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User Manual Interroll DriveControl

1. Multiple RollerDrives in one zone t i i w uw Lu irecti a2 a2 a2 Direction of travel of oc ot ca ca ca EE li UL Zone DriveControl Smarti out s 3 fea H E Sensor1 in 424 VDC in E 24 VDC j e j to downstream to upstream ZPA card ZPA card led f ion Smarti in B 5 Ve e mu GND B el B 424 VDC Es noon ES s EH el el Dependent DriveControls B an L Smartt in B Do e jJ GND B jeg aE 24 VDC sonn S Ea SJ 24 VDC 24 VDC GND GND i A reverse command to the Zone DriveControl will not be communicated to the dependent DriveControls Zone DriveControl DIP switch settings SW5 OFF SW4 OFF SW3 ON OFF SW2 ON OFF SW1 ON OFF Dependent DriveControl DIP switch settings 26 SW5 OFF SW4 OFF SW3 OFF SW2 ON OFF SW1 ON OFF must have the same switch setting as zone DriveControl logic mode NPN or PNP Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110
2. K W w a gt Ow oa PLC start command PS EE Sensor2 in jeg EE Sensor in on B EH GND lej 24 VDC DIP switch settings SW5 ON OFF e SW4 ON OFF specifies if this zone is a transport or entry zone if sensor 2 IN is used SW 4 must be set to ON e SWS ON OFF SW2 ON OFF e SW1 ON OFF Sensor 2 IN start signal by PLC or photoeye Start signal for PNP 24 VDC Start signal for NPN GND If you are using a photoeye as a starting signal connect sensor 2 IN with the photoeye Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Product information HosBrivecontrot is exitzone Upstream device HC DriveControl Downstream device DIP switch 4 Off On Off On DIP switch 5 Off On On Off Upstream peer to peer jog Disabled Functional Disabled Functional reverse Downstream peer to peer Disabled Functional Functional Disabled jog reverse Zone type Smart I O ZPA mode ZPA mode Smart I O entry entry Smart 1 in Perm Jog Jog Perm Reverse in System System System System reverse reverse reverse reverse Smart 1 out Request Motor run Motor run Request Sensor 2 Another Another Another Another C sensor C sensor C sensor C sensor Smart in GND 24 VDC Direction of travel
3. INTERROLL Product information HC DriveControl as motor control board Direction of travel j w iz O a cC a n iNFWD mney n Z mme j Se REV command B a 5 for NPN GND in m e o fol for PNP 24 VDC in ee Ge SE e 24 VDC GND DIP switch settings SW5 OFF SW4 OFF SW3 OFF SW2 ON OFF SW1 ON OFF Start options FWD connected to 24 VDC causes ccw rotation REV connected to 24 VDC causes cw rotation FWD and REV connected to 24 VDC causes coast mode Version 1 2 02 2009 en 27 Original language DriveControl HC EC100 HC EC110 HC DriveControl is entry zone 28 INTERROLL Product information Upstream device Downstream device HC DriveControl DIP switch 4 Off On Off On DIP switch 5 Off On On Off Upstream peer to peer jog Disabled Functional Disabled Functional reverse Downstream peer to peer Disabled Functional Functional Disabled jog reverse Zone type Smart I O ZPA mode Smart I O ZPA mode entry entry Smart 1 in Request Jog Request Jog Reverse in System System System System reverse reverse reverse reverse Smart 1 out Perm Motor run Perm Motor run Sensor 2 Not used Another Not used Another smart I O C sensor smart l O C sensor Standard configuration with PLC or photoeye start command to downstream ZPA card 24 VDC GND Direction of travel GND E 24 VDC LE si
4. llli 10 Inputs and outputs 2 0 es 11 Peer to peer communication llle 13 DIP switches 1 20 0 a a a ea a nh 14 Meaning ofthe LEDs 00000 ce cece eee eee 16 DriveControl label onnaa aaan aa 17 Technical datass uso im BEES a ae She i a exea E 17 Speed settings 202 000 eee 18 Setting options and wiring diagrams 22 0000005 20 Transport and storage TRANS DOW PPP LLL 36 Storage a onnaa naad aa eee 36 Assembly Warning notices concerning assembly lllsllle enn 37 Warning notices concerning the electrical installation 37 Installing the HC DriveControl in a conveyor system 38 Electrical installation llle 38 Initial startup and operation Initial startup z x x7 ias cxx en cel nae a fein Mende E eae Ga 39 Operation c a eua eee cs d E AG ep des AGB ge er pcnc n d e 39 Procedure in case of accident or malfunction 39 Maintenance and cleaning Warnings concerning maintenance and cleaning Less 40 Maintenance 2 ee Inh 40 Cleanings coke ke iE ieee be ee vele wo dee ee ee f a pese va 40 Troubleshooting Enror Sear iaaa A Bae ORTU 41 Abandonment and disposal Abandonment 000 eee eee 45 Disposal eagai tous E ERE eee LA beta wad eee s 45 Appendix AGCCOSSOMGS i ive Pius datas ea ead qus Rib dur okies d 46 GIGS SAN PEPERIT ccce 47 Manufacturer s
5. If the zone continues to run without any communication cables connected and no photoeye input HC DriveControl is damaged Replace HC DriveControl Assembly of the DriveControl see Assembly page 37 41 DriveControl HC EC100 HC EC110 INTERROLL Symptom Multiple zones run continuously Troubleshooting Possible cause Communication cable is defective sending a jog command Help Find the farthest zone in the upstream direction that is running continuously Check the communication cables of this zone Different ground of a multiple power supply Verify that a common ground is shared by all supplies System reverses or jogs without prompting Fuse is blown If DIP switch 4 and 5 are ON for all cards a blown fuse or loss of power in one DriveControl sends a reverse jog command to all DriveControls in the system Check the fuses in all DriveControls of the system and replace the blown one see Replacing fuse page 40 Miswired communication cable Check the communication cables in the entry zone of the system Replace the miswired cables Zone stops when package arrives Zone does not accept package Zone receives the accumulate signal Check that the zone is not receiving the accumulate signal from the downstream zone Ensure that there is no jumper installed from ground to the Accum L stop input terminal on the HC DriveControl of the zone where the package stops If a sw
6. 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 Components Canada Ltd 8900 Keele Street Unit 2 amp 3 Concord Ontario L4K 2N2 Canada Tel 1 905 660 4426 Fax 1 905 660 4159 cdn sales interroll com Interroll Canada Ltd Drives amp Rollers Canada 1201 Gorham Street Newmarket Ontario L3Y 8Y2 Canada Tel 1 905 727 3399 Fax 1 905 727 3299 cdn sales interroll com Brasil Interroll Logistica Elementos para Sistemas Transportadores Ltda Av Alexandrina das Chagas Moreira 945 Bairro Distrito Industrial Pindamonhangaba SP Brasil CEP 12412 800 Tel 55 12 3648 8021 Fax 55 12 3648 8164 sa sales interroll com For other countries in South America please contact Interroll Espa a S A Parc Teconol gic del Vall s C Dels Argenters 5 Edificio 1 m dulos Bp y Cp E 08290 Cerdanyola del Vall s Tel 34 90 211 0860 Fax 34 93 586 4895 e sales interroll com INTERROLL 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 Shimokuzawa Sagamihara shi Kanagawa 229 1134 Japan Tel 81 42 764 2677 Fax 81 42 764 2678 jpn sales interroll
