert the bottom of the light ④ Press firmly into the base. ⑤ Press both sides. It is installed
module. when there is a click.
※Make sure the light module is fixed firmly to the hook after it is mounted to the base.
Press in from one side then to the next side to mount.

Hook is indented Hook is indented

Not locked. Not locked.

Hook is in flat position. Hook is in flat position.

Lock is firmly in place. Lock is firmly in place

※If not hooked correctly, the light module will fall off. Make sure it is securely locked.

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(5) Completion View

Before light modules are mounted. Light modules have been mounted.

Light modules are mounted. Close up view of an installed light module.

※If light modules are not properly installed, they may fall off or cause communication failure. Check each
light module to ensure it is installed correctly.

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4.6.5. Cable Ties

Cables are tied with Insulok ties.


Bundle horizontally and vertically with the Insulock ties of size up to T50.

(Example: TW2209)

* Bundling the cables prevents the connector from disconnecting due to pulling and stretching.
* Do not bundle AC cable with other wires.

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4.7. How to Wire the Batch Display


4.7.1. DIGITAL OUT: Output Port for Batch Display and Signal Light
This is an output port for the batch display and signal light.
Up to 5 units of devices can be connected.
The number depends on the connected light modules.
Wire from the batch display port of the junction box.

5-core cable, greater than 0.75 sq.


Cable length: 50m max.※

※Cross wiring. Up to 5 units※

If there is a mistake in connecting wires, the junction box or connected


devices can be damaged. Before supplying power to the device, check the
Caution direction of the power supply line and communication line.
※Power consumption of connected devices and the length of the cable can
change the number of batch displays that can be connected.

Terminal Name Detail on the Connection

R Power terminal +12V Connects the power of the batch display or other devices (DC12V)

BK GND terminal Connects the GND of the batch display or other devices

Y F.G terminal Connects the FG of the batch display or other devices1

W Signal line S+ terminal Connects the S+ of the batch display or other devices

G Signal line S- terminal Connects the S– of the batch display or other devices

1 Ground the batch display and other devices.

Rated Values of the Connector


Product Name XW4B-05B1-H11
Number of polarity 5
Range of electric Recommended cable: AWG18 (0.75sq), 5-core cable
2 2
wire used Twisted wire: 0.75mm ~ 1.5mm (AWG18 ~ AWG16)
Standard wire 7mm
stripping length
Terminal screw M2 minus screw
Tightening torque 0.22 ~0.25N
Compatible driver XW4BZ-00B ○,-1.2mm

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4.8. Wiring of Signal Lights

Because the TW2209 and TW2210 do not have ports for signal lights, use the TW2911 signal light interface.
Please refer to a section on how to wire batch displays in the TW2911 Signal Light Interface Hardware
Manual.

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5. How to Set Up

5.1. Network Setup (Ethernet type)


AIOI software called “Flowlight” describes the setup method. For more information, refer to the Flowlight User
Manual.
 Flowlight User Manual
To set up the network, set the subnet mask of the PC that performs the setup to match the
subnet mask of the controller. Because the controller is already set up with the default setup of
IP: 192.168.1.254, the PC that performs the setup must have an IP that is accessible to this IP.

5.1.1. Startup Flowlight


(1) Select “Ethernet”from“Controller Type”
(2) In the box next to “IP Address”, the default IP address, “192.168.1.254”  is entered.

If the IP address needs to be changed, enter the IP address you want.
(3) Next to “Port No.”, the default port number, “5003” is displayed.

If the number needs to be changed, input the new port number.
4) Check the above inputs and press the “Add & Connect” button.

(1)
(2)

(3)

(4)

(5) Check the startup screen to make sure the connection was made.

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5.1.2. How to Set Up a Network


(1) From “Tools(T)”, select “Ethernet Controller Configurations. . .”.

(2) Select ”eP” series and log on with the IP address 192.168.1.254.

When multiple controllers are connected, delete the ARP table before logging on、

(3) Setup Screen: Input the items you want and press “Save Changes”.

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(4) The setup confirmation screen will be displayed. It is set up when “Yes” is selected.

Yes No

(5) Log Off and restart the controller.

The network setup takes effect after the controller is restarted.


After making a change to the network setup, always restart the controller.
Record the detail of the network changes you made on the label attached to the product.

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5.2. How to Set Up the Light Module Address


Below is an explanation on how to set up the light module address.

By using the address setup device


Refer to Section 5.2.1. Using the Address Setup Device.

