interroll dc-katalog imperial usa en · 1 day ago · interroll dc platform 6 product overview 8...

INSPIRED BY EFFICIENCY

CATALOGROLLERDRIVECONTROLSPOWER SUPPLIES

PRODUCT LOCATOR

Products

Voltage Interface Power Diameter Protectionrate

Suitable fordeep freeze

areas

page

24 V 48 V AI BI 20 W 35 W 50 W 1.9" 2.36"

RollerDrive EC5000

For straight sections

l l l l l l l l – IP54 – 10

l l l l – l l l – IP54 l 22

l l l l – l l 1.97" – IP66 – 30

l l l l – – l – l IP54 – 26

For curves l l l l l l l l – IP54 – 16

Controls

DriveControl 20 l – l – l l – IP20 – 34

DriveControl 54 l – l – l l – IP54 l 36

DriveControl 2048 l l l – l l l IP20 – 38

ZoneControl l – l – l l – IP20 – 40

MultiControl AI l l l – l l l IP54 l 44

MultiControl BI l l – l l l l IP54 l 48

Switching power supplies

HP5424 l – l l l l l IP54 l 52

HP5448 – l l l l l l IP54 l 56

l = suitable – = not suitable

© 06 | 2020 Interroll

Symbols

Suitable for deep freeze area

24V Voltage 24 V

48V Voltage 48 V

20W Power 20 W

35W Power 35 W

50W Power 50 W

AI Analog interface

BI Bus interface (CANopen)

Contents

The Interroll Group 4

Interroll DC Platform 6

Product overview 8

RollerDrive 10

Controls 34

Switching power supplies 52

Accessories 60

Planning basics 66

Index 80

www.interroll.com

3© 06 | 2020 Interroll

THE INTERROLL GROUP


The Interroll Group is a globally leadingsupplier of high-quality key products andservices for internal logistics. Thecompany, which is listed on the stockexchange and has its headquarters inSwitzerland, employs some 2300 peoplein 32 companies around the globe.

The solutions for our customers' dailylogistical challenges are based on Interrollkey products that are built on a worldwidecommon platform.

Conveyor Rollers Drives and ControlsInterroll is the worldwide leading provider of conveyor rollers that can befound in a multitude of applications in internal logistics. For the rollerproduction, we merge quality, flexibility and speed. More than 13 millionrollers in 60,000 variants leave our plants worldwide every year. Ourproduction is always order-driven, even for the smallest order quantities and,if desired, even with a delivery time of 24 hours. Proven.

Interroll is a leading manufacturer in the segment of DC motor rollers anddrum motors.Interroll RollerDrive and their controls are used in automated conveyortechnology. Energy-efficient DC drives are installed in decentralizedconveyor systems and, as a result, optimize energy demand and materialhandling. The bus interface enables integrating the zero pressureaccumulation conveyor technology into Industry 4.0 systems.Interroll Drum Motors are designed for use in belt conveyors and conveyorsystems. These robust, high-quality belt drives enable the construction ofmaintenance-free, energy-efficient conveyor belt systems for the majority ofindustrial applications as well as for food processing, baggage handling andsupermarket checkouts.

© 06 | 2020 Interroll 5

Holding Global Competence Centers

Sales, Production & Service Regional Competence Centers

Conveyors & Sorters Pallet & Carton FlowThe Modular Conveyor Platform (MCP) from Interroll offers highest flexibility:a broad spectrum of modules, consisting of roller conveyors, belt conveyorsas well as key products such as transfer, high-performance diverts or spirallifts, covers all requirements of the material handling.The Interroll crossbelt sorters were developed with an eye on precision forfast and precise sorting of goods of all types from 2 oz to 77 lbs. More than300 Interroll sorters are used every day by the largest CEP players and E-commerce enterprises worldwide.The brand-new modular pallet conveyor platform (MPP) offers roller andchain conveyors as well as special conveyors such as transfers and turntablesto create a fully integrated, robust, space-saving and energy-saving solutionfor high throughput handling of pallets.

Interroll Pallet Flow and Carton Flow are the first choice when it comes torapid turnarounds and optimizing the storage and commissioning process.Thanks to its efficiency and robustness, Pallet Flow ensures long-termavailability and more flexibility for peaks in orders. The compact designreduces space requirements by up to 50 percent compared to conventionalsolutions. The integrated TimePlus Separator as well as the Magnetic SpeedController increase the safety of the work environment and significantlyreduce the risk of damages to goods.The Interroll Carton Flow solutions are efficient as well as ergonomic, andwere developed to improve the commissioning output.

THE INTERROLL GROUP

INTERROLL DC PLATFORM


Smart solutions

With the market launch of its new DC platform, Interroll is onceagain setting standards in material handling technology. Therange of perfectly matched RollerDrive, control systems andpower supplies enables system integrators and machine builders

to provide an even better fit for their customers’ needs – fromstandard applications to equipment with Industry 4.0functionality. The new DC platform has a solution to match everychallenge.

© 06 | 2020 Interroll 7

Technology at a glance

48-V technologyA 48-V voltage supply allows reducing the numberof power supplies depending on the application. Inaddition, the risk of functional issues due to voltagedrop on the line will be reduced significantly. It alsomeans that longer cabling, or alternatively cableswith a minimized cross section, can be used.

Choice of three power levelsThe RollerDrive EC5000 is available in 20, 35 and50 watt versions. This enables zero pressureaccumulation conveyors that are the perfect fit forboth heavy and lightweight conveying goods.

Bus interfaceA large variety of operating data can be read outvia the bus interface of the new RollerDriveEC5000. Not only can they be used for the analysisof the RollerDrive, but rather for optimizing theentire conveyor line as defined by Industry 4.0. Theservice life indication, for example, allowspurposeful preventive maintenance. Thecooperation of PLC and Interroll MultiControl alsoallows for ultra-precise positioning of conveyinggoods, e.g., for the support of robotics applications.

Control systems for every applicationAlongside DriveControl 2048 for standardapplications with few RollerDrive, MultiControl – afour-zone control compatible with multipleprotocols – offers the right solution for both simpleand demanding applications, from autonomousconveyors with integrated logic to conveyors withcustomized PLC programming via fieldbuscommunication.

New switching power suppliesThe new power supplies do not need to be installedin the control cabinet. Instead, the robust deviceswith protection rating IP54 can be mounted directlywhere the extra-low voltage is needed. Thisenables much shorter cable lengths. Automaticpower limitation and selectable circuit protectionare integrated, as is status evaluation via LED orsignal lines to the PLC.

Everything from a single sourceControl systems, power supplies, different cabling,and other accessory parts. For Interroll, it isextremely important that the products not onlywork together, but actually complement each other.The company always has the right experts on handto answer any questions that arise.

Simple detectionIn addition to the nameplate, the different designvariants of EC5000 can also be identified by acolor ring on the connector. Color assignment:

· White - 24 V, analog interface· Gray - 24 V, bus interface· Black - 48 V, analog interface· Yellow - 48 V, bus interface

INTERROLL DC PLATFORM

PRODUCT OVERVIEW

RollerDrive EC5000

ø 1.9", cylindrical, IP54, for 32 to 104 °Fpage 10

ø 1.9", tapered, IP54, for 32 to 104 °Fpage 16

ø 1.9", cylindrical, IP54, for –22 to +32 °Fpage 22



Controls

DriveControl 20 page 34



ZoneControl page 40

MultiControl AI page 44

MultiControl BI page 48

© 06 | 2020 Interroll8

PRODUCT OVERVIEW


Switching powersupplies

HP5424 page 52

HP5448 page 56

Accessories

PolyVee belt page 60

RollerDrive fastening socket page 61

RollerDrive counter wrench page 62

RollerDrive EC5000 extensioncable page 62

Voltage supply flat cable page 62

MultiControl communicationcable page 63

MultiControl Y-cable page 63

Magnetic key page 65

ROLLERDRIVESERIES EC5000ø 1.9", cylindrical, IP54, for 32 to 104 °F

10 © 06 | 2020 Interroll

Application areaDrive for unit handling conveyorsystems, such as transportingcardboard cartons, containers,platens or tires at normal ambienttemperature. Suitable for straightconveyors, small belt conveyorsand especially zero-pressureaccumulation conveyors. Alsousable in shuttle systems, aligningconveyor segments or transfers toother "conveyor system branches".

Compact designThe motor integrated in the tube allows a very compact design of the conveyor system.

Very energy-efficientThe brushless drive features energy recovery when braking. The conveyor system can operatewithout pneumatics or conventional drives, which must be operated continually.

Flexible possible applicationsRollerDrive is available in many variations, allowing it to be used in all types of differentconveyor systems. For the user, this translates into a single interface instead of many. Dependingon the application area, PolyVee, round or toothed belts can be used for the transmission offorce. Nine gear ratios allow selecting the perfect pairing between speed and torque. Theelectronic holding brake (Zero-Motion-Hold) holds conveying goods in position, even on gravityconveyors.