7. O o o off 1 o o o Lo o LJ olf i 8 o oj off oog E T A OKOLO Fuse Downstream connection Speed potentiometer G DIP switches Label Warning LED amber Motor cable of RollerDrive Fault LED red Sensor connection Power LED green Upstream connection d Fuse LED red Digital I O handshake only on Power input and I O terminal HC EC100 Full Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 Mounting hardware Version 1 2 02 2009 en Original language INTERROLL Product information Dimensions N eo S t 161 mm 6 35 in 3 124 mm 4 9 in N s I qT qT 05052 01925 USA E S oj o INTERROLL AAA z c N oj o V 1 00 REV 0 D N UI oj o Er ee E oj o S E z E ig zP eB ale eR a gp 4 L fe A il i 25 om 79 mm 3 1 in gt Siy The following mounting hardware is supplied 2x button head screw 10 32 UNF x 0 5 2xnut with captive star washer 10 32 UNF ZPA technology ZPA is short for zero pressure accumulation The HC DriveControl provides true zero pressure accumulation and other control options to a conveyor system Each HC DriveControl controls a RollerDrive unit which in turn drives idler rollers using O rings or other belts The HC DriveControl
8. Replace the RollerDrive Voltage over or under limits Power supply fluctuations failure or overload condition Check the power supply On a decline motor is in brake mode momentarily Red fault LED flashes twice No fault output is active or power supply shutdown or fuse blown on card Overvoltage detection caused by over speed or excessive back EMF decline angle too high package weight too high Reduce decline angle Use brake roller to keep speed low Motor overrun overset speed Package enters zone at a higher than anticipated speed Reduce the package entry speed Red fault LED flashes six times 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 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 44 Motor stall condition Obstruction or load too heavy to be conveyed Once the stall condition is removed the RollerDrive will resume normal operation Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Version 1 2 02
9. the RollerDrive and the idler rollers with associated sensors and switches are assembled into a short conveyor section a zone Zero pressure accumulation occurs as zones hold packages until the next downstream zone clears its sensor When accumulation occurs a low signal is passed upstream until each consecutive zone is occupied Packages never push each other and no line pressure occurs A logic controlled zero pressure conveyor is created when a number of zones are connected together and a simple six wire phone cable links each HC DriveControl electronically The RollerDrives only operate when a package is detected by a photoeye If the downstream zone is empty the package moves forward DriveControl HC EC100 HC EC110 INTERROLL Product information Principle of zones ee NE lt C B A OUE A A Typical ZPA conveyor configuration Zone Photoeye Direction of travel HC DriveControl Load Peer to peer communication cable RollerDrive 24 VDC GND Zone A has a package at the photoeye The HC DriveControl of zone A recognizes its presence checks zone B for
10. 2009 en Original language Abandonment and disposal Abandonment N CAUTION 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 45 DriveControl HC EC100 HC EC110 46 INTERROLL Appendix Accessories DriveControls Part Part Z Card EC Easy 89Z2 Z Card EC Full 8973 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 6 pin cage clamp type connector Wago part 734 106 000 004 Wire diameter Minimum 0 08 mm AGW 28 Maximum 1 5 mm AGW 14 Peer to peer cable Cable 6 pos flat cable SPC technology part TXW6205 WF Two plugs 6 pos AMP modular connector plug AMP part 5 641337 3 Conductor Size AWG 24 Assembly tool AMP part 2 231652 8 Dig I O plug o
11. EC100 and 33 of rated speed for HC EC110 DIP switch settings e SW5 ON OFF If SW5 is ON speed setting is transferred downstream SW4 ON OFF If SW4 is ON speed setting is transferred upstream e SW3 ON OFF e SW2 ON OFF SW1 ON OFF External speed set by PLC Direction of travel Speed analog input ummm amn GND input 24 VDC input a g PEDE 424 VDC GND 0 5 VDC PLC analog speed output 0 5 VDC 0 V 10 of rated speed for HC EC100 0 V 83 of rated speed for HC EC110 5 V 100 of rated speed DIP switch settings e SW5 ON OFF If SW5 is ON speed setting is transferred downstream SW4 ON OFF If SW4 is ON speed setting is transferred upstream e SW3 ON OFF e SW2 ON OFF SW1 ON OFF 19 DriveControl HC EC100 HC EC110 20 HC DriveControl is between two HC DriveControls Product information Setting options and wiring diagrams INTERROLL This chapter explains the DIP switch settings for different applications When the DIP switch settings ON OFF are stated both settings are possible for the shown wiring for the meaning of the settings see DIP switches page 14 Upstream device HC DriveControl Downstream device HC DriveControl
12. in Smart OUT downstream request 24 GND HS mg GND 24 VDC OUT for PNP GND for NPN ADS lel ej paves to upstream ZPA card 24 VDC 24 VDC GND GND DIP switch settings SW5 OFF SW4 ON OFF SW3 ON OFF SW2 ON OFF SW1 ON OFF A smart I O based handshake is required at the interface DIP switch 5 must be OFF to make this zone into an exit zone Jog and reverse are enabled only if DIP switch 4 is ON Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Product information HC DriveControl between two PLC handshakes Direction of travel Ti Y dz Oc ca Smarti in run signal I EN 24 VDC in for PNP and GND for NPN B E V e mart1 out downstrean edge presence sensor GND E je E o E sensor in i Non ie and EDS NPN T2AVDE anon S eB unc e e 24 VDC GND DIP switch settings SW5 OFF SW4 OFF SW3 ON OFF SW2 ON OFF SW1 ON OFF i A smart I O based handshake is required at both interfaces DIP switch 4 and DIP switch 5 must both be OFF to make this zone into a dependent zone Version 1 2 02 2009 en 35 Original language DriveControl HC EC100 HC EC110 INTERROLL 36 Transport and storage Transport Each D
13. 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 Do not apply 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 DriveControl or the RollerDrive 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 spin the RollerDrive manually as this generates an induction voltage which could damage the DriveControl Version 1 2 02 2009 en 37 Original language DriveControl HC EC100 HC EC110 INTERROLL 38 Assembly Installing the HC DriveControl in a conveyor system Use the 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
14. objects If the light beam is broken an object is present Usually the light is reflected back to the sensor via a reflector placed on the opposite side of the conveyor frame from the sensor itself The HC DriveControl 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 Request from upstream zone to discharge zone in downstream direction One of several types of DC powered rollers manufactured by Interroll Corporation A method of releasing packages where packages are allowed into downstream zone only after the trailing edge of the package currently occupying that downstream zone clears the zone s downstream edge sensor DIP switch 3 chooses either standard or enhanced singulation significant for all zone types except smart I O dependent The opposite of downstream see definition Typically the zone to the right of another zone 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 HC DriveControl 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 HC DriveControl will resist being rotated by outside forces A segment of conveyor typically comprised of one RollerDrive and multiple
