User Manual Interroll DriveControl
Contents
1. 24 VDC GND to ext analog speed set of next DriveControl DC EC100 Potentiometer 10kQ Pot at minimum equals 23 of rated speed DIP switch settings e SW2 ON OFF e SW1 ON OFF External speed set by PLC Direction of travel x TI Motor cable Ext analog speed set Ol oj 0000 E Lo Oj dP SES Ol o o oT Sensor input NPN PNP Leo o lo Fault Input GND input Ei Ba E o rH DC Common Output 24 VDC input E er Q ij ES Hio o 424 VDC Output Lo 5 24 VDC to ext analog speed set of next DriveControl DC EC100 G ND 0 5 VDC GND PLC analog speed output 0 5 VDC 0 V 23 of rated speed 5 V 100 of rated speed DIP switch settings e SW2 ON OFF e SW1 ON OFF 14 Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Motor start and external direction setting Version 1 0 11 2007 en Original language Product information Wiring diagrams Motor start and external direction setting in PNP mode Direction of travel 6559 A Motor cable o E o o o o FWD Input REV Input DDUDDUDDDD 00000000 o GND Input 24 VDC Input OOOO 24 VDC GND REV Input FWD Input DIP switch settings e SW2 ON OFF e2. Components 1000 O ON 05052 01925 USA o III 6 INTERROLL 8906 DC EC100 o V e EE O o bo O i O o O E o Fuse LED red Power LED green Fault LED red Warning LED amber Label Motor cable of RollerDrive Sensor connection DIP switches Speed potentiometer Fuse Power input and I O terminal 066600 88060 Version 1 0 11 2007 en Original language DriveControl DC EC100 P INTERROLL wy Product information Dimensions 137 mm 5 4 in 102 mm 4 0 in 1 1 i 05052 01925 USA III pa E d INTERROLL 8996 DC EC100 T o V 1 00 REV 0 s ai o x Bail m o e N el se E o E E 3 Ki o E o 0000 o N 3 H o o 2 o E 79 mm 3 1 in i N co e E E N N The following mounting hardware is supplied e 2x button head screw 10 32 UNF x 0 5 e 2x nut with captive star washer 10 32 UNF Mounting hardware Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Features Safety and stall functions Product information Product description The DC EC100 must be used in conjunction with a RollerDrive EC100 Dia
3. Japan Interroll Japan Co Ltd 302 1 Shimokuzawa Sagamihara shi JPN Kanagawa 229 1134 Tel 81 42 764 2677 Fax 81 42 764 2678 jpn sales interroll com Korea Interroll Korea Corporation Room 301 Dongsan Bldg 333 60 Shindang Dong Choong ku Seoul Tel 822 2 231 1900 Fax 822 2 254 36 83 kr sales interroll com Singapore Interroll Asia Pte Ltd 386 Jalan Ahmad Ibrahim 629156 Singapore Republic of Singapore Tel 65 6266 6322 Fax 65 6266 6849 sgp sales interroll com Thailand Interroll Thailand Co Ltd 41 6 Moo 6 Bangchalong Bangplee Samutprakarn 10540 Tel 66 2 337 0188 91 Fax 66 2 337 01 92 th sales interroll com Australia amp New Zealand Australia Conveyor Solutions Australia Pty Ltd 70 Keon Parade Thomastown 3074 Melbourne Tel 61 3 9460 2155 Fax 61 3 9460 2029 aus sales interroll com New Zealand Anthony Group NZ Ltd 42 Parkway Drive Mairangi Bay NZ Auckland 10 Tel 64 9 478 6150 Fax 64 9 479 6394 nz sales interroll com For other countries please see contacts at www interroll com
4. 1 56 56 372 Turkey Roller Makina San Ve Tic Ltd Sti Zihni Sakaryali Ali Sok Ufuk Apt No 1 D 11 Ersoy Sahil Sitesi 81070 Suadiye Istanbul Tel 90 216 386 37 75 Fax 90 216 386 38 22 tr sales interroll com Near East Israel ComrTrans Tech Ltd P O B 17433 Tel Aviv 61174 Israel Tel 972 54 4 27 27 47 Fax 972 3 7 44 08 64 il sales interroll com Africa South Africa Interroll SA Pty Ltd P O Box 327 Isando 1600 ZA Gauteng Tel 27 11 974 1901 Fax 27 11 974 1896 za sales interroll com North amp South America USA Interroll Corporation 3000 Corporate Drive USA Wilmington NC 28405 Tel 1 910 799 11 00 Fax 1 910 392 38 22 usa sales interroll com Canada Interroll Canada Ltd 1201 Gorham Street CDN Newmarket Ontario L3Y 8Y2 Canada Tel 1 905 727 3399 Fax 1 905 727 3299 cdn sales interroll com Argentina Interroll South America Calle 117 No 3591 B1650NRU San Martin Provincia de Buenos Aires Tel 54 11 4753 8005 Fax 54 11 4754 1332 ar sales interroll com Brasil Interroll Brasil Av Portugal 918 CEP 06651 970 Itapevi SP Tel 55 11 41 43 43 43 Fax 55 11 41 43 77 19 br sales interroll com Asia China Interroll Suzhou Co Ltd Unit 10B Modern Industrial Square No 333 Xing Pu Road Suzhou Industrial Park Suzhou Jiangsu Province People s Republic of China Postal Code 215126 Tel 86 512 6256 0383 Fax 86 512 6256 0385 cn sales interroll com