Low-noiseThe use of decoupling elements achieves particularly low-noise running.

Maintenance-free and installation-friendlyThe drive with internal commutation electronics does not require any maintenance. It features anoverload protection that prevents damages due to overtemperature or blockage. It is connectedsecurely without complex screw connection by using a motor cable with 5-pin snap-in plug.

24V

48V

20W

35W

50W

AI

BI

ROLLERDRIVESERIES EC5000

ø 1.9", cylindrical, IP54, for 32 to 104 °F

11© 06 | 2020 Interroll

Technical data

Rated voltage 24 V 24 V 24 V 48 V 48 V 48 V

Power 20 W 35 W 50 W 20 W 35 W 50 W

Rated current 1.4 A 2.4 A 3.4 A 0.7 A 1.2 A 1.7 A

Starting current 3.0 A 5.5 A 7.5 A 1.5 A 2.8 A 3.8 A

Max. noise emission (installed) 55 dB(A), application-dependent

Length of motor cable 19.6"

Max. reference length 59"

Ambient temperature in operation 32 to 104 °F

Motor shaft Stainless steel, 7/16" HEX, thread M12 x 1

Anti-static version Yes (< 10⁶ Ω)

Tube wall thickness ø 1.9": 0.065"

Tube material Zinc-plated steel, stainless steel

Tube sleeving PVC sleeve 0.08"PU sleeve 0.063", 0.125"

Maximum static load capacityThe maximum load capacity of the RollerDrive EC5000 depends on the drive head and the length of the RollerDrive.

Length of RollerDrive ≤ 39" 43" 47" 51" 55" 59"

Maximum load capacity per RollerDrive withoutdrive head

242 lbs 203 lbs 165 lbs 143 lbs 121 lbs 104 lbs

Maximum load capacity per RollerDrive with drivehead (PolyVee, round or toothed belt)

76 lbs

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© 06 | 2020 Interroll12

Design versions

20 W

Gear ratio Max. conveyingspeed[fpm]

Min. conveyingspeed[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blockingtorque[in-lbs]

9:1 382 18 2.2 5.5 5.5

13:1 264 12 3.18 8.0 8.0

18:1 190 8 4.4 11.1 11.1

21:1 163 8 5.2 13.0 13.0

30:1 114 6 7.5 18.8 18.8

42:1 82 4 10.4 26.1 26.1

49:1 70 4 12.1 30.4 30.4

78:1 42 2 17.8 48.0 48.0

108:1 32 2 24.9 67.0 67.0

35 W






9:1 382 18 3.89 9.8 9.8

13:1 264 12 5.6 14.1 14.1

18:1 190 8 7.8 19.6 19.6

21:1 163 8 9.2 22.9 22.9

30:1 114 6 13.1 33.1 33.1

42:1 82 4 18.3 45.8 45.8

49:1 70 4 21.4 53.4 53.4

78:1 42 2 31.4 84.4 84.4

108:1 32 2 43.8 115.0 115.0

24V

48V

20W

35W

50W

AI

BI



13© 06 | 2020 Interroll

50 W






9:1 382 18 5.5 13.98 13.98

13:1 264 12 8.0 20.2 20.2

18:1 190 8 11.2 28.0 28.0

21:1 163 8 13.0 32.7 32.7

30:1 114 6 18.8 47.2 47.2

42:1 82 4 26.1 65.4 65.4

49:1 70 4 30.5 76.3 76.3

78:1 42 2 44.8 115.0 115.0

108:1 32 2 62.5 115.0 115.0

Before the run-in, the values may differ up to ±20 %. After a run-in phase, the values vary only in the range of ±10 % for 95 % of allRollerDrive used.

Dimensions

The minimum reference length depends on the gear box variant, the grooves in the tube and the drive or the bearing assembly. Asufficient axial play is already taken into account, so that the actual clear width between side profiles is required.When using the tapered hexagon spring shaft, it must be ensured that the design of the axial play is not too high. If the RollerDriveselected is too short, the shaft may have play in the hexagon hole. A hexagon hole with a size of at least 0.44" is recommended. If theRollerDrive is installed obliquely, the fastening hole must be designed larger accordingly.

RL = Reference length/ordering lengthEL = Installation length

5/16"-18 or M8 female thread, without grooves

RL

EL=RL+0.35"

0.2"0.52" 19.69" 0.16"

Ø 1

.9"

x 0

.065"

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© 06 | 2020 Interroll14

Hexagon spring shaft, without grooves

0.18" 0.61"

RL

EL=RL+0.38"

0.2"0.52" 19.69"

Ø 1

.9"

x 0

.065"

5/16"-18 or M8 female thread, with grooves

RL

EL=RL+0.35"

0.2"0.52" 19.69" 0.16"

D

C

Ø 1

.50"

Ø 1

.9"

x 0

.065"

Hexagon spring shaft, with grooves

0.18"

0.61" D

C

RL

EL=RL+0.38"

0.2"0.52" 19.69"

Ø 1

.50"

Ø 1

.9"

x 0

.065"

PolyVee drive head with M8 female thread

RL

EL=RL+1.39"

0.2" 1.19"

Ø 1

.69"

Ø 1

.9"

x 0

.065"

0.52" 19.69"

24V

48V

20W

35W

50W

AI

BI



15© 06 | 2020 Interroll

PolyVee drive head with 7/16" hexagon spring shaft

EL=RL+1.41"

RL

0.2"

Ø 1

.9"

x 0

.065"

0.52" 19.69" 1.21"

Ø 1

.69"

0.56"

Round belt drive head with M8 female thread

RL

EL=RL+1.39"

0.2" 1.19"

Ø 1

.49"

Ø 1

.9"

x 0

.065"

0.52" 19.69"

Round belt drive head with 7/16" hexagon spring shaft

Ø 1

.9"

x 0

.065"

EL=RL+1.41"

RL

0.2"0.52" 19.69" 1.21" 0.53"

Ø 1

.49"

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ROLLERDRIVESERIES EC5000Based on ø 1.9", tapered, IP54, for 32 to 104 °F

16 © 06 | 2020 Interroll

Application areaDrive for unit handling conveyorsystems, such as transportingcardboard cartons, containers,platens or tires at normal ambienttemperature. Suitable for roller/belt curves as well as constantlydriven or zero pressureaccumulation conveyor technology.

Compact designThe drive integrated in the tube allows a very compact design of the curve.


Robust designIn contrast to conventional designs, the tapered elements (gray and black) are secured againstaxial shifting. This safeguard prevents the tapered elements from shifting on the tube, similar tothe matching conveyor rollers.

Flexible possible applicationsRollerDrive is available in many variations, allowing it to be used in all types of differentconveyor systems. For the user, this translates into a single interface instead of many. Dependingon the application area, PolyVee or round belts can be used for the transmission of force. Ninegear ratios allow selecting the perfect pairing between speed and torque.



24V

48V

20W

35W

50W

AI

BI


Based on ø 1.9", tapered, IP54, for 32 to 104 °F

17© 06 | 2020 Interroll

Technical data

Rated voltage 24 V 24 V 24 V 48 V 48 V 48 V

Power 20 W 35 W 50 W 20 W 35 W 50 W

Rated current 1.4 A 2.4 A 3.4 A 0.7 A 1.2 A 1.7 A

Starting current 3.0 A 5.5 A 7.5 A 1.5 A 2.8 A 3.8 A






104 lbs

Max. load capacity per RollerDrive with drive head(PolyVee or round belt)

76 lbs


Anti-static version No

Tube wall thickness 0.065"


Tapered cones 1.8° in black (not antistatic)

Design versions

20 W






9:1 382 18 2.2 5.5 5.5

13:1 264 12 3.18 8.0 8.0

18:1 190 8 4.4 11.1 11.1

21:1 163 8 5.2 13.0 13.0

30:1 114 6 7.5 18.8 18.8

42:1 82 4 10.4 26.1 26.1

49:1 70 4 12.1 30.4 30.4

78:1 42 2 17.8 48.0 48.0

108:1 32 2 24.9 67.0 67.0

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© 06 | 2020 Interroll18

35 W






9:1 382 18 3.89 9.8 9.8

13:1 264 12 5.6 14.1 14.1

18:1 190 8 7.8 19.6 19.6

21:1 163 8 9.2 22.9 22.9

30:1 114 6 13.1 33.1 33.1

42:1 82 4 18.3 45.8 45.8

49:1 70 4 21.4 53.4 53.4

78:1 42 2 31.4 84.4 84.4

108:1 32 2 43.8 115.0 115.0

50 W






9:1 382 18 5.5 13.98 13.98

13:1 264 12 8.0 20.2 20.2

18:1 190 8 11.2 28.0 28.0

21:1 163 8 13.0 32.7 32.7

30:1 114 6 18.8 47.2 47.2

42:1 82 4 26.1 65.4 65.4

49:1 70 4 30.5 76.3 76.3

78:1 42 2 44.8 115.0 115.0

108:1 32 2 62.5 115.0 115.0


24V

48V

20W

35W

50W

AI

BI



19© 06 | 2020 Interroll

Dimensions

The minimum reference length depends on the gear box variant, the grooves in the tube and the drive or the bearing assembly. Asufficient axial play is already taken into account, so that the actual clear width between side profiles is required.When using the tapered hexagon spring shaft, it must be ensured that the design of the axial play is not too high. If the RollerDriveselected is too short, the shaft may have play in the hexagon hole. A hexagon hole with a size of at least 0.44" is recommended. If theRollerDrive is installed obliquely, the fastening hole must be designed larger accordingly.