By sending the address setup command through the application


Refer to Section 5.2.3. How to Setup Using Flowlight.

5.2.1. Using the Address Setup Device


How to connect light modules

Mount the light module and connect the AC adapter to the AC Jack on the side, then turn power on.

When power is turned on, the 7-segment display will show “0001” and the ENTER key lights up.

Flash Light up

If the ENTER key does not light up when it is turned on or if the ENTER key is off
when the light module is mounted, a short circuit may have occurred when power was
supplied to the device. Turn it off and check the light module.
When power is supplied to light modules, the CONFIRM button will momentarily flash.
(This may not happen to all modules.)

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How to input an Address

Example: To Input Address “0102”

(1) Make sure the first digit is blinking. Then press the NUMBER key once. After pressing it, “2” will be
displayed as the first digit.

Press the NUMBER key

Blinking Blinking

(2) By pressing the DIGIT key, the blinking digit will shift. When it is pressed twice, the third digit will blink.

Press the Digit key Press the DIGIT key

Blink Blink Blink

(3) Make sure the third digit is blinking. Then press the NUMBER key once. When it is pressed, the third
digit will display “1”.

The 7-segment display will show “0102”.

Press the NUMBER key

Blink Blink

When you press both the DIGIT key and NUMBER key at the same time, the display of the
7-segment LED returns to”0001”.

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Address Setup
Example: To Set Up Address”0102”

(1) Make sure the 7-segment LED shows the address that you are setting up (Example “0102”).

(2) To set up the address, hold down the CONFIRM button (Address Setup Switch) of the light module and
press the ENTER key of the address writer. When it is set up, the light module will flash and will emit a
sound.

Hold down the


CONFIRM button
Blinking
and press the
ENTER key

When the address is set When the address is not set


up up

Beep
! Blinking

All the segments display the setup address. The address displayed on the segment
The “A” command is sent to the light module. flashes. The “A” command is sent to the light
If the module is the type that displays digits, the module. If the module is the type that displays
address can be confirmed. digits, the address can be confirmed.

Refer to 5.2.2 Light Module Address ※ Check if the light module is mounted
Display Operation correctly. If mounted correctly, set up the
address again.
If it is NG again (fails), the light module may
be damaged.

(3) Remove the light module. When removing the light module from the base, you must hold both ends of
the module horizontally so that the contact pins will not be damaged.

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5.2.2. Light Module Address Display Operation


The MWU2706 Address Writer sends the A command to the light module to turn on all the digits when the
ENTER key is pressed. When the light module receives the A command, all the 7-segment LEDs and the
CONFIRM button will turn on.
 The lighting operation at the time of the A command (for digit type only).

Example: To set up
address “1234” Send the “A” command

All the segments light up

Press the CONFIRM button

The entire address is displayed

Press the CONFIRM button

Start of the address display.

Press the CONFIRM button

th
Displays the 4 digit of the
address

Press the CONFIRM button

rd
Displays the 3 digit of the
address

Press the CONFIRM button

nd
Displays the 2 digit of the
address

Press the CONFIRM button

st
Displays the 1 digit of the
address

Press the CONFIRM button

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※If the displayed address on the light module indicates the correct address but the address writer indicates
“NG”, the light module or the address writer may be damaged.

Confirm the Address of the Light Module

It is possible to check the address of the light module that has been set up.
Used for the non-digit type of light module when you don’t know the address.

Example: If the setup address is “1234”


(1) Mount the light module that has the address you want to confirm.
(2) Press both the DIGIT key and NUMBER key at the same time, then press the ENTER key.

ENTER key
NUMBER key
Flash DIGIT key

*Press the DIGIT key


and NUMBER key at
the same time, then
press the DIGIT key.

(3)Shows the setup address on the 7-segment display of the MWU2706

Lights Up

Lights up when the light module address is read. The


“A” command is sent to the light module.

※If the MWU2706 cannot read the address, its 7-segment display will flash. Check to see if the light module
is mounted correctly. If the address writer shows NG again, the light module may be broken.

NG Flash

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5.2.3. How to Set Up Using Flowlight


(1) From Tools, select Light Module Address Setup.

(2) Select and connect the controller.

(3) Make adjustments to the setup values and press the Start button.