5. 79 EC Low Voltage Directive 2006 95 EC EMC Directive 2004 108 EC RoHS Directive 2002 95 EC Applied harmonized norms EN ISO 12100 Part1 and Part2 Wilmington November 7 2007 Richard Keely VP of Manufacturing This declaration can be obtained at www interroll com if needed Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Version 1 0 11 2007 en 27 Original language INTERROLL DRIVES amp ROLLERS Europe Nordic Denmark Interroll Nordic A S Hammerholmen 2 6 DK 2650 Hvidovre Denmark Tel 45 36 88 33 33 Fax 45 36 88 33 72 dk sales interroll com Interroll Service Islandsvej 5 DK 7900 Nyk bing M Tel 45 97 71 15 55 Fax 45 97 71 16 55 dk sales interroll com Iceland IBH ehf Dugguvogur 10 104 Reykjavik Iceland Tel 354 562 6858 Fax 354 562 6862 ingi ibh ehf is Finland Tel 358 9 54 94 94 00 Fax 358 9 54 94 94 16 Norway Tel 47 32 88 26 00 Fax 47 32 88 26 10 Sweden Tel 46 35 227077 Fax 46 35 227078 Western Southern Europe France Interroll S A S ZI de Kerannou B P 34 F 29250 Saint Pol de L on Tel 33 298 24 41 00 Fax 33 298 24 41 02 f sales interroll com Italy Rulli Rulmeca S p A Via A Toscanini 1 1 24011 Alm Bg Tel 39 035 4300111 Fax 39 035 545523 i sales interroll com Portugal Rulmeca Interroll de Portugal Lda Apartado 69 Centro Civico P 6201 909 Covilha Tel 351 275 330 780 Fax 351 275 3
6. DriveControl or the RollerDrive gt Ensure that the RollerDrive the DriveControl and the 24 VDC power source are properly earthed through the frame or supporting structure in which the RollerDrive and the DriveControl are installed Failure to do so could cause the buildup of static electricity or ground loops and can cause the motor or DriveControl to malfunction or fail prematurely Do not spin the RollerDrive manually as this generates an induction voltage which could damage the DriveControl Installing the DC EC100 in a conveyor system Usethe DriveControl as a template and mark the center of the two mounting holes For the distance between the holes see Dimensions page 7 gt Drill two 5 6 6 mm 0 22 0 24 in mounting holes at the marked spots Insert the button head screws in the holes on the opposite side the DriveControl is to be mounted Install the DriveControl to the frame with the screws protruding through the mounting holes Slip the nuts to the screws and tighten Ensure that there is a ground path between the DriveControl and the conveyor frame it is mounted to i The DriveControl and conveyor frame should be at the same potential referenced to earth ground Version 1 0 11 2007 en 17 Original language DriveControl DC EC100 INTERROLL 18 Assembly Electrically installation The connector supplied with the RollerDrive EC100 mates up with the header on the DC EC100 Th
7. here and GND When using a 10 kO external potentiometer the wiper must be connected here The on board potentiometer should be set to maximum CW so it will not affect the external speed setting for the wiring diagrams see page 15 External pot An external 10 kO potentiometer can be used to adjust the speed down to approximately 2396 of the maximum speed The on board potentiometer should be set to maximum CW so it will not affect the external speed setting for the wiring diagrams see page 15 FWD input Normal rotation is CCW seen from the cable end This input is PNP NPN selectable with DIP switch 1 REV input Causes the RollerDrive to operate in reverse transport mode while the signal is active Normal reverse rotation is CW seen from the cable end This input is PNP NPN selectable with DIP switch 1 No fault output Active high 24 VDC when either in NPN or PNP mode Signal goes low only when system faults occur Sensor output Signal passed through from the sensor input This output is PNP NPN selectable with DIP switch 1 Common ground input Must be connected to the main power ground 24 VDC input Main power supply 24 VDC for voltage range see Technical data page 12 00 OG i The DC EC100 is protected against reverse polarity but the power supply must provide a short circuit or over current protection and a voltage ripple tolerance of less than 5 Version 1 0 11 2007 en 9 Ori
8. manual describes the DC EC100 as it is delivered by Interroll Special application designs require validation from Interroll and additional technical instructions gt For trouble free safe operation and warranty claims read the manual and follow the instructions before handling the DC EC100 Keep the manual near to the DC EC100 gt Pass the manual on to any subsequent operator or occupant of the DC EC100 gt Interroll does not accept any liability for malfunctions or defects due to non observance of this manual gt If you have any questions after reading the user manual feel free to contact our customer service See the last page for contact information Warning notices in this manual The warning notices in this document refer to risks which may arise during usage of the DC EC100 For relevant warning notices see Safety page 4 and the warning notices at the beginning of each chapter There are three categories of danger The following signal words are used in the document as required e Danger e Warning Caution Signal word Meaning Danger Indicates a hazardous situation which if not avoided will result in death or serious injury Warning Indicates a hazardous situation which if not avoided could result in death or serious injury Caution Indicates a hazardous situation which if not avoided may result in minor or moderate injury DANGER Nature and source of the hazard Possible consequenc