RL = Reference lengthEL = Installation lengthU = Usable tube length: Length of tapered elements

Reference lengths with tapered elements

Conicity: 1.8°, color: black (not antistatic)

Tapered rated length[inch]

Min. Ø[inch]

Max. Ø[inch]

11.85 2.30 3.05

13.62 2.19 3.05

15.61 2.07 3.05

15.80 2.30 3.30

17.57 2.19 3.30

19.56 2.07 3.30

19.75 2.30 3.56

21.53 2.19 3.56

23.51 2.07 3.56

23.70 2.30 3.81

25.48 2.19 3.81

27.46 2.07 3.81

27.66 2.30 4.06

29.43 2.19 4.06

31.41 2.07 4.06

31.61 2.30 4.32

33.38 2.19 4.32

35.36 2.07 4.32

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© 06 | 2020 Interroll20

Hexagon spring shaft, without grooves

0.52"19.69" 0.2" 0.61"0.18"

RL

U

EL=RL+0.38"

Ø 1

.9"X

0.0

65"

5/16"-18 or M8 female thread, with grooves

0.52"19.69" 0.2" D

C

0.16"

RL

U

EL=RL+0.35"

Ø 1

.50"

Ø 1

.9X0.0

65


0.52"19.69" 0.2" 1.19"

RL

U

EL=RL+1.39"

Ø1.6

9"

Ø 1

.9"X

0.0

65"

24V

48V

20W

35W

50W

AI

BI



21© 06 | 2020 Interroll

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ROLLERDRIVESERIES EC5000ø 1.9", cylindrical, IP54, for –22 to 32 °F

22 © 06 | 2020 Interroll

Application areaDrive for unit handling conveyorsystems, such as transportingcardboard cartons, containers orplatens in deep freeze conditions.Suitable for straight conveyors andespecially zero-pressureaccumulation conveyors. Alsousable in shuttle systems, aligningconveyor segments or transfers toother "conveyor system branches".



Flexible possible applicationsRollerDrive is available in many variations, allowing it to be used in all types of differentconveyor systems. For the user, this translates into a single interface instead of many. Dependingon the application area, PolyVee, round or toothed belts can be used for the transmission offorce. Nine gear ratios allow selecting the perfect pairing between speed and torque. Theelectronic holding brake (Zero-Motion-Hold) holds conveying goods in position, even on gravityconveyors.



24V

48V

20W

35W

50W

AI

BI


ø 1.9", cylindrical, IP54, for –22 to 32 °F

23© 06 | 2020 Interroll

Technical data

Rated voltage 24 V 24 V 48 V 48 V

Power 35 W 50 W 35 W 50 W

Rated current 2.2 A 3.4 A 1.1 A 1.7 A

Starting current 5.5 A 7.5 A 2.8 A 3.8 A




Ambient temperature in operation –22 to 32 °F





Tube sleeving PVC sleeve 0.08"PU sleeve 0.063", 0.125"






76 lbs

Design versions

35 W






30:1 114 6 13.1 33.1 33.1

42:1 82 4 18.3 45.8 45.8

49:1 70 4 21.4 53.4 53.4

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ROLLERDRIVESERIES EC5000ø 1.9", cylindrical, IP54, for –22 to 32 °F

© 06 | 2020 Interroll24

50 W






13:1 264 12 8.0 20.2 20.2

18:1 190 8 11.2 28.0 28.0

21:1 163 8 13.0 32.7 32.7

30:1 114 6 18.8 47.2 47.2

42:1 82 4 26.1 65.4 65.4

49:1 70 4 30.5 76.3 76.3

78:1 42 2 44.8 115.0 115.0

108:1 32 2 62.5 115.0 115.0


Dimensions

The minimum reference length depends on the gear box variant, the grooves in the tube and the drive or the bearing assembly. Asufficient axial play is already taken into account, so that the actual clear width between side profiles is required. A hexagon hole witha size of at least 0.44" is recommended. If the RollerDrive is installed obliquely, the fastening hole must be designed largeraccordingly.

RL = Reference length/ordering lengthEL = Installation length

M8 female thread, without grooves

RL

EL=RL+0.35"

0.2"0.52" 19.69" 0.16"

Ø 1

.9"

x 0

.065"

24V

48V

20W

35W

50W

AI

BI


ø 1.9", cylindrical, IP54, for –22 to 32 °F

25© 06 | 2020 Interroll

M8 female thread, with grooves

RL

EL=RL+0.35"

0.2"0.52" 19.69" 0.16"

D

C

Ø 1

.50"

Ø 1

.9"

x 0

.065"


RL

EL=RL+1.39"

0.2" 1.19"

Ø 1

.69"

Ø 1

.9"

x 0

.065"

0.52" 19.69"

PolyVee drive head with 7/16" hexagon spring shaft

EL=RL+1.41"

RL

0.2"

Ø 1

.9"

x 0

.065"

0.52" 19.69" 1.21"

Ø 1

.69"

0.56"

Round belt drive head with M8 female thread

RL

EL=RL+1.39"

0.2" 1.19"

Ø 1

.49

Ø 1

.9"

x 0

.065"

0.52" 19.69"

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26 © 06 | 2020 Interroll

Application areaDrive for unit handling conveyorsystems, such as transportingcardboard cartons, containers,platens, (truck) tires or lightweightpallets at normal ambienttemperature. Suitable for straightconveyors, small belt conveyorsand especially zero-pressureaccumulation conveyors. Alsousable in aligning conveyorsegments or transfers or other"conveyor system branches".



Flexible possible applicationsRollerDrive is available in many variations, allowing it to be used in all types of differentconveyor systems. For the user, this translates into a single interface instead of many. Nine gearratios allow selecting the perfect pairing between speed and torque. The electronic holdingbrake (Zero-Motion-Hold) holds conveying goods in position, even on gravity conveyors.



24V

48V

20W

35W

50W

AI

BI



27© 06 | 2020 Interroll

Technical data

Rated voltage 24 V 48 V

Power 50 W 50 W

Rated current 3.4 A 1.7 A

Starting current 7.5 A 3.8 A





Max. load capacity per RollerDrive with PolyVeedrive head

123 lbs



Tube wall thickness 0.079"


Tube sleeving PVC sleeve 0.079"Lagging 0.079"

Design versions

50 W






9:1 474 23 5.5 13.9 13.9

13:1 328 18 8.0 20.2 20.2

18:1 236 12 11.2 28.0 28.0

21:1 202 10 13.0 32.7 32.7

30:1 141 6 18.8 47.2 47.2

42:1 102 6 26.1 65.4 65.4

49:1 86 6 30.5 76.3 76.3

78:1 55 2 44.8 115.0 115.0

108:1 39 2 62.5 115.0 115.0


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© 06 | 2020 Interroll28

Dimensions

RL = Reference length/ordering lengthEL = Installation length, clear width between side profiles

The minimum reference length depends on the gear box variant and the drive or the bearing assembly. A sufficient axial play isalready taken into account, so that the actual clear width between side profiles is required. A hexagon hole with a size of at least0.44" is recommended. If the RollerDrive is installed obliquely, the fastening hole must be designed larger accordingly.

Note: This model is available in metric sizes only (millimeters) as shown below.

PolyVee drive head with female thread

EL=RL+36

RL

5 3113.1 500

Ø 6

0x2

Ø 4

3

24V

48V

20W

35W

50W

AI

BI



29© 06 | 2020 Interroll

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30 © 06 | 2020 Interroll

Application areaDrive for unit handling conveyorsystems, such as transportingcardboard cartons, containers orplatens at normal ambienttemperature. Suitable for straightconveyors and especially zero-pressure accumulation conveyors.Often used at locations forcleaning with water jets due to thehigh protection rating.



Flexible possible applicationsRollerDrive is available in many variations, allowing it to be used in all types of differentconveyor systems. For the user, this translates into a single interface instead of many. Dependingon the application area, PolyVee or round belts can be used for the transmission of force. Themany gear ratios allow selecting the perfect pairing between speed and torque.



