User Manual Interroll RollerDrive
Contents
1. 5 0 8 8 6 to 24 2 0 394 6 to 24 1 23 242 1 1 9 8 3 1 83 360 5 03 0 92 181 1 2 A 7 75 1 68 330 4 0 0 68 133 9 3 B 7 31 1 55 305 3 75 0 52 102 4 4 C 6 3 1 27 250 3 30 0 38 74 8 5 D 6 0 1 17 230 2 93 0 27 53 1 6 E 5 75 1 08 212 2 68 0 19 37 4 7 F 5 5 1 02 200 2 44 0 12 23 6 Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL Product information RL definition There are two definitions of the roller length RL e RLey is mainly used in Europe and Asia e RLusis mainly used in North and South America Spring loaded 11 mm 0 44 in hex Female threaded M8 FTM8 floating Dimensions of the motor shaft Standard configuration 17 5 mm 0 69 in 11 5 mm 0 45 in H shaft AF 10 5 mm 0 41 in 160 mm 6 3 in lt gt M12 x 1mm Version 1 0 11 2007 en 13 Original language RollerDrive EC 3200 INTERROLL Product information Dimensions of idler cartridges 11 mm 0 44 in hex Female threaded M8 FTM8 spring loaded floating Straight RL RLey 5 mm 0 2 in 5 mm 0 2 in 15 5 mm 0 61 in mmg K 13 mm 0 51 in O ring hub DL j 31 mm 1 22 in DL 31 mm 1 22 in 13 5 mm 0 53 in 13 mm 0 51 in 13 5 mm 0 53 S 13 mm 0 51 in 4 mm 0 16 in 4 mm2. it has to be replaced gt Install a new RollerDrive see Abandonment page 26 and see Inserting the RollerDrive EC300 in the conveyor frame page 19 Cleaning Increased surface friction reduces the roller speed since more power is used to overcome the resistance Therefore in a dirty environment periodic cleaning will ensure good contact with the goods and reduce friction gt Remove foreign material from the roller with standard cleaners gt Do not use sharp edged tools to clean the roller Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL Troubleshooting Error search Risk of injury due to accidental motor starts gt Error search may only be executed by qualified and authorized persons Only perform error search after switching off the power Ensure that the RollerDrive cannot be turned on accidentally Use caution while searching the error Symptom Possible cause Help RollerDrive is not operating No power supply Check 24 VDC power supply Plugs not connected properly Check cable connection RollerDrive is rotating in the wrong Wrong DriveControl setting at speed Change setting on DriveControl direction or at the wrong speed and direction rotary switch Wrong voltage at speed setting pin Check the voltage of the speed setting if the RollerDrive is not operated pins at the motor plug with the recommended Interroll DriveControl Abnormal noise coming out
3. 0 16 in 11 mm 0 44 in S pik H TTT r 7 ree a Le d p y 937 8 mm 1 49 in l 937 8 mm 1 49 in Rlus AF 19 mm 0 75 in RLus Multi rib hub 31 mm 1 22 in 4 mm 0 16 in 11 mm 0 44 in y 343 mm 1 7 in 31 mm 1 22 in 4 mm 0 16 in lt eg ARN 243 mm 1 7 in Alus AF 19 mm 0 75 in Timing belt hub 14 Poly Chain GT 8 mm pitch 18 teeth RLey 35 mm 1 38 in 27 5 mm 1 08 in 4 mm 0 16 in Te N 245 8 mm 1 8 in DL AF 11 mm 0 44 in hex gt Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL Product information 11 mm 0 44 in hex Female threaded M8 FTM8 spring loaded floating Roller chain hub 11 mm 0 44 in hex shaft 3 8 in pitch 20 teeth FTM8 floating single bearing Spring loaded hex double bearing Version 1 0 11 2007 en Original language 16 8 mm 0 66 in Rey 9 5 mm 0 37 in HEH Let 260 9 mm 2 4 in 35 mm 1 38 in RLus Groove locations min 30 mm 1 2 in min 30 mm 1 2 in 938 5 mm 1 52 in I AA Die 9 1 min 20 mm 1 2 in min 50 mm 1 9 in 938 5 mm 1 52 in fo SHES Other tube groove locations possible Conical RollerDrives Conical RollerDrives are only available in th
4. 1 13 1 Nominal torque 0 70 Nm 6 20 Ibf in 0 90 Nm 7 97 Ibf in Peak torque 1 0 Nm 8 9 Ibf in 1 6 Nm 14 2 Ibf in Speed range 1 02 to 2 0 m s 201 to 394 ft min 0 12 to 1 27 m s 23 to 249 ft min Nominal load 1 50 kg 110 Ib 65 kg 143 Ib 1 Maximum static load per Roller not more than 40 kg 88 Ib Data refer to continuous operation under maximum load S1 operation RollerDrive EC 3200 10 Product information Performance charts EC300 7 85 1 2037 400 6 1 914 375 Speed Pa T L 178 350 E 5 Lc EAR a T a A A L4 E 1501 am A 5 kol D Area of E S g 2 continuous Maximum o a Eh eer operation y continuou 4 2 jik 127 S 250 A curen oe po we 1144 225 ES H2 1 024 200 SS Seen I vs Torque 0 894 175 E Ki La a Fe 0 76 150 0 64 125 0 Torque in Ib o 2 4 6 8 10 Torque Nm T T T I T y 0 00 0 23 0 45 0 68 0 90 1 13 Tangential T T T T d force F Ibf 0 00 2 11 4 22 6 33 8 44 10 55 Tangential T T T T 1 N 0 00 9 04 18 08 27 12 36 16 45 20 force Fy EC300 13 1 1405 275 5 1 274 250 ENT gt Speed 2 E E aren Is Torque E1144 amp 225 q A E o o Area of A Maximum r 5 L continuons E continuous G Q Qo operation current 1 024 q 200 2 2 a es La 0894 175 l 7 Ke Current 1 24 vs