9. may occur while working with the DC EC100 Maintenance or repair work must only be executed by authorized and qualified persons in accordance with the applicable regulations Before using the DriveControl ensure that no unauthorized persons are near the conveyor v Only perform installation and maintenance work after you have switched off the power Ensure that the power cannot be turned on accidentally Do not use the DriveControl in explosive atmospheres Remove equipment or material which is not required from the workspace Regularly check the DriveControl for visible damage In case of fumes turn off the power at once and ensure that it cannot be turned on accidentally Contact qualified personnel immediately to find the source the malfunction VV VV v gt As the product is maintenance free you only need to check regularly for visible damage and that all leads and screws are still tightened Interfaces By assembling the DriveControl in a conveyor module potential hazards may occur These are not part of this manual and have to be analyzed during the design installation and startup of the conveyor module gt After assembling the DriveControl in a conveyor module check the whole system for a new potential dangerous spot before turning on the conveyor DriveControl DC EC100 INTERROLL Product information
10. page for contact information Intended use The DC EC100 may only be used for industrial applications and in an industrial environment to control a RollerDrive EC100 It must be integrated in a conveyor module or a conveying system Any other use is considered inappropriate Use of the DC EC100 is only allowed in the areas described under product information Any changes that affect the safety of the product are not allowed The DC EC100 may only be used within the given operation limits Unintended use Applications not according to the intended use of the DC EC100 require approval from Interroll Qualified persons Qualified persons are persons who read and understand the manual and taking national regulations into account can competently execute incidental work Only instructed and qualified persons may work with the DriveControl taking the following into account e the relevant manuals and diagrams e the warning and safety instructions in this manual e the system specific regulations and requirements national or local regulations and requirements for safety and accident prevention Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL A Persons Electricity Working environment Avoiding malfunctions in operation Maintenance Version 1 0 11 2007 en Original language Safety Risks The following list informs you about the various types of danger or damage that
11. 30 789 p sales interroll com Spain Interroll Espa a S A C I Santiga C Puig dels Tudons 5 E 08210 Barbera del Vall s Tel 34 93 729 96 50 Fax 34 93 718 96 50 e sales interroll com Version 1 0 11 2007 en Original language United Kingdom Interroll Ltd Brunel Road Earlstrees Industrial Estate GB Corby Northants NN17 4UX Tel 44 1536 200 322 Fax 44 1536 748 505 gb sales interroll com Central Europe Germany Interroll F rdertechnik GmbH H ferhof 16 D 42929 Wermelskirchen Tel 49 2193 230 Fax 49 2193 20 22 d sales interroll com Austria Tel 49 2193 23 187 Fax 49 2193 23 164 Belgium Tel 49 2193 23 131 Fax 49 2193 23 164 Luxembourg Tel 49 2193 23 190 Fax 49 2193 23 164 Netherlands Tel 49 2193 23 151 Fax 49 2193 23 164 Switzerland Tel 49 2193 23 190 Fax 49 2193 23 164 Benelux Interroll Trommelmotoren b v Veldweg 38 NL 6075 Herkenbosch Tel 31 4755 33701 Fax 31 4755 32597 nI drummotors interroll com Eastern Europe Czech Republic Interroll CZ s r o G Simka 3147 CZ 69003 B eclav Tel 420 519 330 210 Fax 420 519 330 211 cz sales interroll com Hungary Tel 36 23 337 891 Fax 36 23 337 892 Poland Interroll Polska Sp z 0 0 ul Jagiellonska 78 lok 3 31 PL 03 301 Warszawa Tel 48 22 334 63 43 Fax 48 22 675 72 92 pl sales interroll com Slovakia Tel 421 2 4363 8102 Fax 421 2 4342 7294 Slovenia Tel 386 1 56 56 370 Fax 386