24V

48V

20W

35W

50W

AI

BI



31© 06 | 2020 Interroll

Technical data

Rated voltage 24 V 24 V 48 V 48 V

Power 35 W 50 W 35 W 50 W

Rated current 2.4 A 3.4 A 1.2 A 1.7 A

Starting current 5.5 A 7.5 A 2.8 A 3.8 A








Tube material Stainless steel

Tube sleeving PVC sleeve 0.08", 0.19"PU sleeve 0.08"

Lagging 0.08" to 0.19"






76 lbs

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© 06 | 2020 Interroll32

Design versions

35 W






18:1 196 8 7.8 19.6 19.6

21:1 169 8 9.2 22.9 22.9

30:1 118 6 13.1 33.1 33.1

42:1 84 4 18.3 45.8 45.8

49:1 72 4 21.4 53.4 53.4

78:1 45 2 31.4 84.4 84.4

108:1 33 2 43.8 115.0 115.0

50 W






18:1 196 8 11.2 28.0 28.0

21:1 169 8 13.0 32.7 32.7

30:1 118 6 18.8 47.2 47.2

42:1 84 4 26.1 65.4 65.4

49:1 72 4 30.5 76.3 76.3

78:1 45 2 44.8 115.0 115.0

108:1 33 2 62.5 115.0 115.0


24V

48V

20W

35W

50W

AI

BI



33© 06 | 2020 Interroll

Dimensions

The minimum reference length depends on the gear box variant, the grooves in the tube and the drive or the bearing assembly. Asufficient axial play is already taken into account, so that the actual clear width between side profiles is required. A hexagon hole witha size of at least 0.44" is recommended. If the RollerDrive is installed obliquely, the fastening hole must be designed largeraccordingly.

RL = Reference length/ordering lengthEL = Installation length, clear width between side profiles

The female thread solution for the IP66 designs consists of a shaft bolt using a floating bearing. Ball bearings are not used.

Note: This model is available in metric sizes only (millimeters) as shown below.

Female thread, without grooves

13.3 500 4 10

RL

EL=RL+14

Ø 5

0x1.5

Female thread, with grooves

13.3 500 104

RL

EL=RL+14

D

C

Ø 5

0x1.5

Ø 3

8.4

PolyVee drive head with female thread

13.3 500 4 31

RL

EL=RL+35

Ø 5

0x1.5

Ø 4

3

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CONTROLSDRIVECONTROL 20For EC5000, 24 V20 W, 35 W, with analog interface

34 © 06 | 2020 Interroll

Application areaControl of RollerDrive EC5000 inapplications without start-stopoperation, e.g. in roller curves.Mechanical engineeringapplications. Applications with PLC,but without fieldbus. Smallapplications with max. tenRollerDrive.

Product descriptionThe DriveControl 20 is a simple control for the RollerDrive EC5000. It does not contain any logic(e.g. for zero-pressure accumulation conveying) and requires external signals.

DIP switches can be used to set the direction of rotation, a start and braking ramp and the speedin 15 increments. Digital inputs and outputs serve as interface to a higher-level control. Signalsallow adjusting the direction of rotation and the speed in seven increments. The braking energyof the RollerDrive EC5000 is fed back into the DC supply system. The voltage fed back from theRollerDrive EC5000 is limited at 30 V by means of the integral brake chopper (voltage-dependently switched load resistance).

Functions· Speed setting (DIP switches 15x, digital input 7x)· Selection of direction of rotation (via DIP switches or digital input)· Error signal output· Status display with LEDs· Voltage limitation via brake chopper

24V

48V

20W

35W

50W

AI

BI

CONTROLSDRIVECONTROL 20

For EC5000, 24 V20 W, 35 W, with analog interface

35© 06 | 2020 Interroll

Technical data

Electrical data

Rated voltage 24 V DC

Voltage range 19 to 26 V DC

Current consumption DriveControl: approx. 0.5 A + current of RollerDrive EC5000*

Fuse Present, non-replaceable

Protection rate IP20

Ambient conditions


Ambient temperature during transportand storage

–40 to 176 °F

Max. installation height above sea level 3280 ft (at higher altitudes, a reduction of performance values is possible)

Cable cross-sections

Power supply Fine-wired, 1.5 mm² (AWG 16)

Inputs/outputs (I/O) Fine-wired, 0.08 to 0.5 mm² (AWG 28 to 20)

* The power of EC5000 depends on the application, e.g., conveying good weight, conveying speed, acceleration ramp, and on the EC5000 used (refer to thecorresponding chapter).

Dimensions

4.65“ 0.24“

5.12“

1.6

5“

(0.2

6“)

4.25“(0.24“)

(0.2

6“)

Ø 0.24“

0.1“

0.95“

2.1

7“

Accessories

· RollerDrive EC5000 extension cable, page 62· Switching power supply HP5424, page 52

Ordering information

· Article number: S-1001415· Scope of supply: 2 plugs for voltage supply, 1 plug for inputs and outputs, polymer tool for cabling

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CONTROLSDRIVECONTROL 54For EC5000 24 V20 W, 35 W, with analog interface

36 © 06 | 2020 Interroll

Application areaControl of RollerDrive EC5000 inapplications without start-stopoperation, e.g. in roller curves.Mechanical engineeringapplications. Applications with PLC,but without fieldbus. Smallapplications with max. tenRollerDrive. Applications withsplashing water (e.g. Sprinklersystems) or applications in deepfreeze area.

Product descriptionThe DriveControl 54 is a simple control for the RollerDrive EC5000. It does not contain any logic(e.g. for zero-pressure accumulation conveying) and requires external signals. The DriveControl54 has a protection rating of IP54 and, as a result, is suitable for use in wet environments ordeep freeze conditions.

DIP switches can be used to set the direction of rotation, a start and braking ramp and the speedin 15 increments. Digital inputs and outputs serve as interface to a higher-level control. Signalsallow adjusting the direction of rotation and the speed in seven increments. The braking energyof the RollerDrive EC5000 is fed back into the DC supply system. The voltage fed back from theRollerDrive EC5000 is limited at 30 V by means of the integral brake chopper (voltage-dependently switched load resistance).

Functions· Speed setting (DIP switches 15x, digital input 7x)· Selection of direction of rotation (via DIP switches or digital input)· Error signal output· Status display with LEDs· Voltage limitation via brake chopper

24V

48V

20W

35W

50W

AI

BI


For EC5000 24 V20 W, 35 W, with analog interface

37© 06 | 2020 Interroll

Technical data

Electrical data






Ambient conditions



–40 to 176 °F






Dimensions

Ø 0

.18“

0.3

1“

4.72“

(0.3

1“)

2.1

2“

0.31“

(0.31“)4.09“

2.7

5“

1.06“

Accessories



Article number: S-1001416

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CONTROLSDRIVECONTROL 2048For EC5000 24 V, 48 V20 W, 35 W, 50 W, with analog interface

38 © 06 | 2020 Interroll

Application areaControl of RollerDrive EC5000 inapplications without start-stopoperation, e.g. in roller curves.Mechanical engineeringapplications. Applications with PLC,but without fieldbus. Smallapplications with max. tenRollerDrive.

Product descriptionThe DriveControl 2048 is a simple control for the RollerDrive EC5000. It does not contain anylogic (e.g. for zero-pressure accumulation conveying) and requires external signals.

2 rotary coding switches can be used to set the direction of rotation, 8 different start andbraking ramps and the speed in 15 increments. Digital inputs and outputs serve as interface to ahigher-level control. Signals allow adjusting the direction of rotation and the speed in sevenincrements. The braking energy of the RollerDrive EC5000 is fed back into the DC supply system.The voltage fed back from the RollerDrive EC5000 is limited at 30 V by means of the integralbrake chopper (voltage-dependently switched load resistance).

Functions· Speed setting (rotary coding switch 15x, digital input 7x)· Selection of direction of rotation (via rotary coding switch or digital input)· Adjustment of acceleration and braking ramp (rotary coding switch 8x)· Status display with LEDs· Voltage limitation via brake chopper

24V

48V

20W

35W

50W

AI

BI


For EC5000 24 V, 48 V20 W, 35 W, 50 W, with analog interface

39© 06 | 2020 Interroll

Technical data

Electrical data

Rated voltage 24 or 48 V DC

Voltage range 24 V DC: 19 to 28 V DC 48 V DC: 38 to 56 V DC




Ambient conditions



–40 to 176 °F






Dimensions

Ø0.24

“

0.24“

5.12“

(0.26“)

4.25“

1.65“

4.65“

0.1“

0.95“

2.17“

(0.24“)

(0.26“)

Accessories

· RollerDrive EC5000 extension cable, page 62· Switching power supply HP5424, page 52· Switching power supply HP5448, page 56

Ordering information· Article number: S-1113898· Scope of supply: 2 plugs for voltage supply, 1 plug for inputs and outputs, polymer tool for cabling

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CONTROLSZONECONTROLFor EC5000 24 V20 W, 35 W, with analog interface

40 © 06 | 2020 Interroll

Application areaZero-pressure accumulation (ZPA)conveying for systems with mediumto high number of conveyor zones.Applications with or without PLC,but without fieldbus.