5. Handling of the user manual This manual contains important advice notes and information about the RollerDrive EC300 in all phases of its lifecycle e Transport assembly and commissioning e Safe operation maintenance and troubleshooting disposal e Accessories The manual describes the RollerDrive EC300 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 RollerDrive EC300 gt Keep the manual near to the RollerDrive EC300 gt Pass the manual on to any subsequent operator or occupant of the RollerDrive EC300 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 RollerDrive EC300 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 e Caution Signal word Meaning Danger Indicates a hazardous situation which if not av
6. VDC to 8 6 VDC 2 VDC to 5 VDC Max speed 8 6 VDC to 24 VDC 5 VDC to 24 VDC also see Speed settings page 12 i In case the RollerDrive is not directly connected to the refering DriveControl or the Interroll extension cable connect the motor plug by use of a Lumberg Fixcon Coupling 5 FKT NOTICE Pins 1 and 3 are not protected against incorrect polarity connection Damage to the motor gt Ensure the correct polarity Version 1 0 11 2007 en 11 Original language RollerDrive EC 3200 INTERROLL 12 Product information Speed settings If you do not use the recommended DriveControl see DriveControls for the RollerDrive EC300 page 10 you may change the speed of the RollerDrive EC300 by altering the voltage on pin 5 of the motor plug NOTICE Input voltage of Pin 5 at motor plug is not polarity proof Damage to the RollerDrive gt Ensure the correct polarity EC300 7 85 1 EC300 13 1 Speed Percentage Speed Percentage 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 Analog voltage setting on pin 5 of motor plug VDC Analog voltage setting on pin 5 of motor plug VDC In the hatched area the RollerDrive does not run within the specified tolerance of 250 Rotary EC300 7 85 1 EC300 13 1 switch speed voltage Speed of Voltage Speed of setting at setting on transport setting on transport DriveControl pin 5 m s ft min pin 5 m s ft min VDC 5 VDC
7. of the Motor or gearbox is damaged Replace RollerDrive RollerDrive Interrupted RollerDrive operation Damaged motor cable Check motor cable for damages If motor cables are damaged replace RollerDrive RollerDrive overload see Overload protection devices page 7 Version 1 0 11 2007 en 25 Original language RollerDrive EC 3200 INTERROLL 26 Abandonment and disposal Abandonment Risk of injury due to improper handling gt Abandonment may only be executed by qualified and authorized persons Only abandon the RollerDrive after switching off the power Ensure that the RollerDrive cannot be turned on accidentally Disconnect the motor cable from the control Unscrew the outer nut at the threaded motor shaft If the RollerDrive has a spring loaded idler shaft push the idler shaft inwards If the RollerDrive has a FTM8 idler shaft unscrew the bolt at the idler shaft Extract the RollerDrive from the conveyor frame Y NY Y Y Y Disposal The operator is responsible for the proper disposal of the RollerDrive In doing so industry specific and local provisions must be observed for the disposal of the RollerDrive and its packaging Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL Appendix Accessories Bells Part Characteristics Toothed belt e Gates Poly Chain GT or similar pitch 8 mm 0 31 in e Toothed belt width 11 2 mm 0 44 in e Hub with 18 teeth R
8. 007 en Original language Product information Product description The RollerDrive EC300 a completely self contained electronically powered roller replaces external components such as motors and gearboxes that require frequent maintenance The RollerDrive EC300 can be used in dusty and or moist environments due to its protection class IP54 The RollerDrive EC300 is powered by a brushless electronically commutated 24 VDC motor with an integrated 4 quadrant motor control This control system guarantees a constant speed over the whole load range and a constant torque over all selectable speed settings There are several overload protection devices installed e Stall timing device If the RollerDrive EC300 is stalled while there is a run command the motor tries to restart ten times each three seconds for one second If stall continues after these ten attemps a failure signal is set and the RollerDrive tries to restart with a 60 1 cycle restart for one second every 60 seconds until the stall is removed The RollerDrive will not be damaged by operating in a stall time device mode for long periods of time If the RollerDrive is running at chosen speed again or the run command is withdrawn the failure signal will be cancelled e Slow run If there is a speed deviation of 20 from the chosen value for more than 10 seconds the motor will be switched off and the failure signal will be set The RollerDrive EC300 will try to start again af