12. INTERROLL WE MAKE THE WORLD MOVE User Manual Interroll DriveControl DC EC100 Manufacturer Interroll Corporation 3000 Corporate Drive USA Wilmington NC 28405 Tel 1 910 799 11 00 Fax 41 910 392 38 22 www interroll com Copyright The copyright of this manual remains with Interroll Corporation This manual includes regulations and technical drawings which may not be copied or duplicated either whole or in part Unauthorized use publication or application of this document is prohibited Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Table of contents Introduction Handling of the user manual 2 Warning notices in this manual 2 Further symbols sexo 05 a s RTE sed d a diel we A m doe 3 Safety General safety instructions 4 Intended USE mn se e I et d ede ne etm a RR ne RC TE BA JB Rs 4 Unintended use A Qualified persons 4 Eeer AN Hang AL be ae RACKS UR A Ag feces mene tc eret DN Ie s e c RC A Ree 5 liiterface S o o e outage dr a ORC neat eee CEA Rede us 5 Product information COMPONENTES o ici fld eene cate SO pope e Rd QU d RAR 6 DIMENSIONS P TT 7 Product description 8 Incline and decline applications 8 Inputs and outputs eh 9 DIP Switches cust ENER HN ur Rd mum boar es AE TG 10 Meaning of the LEDs sa rss ss ss rs ARKA RAR RA sa 11 DriveControl label 12 Technical data o cc luu a a NN e RR 12 Speed settings ee
13. In case of damage take photos of the damaged parts To maintain the warranty report any damage caused by transport instantly to the transport company and Interroll Do not transfer the DriveControls between warm and cold environments This may cause condensing water VVVVVV v Storage Risk of injury due to improper storage gt Do not stack more than four carton boxes gt Check each DriveControl for damage after storage Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Assembly Warning notices concerning assembly NOTICE Risk of damage leading to failure or shortened life expectancy of the DriveControl gt Observe the following notices gt Do not drop or mishandle the DriveControl to avoid internal damage gt Check each DriveControl visually for damage before assembly Warning notices concerning the electrical installation NOTICE Risk of damage to the DriveControl gt Observe the following notices The electrical installation may only be executed by qualified and authorized persons gt Disconnect the power before installing removing or rewiring the DriveControl gt Do not apply AC current to the RollerDrive or DriveControl device at any time as this will cause irreparable damage Donotapply too much stress to the connector pins Bending the wires at the connector can cause damage to the insulation of the wires which could result in failure of the
14. SW1 ON RollerDrive rotation direction e FWD connected to 24 VDC at PNP mode causes ccw rotation e REV connected to 24 VDC at PNP mode causes cw rotation e FWD and REV connected to 24 VDC at PNP mode causes coast mode Motor start and external direction setting in NPN mode Direction of travel S GE CT o idk Motor cable plo FWD Input CN ol o REV Input m 9 npu SE o O 2 o GND Input oj o Dunn gt 24 VDC Input c eu Q iji ell de n 24 VDC GND REV Input FWD Input DIP switch settings e SW2 ON OFF e SW1 OFF RollerDrive rotation direction e FWD connected to GND at NPN mode causes ccw rotation REV connected to GND at NPN mode causes cw rotation e FWD and REV connected to GND at NPN mode causes coast mode 15 DriveControl DC EC100 INTERROLL 16 Transport and storage Transport e Each DriveControl is packed in its own carton case Risk of injury due to improper transport Transport may only be carried out by qualified and authorized persons gt Observe the following notices Do not stack more than four carton boxes Check the fixation of the DriveControls before transport Avoid hard shocks during transport Check each DriveControl visually for damage after transport
15. and dirt in combination with humidity may bridge the electric circuit Therefore in a dirty environment periodic cleaning will help to avoid short circuits which could damage the DriveControl Regularly blow off dust and dirt with low compressed air Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Troubleshooting Error search Symptom Possible cause Help System is not operating No power supply Check whether the output voltage of Version 1 0 11 2007 en Original language the power supply is within the specified voltage range Wrong polarity of the bus line inputs Verify the polarity of the bus line inputs to the DC EC100 see Inputs and outputs page 9 Wrong position of the DIP switch 1 Verify that the position of the DIP switch 1 Logic NPN or PNP matches the sensor type see DIP switches page 10 Fuse is blown Replace the fuse see Replacing fuse page 20 21 DriveControl DC EC100 INTERROLL Symptom Motor is in brake mode red fault LED is on and error output is active No fault output is active Troubleshooting The following errors are reported by illuminated LEDs also see Meaning of the LEDs page 11 Possible cause Invalid state of motor hall effect sensor e Broken wire e Failed hall effect sensor Help Replace the RollerDrive Voltage over or under limits e Power supply fluctuations failure or overload condition C