Wait Time Before Starting


The time it takes from pressing the Start
button until the address setup command is
sent. If the first address setup location is
far, use a larger value.
Interval
Interval of sending the address setup
command. If the distance between light
modules is far, assign a larger value.
Start Address
Enter the start address to set up.
Increment
At first: Setup Address = Start address +
Increment.
Thereafter: Setup Address = Previous
Setup address + Increment
End Address
The last address to set up.
If it is smaller than the second last address
added by increment, this address will not be
set.

(4) After pressing the Start button for the amount of time you have set up, the address setup command is
sent for the first address. Until then, keep the first light module’s CONFIRM button pressed.
(5) When the first light module emits a “peep” sound, the CONFIRM button flashes momentarily. This is a cue
that the address has been set up. According to the specified address setup intervals, press the next light
module’s CONFIRM button.
(6) When the last light module address has been set up, a command to light up the light modules is sent and
all the light modules will light up. The address can be checked by pressing the individual light module’s
CONFIRM button.

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5.3. Checking the Operation of Devices


Presented here is AIOI’s checking software for the picking system called Flowlight. For more information,
please refer to Flowlight User’s Manual.

5.3.1. Checking the Light Module Operation


(1) Under the Light Module tab, right click the module list area and select Add New. . .

(2) Enter the addresses.


To enter continuous addresses, use a hyphen between the first and last addresses; for multiple addresses,
use a comma between the addresses.

(3) The addresses are registered.

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(4) Right click on the address portion and choose “Select All”. When “Start Operation” is selected, the
registered light modules will light up.

(5) After leaving the lights ON for about 5 minutes, press all the CONFIRM buttons.
The status of these modules then becomes normal.
If an abnormal module is found, check the address of the abnormal module. If there are multiple
abnormal modules, check the wire.

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5.3.2. Checking the Operation of the TW2911 Signal Light Interface


(1) Register the Address
Right click the signal light tab and select Add New.

Enter the addresses of the devices that you are adding. Use a hyphen (-) between a sequence of addresses
and comma between multiple addresses. Then select Add.

The addresses are displayed.

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(2) Output Test


Right click the address you want to light up and select Turn-ON.

A command is sent and lights up the signal light.

Be sure to visually check if the signal light is turned on. Turn on each light one by one and check if the
address matches its corresponding light.
To turn off the light, select Turn-OFF.

Because the signal light interface (I/F) is an output device, there is no way to check the
status through the application.
Check the wiring. Also, make sure to send an instruction to each address to Turn-ON
and check if the corresponding light turns on.

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5.3.3. Checking the Operation of the AW2821 and RS232C I/F


(1) Address Registration

Right click the RS-232C I/F tab and select Add New.

Enter the address in the Adding New Devices RS-232C Interface screen. (Use a hyphen (-) between a
sequence of addresses and comma between multiple addresses) Next, select Add(A) to add.

The addresses are displayed.

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(2) Test the Input


Right click on the address that you want to operate and select Open.

Check if the status of the 7-segment LED is “oo”.


When the code is read by the barcode scanner, the scanned data will be displayed on the Incoming Data.
Check if the code matches the input data.

To end the read operation, select Close.


Because barcode scanners have different factory default settings, make sure the setting
matches the communication specifications of the RS-232C of the eP2821.
Also, the factory default setting of the type and maker of barcode sanners is different.
Always make sure the barcode reader you use for the system is able to read.

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5.3.4. Maintenance Command


[“A” command (Turn all lights on) / “Z” command (Initialize)]

The maintenance command is sent by clicking the buttons shown below.

Device “A” Command “Z” Command


Light Module All the light modules will be in the All the light modules will turn off.
maintenance mode. Press the CONFIRM
button to check the address (only for the
digit type light modules).
Signal Light All the lights will light up. All the lights will turn off.
TW2911
AW2821 Displays the last 2 digits of the address Becomes Close status.
RS-232C I/F on the 7-segment LED.

After the light modules have been installed, send the A command to check if the
addresses are correct.
The A command is only for checking the light operation. It cannot check
communication.
After installing the light modules, make sure to check the communication in
addition to checking the lights.