9. Assembly Securing the RollerDrive in There is a nut and a washer on the shaft next to the tube This inner nut has been the conveyor frame preassembled and secured in the correct position i Do not adjust the inner nut and washer gt Prevent the inner nut from rotating with a flattened wrench AF 19 mm gt Slip a second star washer and a hex nut over the motor cable and screw it onto the threaded motor shaft Ensure that star washers are mounted on both sides of the profile gt Use a torque wrench to tighten this outer nut with 35 Nm 308 in Ibf while ensuring that the inner nut is not rotating i To prevent bending forces on conical RollerDrives an angular compensation on the motor end is needed Mounting tool For mounting the multi rib belt you may want to build a mounting tool as shown in the figure below gt Place the mounting tool between two rollers to reduce the gap between the adjacent rollers i The dimensions of the mounting tool depend on the roller pitch and the roller tube diameter Version 1 0 11 2007 en 21 Original language RollerDrive EC 3200 INTERROLL 22 Assembly Electrical installation gt If you use the recommended DriveControl see DriveControls for the RollerDrive EC300 page 10 connect the motor plug to the DriveControl gt If you do not use the DriveControl connect your control to the pins of the motor plug for the pin d
10. INTERROLL User Manual Interroll RollerDrive EC300 Manufacturer Interroll Corporation 3000 Corporate Drive USA Wilmington NC 28405 Tel 1 910 799 11 00 Fax 1 910 392 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 RollerDrive EC 3200 INTERROLL Table of contents Introduction Handling of the user manual lt ee 2 Warning notices in this manual 2 Further nl sle e AN ngn Seele a d dE Ne a ok TANG ee A TN A 3 Safety General safety Instructions o 4 Intended USE ici a eve sr a a dE eae Ne 4 Unintended use A Qualified perSONS lt sasaka ER NEEN KSE E HERE de N Re A EIERE EH 5 lala 5 Product information COMPONEN S sia isa KEEN NN EN d e EEN E ae Ae a EA cee eed 6 Product description 7 RollerDrive Jabel 8 Product identification 8 Technical data 4 4263 anm Ge Aa e hee eRe eee VO ORs 9 Performance data 9 Performance ChartS aa eee ee eee 10 DriveControls for the RollerDrive EC3 00 cee eee eee 10 Motor plug geg a Ga ack CRY AM a ee Tak ra ee eh 11 Speed settings 12 RL dehi acs aka sag a a S R a a RR eee 13 Dimensions of the motor shaft lt a cece eee eee eee 13 D
11. 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 ComtTrans 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 Japan Interroll Japan Co Ltd 302 1 Shimokuzaw
12. Torque La 0 764 150 L 0 64 J 125 0 Torque in Ib o 2 4 6 8 10 Torque Nm T T r T T 0 00 0 23 0 45 0 68 0 90 1 13 Tangential d force Fr Ibf 0 00 2 11 4 22 6 33 8 44 10 55 Tangential T T T T 1 force Fy N 0 00 9 04 18 08 27 12 36 16 45 20 DriveControls for the RollerDrive EC300 Interroll recommends using the RollerDrive EC300 in combination with the corresponding Interroll DriveControl RollerDrive RollerDrive EC300 7 85 1 Corresponding DriveControl DC EC300 7 85 1 RollerDrive EC300 13 1 DC EC200 EC300 13 1 RollerDrive EC300 RollerDrive EC300 7 85 1 13 1 ci jr a ee Z Card EC For DriveControl details see the corresponding operation manual catalogs or publications on www interroll com Version 1 0 11 2007 en Original language INTERROLL RollerDrive EC 3200 INTERROLL Product information Motor plug 5 4 3 1 2 Pin Color Function Value 1 brown Power input from Nominal 24 VDC power supply Range 18 to 28 VDC 2 white Rotation direction Low U lt 0 8 V ccw seen from cable end High U gt 2 4 V cw of the RollerDrive 3 blue Ground for power Ground and signal 4 black Failure output Low no failure High failure 5 gray Speed start signal see table below analog Speed start signal analog Pin 5 Gear ratio 7 85 1 13 1 Range 0 to 24 VDC 0 to 24 VDC Stop brake 0 to 2 VDC 0 to 2 VDC Speed 2
13. a 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