15. qu VM E Standard configuration with Smart 1 IN start command ROLLER DRIVE Sensori in 24 VDC 24 VDC to upstream ZPA card 24 VDC GND GND DIP switch settings e SW5 ON OFF specifies if this zone is a transport or exit zone SW4 ON OFF SW3 ON OFF e SW2 ON OFF e SW1 ON OFF Smart 1 IN signal by PLC or photoeye Start signal for PNP 24 VDC Start signal for NPN GND Version 1 2 02 2009 en Original language 29 DriveControl HC EC100 HC EC110 HC EC100 Full in conjunction with Z Cards EC Product information INTERROLL Only the HC EC100 Full Art 9001 is equipped with a digital I O handshake terminal It is specially designed for easy Z Card EC connection HC EC110 is not available with digital I O handshake terminal HC EC100 HC EC100 Full before Z Card HC EC100 Full after Z Card Full between Z Cards Upstream device Z Card EC HC EC100 Full Z Card EC Z Card EC Downstream device Z Card EC Z Card EC Z Card EC HC EC100 Full DIP switch 4 Off Off On Off Off DIP switch 5 Off Off Off Off On Upstream peer to peer jog reverse Disabled Disabled Functional Disabled Disabled Downstream peer to peer jog Disabled Disabled Disabled Disabled Functional reverse Digital I O on board Yes Yes Yes Yes Yes Zone type Digital Digital Digital Digital Di
16. 0 13 m s 0 4 to 0 13 m s 135 to 14 fpm 79 to 26 fpm 36 1 0 44 to 0 05 m s 0 27 to 0 09 m s 88 to 9 fpm 53 to 17 fpm 48 1 0 35 to 0 04 m s 0 2 to 0 07 m s 68 to 7 fpm 40 to 13 fpm 64 1 0 25 to 0 03 m s 0 15 to 0 05 m s 50 to 5 fpm 30 to 10 fpm 96 1 0 17 to 0 02 m s 34 to 3 fpm If more than one DriveControl has to run with reduced speed it is recommended to set the speed externally by PLC or external potentiometer see External speed setting page 19 and activate peer to peer communication using DIP switch 4 Upstream and DIP switch 5 Downstream Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL External speed setting Version 1 2 02 2009 en Original language Product information Apart from the potentiometer on the DriveControl there are other ways to set the speed When the DIP switch settings ON OFF are stated both settings are possible for the shown wiring for the meaning of the settings see DIP switches page 14 External speed set by potentiometer Direction of travel Speed analog input de 7 Pot El 3 e e Bl 3 E j e B GND input EP elg B 24 VDC input L le S ia 24 VDC GND Potentiometer 10 KQ Pot at minimum equals 10 of rated speed for HC
17. Card EC Ma Fr e ew 183 eg A Egon a O t LT a p EA o0 4 mmm 24 VDC ig DH 424 VDC ges RD fo xr Laos iei I xr Ug B LI sat B o 2i i edet EJEA eed H fal esis fes Een eed SPS1 connector SPS4 connector Digital I O handshake connector 24 VDC 24 VDC GND GND DIP switch settings SW5 ON OFF SW4 ON OFF SW3 ON OFF SW2 ON OFF SW1 ON OFF Digital I O connection to Z Card Direction of travel Ra NE lt ERES RA lt E E M I woof I rr 3 bi zy HN Ae JO TIONNILNI a EO JO mee m T E 7 n M I g wb i Ed egt mj i i sed fess peed Een Eee Z Card EC i Z Card E O gH SPS1 connector i 1 23 SPS4 connector HC EC100 Full 9001 _ CEU 31 DriveControl HC EC100 HC EC110 INTERROLL HC DriveControl in conjunction with PLC handshakes Product information HC DriveControl after PLC handshake entry zone HC DriveControl before PLC handshake exit zone HC DriveControl between PLC handshakes Upstream device PLC HC DriveControl PLC Downstream device HC DriveControl PLC PLC DIP switch 4 Off Off Off On Off DIP switch 5 Off On Off Off Off Upstream peer to peer jog reverse Disabled Disabled Disabled Functional Disabled Downstream peer to peer jog Disabled Functional Disabled Disabled Disabled reverse Zone type Smart I O Smart I O Smart I O Smart I O Smart I O entry entry exit exit dependent Smart 1 in Request Request Per
18. DIP switch 4 Off On Off On DIP switch 5 Off On On Off Upstream peer to peer jog Disabled Functional Disabled Functional reverse Downstream peer to peer Disabled Functional Functional Disabled jog reverse Zone type ZPA mode ZPA mode ZPA mode ZPA mode Smart 1 in Jog Jog Jog Jog Reverse in System System System System reverse reverse reverse reverse Smart 1 out Motor run Motor run Motor run Motor run Sensor 2 Another Another Another Another C sensor C sensor C sensor C sensor Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Product information Standard configuration cc Direction of travel ul or ca Hd fion ee o jJ 3 e to downstream ZPA card to upstream ZPA card 24 VDC 24 VDC GND GND DIP switch settings SW5 ON OFF SW4 ON OFF SW3 ON OFF SW2 ON OFF SW1 ON OFF Accumulation L stop in PNP mode cc Direction of travel Ww wy E On ca Hs Ne e Accum in L stop B fie e E Sensor in N 424 VDC Hs ns E s E Soc le e to downstream ZPA card to upstream ZPA
19. INTERROLL WE MAKE THE WORLD MOVE oOoooooooqQp User Manual Interroll DriveControl HC EC100 HC EC110 Manufacturer Interroll Engineering GmbH Hoferhof 16 D 42929 Wermelskirchen Tel 49 2193 230 Fax 49 2193 2022 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 in whole or in part Unauthorized use publication or application of this document is prohibited Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Table of contents Introduction Handling of the user manual 00000 llle 2 Warnings in this manual 0 00000 ee ee 2 Further symbols 0 0 0 0 eee 3 Safety General safety instructions 000000 ce eee eee 4 Intended use e Poe dee be Ee ace hoe hee vee eed 4 Unintended usSe 0 0 0 eee 4 Qualified persons 0000 cee eee 5 RISKS P 5 Interfaces saasa Eo E eae PEE oe Eu eG ae idu ee Ried d un 5 Product information Versions of the HC DriveControl 0000000 cee eee eee 6 Gomponents ce use WE ee eh asa he Pda ERAN 6 DIMENSIONS 2 une Reo de mx ee E a de bae qe x S ER eie ice Reden Bs 7 ZPA technology 200 eee eee eee 7 Product description a aaau aaea 9 Incline and decline applications
20. Install the DriveControl to the frame with the screws protruding through the mounting holes Slip the nuts to the screws and tighten gt Ensure that there is a ground path between the DriveControl and the conveyor frame it is mounted to The DriveControl and conveyor frame should be at the same potential referenced to earth ground Electrical installation The connector supplied with the RollerDrive EC1xx mates up with the header on the DriveControl The 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 Plugin the RollerDrive connector Plugin the peer to peer connection cable if applicable Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Initial startup and operation Initial startup Inspections before initial startup Ensure that all bolts are tightened according to the specifications Ensure that no additional dangerous areas arise due to interfaces with other components Ensure that the wiring is in accordance with specifications and legal guidelines Check all protection devices 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 gt Do not push items along the roller conveyor by hand Inspec