Product descriptionThe ZoneControl is a single-zone control for a RollerDrive EC5000 and a zone sensor. TheZoneControl can be used to create stand-alone, zero-pressure accumulation conveyors whichrequire no higher-level control (PLC). Additional functions and communication to upstream anddownstream conveyors can be implemented via digital inputs and outputs (I/Os).

The advantage is that the ZPA logic is contained in the ZoneControl and does not have to beprogrammed within a PLC. DIP switches can be used to set the RollerDrive speed and direction ofrotation as well as the logic (single or train release). For all ZoneControl connected with eachother, the speed can also be changed with an analog signal and a cumulative error signal canbe read out.

The wiring of the voltage supply is done via switching wire and communication using commercialCAT5 patch cables (Ethernet cable). The ZoneControl is only partially suited when a tracking ofconveying goods or the control of the RollerDrive with start and brake ramps is being plannedor a large number of additional functions is to be used.

The ZoneControl shows its strength in the fact that it does not have to be addressed, whichmakes an exchange in case of a failure extremely easy, and it can easily be configured with DIPswitches.

24V

48V

20W

35W

50W

AI

BI

CONTROLSZONECONTROL


41© 06 | 2020 Interroll

Functions

· Logic for zero-pressure accumulation conveying incl. initialization· Communication with upstream and downstream zones via peer-to-peer connection· Speed setting in 8 increments via DIP switches or analog signal· Direction of rotation setting via DIP switches or external digital signal· Connection of a zone sensor· Connection of a start sensor for the start of the conveyor line· Determination of NPN or PNP switching logic· Switching a second RollerDrive into the zone· Additional functions: Running the conveyor empty, error signaling of all connected zones, external start or stop signal· Voltage limitation via brake chopper

Technical data

Electrical data



Current consumption ZoneControl with sensor: approx. 0.5 A + current of RollerDrive EC5000*



Ambient conditions



–40 to 176 °F






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CONTROLSZONECONTROLFor EC5000 24 V20 W, 35 W, with analog interface

© 06 | 2020 Interroll42

Dimensions

4.65“ 0.24“

5.12“

1.6

5“

(0.2

6“)

4.25“

(0.24“)

(0.2

6“)

0.1“

0.95“

2.1

7“

Ø 0.24“

Accessories



· Article number: S-1101459· Scope of supply: Plug for voltage supply, plug for inputs and outputs, one plug each for start and zone sensor, polymer tool for

cabling

24V

48V

20W

35W

50W

AI

BI

CONTROLSZONECONTROL


43© 06 | 2020 Interroll

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CONTROLSMULTICONTROL AIFor EC5000 24 V, 48 V20 W, 35 W, 50 W with analog interface

44 © 06 | 2020 Interroll

Application areaZero-pressure accumulationconveying (ZPA) for systems withmedium to high number ofconveyor zones. Control of theInterroll Transfer and HighPerformance Divert as well asInterroll Pallet Drive (via PalletControl).

Product descriptionThe MultiControl is a four-zone control. This means that up to four RollerDrive EC5000 AI andfour zone sensors can be connected. The use of Y-cables enables connecting four additionalinputs or outputs. The connections can be configured individually.

MultiControl is multi-protocol-capable. PROFINET, EtherNet/IP and EtherCat can be used viasimple switching.

With help of the MultiControl, sensors and RollerDrive are directly integrated into the field buslevel. An additional sensor/actuator level and, as a result, additional communication lines or agateway become redundant. A standard flat cable is used for power supply. They can simply becut to the desired length and can be connected very quickly using the piercing technology ofMultiControl.

The separate voltage supply allows a safe power-off of the RollerDrive while the buscommunication and sensors can continue to be used.

Addressing and naming is done over PLC software, a web user interface, or with the Interrollteach-In method. With the Teach-In method, automatic addressing and configuration of allMultiControl is possible. In addition, the sequence of all MultiControls in the conveyor line can bedetermined. This saves time during the commissioning on site.

24V

48V

20W

35W

50W

AI

BI

CONTROLSMULTICONTROL AIFor EC5000 24 V, 48 V

20 W, 35 W, 50 W with analog interface

45© 06 | 2020 Interroll

Functions

· Easy handling – One control card for PROFINET, EtherNet/IP and EtherCat (simple toggling of bus protocols)· Independent power supply for RollerDrive· Plug & Play in case of replacements – no addressing or configuration required· Status display with LEDs for all functions and I/Os· Integrated logic for zero-pressure accumulation conveying incl. initialization· Secure communication with the use of certificates: PROFINET Conformance Class B, EtherNet/IP ODVA Conformance, EtherCat

Conformance· Configuration via PLC, web browser menu and via teach-In method of:

– Speed, direction of rotation, start and stop ramp of RollerDrive– Sensor properties– Timer– Error handling– Logic (single/train release)

· UL-listed· Voltage limitation via brake chopper· Variable process images for optimizing the data volumes transferred between MultiControl and PLC· Functional ground connection for shield of communication line· Polarity reversal protection of voltage supply· Short circuit-proof design of voltage supply of inputs and outputs

Possible applications

Use of a PLC Function of a PLC Function of MultiControl

No • None • Implementation of ZPA logic

Yes • Influencing the ZPA logic• Tracking of conveying goods• Error diagnostics

• Implementation of ZPA logic• Implementation of PLC specifications

Yes • The PLC must be programmed and controls all connectedRollerDrive via this program

• Tracking of conveying goods and error diagnostics

• Function as input/output card• Transmits the status of all sensors, RollerDrive and, if

necessary, error information to the PLC

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CONTROLSMULTICONTROL AIFor EC5000 24 V, 48 V20 W, 35 W, 50 W with analog interface

© 06 | 2020 Interroll46

Technical data

Electrical data


Voltage range 24 V DC: 22 to 28 V DC 48 V DC: 44 to 56 V DC (voltage supply of RollerDrive only)

Current consumption Logic supply voltage:MultiControl: max. 0.2 A + connected sensors/actuators = max. 1.6 A+ current of RollerDrive EC5000*

Fuses – For logic– For RollerDrive– For sensors and I/Os, can be reset


Ambient conditions



–40 to 176 °F

Max. installation height above sea level 3280 ft**


** The installation in systems at an altitude above 3280 ft is possible. However, this can lead to a reduction of the performance values.

Dimensions

MultiControl

0.45“1.69“ 0.45“

2.76“

7.28“

8.35“

24V

48V

20W

35W

50W

AI

BI

CONTROLSMULTICONTROL AIFor EC5000 24 V, 48 V

20 W, 35 W, 50 W with analog interface

47© 06 | 2020 Interroll

Base plate

2.36“

3.54“0.59“ 0.59“

5.95“

6.42“

1.0

2“

1.28“1.28“

Ø 0

.26“

Ø 0

.26“

Ø 0

.26“

0.26“

0.1

6“

2.7

6“

0.2

6“

To be able to position the magnetic key, the distance from the top edge of MultiControl to adjacent components must be at least 0.4".

Accessories

· Flat cable for voltage supply, page 62· Magnetic key, page 65· MultiControl dummy plug, page 64· RollerDrive EC5000 extension cable, page 62· MultiControl communication cable, page 63· MultiControl Y-cable, page 63· Switching power supply HP5424, page 52· Switching power supply HP5448, page 56· Cable distribution, page 63· Shield connection cable, page 64


· Article number: S-1103563· Scope of supply: Base plate

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CONTROLSMULTICONTROL BIFor EC5000 24 V, 48 V20 W, 35 W, 50 W, with bus interface (CANopen)

48 © 06 | 2020 Interroll

Application areaZero-pressure accumulationconveying (ZPA) for systems withmedium to high number ofconveyor zones. Control of theInterroll Transfer and HighPerformance Divert as well asInterroll Pallet Drive (via PalletControl). Control of RollerDriveEC5000 BI in applications withpositioning demand.

Product descriptionThe MultiControl is a four-zone control. This means that up to four RollerDrive EC5000 BI andfour zone sensors can be connected. The use of Y-cables enables connecting four additionalinputs or outputs. The connections can be configured individually.

MultiControl is multi-protocol-capable. PROFINET, EtherNet/IP and EtherCat can be used viasimple switching.

With help of the MultiControl, sensors and RollerDrive are directly integrated into the field buslevel. An additional sensor/actuator level and, as a result, additional communication lines or agateway become redundant. A standard flat cable is used for power supply. They can simply becut to the desired length and can be connected very quickly using the piercing technology ofMultiControl.

The separate voltage supply allows a safe power-off of the RollerDrive while the buscommunication and sensors can continue to be used.

Addressing and naming is done over PLC software, a web user interface, or with the Interrollteach-In method. With the Teach-In method, automatic addressing and configuration of allMultiControl is possible. In addition, the sequence of all MultiControls in the conveyor line can bedetermined. This saves time during the commissioning on site.