14. als and diagrams e the warning and safety instructions in this manual e the system specific regulations and requirements e national or local regulations and requirements for safety and accident prevention Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL A Persons Electricity Rotating parts Working environment Avoiding malfunctions in operation Maintenance Accidental motor starts Version 1 0 11 2007 en Original language Safety Risks The following list informs you about the various types of danger or damage that may occur while working with the RollerDrive EC300 gt gt VV Y NY NY NYY N N Y v Y Y Maintenance or repair work must only De executed by authorized and qualified persons in accordance with the applicable regulations Before turning on the RollerDrive ensure that no unauthorized persons are near the conveyor Only perform installation and maintenance work after you have switched off the power Ensure that the RollerDrive cannot be turned on accidentally Keep fingers and hair away from the torque transmission between rollers Tie up long hair Do not wear loose clothing Remove jewellery such as bracelets or wristbands Do not use the RollerDrive in explosive atmospheres Remove equipment or material which is not required from the workspace Always wear safety shoes Clearly specify and monitor the way goods are placed on the conveyor Reg
15. ay work with the RollerDrive gt Always keep the user manual at hand when working at the RollerDrive so you can consult it quickly if required gt 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 page for contact information Intended use The RollerDrive EC300 may only be used for industrial applications and in an industrial environment to convey goods such as parts cartons totes or boxes It must be integrated in a conveyor module or a conveying system Any other use is considered inappropriate Use of the RollerDrive EC300 is only allowed in the areas described under product information Any changes that affect the safety of the product are not allowed The RollerDrive EC300 may only be used within the given operation limits Unintended use The RollerDrive EC300 may not be used to transport persons bulk cargo or small parts The RollerDrive is not intended for use under impact or shock loads Applications not according to the intended use of the RollerDrive EC300 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 RollerDrive taking the following into account e the relevant manu
16. efinition see Motor plug page 11 Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL Initial startup and operation Initial startup Inspections before initial gt Ensure that no objects are in contact with rotating or moving parts startup gt Ensure that all bolts are tightened according to the specifications gt Ensure that no additional dangerous areas arise due to interfaces to other components gt 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 i For information about startup see the manual for the DriveControl or your control Operation Rotating parts and accidental starts Risk of pinched fingers gt Do not insert fingers between the RollerDrive and the O ring belt multi rib belt or roller chain gt Do not remove the protection device gt Keep fingers hair and loose clothing away from the RollerDrive NOTICE Damage to the motor or the control due to induction gt Do not push items along the roller conveyor by hand gt Do not spin the RollerDrive manually Inspections before every startup Check the RollerDrive for visible damage Check all protection devices Ensure that no bystanders are in dangerous areas around the conveyor Clearly specify and monitor the way goods are placed on the conveyor Ensure that the Ro
17. imensions of idler cartridges aaa aaa 14 Groove lOCaLIONS isi sien cea eee SREB eee ba Se eo 15 Conical RollerDrives 15 Transport and storage TANDO ico Gen EEN A ER E Pee eee ee eRe A 16 o A hanaan an a E a a a a a E A A aA 16 Assembly Warning notices concerning assembly 17 Warning notices concerning the electrical installation 18 Setting up a roller conveyor 18 Inserting the RollerDrive EC300 in the conveyor fame 19 Mounting tool i s aks aan atea ak a eee 21 Electrical installation lt ers eee 22 Initial startup and operation Initial Startups Aere dir IER NC NNN NN NEE ANE NN der KA Wd eA K 22 Operation A d In ios a Ee eee ee Eee N ag ER a 23 Procedure in case of accident or malfunction ae 23 Maintenance and cleaning Warning notices concerning maintenance and cleaning 24 Maintenance 24 CIGANING aja een ed a boa Kanan aa A jah Aga dd aa A bi A 24 Troubleshooting Error Seah 4 aa a medd be RR RI dE ARR da ENEE A do ad 25 Abandonment and disposal Abandonment wisa sc a ssh dis an NN d a NT EN NEEN EEN ae Waa N 26 Ee tt ee A EE a RE EE EN 26 Appendix ACCOSSOMOS TTT 27 Manufacturer s declaration lt aa eee 28 Version 1 0 11 2007 en 1 Original language RollerDrive EC 3200 INTERROLL Content of the manual Validity of the manual The manual is part of the product Structure of warning notices Introduction