21. This means that if a signal passing from board to board is high it is not in operation If it is low grounded it is either performing its designated function or sending the function signal to a nearby board All logic operates from a regulated and filtered 5 VDC power supply on the HC DriveControl The 5 VDC power is delivered by a converter on the board which converts the 24 VDC power that the board receives into 5 VDC for the internal logic and peer to peer board communications For communication cable hardware see Accessories page 46 OQOO0099 eeoe o Downstream peer to peer Upstream peer to peer Jog I O left Jog I O right Reverse I O Reverse I O Accumulation I O Accumulation I O B sensor OUT C sensor IN Ground amp NPN IN NPN IN right Ground left i While different segments of a system may operate at different input voltages the DC ground for each system must be held at the same potential 0 VDC to ensure good operation and clean signals In other words when multiple power supplies are used the DC grounds must always be connected together i When a peer to peer port is connected to another ZPA product the NPN in signal is pulled low except for the case where a HC DriveControl is upstream Version 1 2 02 2009 en 13 Original language DriveControl HC EC100 HC EC110 INTERROLL Product information DIP switches The DIP switches al
22. anders Adverse effects of the DriveControl and other material Disregarding the warnings 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 herein in full Only instructed and qualified persons may work with the DriveControl Always keep this user manual at hand when working on the DriveControl so that you can consult it quickly if required Always comply with relevant national safety regulations gt f you have any questions after reading this user manual feel free to contact our customer service See the last page for contact information Intended use The HC DriveControl may only be used for industrial applications and in an industrial environment to control a RollerDrive EC1xx It must be integrated in a conveyor module or a conveying system Any other use is considered inappropriate Use of the HC DriveControl is only allowed in the areas described under product information Any changes that affect the safety of the product are not allowed The HC DriveControl may only be used within the given operation limits Unintended use Applications not according to the intended use of the HC DriveControl require approval from Interroll Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL A Persons Electricity Working environment Av
23. any Interroll F rdertechnik GmbH H ferhof 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 Eastern Europe Czech Republic Interroll CZ s r o Na Radku 7 3172 CZ 69002 Breclav 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 Plochocinska 85 PL 03 044 Warszawa Tel 48 22 741 7410 Fax 48 22 741 741 1 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 Rol er Makina San Ve Tic Ltd Sti Pembegul Sok Dostlar Apt No 12 D 10 Suadiye 347 40 Istanbul Turkiye Tel 90 216 386 37 75 Fax 90 216 386 38 22 tr sales interroll com Near East Israel ComTrans 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 37 Director Road Spartan Ext 2 1619 South Africa Tel 27 11 281 9900 Fax 27 11 252 9083 za sales interroll com North amp South America USA
24. ark 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 Z 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 351 275 990 789 p sales interroll com Spain Interroll Espafia S A Parc Teconol gic del Vall s C Dels Argenters 5 Edificio 1 m dulos Bp y Cp E 08290 Cerdanyola del Vall s Tel 34 90 211 0860 Fax 34 93 586 4895 e sales interroll com Version 1 2 02 2009 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 748 515 gb sales interroll com Central Europe Germ
25. availability and requests permission to transfer the package to zone B Since zone B has also a package its HC DriveControl denies the permission until this package has been transfered to zone C singulation mode or has at least started being transfered enhanced singulation mode The singulation method depends on the setting of DIP switch SW3 The HC DriveControl of zone A will only start to operate the RollerDrives in its zone after it gets permission from the HC DriveControl of zone B 8 Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Features Operation modes Version 1 2 02 2009 en Original language Product information Product description Zone to zone communication Activities in upstream and downstream zones are monitored by photoeyes to permit control in various situations Diagnostics LEDs provide motor sensor and jam diagnostics as well as power fuse and temperature status Reverse or jog entire system Switch settings and connections on the board allow the user to reverse the zone to zone logic jog the entire system or reverse or jog parts of the system or bypass those functions altogether default without the use of external cards NPN or PNP All inputs and outputs can be switched collectively for NPN or PNP with one switch Only No fault output is always active high failsafe function with 24 VDC in No fault status Multiple dependent RollerDr
26. ble Affects upstream peer to peer propagation of speed jog and reverse signals for certain scenarios Affects downstream peer to peer propagation of speed jog and reverse signals for certain scenarios Normally this is the zone to the left of another given zone The reference is always that packages move from upstream to downstream 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 Short form for Interroll 24 VDC brushless RollerDrive versions e EC100 e EC110 Also referred to as product waiting It indicates that an upstream zone has a product at its downstream edge sensor waiting to be moved into the next downstream zone Edge full is a signal transmitted across the peer to peer cable used by the HC DriveControl for zone to zone communication Also called wave release A method of release which allows the upstream release of a package as soon as the downstream package blocks the photoeye of the downstream zone with its leading edge This dramatically increases throughput over singulated release but can sometimes result in lost packages There is also a short delay that is propagated upstream to eliminate all packa
27. card 24 VDC 24 VDC GND GND DIP switch settings Version 1 2 02 2009 en Original language SW5 ON OFF SW4 ON OFF SW3 ON OFF SW2 ON OFF SW1 ON 21 DriveControl HC EC100 HC EC110 INTERROLL 22 Product information Accumulation L stop in NPN mode Direction of travel nuumuuuuu nnn GND 24 VDC je E MTENROLL of NA I ROLLER DRIVE Accum in L stop Booooo Inlatataia Sensor1 in GND 24 VDC to downstream ZPA card to upstream ZPA card 24 VDC 24 VDC GND GND DIP switch settings SW5 ON OFF SW4 ON OFF e SW3 ON OFF SW2 ON OFF SW1 OFF Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 Version 1 2 02 2009 en Original language INTERROLL Product information External direction set in PNP mode i iai Direction of travel Li uj gt ad Reverse direction of travel x Cle Rou Smart 1 Fwd in H3 e e J B 3 TEE E Sensor1 in 424 VDC H Shi S23 Voc e e to downstream ZPA ca