24V

48V

20W

35W

50W

AI

BI

CONTROLSMULTICONTROL BI

For EC5000 24 V, 48 V20 W, 35 W, 50 W, with bus interface (CANopen)

49© 06 | 2020 Interroll

Functions

· Easy handling – One control card for PROFINET, EtherNet/IP and EtherCat (simple toggling of bus protocols)· Independent power supply for RollerDrive· Plug & Play in case of replacements – no addressing or configuration required· Status display with LEDs for all functions and I/Os· Integrated logic for zero-pressure accumulation conveying incl. initialization· Secure communication with the use of certificates: PROFINET Conformance Class B, EtherNet/IP ODVA Conformance, EtherCat

Conformance· Configuration via PLC, web browser menu and via teach-In method of:

– Speed, direction of rotation, start and stop ramp of RollerDrive– Sensor properties– Timer– Error handling– Logic (single/train release)

· UL-listed· Voltage limitation via brake chopper· Variable process images for optimizing the data volumes transferred between MultiControl and PLC· Functional ground connection for shield of communication line· Polarity reversal protection of voltage supply· Short circuit-proof design of voltage supply of inputs and outputs· Precise error diagnostics of EC5000 – Analysis via web browser menu and PLC· Automatic addressing of all connected EC5000s· Test operation without previous configuration or connection of a PLC· Positioning the connected EC5000 together with a PLC· Analysis of various RollerDrive data via web browser menu and PLC:

– Operating hours– Throughput– Temperature of EC5000– System status indicators– Life cycle indicator (allows preventive maintenance, resulting in increased availability)

Possible applications

Use of a PLC Function of a PLC Function of MultiControl

No • None • Implementation of ZPA logic• Visualization of EC5000 data

Yes • Influencing the ZPA logic• Tracking of conveying goods• Error diagnostics

• Implementation of ZPA logic• Implementation of PLC specifications

Yes • The PLC must be programmed and controls all connectedRollerDrive via this program

• Tracking of conveying goods and error diagnostics• Specification of target position in positioning mode

• Function as input/output card• Transmits the status of all sensors, RollerDrive and, if

necessary, error information to the PLC

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CONTROLSMULTICONTROL BIFor EC5000 24 V, 48 V20 W, 35 W, 50 W, with bus interface (CANopen)

© 06 | 2020 Interroll50

Technical data

Electrical data


Voltage range 24 V DC: 22 to 28 V DC 48 V DC: 44 to 56 V DC (voltage supply of RollerDrive only)

Current consumption Logic supply voltage:MultiControl: max. 0.2 A + connected sensors/actuators = max. 1.6 A+ current of RollerDrive EC5000*

Fuses – For logic– For RollerDrive– For sensors and I/Os, can be reset


Ambient conditions



–40 to 176 °F

Max. installation height above sea level 3280 ft**


** The installation in systems at an altitude above 3280 ft is possible. However, this can lead to a reduction of the performance values.

Dimensions

MultiControl

2.76“

0.45“1.69“ 0.45“7.28“

24V

48V

20W

35W

50W

AI

BI

CONTROLSMULTICONTROL BI

For EC5000 24 V, 48 V20 W, 35 W, 50 W, with bus interface (CANopen)

51© 06 | 2020 Interroll

Base plate

2.36“

3.54“0.59“ 0.59“

5.95“

6.42“

1.0

2“

1.28“1.28“

Ø 0

.26“

Ø 0

.26“

Ø 0

.26“

0.26“

0.1

6“

2.7

6“

0.2

6“

To be able to position the magnetic key, the distance from the top edge of MultiControl to adjacent components must be at least 0.4".

Accessories

· Flat cable for voltage supply, page 62· Magnetic key, page 65· MultiControl dummy plug, page 64· RollerDrive EC5000 extension cable, page 62· MultiControl communication cable, page 63· MultiControl Y-cable, page 63· Switching power supply HP5424, page 52· Switching power supply HP5448, page 56· Cable distribution, page 63· Shield connection cable, page 64


· Article number: S-1103564· Scope of supply: Base plate

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SWITCHING POWER SUPPLIESSWITCHING POWER SUPPLY HP5424

52 © 06 | 2020 Interroll

Application areaVoltage supply of MultiControl orConveyorControl system via flatcable. Voltage supply ofDriveControl or ZoneControl viaround cable. Basic voltage supplyof 24-V DC products.

Product descriptionThe Interroll switching power supply HP5424 is a three-phase power supply for providing 24-VDC voltage. The robust housing achieves a protection rating of IP54. This allows placement in theimmediate vicinity of the products to be supplied with 24 V DC, such as Interroll MultiControl.The central voltage supply saves costs for control cabinets and allows very short lines which, inturn, lead to cost savings and error reduction with respect to voltage drops on the line.

The HP5424 is immediately operational, all required functions, such as circuit protection ormaintenance switches, are already present. Given its high level of overload capability, the powersupply is perfectly adjusted to the current requirements of the RollerDrive EC5000. This ensuresthe power supply of several RollerDrive starting at the same time.

Properties· No installation in switch cabinet required· Compact design using heat dissipation element· Very high peak output (150 %)· Adjustable circuit protection (jumper)· Overcurrent protection with resettable fuse· Status signal· LED status display· 400 V AC can be looped through· 4 24-V DC outputs are available· Multiple terminal points, no special and expensive connectors required· Brake chopper for limiting feedback voltage – resulting in feedback capability· Lockable maintenance switch against reactivation· Screw for connecting/disconnecting ground potential of primary side with ground of

secondary side· Maintenance-free· No power reduction (derating) over the entire operating temperature range

24V

48V

20W

35W

50W

AI

BI


53© 06 | 2020 Interroll

Technical data

Electrical data

Rated supply voltage 400 V AC, 3 phases

Supply system voltage range 380 to 480 V AC ± 10 %

Supply system frequency 50 to 60 Hz ± 6 %

Supply system power consumption Typically 1.6 A per phase at 3 x 400 V AC

Rated output voltage 24 V DC

Rated output power 960 W

Rated peak power Max. 1440 W at 24 V DC for 4 s, repetition rate depends on duration and actual peak load

Maximum output current 60 A at 24 V DC for 4 s

Current limitation for each output 10, 16, 25 A

Efficiency Min. 92 %

Feedback resistance ≤ 35 V DC

Brake chopper 30 W (briefly 200 W)

Ambient conditions




–40 to 176 °F

Max. installation height above sea level 3280 ft*

Miscellaneous data

Weight 9 lbs

Color RAL9005 (black)

* The installation in systems at an altitude above 3280 ft is possible. However, this can lead to a reduction of the performance values.

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© 06 | 2020 Interroll54

Dimensions

8.23“

SW29

SW15

SW24

6.3“

10“

10.95“

12.17“

1.84“

1.97“

5.51“

9.06“

Ø0.4“

1.4“

1.16“

1.68“

Accessories

Set of rubber seals for all cable screw connections

· 24-V DC output for one flat cable, article number: S-1115406· 24-V DC output for two flat cables, article number: S-1115407· 24-V DC output for a round cable (ø 0.19" up to 0.51”), article number: S-1115405

Scope of delivery

· Fit all cable screw connections (in the screwed-on condition) with dummy plugs. Jumper for current limitation of all cables.

24V

48V

20W

35W

50W

AI

BI


55© 06 | 2020 Interroll

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56 © 06 | 2020 Interroll

Application areaVoltage supply of MultiControl viaflat cable. Voltage supply ofDriveControl via round cable. Basicvoltage supply of 48-V DCproducts.

Product descriptionThe Interroll switching power supply HP5448 is a three-phase power supply for providing 48-VDC voltage. The robust housing achieves a protection rating of IP54. This allows placement in theimmediate vicinity of the products to be supplied with 48 V DC, such as Interroll MultiControl.The central voltage supply saves costs for control cabinets and allows very short lines which, inturn, lead to cost savings and error reduction with respect to voltage drops on the line.

The HP5448 is immediately operational, all required functions, such as circuit protection ormaintenance switches, are already present. Given its high level of overload capability, the powersupply is perfectly adjusted to the current requirements of the RollerDrive EC5000. This ensuresthe power supply of several RollerDrive starting at the same time.