18. irective 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 RollerDrive EC300 INTERROLL Version 1 0 11 2007 en 29 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 351 275 330 789 p sales interroll com Spain Interroll Es
19. le at the motor shaft Leave a minimum of 12 mm 0 5 in of excess cable for stress relief gt Place one or two standard 4 mm max 5 mm 3 16 in O rings or RollerDrive belts if used on the idler end of the RollerDrive 19 RollerDrive EC 3200 INTERROLL Assembly Inserting the idler shaft How the idler shaft is inserted in the conveyor frame depends on the idler shaft option The easiest installation option is the spring loaded shaft option Inserting the spring loaded idler shaft gt Push the spring loaded idler shaft inwards and align the shaft with the hole in the frame gt Release the idler shaft and allow it to pop into the hole in the frame Inserting the FTM8 idler shaft gt Place a split lock washer onto a M8x20 bolt gt Align the RollerDrive with the hole in the frame and thread the M8 bolt and split lock washer into the shaft Use a wrench to prevent the idler shaft from turning width across flats AF 13 mm or AF 19 mm depending on the idler type see Groove locations page 15 gt Use a torque wrench to tighten the bolt with 20 Nm 177 in Ibf until the split washer is completely compressed i For information about assembling the idler rollers see the corresponding manuals or information at www interroll com 20 Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL
20. ler conveyor usually consists of conveyor zones Each zone is composed of one RollerDrive and several idler rollers which are driven by the RollerDrive The idler rollers can be linked using either flat belts timing belts O ring belts multi rib belts or roller chains The number of idler rollers in each zone depends on the application gt Before installing the RollerDrive define the position of the conveyor zone within the conveyor and the position of the RollerDrive within the conveyor zone Locate the RollerDrive near the center of the zone or the center of gravity of the object being conveyed to improve the transmission of the force between RollerDrive and goods Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL Inserting the motor shaft Version 1 0 11 2007 en Original language Assembly Inserting the RollerDrive EC300 in the conveyor frame gt Remove the shipping tube from the RollerDrive harness assembly Use caution when cutting the tie wrap from the harness Do not cut any of the sleeving or wires on the assembly gt Place a first star washer on the motor shaft gt E gt Pass the motor cable through the 11 mm 0 44 in hex hole in the conveyor frame and insert the motor shaft into the hex hole Internal damage of the RollerDrive due to improper handling gt Do not install the securing hardware at this time gt Do not bend the motor cab
21. llerDrive is not blocked Y Y Y Y Y Ambient operating conditions see Technical data page 9 Procedure in case of accident or malfunction Stop the conveyor at once and ensure that it cannot be started accidentally In case of an accident Provide first aid and make an emergency call Inform the responsible person Have the malfunction repaired by qualified persons Start the conveyor only after this has been approved by qualified persons vv NY Y Y Version 1 0 11 2007 en 23 Original language RollerDrive EC 3200 INTERROLL 24 Checking the RollerDrive Replacing a RollerDrive Maintenance and cleaning Warning notices concerning maintenance and cleaning Risk of injury due to improper handling or accidental motor starts gt Maintenance work and cleaning may only be executed by qualified and authorized persons gt Only perform maintenance work after switching off the power Ensure that the RollerDrive cannot be turned on accidentally Set up signs indicating maintenance work Maintenance If the RollerDrive is not secured as specified in the installation instructions see Assembly page 17 it may rotate in the hole in the conveyor frame This will result in the roller leads becoming twisted and eventually severed gt Monthly check the RollerDrive for visible damage gt Annually ensure that the roller shart is secured properly in the conveyor frame If a RollerDrive is damaged or broken down