28. com Korea Interroll Korea Corporation Room 301 Dongsan Bldg 333 60 Shindang Dong Choong ku Seoul Korea Tel 822 2 231 1900 Fax 822 2 254 36 83 kr sales interroll com Singapore Interroll Asia Pte Ltd 386 Jalan 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 Thailand Tel 66 2 337 0188 91 Fax 66 2 337 01 92 th sales interroll com India Interroll Drives and Rollers India Private Limited SF 12 KSSIDC Building 3rd Stage Peenya Bangalore Bangalore 560058 Kamataka India Tel 91 80 2359 5904 Fax 91 80 2349 5241 in drummotors interroll com Australia amp New Zealand Australia Conveyor Solutions Australia Pty Ltd 70 Keon Parade Thomastown VIC 3073 Australia Tel 61 3 9460 2155 Fax 61 3 9460 2029 aus sales interroll com New Zealand Automation Equipment NZ Ltd 45 Colombo Street Frankton Hamilton New Zealand Tel 64 7847 2082 Fax 64 7847 7160 nz sales interroll com For other countries please see contacts at www interroll com
29. declaration 0000 0 ccc eee 49 Version 1 2 02 2009 en 1 Original language DriveControl HC EC100 HC EC110 INTERROLL Content of the manual Validity of the manual This manual is part of the product Structure of warnings Introduction Handling of the user manual In this manual the DriveControls HC EC100 and HC EC1 10 are referred to as HC DriveControl This manual contains important advice notes and information about the HC DriveControl in all phases of its lifecycle Transport assembly and commissioning Safe operation maintenance troubleshooting and disposal Accessories The manual describes the HC DriveControl 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 this manual and follow the instructions before handling the HC DriveControl Keep this manual near to the HC DriveControl gt Pass this manual on to any subsequent operator or occupant of the HC DriveControl gt Interroll does not accept any liability for malfunctions or defects due to non observance of this manual gt f you have any questions after reading this user manual feel free to contact our customer service See the last page for contact information Warnings in this manual The warnings in this document refer to risks which may arise while using the HC Driv
30. eControl For relevant warnings see Safety page 4 and the warnings at the beginning of each chapter There are three categories of danger The following signal words are used in the document as required Danger 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 A DANGER Nature and source of the hazard Possible consequence of non observance gt Information about how to avoid the hazard Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Version 1 2 02 2009 en Original language ep Introduction Further symbols NOTICE This symbol identifies possible material damage gt Information about how to avoid 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 HC EC100 HC EC110 INTERROLL Safety General safety instructions The HC DriveControl 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 byst
31. ges starting at the exact same time Maximum allowable current is decreased by the DriveControl Short form for a single zone DriveControl for Interroll 24 VDC brushless RollerDrives HC EC100 Can be used as DriveControl motor control and as ZPA zone control for RollerDrives EC100 HC EC110 Can be used as DriveControl motor control and as ZPA zone control for RollerDrives EC110 47 DriveControl HC EC100 HC EC110 INTERROLL Idler rollers Jam protection Jog N C NPN override O rings Perm Photoeye Req RollerDrive Singulated release Singulation Upstream Zero motion hold Zone ZPA 48 Appendix Non powered rollers attached to a RollerDrive typically via O rings or multi rip belts A method of protecting packages that are possibly jammed in a zone If the HC DriveControl detects a jam or obstruction at the downstream end of the zone it sends an accumulation signal to the upstream zone preventing a buildup of accumulation pressure RollerDrive runs continuously as long as the command is set If jog mode is activated DriveControl disregards ZPA or photoeye signals No care affects nothing DIP switch 4 is for upstream DIP switch 5 is for downstream O rings made of materials such as polyurethane that connect RollerDrives to their associated idler rollers Permission Signal to upstream zone to discharge zone send load An ON OFF sensor that uses light to sense the presence of
32. gital I O dependent O exit I O exit I O entry I O entry Smart 1 in Jog Jog Jog Jog Jog Reverse in System System System System System reverse reverse reverse reverse reverse Smart 1 out B sensor B sensor B sensor B sensor B sensor Sensor 2 Not used Another Another Not used Not used digital I O C sensor C sensor digital I O digital I O Upstream digital I O Req out N C N C N C In use In use Perm in N C N C N C In use In use Downstream digital I O Req out In use In use In use N C N C Perm in In use In use In use N C N C 30 Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Version 1 2 02 2009 en Original language Product information Standard configuration Direction of travel ROLLER DRIVE Z Card EC ge o L Z
33. idler rollers interconnected by O rings or some other device for driving the idlers Zero pressure accumulation The process of moving packages on a conveyor in such a manner that they do not touch each other also see ZPA technology page 7 Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Version 1 2 02 2009 en Original language 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 Engineering GmbH H ferhof 16 D 42929 Wermelskirchen Germany hereby declares with sole responsibility that the product range DriveControl HC EC100 DriveControl HC EC100 Full DriveControl HC EC110 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 Directive 2004 108 EC RoHS Directive 2002 95 EC Applied harmonized norms EN ISO 12100 Part1 and Part2 Wermelskirchen November 7t 2007 Armin Lindholm Managing Director This declaration can be obtained at www interroll com if needed 49 Europe Nordic Denm
34. irection setting is transferred upstream e SW3 ON OFF If REV signal is active SW3 has to be OFF SW2 ON OFF SW1 OFF Start options FWD connected to GND at NPN mode causes cew rotation REV connected to GND at NPN mode causes cw rotation FWD and REV connected to GND at NPN mode causes coast mode FWD signal acts like a jog signal disregarding ZPA functionality and photoeye signals REV signal reverses motor and logic direction upstream becomes downstream and C sensor becomes B sensor Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Version 1 2 02 2009 en Original language Product information Left to right conveyor to upstream ZPA card Direction of travel a ROLLER DRIVE to downstream ZPA card GND 24 VDC 24 VDC Sensor1 in Bei l3 e ie F 24 VDC e GND GND 24 VDC DIP switch settings e SW5 ON OFF SW4 ON OFF SW3 ON OFF SW2 ON OFF SW1 ON OFF Works like a standard configuration only the HC DriveControl is turned upside down 25 DriveControl HC EC100 HC EC110 INTERROLL Product information