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 The Operation of the “A” Command (turn light on command)

Example: When the address is “1234”


setup Send the “A” command

All the segments light up

Press the CONFIRM button

The entire address is displayed

Press the CONFIRM button

Start of the digit display

Press the CONFIRM button

th
Displays the 4 digit of the
address

Press the CONFIRM button

rd
Displays the 3 digit of the
address

Press CONFIRM button

nd
Displays the 2 digit of the
address

Press CONFIRM button

st
Displays the 1 digit of the
address

Press CONFIRM button

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6. Troubleshooting

6.1. Controller Junction Box

Phenomenon Main Reason Check


Cannot connect with the The IP address is not set up. Check to see if the IP address
controller exists with the PING command
The IP address is incorrect.
from the connected PC.
If the IP address is unknown,
supply power while pressing
down the INIT switch to set to
the default value
(192.168.1.254).
The netmask that connects the Check to see if the connected
PC and controller is incorrect. PC setup is DHCP, which is
inaccessible to the controller.
The IP address is duplicated. Turn OFF the controller’s power
and send the PING command to
check if the IP address exists.。
The netmask of the connecting Check the PC’s netmask.
PC is incorrect.
If the setup is DHCP, the
connection cannot be made.。
Cross / Straight LAN cables are If connected directly with the
wrong connecting PC, use the cross
cable. If connected via HUB,
use the straight cable.
Modular cables between junction
boxes cannot be used.
“Good Link “is not lit. Check the LAN connection
environment.
Controller is damaged. Check to see if the green
POWER light is ON.
It takes about 10 seconds for the
green POWER light to come ON.
If it does not turn ON, the AC
power source may be damaged.
Replace it. If it is ON, initialize,
turn power ON/OFF and
recheck. Replace the device if
unable to restore.
Red “CK” light is turned ON Shorting detected in JB’s CH. Check to see if the JB’s CH
lights are all ON.
Error light is turned ON red.
If OFF, check the wires of the
CH that is OFF, fix the shorted
wires, and resupply power.

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Phenomenon Main Reason Check


Red “CK” light is flashing. Light module communication From the application, check all the
malfunction. connected light modules by
Communication instruction was communicating with the
sent to a non-existent address. addresses. If there is a
malfunction, refer to the item on
the light module.
CH light is OFF. If the CH light is OFF, it Shorting may have occurred in the
*TW2209,TW2210 indicates shorting somewhere. CH that light is OFF. Check the
wires.
Check if shorting has occurred
between the 2 wires or if 2 wires
have shorted with the FG wire.
Shorting may be detected due to
the inrush current when power is
supplied and the CH connector is
inserted.
Power light turns ON / OFF Shorting may have occurred Shorting may have occurred with
somewhere. the output line of “DIGITAL OUT”.
Check the DIGITAL OUT wiring.
Instant power failure on the AC Check the AC power.
power source
Light module light is slow to Poor network connection If the network is the same as the
turn ON. environment. company network, other PCs will
affect the network load and cause
a slow response.
Wireless LAN may cause a slow
response.
Please check the network
environment.
Communication command is Check the address.
sent to a non-existent light
module address.
When power is provided, all The controller’s dipswitch 1 is When the DIP switch 1 is ON and
the light modules turn ON. ON. power is supplied, a command will
be sent to turn all lights ON.
When you are not checking, turn
DIP switch 1 to OFF.
Abnormal communication. Power leakage and AC power Check the primary power source.
failure.
Communication line and FG Remove the CH wire and check for
have shorted. shorting with FG using a mega
ohmmeter.
If light modules have already been
installed, do not place the mega
ohmmeter between the 2 sires.
Shorting with the modular Check the cable with a LAN cable
cable.
checker.
The LAN cable and modular
cable are different.

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6.2. Light Module

Phenomenon Cause Check

Does not turn ON Incorrect address. With the “A” command from the control PC,
(turn ON the controller’s dipswitch 1) and
supply power. Then check the address.
If there is no address setup instruction, the
address is the default value “0000”.
Power supply pin is Remove the light module and check if the pin
damaged. is bent.
Shorting in the wiring. Check the CH light of the connected junction
box.
If the light is OFF, check the wire; then
resupply power.
Light turns ON but Duplicate addresses Send a light instruction only to the light
becomes abnormal There is another light showing an error to check if no other lights are
with the same address. turned ON.
Too many lights are Check the wire length and the total connecting
connected. units for the CH. Check them against the
connection formula to find out if they are within
the criteria.
Light module is Check by reading the address in the address
damaged. setting.
If unable to read, replace the light module.

After power is supplied, Status when the This is the status when power is supplied with
the CONFIRM button CONFIRM button has the CONFIRM button pressed, the light turns
turns ON but it cannot been pressed. ON.
be pressed Check if the switch has been pressed or not.
If the light module is malfunctioning, replace it.