22. oating see Dimensions of idler cartridges page 14 Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL Version 1 0 11 2007 en Original language Product information Technical data Nominal voltage 24 VDC Voltage range 18 28 VDC No load current 0 4A Maximum continuous current EC300 7 85 1 4 0 A EC300 13 1 3 5 A Maximum peak current 5 5 A Mechanical Performance EC300 7 85 1 52 W EC300 13 1 44 W System Efficiency Drive 54 Maximum ripple from power supply 3 Noise emission mounted 50 dB A Lifetime under nominal conditions 20000 h Maximum Start Stop per minute EC300 7 85 1 20 EC300 13 1 33 Protection classification IP54 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 e UL approval is not required for RollerDrive products as they operate under a recommended maximum voltage of 30 VDC The RollerDrive EC300 is recognized as an UL Class II product e Mechanical performance performance data and performance charts are on basis of 20 C 68 F Performance data Gear ratio 7 85
23. oided 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 consequence of non observance gt Information about how to avoid the hazard Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL 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 a gt This symbol marks the steps that have to be carried out Version 1 0 11 2007 en 3 Original language RollerDrive EC300 INTERROLL Safety General safety instructions The RollerDrive EC300 is designed according to the technical state of the art and is reliable in operation once distributed However risks may still arise e Risks of physical injury to the user or bystanders e Adverse effects of the RollerDrive and other material Disregarding the warning notices in this manual may lead to serious injury gt Always read the entire operating and safety instructions before starting to work with the RollerDrive and follow the information contained therein in full gt Only instructed and qualified persons m
24. ound belt e Belts of 4 mm 0 16 in and max 5 mm 0 20 in diameter Multi rib belt e Drive head with 9 grooves for flexible V ribbed belts e PJ form ISO 9981 DIN 7867 e Pitch 2 34 mm 0 09 in e Belts with a max of 4 ribs DriveControls Part Part 8 DC EC200 EC300 13 1 for RollerDrive EC300 13 1 89QU DC EC300 7 85 1 for RollerDrive EC300 7 85 1 89QV Z Card EC Easy 89Z2 Z Card EC Full 8923 Wiring accessorigs Part Characteristics Part Power supply 230 V 150 W 24 VDC 89NT Extension cable Length 1600 mm 89VK RollerDrive DriveControl Extension cable Length 1000 mm 89VE RollerDrive Z Card EC Length 2000 mm 89VF Version 1 0 11 2007 en Original language 27 RollerDrive EC 3200 INTERROLL 28 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 RollerDrive Type EC300 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 79 EC Low Voltage Directive 2006 95 EC EMC D
25. pafia 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 Hoferhof 16 D 42929 Wermelskirchen Tel 49 2193 23 0 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 nl drummotors interroll com Eastern Europe Czech Republic Interroll CZ s r o G Simka 3147 CZ 69003 Bfeclav 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 1 56 56 372 Turkey Roller Makina San Ve Tic
26. ree versions e Without roll to roll transmission no grooves e With grooved tubes RLgy B F 11 mm 0 44 in RLyg B F 3 mm 0 12 in e With O ring hub RLey B F 37 mm 1 46 in RLys B F 3 mm 0 12 in B F Width between the conveyor frames Due to the conical sleeves they are only available in certain standard lengths For conical RollerDrives there must be a 1 8 angle compensation on the motor end to avoid bending forces on the RollerDrive For details contact Interroll see the catalogs or refer to publications at www interroll com 15 RollerDrive EC 3200 INTERROLL 16 Transport and storage Transport VVVVVV v Each RollerDrive is covered at its ends with end protectors Risk of injury due to improper transport gt Transport may only be carried out by qualified and authorized persons gt Observe the following notices Do not stack pallets Check the fixation of the RollerDrives before transport Avoid hard shocks during transport Check each RollerDrive visually for damage after transport 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 RollerDrives between warm and cold environments This may cause condensing water Storage Risk of injury due to improper storage gt Do not stack pallets gt Do not stack more than four ca