35. itch is used instead of a jumper check that the switch is off Communication cable to or between the zones is miswired Check the communication cables and replace them if they are miswired No power supply of the HC DriveControl Check the power input to HC DriveControl No power supply of the RollerDrive EC1xx Verify that the motor wires are terminated properly Communication cable is miswired between the zone that is operating and the zone that is not Replace the cable Package stops within a zone 42 Photoeye is not aligned properly Check the alignment of the photoeye Speed of the RollerDrive EC1xx is too slow Calculate the speed and the distance to ensure the time limit is not exceeded The package has max 4 5 seconds to clear the upstream photoeye and reach the next downstream photoeye Adjust the speed of the RollerDrive Jammed package Remove jammed packages Jammed roller Remove the cause of the jam or replace the roller Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Symptom Package coasts into the next zone instead of stopping immediately Troubleshooting Possible cause Package is heavy or has a low coefficient of friction Help Move the photoeye further back into the zone Apply a coating that increases the friction between the rollers and the packages Zone does not reverse Communicatio
36. ives in one zone Up to three RollerDrives can be run from one HC DriveControl and two dependent cards to achieve multiple RollerDrives in a single zone This signal can also be used by a PLC as a motor running status input Smart braking Depending on upstream and downstream zone occupancy the RollerDrive will brake if needed and coast if no braking is required This saves on power heat and vibration in the RollerDrive and ultimately in the system When no photoeyes are blocked in the system all RollerDrives are in coast mode Dynamic braking RollerDrive acts like a generator and DriveControl feeds back current into the RollerDrive windings Zero motion hold When the DriveControl has no start signal the RollerDrive will be held in place Advanced braking The combination of dynamic braking followed by zero motion hold provides superior braking and holding for many applications The operation modes of a RollerDrive conveyor with HC DriveControls include Standby The RollerDrives are turned off if the zone is empty Accept When a load reaches the sensor at the upstream end of the zone the RollerDrives turn on to accept it Transfer The RollerDrives continue to run to ensure that the load entering the upstream end of the zone is transferred to the downstream end This creates a smooth transition and high throughput Discharge The RollerDrives in the zone continue running to discharge the load if no accumulation c
37. l inputs photoeye inputs and outputs are active high 24 VDC NPN all external inputs photoeye inputs and outputs are active low 0 VDC ground This excludes the No fault output which is always active high 24 VDC when in either NPN or PNP mode Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Product information i Local jog and reverse are always enabled but upstream and downstream propagation are controlled by DIP switch 4 and DIP switch 5 respectively e Itis now simple to use DIP switch 4 and DIP switch 5 to define jog reverse groups or to defeat jog and reverse completely recommended whenever not in use e If the RollerDrive is mounted with the cable exiting the opposite side of the conveyor frame switch SW2 has to be set in the opposite position to maintain equal direction of travel e For special cases see Setting options and wiring diagrams page 20 Version 1 2 02 2009 en 15 Original language DriveControl HC EC100 HC EC110 INTERROLL Product information Meaning of the LEDs The LEDs provide motor sensor and jam diagnostics as well as power fuse and temperature status The following table shows the meaning of the LEDs flashes are second on and 74 second off in a fixed 4 second time period LED Color Status Meaning Fuse red on steady all other Fuse blown LEDs are off Power green on steady Power ok Faul
38. low the selection of various types of control operations The default DIP switch settings are all OFF This would provide Standard HC DriveControl connectivity upstream and downstream SWA SW5 n standard singulate mode SW3 Motor running counter clockwise SW2 All NPN inputs and outputs SW1 DIP switch settings are read at reset power up only DIP switch settings ON OFF SW5 Downstream Override Standard SW4 Upstream Override Standard SWS Singulation Enhanced Standard SW2 Rotation CW CCW SW1 Logic PNP NPN The following table shows the switch position for different situations DIP switch SW5 Downstream ON left position Override the downstream peer to peer cable is connected to another HC DriveControl and the jog reverse signal is transmitted OFF right position Standard the jog reverse signal is not transmitted SWA Upstream Override the upstream peer to peer cable is connected to another HC DriveControl and the jog reverse signal is transmitted Standard the jog reverse signal is not transmitted SW3 Singulation Override enhanced singulated release see Glossary page 47 is needed Standard singulated release see Glossary page 47 is needed SW2 Rotation Clockwise rotation of the RollerDrive seen from the cable end Counter clockwise rotation of the RollerDrive seen from the cable end SW1 Logic 14 PNP all externa
39. m Perm Run Reverse in System System System System System reverse reverse reverse reverse reverse Smart 1 out Perm Perm Request Request B sensor Sensor 2 Not used Not used Another Another Not used smart I O smart I O C sensor C sensor 32 Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Product information HC DriveControl after PLC handshake entry zone oc Direction of travel EIC LEE iz oc cao 24 VDC infor PNP GND for NPN He LC Ree out upstream permission Loser 3 Er BEND n 24 VDC out for PNP GND for NPN la ej ANDE to downstream ZPA card 24 VDC GND DIP switch settings SW5 ON OFF SW4 OFF SW3 ON OFF SW2 ON OFF SW1 ON OFF A smart I O based handshake is required at the interface DIP switch 4 must be OFF to make this zone into an entry zone Jog and reverse are enabled only if DIP switch 5 is ON Version 1 2 02 2009 en 33 Original language DriveControl HC EC100 HC EC110 INTERROLL 34 Product information HC DriveControl before PLC handshake exit zone c Direction of travel ul ul m a oc ra Smartt IN d str issi 24 VOC IN for PNP GND for NPN He 3 EE Sensort
40. n cable to upstream zone is miswired Replace the communication cable Signal has not been sent and received properly Check the output of the upstream DriveControl and the input to the DriveControl Different ground of the zones Check that a common ground exists between both zones System turns off when several zones are in use at the same time Power supply is not sufficient Ensure that the 24 VDC power supply has adequate power for the system requirements Check that the AC voltage source and DC voltage power supply are installed correctly DriveControl does not recognize the start sensor Sensor and reflector are not aligned properly Check the alignment of the sensor and reflector Check the settings of DIP switch 4 and 5 RollerDrive EC1xx is not in braking mode without any packages on the conveyor system Version 1 2 02 2009 en Original language This is not an error It is a power saving feature The RollerDrive EC1xx is in coast mode until it is commanded to run or accumulate 43 DriveControl HC EC100 HC EC110 INTERROLL Symptom Motor is in brake mode red fault LED flashes once 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 16 Possible cause Invalid state of motor hall effect sensor Broken wire Failed hall effect sensor Help