16. ds are placed on the conveyor To reduce the speed manually turn the potentiometer counterclockwise with a small screwdriver To increase the speed manually turn the potentiometer clockwise with a small screwdriver To set the DIP switches carefully use a small screwdriver 19 DriveControl DC EC100 INTERROLL 20 Checking the DriveControl Replacing the DriveControl Replacing fuse Maintenance and cleaning Warning notices concerning maintenance and cleaning Risk of injury due to improper handling or accidental motor starts Maintenance work and cleaning may only be executed by qualified and authorized persons Only perform maintenance work after switching off the power Ensure that the DriveControl cannot be turned on accidentally Set up signs indicating maintenance work Maintenance The DriveControl must be checked at regular intervals to avoid malfunctions Monthly check the DriveControl and its leads for visible damage Annually ensure that the screws of the DriveControl are still tight and that the cables are still laid properly and connected to the terminals If a DriveControl is damaged it has to be replaced gt Install a new DriveControl see Abandonment page 23 and see Installing the DC EC100 in a conveyor system page 17 Carefully use tweezers to remove and insert the fuse Ensure you do not damage the fuse holder the circuit board or its devices Cleaning Dust
17. e Dynamic braking Idler rollers O rings Photoeye RollerDrive Zero motion hold Version 1 0 11 2007 en Original language Appendix Glossary Electromotive force voltage generated by a package arriving at high speed at a powered RollerDrive under no load prior to the package s arrival EMF is a counter voltage phenomenon that is always present in a motor Excessive back EMF can cause a current backlash that may damage the DriveControl or power supply Care should be taken to minimize excessive back EMF by minimizing the speed differences between the gravity conveyor and or different zones of powered conveyor sections The RollerDrive is running freely without power or braking For DC motors dynamic braking is a method of stopping a motor by applying a resistive load across the motor winding leads after disconnection from the DC supply The motor operates as a generator By its nature dynamic braking has no holding power by itself i e the motor can still be rotated by outside forces Interroll has added zero motion hold to achieve this Non powered rollers attached to a RollerDrive typically via O rings or multi rip belts O rings made of materials such as polyurethane that connect RollerDrives to their associated idler rollers An ON OFF sensor that uses light to sense the presence of objects If the light beam is broken an object is present Usually the light is reflected back to the sensor via a reflector placed
18. e connectors Power input and I O terminal and Sensor connection are cage clamp terminals To actuate the cage clamp use the supplied tool or insert a small screwdriver gt Plug in the RollerDrive connector Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Initial startup and operation Initial startup Inspections before initial Ensure that all bolts are tightened according to the specifications startup Ensure that no additional dangerous areas arise due to interfaces to other components Ensure that the wiring is in accordance with the specification and legal directives gt Check all protection devices gt Ensure that no bystanders are in dangerous areas around the conveyor Operation NOTICE Damage to the DriveControl or the motor of the RollerDrive due to induction Do not push items along the roller conveyor by hand gt Do not spin the RollerDrive manually Inspections before every startup Changing settings Version 1 0 11 2007 en Original language Check the position of the DIP switches see DIP switches page 10 Check the speed settings at the speed potentiometer It is recommended to run the RollerDrive at maximum speed Check the DriveControl for visible damage Check all protection devices Ensure that no bystanders are in dangerous areas around the conveyor Clearly specify and monitor the way goo