An invalid command was Check the application specification.


sent by the application.
Lights up when an error Became “0” (zero) light When the light module address is “0000”, it
occurs. module address. becomes maintenance mode. When an error
occurs, it displays the error code and abnormal
address.

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6.3. Interface and Other Devices


[TW2911] Barcode Reader Interface

Phenomenon Cause Check


Mistake in wire connection. Turn OFF the junction box and check the
Shorting of wire. connected wires.

Address error. Check the address with the “A” command


Becomes abnormal
Verify the scanner’s absolute maximum
communication
rating (a value of electrical or mechanical
Scanner’s electric current is
quantity which must not exceed such as
excessive.
input voltage or amount of mechanical
shock).
Mistake in wire connection Turn OFF the junction box’s power and
Shorting of wire. check the connected wires.

Address error. Check the address using the “A” command.


Cannot read the
data Setup of the scanner is
Check the setup of the scanner.
incorrect.
Exchange if there is a spare scanner and
Scanner cable is disconnected.
check.
Data length is too long.
Check the data length of the code that has
Displays “E3” on the 7 segment
been read.
display.
Scanner’s communication setup
is incorrect.
Check the scanner setup.
Displays “E4” on the 7
There is scanning segment.
sound, but unable A possible communication
to capture the data abnormality between the control
computer and controller. Check the wiring of the system.
Displays “E2” on the 7
segment.
Communication of the barcode
Again, “Open” the barcode reader
reader interface is abnormal.
interface.
Displays “E2” on the 7
segment.
After power has been supplied, some
From the time power is devices can read the setup book only for a
Unable to read the
supplied, the scanner book can fixed number of seconds. If power is
scanner’s setup
be read with the scanner only supplied by the eP2821, first have in the
book
for a fixed number of seconds. “Open” status, then read in the setup book
within the timeframe.

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[TW2911] Signal Light Interface

Phenomenon Cause Check


Mistake in connection
Turn the junction box (JB) OFF and check
wiring.
the connection wiring.
Short circuit.
Check the address of the dipswitch.
The address of the dipswitch is reflected
Does not light up Address is incorrect. only when power is supplied. If you make a
change while power is being supplied,
resupply power.
Replace bulbs.
The bulb is out. Flash operation will shorten the usage life
of the bulb type.
Mistake in connection
Turn OFF JB’s power and check the wiring
wiring.
to connecting devices.
Electric short circuit.
Check the address of the dipswitch.
Instruction was not sent
The dipswitch address will be reflected only
but the light turns ON
Incorrect address. when power is supplied. If an address is
and OFF
changed while power is being supplied,
resupply power.
The address is the same as
Check the light module’s control command.
the address of the block
Check the address.
number.
Mistake in connection
Turn OFF the junction box’ power and check
wiring.
the connecting wires.
Electric short circuit.
Check the address of the dipswitch.
The dipswitch address will be reflected only
Incorrect address. when power is supplied. If an address is
changed while power is being supplied,
Becomes abnormal with
resupply power.
a module inquiry
The signal light interface contains +4
addresses even when the OUT terminal is
not used.
If multiple interfaces are installed, check to
Duplicate addresses.
see if addresses are not duplicated.
There are times addresses are duplicated
through application.

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[MWU2706] Small Address Setup Device

Phenomenon Main Cause Check


AC adapter is not
Check to see if the adapter is connected.
connected.
Cannot power up
A short-circuit in the MWU
Remove the light module and turn it back on.
power supply area.
A short circuit in the MWU Remove the light module and check to see if
power supply area. the power supply is normal.
Remove the light module and check if the
The ENTER key does
power supply area is normal. With the light
not light up
The light module is broken. module not yet been mounted, turn on the
address writer and check if the ENTER key
will light up.
The ENTER key is not The address will be set up by holding down
After setting up an pressed while holding down the CONFIRM button and pressing the
address, the 7-segment the CONFIRM button ENTER key of the MWU2706 at the same
display is blinking (Address Setup Switch). time.
The light module has not
Check if the light module is mounted.
been mounted.
Check if the light is mounted. Also check the
The light module is broken. address and read the setup address of the
light module.
When confirming the The light module has not
Check if the light module is mounted.
address, the 7-segment been mounted.
display flashes without Check if the light module is mounted. If you
displaying the address cannot confirm the address even after
The light module is broken.
repeated tries, the light module may be
broken.

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Note: The specifications and the contents of this manual may be revised without prior notice. No part

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Installation user manual 2017-08-31

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