Properties· No installation in switch cabinet required· Compact design using heat dissipation element· Very high peak output (150 %)· Adjustable circuit protection (jumper)· Overcurrent protection with resettable fuse· Status signal· LED status display· 400 V AC can be looped through· 2 48-V DC outputs are available· Multiple terminal points, no special and expensive connectors required· Brake chopper for limiting feedback voltage – resulting in feedback capability· Lockable maintenance switch against reactivation· Screw for connecting/disconnecting ground potential of primary side with ground of

secondary side· Maintenance-free· No power reduction (derating) over the entire operating temperature range

24V

48V

20W

35W

50W

AI

BI


57© 06 | 2020 Interroll

Technical data

Electrical data

Rated supply voltage 400 V AC, 3 phases

Supply system voltage range 380 to 480 V AC ± 10 %

Supply system frequency 50 to 60 Hz ± 6 %

Supply system power consumption Typically 1.6 A per phase at 3 x 400 V AC

Rated output voltage 48 V DC

Rated output power 960 W

Rated peak power Max. 1440 W at 48 V DC for 4 s, repetition rate depends on duration and actual peak load

Maximum output current 30 A at 48 V DC for 4 s

Current limitation for each output 10, 16, 20 A

Efficiency Min. 92 %

Feedback resistance ≤ 60 V DC

Brake chopper 30 W (briefly 200 W)

Ambient conditions




–40 to 176 °F

Max. installation height above sea level 3280 ft*

Miscellaneous data

Weight 9 lbs

Color RAL9005 (black)

* The installation in systems at an altitude above 3280 ft is possible. However, this can lead to a reduction of the performance values.

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© 06 | 2020 Interroll58

Dimensions

Ø0.4“

5.51“

10.9

5“

12.1

7“

6.3

“

9.0

6“

8.23“

1.8

4“

1.9

7“

1.4

“1.1

6“

1.6

8“

SW15

SW24SW29

10“

Accessories

· Set of rubber seals for all cable screw connections– 48-V DC output for one flat cable, article number: S-1115406– 48-V DC output for two flat cables, article number: S-1115407– 48-V DC output for a round cable (ø 0.19" up to 0.51”), article number: S-1115405

Scope of delivery

· Fit all cable screw connections (in the screwed-on condition) with dummy plugs. Jumper for current limitation of all cables.

24V

48V

20W

35W

50W

AI

BI

ACCESSORIES

60 © 06 | 2020 Interroll

PolyVee belt

A PolyVee belt is used for the drive from roller to roller orRollerDrive for straight sections and for curves.

Product description

· Elastic standard belt, 1 to 3 % pretension, for fixed shaftdistances

· Significantly longer service life than round belts· Up to 300 % higher torque transmission than with comparable

round belts· Much better efficiency compared to toothed belts since much

less flexing work is required· Curve application: Use of 2-rib or 3-rib belts· Suitable for normal and freezer temperatures· Belts are antistatic

Technical data

· Temperature range: –22 to 104 °F (in operation)· Color: Black· Belt acc. to Type PJ; ISO 9982; DIN 7867

Design versions

Number of ribs Roller pitches ±0.04" Max. weight of conveyinggood[lbs]

Article number

2 3" 110 S-1001109

3 3" 660 S-1001113

Material specification

Standards ISO 9982 (DIN 7867) PJ profile for 2-rib and 3-rib V-ribbed belts (PolyVee)

Material Complies with the Directive 2011/65/EC (RoHS)Contains only materials, which have been tested and registered to comply with theREACH Directive (EC No. 1907/2006)Halogen-free, silicon-free, PVC-free, flame-resistant

Certification UL-certified

Hardness Ribs 70 Shore A

Electrical conductivity < 7 MΩ (antistatic)

Temperature range –22 to 176 °F (transport and storage)

Dimensions In accordance with ISO 9982 (DIN 7867), profile PJ

Please contact the relevant manufacturer for information on otherdrives.

61© 06 | 2020 Interroll

Fastening socket

The fastening socket is used for tightening according to thetorque of the RollerDrive fastening nut using a torque wrench.The socket features a lateral opening through which theRollerDrive connecting cable can be fed to the outside.


Dimensions

17

12

.7 (

1/2

")

12

14

34

2Ø 23.5

85

3

Note: Measurements in mm.A

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ACCESSORIES

62 © 06 | 2020 Interroll

Counter wrench

The RollerDrive has a glued-on ribbed nut that is located at thebearing housing. An additional nut is used to screw theRollerDrive in the side profile. Depending on the condition of theside profile, the glued-on nut must be secured with a counterwrench while tightening the outside nut.

The counter wrench size 17 WAF fits perfectly between theflange of the ribbed nut and the bearing housing of theRollerDrive.


Dimensions

24.5

12

4

17.5

1.5

A-A ( 1 : 1 )

A

A

Note: Measurements in mm.

RollerDrive EC5000 extension cable

The connecting cable of the EC5000 can be extended easily witha plug connection by using the RollerDrive extension cable.


Technical data

· Temperature range: –22 to 104 °F· Color: Black· Length: 78.7"· Outside diameter: 0.2"· Plug connection: M8 snap-in plug and socket· Protection rate: IP67 in connected state· Cross sections: 3 x 0.14 mm² and 2 x 0.5 mm²· Type designation of the cable: Li9Y11Y· Bending radius with fixed laying: > 5 * diameter of the cable· Bending radius with flexible application: > 10 * diameter of the

cable· Properties: Halogen-free, UL-certified cable· Suitable for drag chains: Yes

Voltage supply flat cable

The flat cable is used for the voltage supply of ConveyorControland MultiControl. The outer contour of the line corresponds tothe standard of AS interface. The shell of the line covers holesthat were created by piercing contacts. This means that the cablemaintains the protection rating even after disconnecting a control.

63© 06 | 2020 Interroll


Technical data

· Temperature range: –18 to 104 °F· Strand insulation: Brown for voltage, blue for ground· Length: 164 ft· Cross section of braids: 2.5 mm²· Maximum voltage: 60 V DC· Protection rate: IP54 in contacted state· UL CL2· Halogen-free

Dimensions

2

4

10

3.6

6.5

9


MultiControl communication cable

The prefabricated Ethernet cable is used for communication withMultiControl. The cable allows connecting one MultiControl withanother MultiControl, another bus node, a switch or a PLC.


Technical data

· Temperature range: –22 to 104 °F· Color: Green· Length: 118"· Outside diameter: 0.26"· Plug connection: M12, straight on M12, straight· Protection rate: IP67 in contacted state· Line: Cat5, shielded· UL1581

MultiControl Y-cable

The Y-cable with M8 plugs enables the use of an additional inputor output at the MultiControl.


Technical data

· Temperature range: –22 to 104 °F· Color: Black· Length: 11.81" (+ plug)· Outside diameter: 0.2"· Plug connection with single connector: M8, straight, screwed, 4-

pin, for connecting to a MultiControl· Plug connection with dual connector: A) M8, straight, screwed,

4-pin, for connecting to a zone sensorB) M8, straight, screwed, 4-pin, for connecting to an input oroutput

· Protection rate: IP67 in contacted state

Cable distribution

The cable distribution allows splitting a flat cable. MultiControl inits initial design (article number S-1101834) allowed connecting asecond flat cable as an option for the voltage supply ofconnected RollerDrive. MultiControl in its new design (articlenumber S-1103563) requires two voltage supplies in principle. Ifthe new design of MultiControl is to be used as spare part in asystem that features only flat cables for voltage supply, the cabledistribution can be used.

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ACCESSORIES

64 © 06 | 2020 Interroll

The cable distribution includes two end caps for left and rightdesign to protect the cable ends and to maintain the systemprotection rating of IP54.


Dimensions

21

10

29.5

4.3

2.7

48.4

18.3 14.5


Shield connection cable

To reduce the risk of interference effects on the communicationline of MultiControl, the shield of the cable can be grounded.Both sides of the MultiControl feature a contact that is connectedwith the shield of the respective communication cable. The shieldconnection cable can be used to connect the contact withfunctional ground or to connect the two contacts of MultiControlwith each other. The shield connection cable is 13" long andfeatures a cable lug at each end. The cable lugs allow connectingthe cable to one or both contacts of the MultiControl. Therequired screws and toothed washers are part of the scope ofdelivery.


MultiControl dummy plug

The MultiControl features 4 RollerDrive, 2 communication and 4sensor or I/O connections. If all connections are occupied, thenthe MultiControl has a protection rating of IP54. Based on theapplication, it is also possible that not all connections areoccupied. If the protection rating of IP54 is to be maintained in

such cases, then it is necessary to close the open connections. Thedummy plug package contains as many plugs as needed if theMultiControl has only the minimum connections.


Dummy plug package

MultiControlconnection

Dummy plugsize

Use Dummy plugsincluded

RollerDrive M8 Insert 3

Sensor or I/O M8 Screws 3

Communication M12 Screws 1

The dummy plugs are delivered prefabricated for the requiredconnections.

Technical data

· Temperature range: –22 to 104 °F· Color: Black

Sealing insert for switching power supplies

The Interroll switching power supplies feature different cablegrommets sealed with dummy plugs. Three different sets ofsealing inserts are available for the line connection. For lineconnection, they ensure maintaining protection rating IP54 andproviding cable relief.