19. e of non observance Information about how to avoid the hazard Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Version 1 0 11 2007 en Original language eb Introduction Further symbols NOTICE This symbol identifies possible material damage gt Information about how to avoid the damage This symbol displays safety instructions This symbol marks useful and important information This symbol marks the steps that have to be carried out DriveControl DC EC100 INTERROLL Safety General safety instructions The DC EC100 is designed according to the technical state of the art and is reliable in operation once distributed However risks may still arise Risks of physical injury to the user or bystanders e Adverse effects of the DriveControl and other material Disregarding the warning notices in this manual may lead to serious injury Always read the entire operating and safety instructions before starting to work with the DriveControl and follow the information contained therein in full Only instructed and qualified persons may work with the DriveControl Always keep the user manual at hand when working at the DriveControl so you can consult it quickly if required Always comply with relevant national safety regulations gt If you have any questions after reading the operation manual feel free to contact our customer service See the last
20. e potentiometer on the DriveControl Default setting is maximum Gear ratio Speed range RollerDrive EC100 DC EC100 12 1 1 32 to 0 44 m s 260 to 87 fpm 16 1 1 03 to 0 34 m s 202 to 67 fpm 24 1 0 69 to 0 22 m s 135 to 45 fpm 36 1 0 44 to 0 15 m s 88 to 29 fpm 48 1 0 35 to 0 12 m s 68 to 22 fpm 64 1 0 25 to 0 08 m s 50 to 17 fpm 96 1 0 17 to 0 06 m s 34 to 11 fpm 13 DriveControl DC EC100 INTERROLL Product information External speed setting Apart from the potentiometer on the DriveControl there are other ways to set the speed i When the DIP switch settings ON OFF are stated both settings are possible for the wiring shown for the meaning of the settings see DIP switches page 10 External speed set by potentiometer Direction of travel Rosa Ext analog speed set Ext pot o o GND Input H oooO 24 VDC Input Q ii elm uggaagagaag 0000000 O Sensor input NPN PNP Fault Input I DC Common Output g e AT n Motor cable S Tol gt gt gt 0000 0000 24 VDC Output gt 5
21. ed to use the DriveControl as intended lt 05052 01925 8996 V 1 00 Ni e HIERHER USA DC EC100 Q amp REV 0 J Serial number Country of production Product name Revision information Article number Identification barcode The serial number contains the following information about the production date 05052 01925 Year Day of the year Sequential number of the produced units on that day Technical data Nominal voltage 24 VDC Voltage range 18 to 28 VDC Voltage ripple tolerance lt 5 lt 1 recommended Continuous current 1 8 A Peak current 4 1 A Fuse 5 A slow blow Littlefuse 0452005 Protection classification IP20 Ambient temperature for operation 0 C to 40 C 32 F to 104 F Ambient temperature for transport and storage 20 C to 75 C 4 F to 167 F Ambient temperature changes max 1 K min 3 h two cycles according to IEC 68 2 14 Ambient humidity max 90 not condensing Installation altitude above sea level max 1000 m max 3300 ft Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL On board speed setting Version 1 0 11 2007 en Original language Product information Speed settings The speed can be continuously adjusted between 10096 and approximately 3396 by th
22. ginal language DriveControl DC EC100 INTERROLL 10 Sensor connection Product information Sensor input Sensor fault input Sensor common ground output D Sensor 24 VDC output Sensor input Signal from external source typically a photoeye Passed through to the sensor output This input is PNP NPN selectable with DIP switch 1 Sensor fault input If sensor has a fault output for low gain it can be connected to this input This input is PNP NPN selectable with DIP switch 1 Sensor common ground output Power ground connection for sensor O Sensor 24 VDC output 24 VDC power supply for sensor DIP switches The DIP switches allow the selection of the logical convention and the direction The default DIP switch settings are all OFF DIP switch settings are read at reset power up only Lr des DIP switch settings SW2 Rotation SW1 Logic ON OFF Cw CCW PNP NPN The following table shows the switch position for different situations DIP switch ON left position OFF right position sw2 Clockwise rotation of the Counter clockwise rotation Rotation RollerDrive seen from the of the RollerDrive seen from cable end the cable end SW1 PNP all external inputs NPN all external inputs Logic photoeye input and output are photoeye input and output are active high 24 VDC active low 0 VDC ground This excludes the No fault o