41. nly on HC EC100 Full 9001 Double stack header on the board Phoenix Contact socket part 1961164 Plugs Phoenix Contact part 1881341 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 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Back EMF B sensor C sensor Coast mode Digital I O DIP switch 4 DIP switch 5 Downstream Dynamic braking EC1xx Edge full Enhanced Singulated release Foldback current HC DriveControl Version 1 2 02 2009 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 Downstream edge presence sensor of own zone Downstream edge presence sensor of upstream zone The RollerDrive is running freely without power or braking Software automatically detects if circuitry is on board Digital I O handshake only on HC EC100 Full availa
42. ntinuous current This 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 harming the DriveControl or motor DriveControl temperature shutdown At a DriveControl temperature of 90 C 194 F the DriveControl will shutdown the motor and the motor will go into dynamic braking This is indicated by the red LED flashing four times When the DriveControl cools back down the red LED stops flashing and motor and DriveControl operation will resume Incline and decline applications Due to the zero motion hold and regenerative braking features the HC DriveControl and RollerDrive EC1xx can be used for incline and decline applications up to an angle of 15 Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Power input and I O connections Version 1 2 02 2009 en Original language Product information Inputs and outputs i e oh Speed analog input External pot Q Smart 1 FWD input 6 o REV input No fault output Smart 1 output 3 Common ground input 24 VDC input 1 00000000 e Speed analog input External speed control down to a
43. oiding malfunctions in operation Maintenance Version 1 2 02 2009 en Original language Safety 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 the relevant manuals and diagrams the warning and safety instructions in this manual the system specific regulations and requirements national or local regulations and requirements for safety and accident prevention Risks The following list informs you about the various types of danger or damage that may occur while working with the HC DriveControl 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
44. ommand is received from the downstream zone DriveControl HC EC100 HC EC110 INTERROLL 10 Safety and stall functions Product information There are different levels of over temperature or stall related functions Jam protection If the HC DriveControl detects a jam or obstruction at the downstream end of the zone it sends an accumulation signal to the upstream zone preventing a build up of accumulation pressure that could cause product damage or personal injury 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 motor Motor temperature shutdown At a motor temperature of 100 C 212 F the HC DriveControl will shut down the motor and the motor will go into dynamic braking This is indicated by the red led flashing five times When the RollerDrive cools back down the red LED stops flashing and motor 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 foldback peak current down to co
45. ommon DC ground NPN or 24 VDC PNP This input is PNP NPN selectable with DIP switch 1 Sensor 2 input Used as a start sensor It is located at the upstream edge of the zone and tells the first zone in a conveyor to run This input is PNP NPN selectable with DIP switch 1 Sensor 1 input Located at the downstream edge of the zone This input is PNP NPN selectable with DIP switch 1 Sensor fault input If sensor 1 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 1 and sensor 2 Sensor 24 VDC output 24 VDC power supply for sensor 1 and sensor 2 OG i Only the sensors mentioned below may be chosen sensor supply current from the board is 50 mA max NPN retro reflective reflector required dark operate normally closed NC contact NPN diffused no reflector light operate normally open NO contact PNP retro reflective reflector required dark operate normally closed NC contact e PNP diffused no reflector light operate normally open NO contact 12 Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Product information Peer to peer communication Even though all of the external inputs and outputs are NPN and PNP switchable the HC DriveControl peer to peer communications always use NPN TTL logic
46. pproximately 3396 of the maximum speed When using a 10 KQ 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 19 External pot An external 10 kQ potentiometer can be used to adjust the speed down to approximately 3396 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 19 Smart 1 FWD input Has various functions depending on zone type n entry zone acts as a start signal for the handshake with previous machines or conveyors n exit zone acts as a start signal to discharge the conveyor as handshake to following systems n transport zone acts as jog signal for the specific zone or the whole conveyor depending on the DIP switch settings n dependent zone acts as jog command to run the motor This input is PNP NPN selectable with DIP switch 1 REV input Invokes the system reverse function causing all interconnected controls to operate in reverse transport mode while the signal is active When in dependent mode the motor will simply run in reverse while this signal is active 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 Smart 1 o
47. r contains the following information about the production date 05052 01925 00 Year Day of the year Sequential number of the produced units on that day Technical data Nominal voltage 24 VDC Voltage range 22 to 28 VDC Voltage ripple tolerance lt 5 lt 1 recommended Continuous current HC EC100 1 8 A HC EC110 2 5 A Peak current 41A 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 20 C to 75 C 4 F to 167 F storage 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 17 DriveControl HC EC100 HC EC110 INTERROLL 18 On board speed setting Product information Speed settings The speed can be continuously adjusted between 10096 and approximately 1096 for the HC EC100 and 33 for the HC EC110 by the potentiometer on the DriveControl Default setting is maximum Gear ratio Speed range EC100 HC EC100 EC110 HC EC110 4 1 2 41 to 0 8 m s 475 to 157 fpm 9 1 1 07 to 0 36 m s 211 to 70 fpm 12 1 1 32 to 0 15 m s 0 8 to 0 26 m s 260 to 30 fpm 158 to 52 fpm 16 1 1 03 to 0 1 m s 0 6 to 0 2 m s 202 to 20 fpm 119 to 39 fpm 24 1 0 69 to
48. rd to upstream ZPA card 24 VDC GND REV in FWD in DIP switch settings SW5 ON OFF If SW5 is ON direction setting is transferred downstream SW4 ON OFF If SW4 is ON direction setting is transferred upstream SW3 ON OFF If REV signal is active SW3 has to be OFF SW2 ON OFF SW1 ON Start options FWD connected to 24 VDC at PNP mode causes ccw rotation REV connected to 24 VDC at PNP mode causes cw rotation FWD and REV connected to 24 VDC at PNP mode causes coast mode FWD signal acts like a jog signal disregarding ZPA functionality and photoeye signals REV signal reverses motor and logic direction upstream becomes downstream and C sensor becomes B sensor 23 DriveControl HC EC100 HC EC110 24 INTERROLL Product information External direction set in NPN mode Un x Direction of travel W wy r a2 Reverse direction of travel Og ES frio Smart 1 Fwd in H3 e e NN B e sm E Sensor1 in e da SE HI Jane le 24 VDC to downstream ZPA card to upstream ZPA card 24 VDC GND REV in FWD in DIP switch settings e SW5 ON OFF If SW5 is ON direction setting is transferred downstream SW4 ON OFF If SW4 is ON d