27. rton boxes With IP66 RollerDrives due to the sealing condensing water inside the RollerDrive may cause corrosion gt Check each RollerDrive for damage after storage Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL Version 1 0 11 2007 en Original language Assembly Warning notices concerning assembly Rotating parts and accidental motor starts Risk of pinched fingers gt Do not insert fingers between the RollerDrive and the O ring belt multi rib belt or roller chain gt Install a protection device such as a guard plate to prevent fingers from getting trapped in the O ring belt multi rib belt or roller chain Install an appropriate warning on the conveyor NOTICE Risk of damage leading to failure or shortened life expectancy of the RollerDrive gt Observe the following notices gt Do not drop or mishandle the RollerDrive to avoid internal damage gt Check each RollerDrive visually for damage before assembly gt Do not hold carry or support the RollerDrive by the wires extending out of the mounting shaft to avoid damage to the internal solder joints gt Do not force the RollerDrive when inserting it into the conveyor frame It should fit easily into the holes in the frame gt Ensure that the proper torque see assembly instructions is applied to the RollerDrive hex nut to prevent the shaft spinning in the frame and the wires twisting gt Do not twist
28. ter 60 seconds If the RollerDrive is running at chosen speed again or the run command is withdrawn the failure signal will be cancelled e Temperature monitor The motor and electronic assemblies are temperature controlled If the temperature is too high the incline of the accelerating ramps will be reduced and the motor will go back to nominal current This reduces the heat in the motor If suitably applied the roller can be installed in the conveyor with the required controls and then left alone for the life of the product RollerDrive EC 3200 INTERROLL Product information RollerDrive label The specifications on the RollerDrive label are used to identify the RollerDrive This is required to use the RollerDrive EC300 as intended OOO 1 27 0 12 m s SIS O O Type of RollerDrive Date of production Gear ratio Speedrange Nominal voltage Product name Manufacturer Product identification To identify a RollerDrive the following information is required You may enter the values of your RollerDrive in the last column Information Possible value Own value RollerDrive label Motor type RollerDrive EC300 Gear ratio Tube diameter 50 mm Tube material Zinc plated aluminum or stainless steel with or without sleeves Roller length RLus or Heu see RL definition page 13 Roller see Groove locations transmission page 15 Idler shaft Spring loaded or fl
29. the motor cable L RollerDrive EC 3200 INTERROLL 18 Assembly Warning notices concerning the electrical installation NOTICE Risk of damage to the motor and or the wires of the RollerDrive gt Observe the following notices gt The electrical installation may only be executed by qualified and authorized persons gt Disconnect the power before installing removing or rewiring the RollerDrive gt Do not apply AC current to the RollerDrive or DriveControl device at any time as this will cause irreparable damage gt Do not apply too much stress to the connector pins Bending the wires at the connector and forcing the star washer over them can cause damage to the insulation of the wires which could result in failure of 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 gt Do not bend the motor cable at the motor shaft Leave a minimum of 12 mm 0 5 in of excess cable for stress relief Minimum motor cable bend radius 5x cable diameter gt Do not spin the RollerDrive manually as this generates an induction voltage which could damage the DriveControl Setting up a roller conveyor A rol
30. ularly check the RollerDrive for visible damage In case of fumes unusual noise or blocked or damaged goods stop the RollerDrive at once and ensure that the RollerDrive cannot be started accidentally Contact qualified personnel immediately to find the source the malfunction Do not step on the RollerDrive during operation As the product is maintenance free you only need to check regularly for visible damages unusual noise and that the screws and nuts are still tightened gt Do not open the RollerDrive gt Use caution while installing or maintaining the RollerDrive or while it is under error conditions since it may start accidently Interfaces By assembling the RollerDrive 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 RollerDrive in a conveyor module check the whole system for a new potential dangerous spot before turning on the conveyor RollerDrive EC 3200 INTERROLL Product information Components 000 00 Motor plug with cable Idler bearing housing assembly E Motor cartridge shart Tube Fixed bearing housing assembly Non slip drive amp Motor Gearbox Idler cartridge shaft Version 1 0 11 2007 en Original language RollerDrive EC 3200 INTERROLL Overload protection devices Version 1 0 11 2
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