23. gnostics LEDs provide motor and sensor diagnostics as well as power fuse and temperature status NPN or PNP All inputs and outputs can be switched for NPN or PNP with one switch The No fault output is always PNP fail safe Zero motion hold When the RollerDrive is stopped it will be held in place Regenerative braking Motor acts like a generator and feeds back energy to the power bus There are different levels of over temperature or stall related functions Motor temperature foldback At a motor temperature of 80 C 176 F the DriveControl will fold back peak current down to continuous current This is indicated by the amber LED lighting up constantly When the RollerDrive cools down the amber LED extinguishes and the maximum peak current is now possible again The motor can run at this reduced current limit indefinitely without harming the DriveControl or RollerDrive Motor temperature shutdown At a motor temperature of 100 C 212 F the DC EC100 will shut down the motor and the motor will go into regenerative braking This is indicated by the red LED When the RollerDrive cools back down the red LED extinguishes and RollerDrive operation will resume Motor stall current limiting When the motor is stalled the current will fold back to 1 4 A until the stall is cleared DriveControl temperature foldback At a card temperature of 70 C 158 F the DriveControl will fold back peak current down to continuous current Thi
24. heck the power supply On a decline motor is in brake mode momentarily Red fault LED is on No fault output is active or power supply shutdown Over voltage detection caused by over speed or excessive back EMF e decline angle too high e package weight too high e Reduce decline angle e At decline conveyors use brake roller to keep speed low Motor overrun overset speed e Package enters zone at a higher than anticipated speed Reduce the package entry speed Red fault LED is on and error output is active No fault output is active Low gain signal from sensor Dirty sensor lens or misaligned Clean the sensor lens and align the sensor Current folds back to maximum continuous current amber fault LED is on Card or motor over temperature e Excessive load or duty cycle Reduce the load of packages or throughput of the zone Current folds back to approximately 1 5 A while applying consistent torque Red fault LED is on and error output is active No fault output is active Motor stall condition e Obstruction or load too heavy to be conveyed Once the stall condition is removed the RollerDrive will resume normal operation Red fuse LED is on all other LED s are off 22 Fuse is blown Replace fuse and check for possible reasons Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Version 1 0 11 2007 en Original language Abando
25. nment and disposal Abandonment Risk of injury due to improper handling Abandonment may only be executed by qualified and authorized persons Only abandon the DriveControl after switching off the power Ensure that the DriveControl cannot be turned on accidentally Disconnect all cables from the DriveControl Unscrew the screws attaching the DriveControl to the conveyor frame Extract the DriveControl from the conveyor frame Disposal The operator is responsible for the proper disposal of the DriveControl In doing so industry specific and local provisions must be observed for the disposal of the DriveControl and its packaging 23 DriveControl DC EC100 24 INTERROLL Appendix Accessories DriveControls Part Part Z Card EC Easy 89Z2 Z Card EC Full 8923 Plugs and cables Part Description Power and I O plug 8 pin cage clamp type connector Wago part 231 308 026 004 Wire diameter Minimum 0 08 mm AGW 28 Maximum 2 5 mm AGW 12 Sensor plug 4 pin cage clamp type connector Wago part 734 104 000 004 Wire diameter Minimum 0 08 mm AGW 28 Maximum 1 5 mm AGW 14 Motor plug The motor plug for the RollerDrive consists of a plug and terminal pins Plug AMP part 175778 8 Terminal pins AMP part 1 175102 1 Crimping tool AMP part 9184381 Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Back EMF Coast mod
26. on the opposite side of the conveyor frame from the sensor itself The DC EC100 can use either NPN type or PNP type photoeyes NPN sensors indicate an active state by a grounded connection being made NPN mode or a 24 VDC connection being made PNP mode One of several types of DC powered rollers manufactured by Interroll Corporation For DC motors zero motion hold is a method of holding a motor by applying a small amount of current to the motor winding leads When the DC EC100 is commanded to stop and accumulate the braking action is twofold First the motor package is stopped using dynamic braking Second the motor is held in place by zero motion hold In this state the DC EC100 will resist being