49. riveControl is packed in its own carton case N CAUTION 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 In case of damage take photos of the damaged parts To maintain the warranty instantly report any damage caused during transport to the transport company and to Interroll Do not transfer the DriveControls between warm and cold environments as this may cause condensing water VVVVVV v Storage N CAUTION Risk of injury due to improper storage Do not stack more than four carton boxes Check each DriveControl for damage after storage Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 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 gt The electrical
50. s the symptoms might exist either in the zone or in the neighboring zone Keep in mind that information travels downstream The cause of most control problems can be found upstream Possible cause No power supply Help Check whether the output voltage of 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 DriveControl see Inputs and outputs page 11 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 14 Fuse is blown Replace the fuse see Replacing fuse page 40 Zone runs without package Version 1 2 02 2009 en Original language Wrong sensor output Check the type of sensor output see Sensor connection page 12 Wrong alignment of sensors Verify the alignment of the sensors Align the photoeyes to see the conveyor field only no overhead lights side frames etc Jog command by an inadvertently grounded Smart 1 FWD input command Check the connection of Smart 1 FWD input Communication cable is twisted or defective Check the communication cable upstream Photoeye is not connected properly Check the connection of the photoeye to HC DriveControl Verify the photoeye pin assignment see Sensor connection page 12 Photoeye is damaged Replace the photoeye
51. source the malfunction VV VY v Y 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 described in 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 any new potential dangerous condition prior to turning on the conveyor DriveControl HC EC100 HC EC110 INTERROLLE Product information Versions of the HC DriveControl Version Characteristics Part HC EC100 HybridControl for RollerDrive EC100 1 9000 HC EC100 Full Like HC EC100 but with digital I O handshake 2 9001 HC EC110 HybridControl for RollerDrive EC110 1 9004 1 The HybridControl has ZPA and motor control functionality on board If no peer to peer port is connected and DIP switches 4 and 5 are set to OFF it Switches automatically from ZPA mode to motor control mode only 2 The HC EC100 Full has two pins per signal and all four signals are isolated In this version the digital signals are used instead of Smart I O for exit and entry Components ii L 05052 01925 USA ne IEOU UN INTERROLL 1
52. t red on steady Stalled motor Jam at or between sensors flashing once Motor or motor cable open or disconnected flashing twice Over voltage detection 29 VDC x 0 2 VDC will cease normal operation flashing three times Under voltage detection 19 VDC x 0 2 VDC will cease normal operation flashing four times DriveControl severe temperature shut down will cease normal operation until cool flashing five times Motor severe temperature shut down will cease normal operation until cool flashing six times 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 flashing four times Motor current is limited to maximum continuous current due to card over temperature There is no error output if the amber LED is flashing i 16 Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Version 1 2 02 2009 en Original language Product information DriveControl label The specifications on the DriveControl label are used to identify the HC DriveControl This is required to use the DriveControl as intended 05052 01925 USA IHHHIHIIIHHHHI 9 9000 HC EC100 3 V 1 00 REV 0 me Serial number Revision information Country of production G Article number Product name Identification barcode The serial numbe
53. tal 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 Install a new DriveControl see Abandonment page 45 and see Assembly page 37 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 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 gt Regularly blow off dust and dirt by using low compressed air Version 1 2 02 2009 en Original language DriveControl HC EC100 HC EC110 INTERROLL Symptom System is not operating Troubleshooting Error search When troubleshooting the conveyor system keep in mind that each HC DriveControl controls a zone If a problem exists in a zone or a section of zone
54. tions before every startup Changing settings Do not spin the RollerDrive manually Check the position of the DIP switches see DIP switches page 14 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 goods 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 Procedure in case of accident or malfunction VVVVV Version 1 2 02 2009 en Original language Stop the conveyor at once and ensure that it cannot be started accidentally In case of an accident Provide first aid and call for emergency assistance Inform responsible persons Have the malfunction repaired by qualified persons Start the conveyor only after this has been approved by qualified persons 39 DriveControl HC EC100 HC EC110 INTERROLL 40 Checking the DriveControl Replacing the DriveControl Replacing fuse Maintenance and cleaning Warnings concerning maintenance and cleaning N CAUTION Risk of injury due to improper handling or acciden
55. utput Has various functions depending on zone type In entry zone reflects the status of the zone occupied or free for handshake with previous systems In exit zone reflects the status of the zone occupied or free for handshake with following systems In transport zone is the connection to control a second RollerDrive in the zone by interfacing with Smart 1 IN of the dependent zone n dependent zone reflects the status of the sensor This output is PNP NPN selectable with DIP switch 1 Common ground input Must be connect to the main power ground 24 VDC input Main power supply 24 VDC voltage range see Technical data page 17 11 DriveControl HC EC100 HC EC110 INTERROLL Product information i The HC DriveControl 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 596 Sensor connection Accum L stop input Sensor 2 input Sensor 1 input Sensor fault input Sensor common ground output Sensor 24 VDC output OOoOooOoooO ONOG Accum L stop input An active signal NPN PNP switchable on this terminal input will cause the HC DriveControl to accumulate in this zone until the signal is removed A manual switch or a PLC controller can provide the signal referenced to a c

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