rotated by outside forces 25 DriveControl DC EC100 INTERROLL 26 Appendix Manufacturer s declaration in terms of the EC Machine Directive 98 37 EC and its amendment 98 79 EC Annex II B The manufacturer Interroll Corporation 3000 Corporate Drive Wilmington NC 28405 hereby declares with sole responsibility that the product range e DC EC100 is not a ready to use assembly in terms of the EC Machine Directive and therefore does not fully comply with the requirements of this directive It must not be put into service until the machinery into which it is to be incorporated has been declared to conform with the provisions of the Machine Directive Applied EC Directives Machine Directive 98 37 EC and its amendment 98
27. s is indicated by the amber LED lighting up constantly When the DriveControl cools down the amber LED extinguishes and the maximum peak current is now possible again The DriveControl can run at this reduced current limit indefinitely without harm to the DriveControl or RollerDrive DriveControl temperature shutdown At a DriveControl temperature of 90 C 194 F the DriveControl will shut down the RollerDrive and the motor will go into regenerative braking This is indicated by the red LED When the DriveControl cools back down the red LED extinguishes and RollerDrive and DriveControl operation will resume Incline and decline applications Due to the zero motion hold and regenerative braking features the DC EC100 and RollerDrive EC100 can be used for incline and decline applications up to an angle of 15 Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Product information Inputs and outputs Power input and I O connections Speed analog input External pot FWD input REV input No fault output Sensor output 3 Common ground input 2 24 VDC input O 00000000 ol FRRRRI Speed analog input External speed control down to approximately 2396 of the maximum speed if a O to 5 VDC PLC or analog input is connected between
28. s 13 Wiring diagrams sp secessu RR he 15 Transport and storage Trans DOME MC mc 16 Stoldge cuu Ee be eoe b delen SOURCE BOR AG AA BR B P 16 Assembly Warning notices concerning assembly 0 eee eee eee 17 Warning notices concerning the electrical installation 17 Installing the DC EC100 in a conveyor system 17 Electrically installation 2l 18 Initial startup and operation Initial Startups isis em ER ER RE ERR Rem EN NR NEEN NEEN 19 Operation usd bu ENEE EX DAR Rive RA A REX baba eee p Ron 19 Maintenance and cleaning Warning notices concerning maintenance and cleaning 20 Maintenance hrs 20 AO 22 T PTT 20 Troubleshooting Error search ui ous vA RARE Lade Ow de hein des 21 Abandonment and disposal Abandonment eller hr 23 DISPOSAl MP P 23 Appendix AGCOSSOLIOS uti oh EROR a kk Mae de LR X EP RR do un Rae 24 COSSA Vision artritis EE RR AE EEA 25 Manufacturer s declaration llli 26 Version 1 0 11 2007 en 1 Original language DriveControl DC EC100 INTERROLL Content of the manual Validity of the manual The manual is part of the product Structure of warning notices Introduction Handling of the user manual This manual contains important advice notes and information about the DC EC100 in all phases of its lifecycle e Transport assembly and commissioning e Safe operation maintenance and troubleshooting disposal e Accessories The
29. utput which is always active high 24 VDC when in either NPN or PNP mode Version 1 0 11 2007 en Original language DriveControl DC EC100 INTERROLL Product information Meaning of the LEDs The LEDs provide motor and sensor diagnostics as well as power fuse and temperature status The following table shows the meaning of the LEDs LED Color Status Meaning Fuse red on steady all other Fuse blown LEDs are off Power green on steady Power OK Fault red on steady Stalled motor Low gain signal from sensor Motor or motor cable disconnected Over voltage detection 29 VDC 0 2 VDC will cease normal operation Under voltage detection 19 VDC 0 2 VDC will cease normal operation DriveControl severe temperature shut down will cease normal operation until cool Motor severe temperature shut down will cease normal operation until cool Low gain or bad sensor sensor with fault output connected Warning amber on steady Motor current is limited to maximum continuous current due to motor over temperature Motor current is limited to maximum continuous current due to card over temperature i There is no error output if the amber LED is on Version 1 0 11 2007 en 11 Original language DriveControl DC EC100 INTERROLL 12 Product information DriveControl label The specifications on the DriveControl label are used to identify the DC EC100 This is requir
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