Design versions

Three different sets of sealing inserts are available:

Set 1 Set 2 Set 3

400-VACconnections

2 pieces M25 sealing inserts for round cableø0.31" to 0.67”

Errorconnection

1 piece M12 sealing insert for round cableø0.08" to 0.2”

24/48-VDCconnections

2 pieces M20sealing inserts

for round cableø0.2" to 0.51”

2 pieces M20sealing insertsfor a flat cable

2 pieces M20sealing inserts

for two flatcables

Article number S-1115405 S-1115406 S-1115407

Every power supply is delivered with a matching set. The sets canalso be ordered individually.

65© 06 | 2020 Interroll

Cable bridge for flat cable

The cable bridge allows electrically combining two flat cables andchanging the position of one flat cable. The ends of both flatcables have to point in the same direction.


1 Conveyor2 SegmentControl or ComControl3 Cable bridge4 Obstacle (wall, column or similar)

Technical data

· Temperature range: –22 to 104 °F· Protection rate: IP54· Suitable for the communication cable of the ConveyorControl

system· Suitable for the voltage line of the ConveyorControl system or

the MultiControl: can be loaded up to 6 A

Magnetic key

The magnetic key with a high-quality neodyme magnet offersmany functions. For the MultiControl, it enables switching the busprotocol or the use of the Teach-In method. For theConveyorControl, it enables addressing or, for example,performing a self-test.


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PLANNING BASICSCONVEYING GOOD

66 © 06 | 2020 Interroll

Conveying goodThis chapter is intended to provide support in the planning ofconveyor systems and the selection of matching products.

The properties of the conveying good, the requirements withregards the conveyor system and the ambient conditions are thebasis for the planning of the system.

Length and width of conveying goodThe length and width of the conveying good have an effect onseveral factors:

Straight running: The higher the ratio of length to width, themore stable will be the straight running of your items. Withsmaller length to width ratios, it may be necessary to put in placeadditional measures to stabilize the straight running of theconveying goods.

Reference length: As a rule, the reference length corresponds tothe conveyor width +1.97" or for large conveying goods, such aspallets, +3.94". In curves, Interroll recommends the use oftapered conveyor rollers and RollerDrive whose length must becalculated separately (see Curve dimensioning).

Roller pitch: To transport the conveying good without problems,the roller pitch must be selected so that the conveying good iscarried by three conveyor rollers at any given time.

Surface pressure: The different Interroll conveyor rollers andRollerDrive can be loaded with different forces. The static loadcapacity can be taken from the respective chapter. The valuesare based on the assumption that a conveying good rests on thecomplete usable tube length and not just on a part of it. If aconveying good has contact with less than approx. 50 % of theusable tube length, please have the application checked byInterroll beforehand.

Very long conveying goods generally do not rest on all conveyorrollers and RollerDrive that are located under them. If, forexample, 20 conveyor rollers are under a piece of conveyinggood, but the conveying good contacts only 15 conveyor rollers,then the load capacity of a roller must be greater than one-fifteenth of the conveying good weight. For very long conveyinggoods, the tolerance of the roller fastening height for conveyorrollers and RollerDrive should be kept as low as possible so thatas many conveyor rollers as possible can carry the conveyinggood.

Height of conveying goodThe greater the height of the conveying good in relation to itsbottom area, the higher is the risk of it tipping over whentraveling on the conveyor. The following must be taken intoconsideration:

· Minimize the roller pitch as much as possible to ensure that theproducts are conveyed smoothly with as large a base surfaceas possible.

· Avoid rapid acceleration and harsh braking. Use MultiControlor ConveyorControl as far as possible for controlling EC5000.These control systems allow for purposeful matching ofacceleration and deceleration of the RollerDrive.

· With inclined conveyor tracks, determine the center of gravityof the conveying good and check whether there is a risk of ittipping.

Weight and weight distribution of the conveyinggoodThe weight of the conveying good must be distributed on anumber of conveyor rollers so that the maximum load capacity ofthe individual conveyor roller and RollerDrive is not exceeded.This may mean that more than three conveyor rollers mustsupport the conveying good.

In principle the weight of the conveying good should bedistributed as evenly as possible. The more uneven the weightdistribution is, the more difficult a reliable conveyance is.

If the weight of the goods is mostly at the front, then it is verylikely that the rollers at the end of the load carrier support onlyvery little weight. In the worst case scenario, the rollers at thestart of the load carrier could be overloaded.

The load capacity increases with larger tube diameter. For heavyconveying goods, RollerDrive with a diameter of 2.36" should beused instead. The load capacity is increased by rollers withthreaded shafts. In addition, the shafts reinforce the conveyorand act as a cross tie.

Drive elements, such as round belts or toothed belts, must also beselected while taking the conveying good weight intoconsideration. Interroll recommends PolyVee belts for conveyingcontainers and cardboard cartons. Their service life and torquetransmission is significantly higher compared to round belts.

Material of conveying goodThe material, and especially the condition of the base, has aneffect on the rolling and starting resistance.

Hard materials, such as polymer containers, feature lower rollingand starting resistances than soft materials, such as cardboardcartons. This has a direct impact on the required drive output andmust be included in its calculation. The softer the underside of theconveying good, the higher is the drive output required for aproduct with the same weight but with a hard underside. Inprinciple, the softer the conveying good, the smaller the rollerpitch needs to be.

PLANNING BASICSCONVEYOR REQUIREMENTS

67© 06 | 2020 Interroll

Ribs, keyways, strips or grooves in the bottom of conveying goodsthat run parallel to the direction of conveyance, do not pose aproblem concerning transportability. The required drive outputincreases depending on their shape. Cross ribs can negativelyimpact the transporting. It may be necessary to determine theroller pitch empirically.

When checking whether a roller has sufficient load capacity foran application, it is important to take the condition of theconveying good into consideration. Conveying goods with anuneven bottom generally do not rest on all rollers that arelocated under them. With pallets, it must be ensured that only therollers under the bulk of the pallet are actually bearing the load.The following diagram shows which runner load distributionoccurs for an evenly loaded euro-pallet.

13% 24% 13%

13% 24% 13%

Fig.: Support of 2 runners

8% 12% 8%

8% 12% 8%

20%12% 12%

Fig.: Support of 3 runners

Conveyor requirementsThe following fundamental parameters determine theconfiguration of the conveyor:

· Maximum throughput per time unit· Geometry of conveying good· Weight and weight distribution of the conveying good· Control requirements· Environmental conditions

The topic of environmental conditions is discussed below.

Static chargingIn principle, conveyance via rollers creates electrostatic chargingwhich, among other things, depends on the properties of theconveying good and the tube material.

To prevent electrostatic charging from occurring or dissipate itimmediately and without creating sparks, Interroll offers antistaticversions for rollers with steel tube. RollerDrive feature anantistatic design in principle. Sleeves, lagging and gray taperedelements do not feature an antistatic design. For this reason,Interroll recommends the use of black tapered elements forcurves.

Antistatic conveyor rollers and RollerDrive require the propermanufacturing and check of the conducting connection betweenshaft and side profile and the grounding of the side profile by thesystem manufacturer .

Noise levelNoise is created by different components of a conveyor and theconveying good itself.

Every drive creates noise. The RollerDrive is designed withdecoupling elements which reduce the noise of the gear box. Inmost cases, the noise level of the RollerDrive is below 50 dBA.More and more zero-pressure accumulation conveyor systemsare converted from pneumatic solutions with a centrally arrangeddrive to a RollerDrive solution. The significantly lower noise levelis a deciding factor here.

The following applies to the noises of drive elements: A chaindrive causes more noise than a belt drive. At high accelerationsand decelerations, slipping round belts can cause squealingnoises. Interroll recommends reducing the acceleration anddeceleration of RollerDrive or using PolyVee belts. In this case, therisk of squealing noises is greatly minimized.

Very quiet rollers, RollerDrive and drive elements are of little useif the conveying good on the conveyor creates noise. Variousmeasures can counteract it. The following should be observed inthis case:

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PLANNING BASICSDRIVE CONCEPTS

68 © 06 | 2020 Interroll

· A small roller pitch generally causes less noise than a largeroller pitch.

· Keep height tolerances at transitions from conveyors and at thefastening of rollers/RollerDrive as small as possible.

· Fitting the rollers/RollerDrive with noise-reducing materials, e.g.with a PVC or PU sleeve

· Use of noise reduction inside of rollers for rollers with adiameter of 1.97".

HumidityHumidity can occur in different forms as a result of the following:

· moist conveying goods, e.g. bottle crates stored in the rain· moist environment, e.g. sculleries· applications that become moist, e.g. because of cleaning or

tripped sprinkler systems

If humidity can be expected in a system, then all componentsshould be checked for corresponding resistance.

Interroll offers a series of products that are suitable forapplications with humidity, water exposure, or water jets:

Tube material: Rollers and RollerDrive can be manufacturedfrom rust-free material, such as stainless steel. In addition,materials can be protected with different finishing processes, suchas zinc-plating.

Shaft material: Shafts for conveyor rollers can be manufacturedfrom rust-free material, such as stainless steel.

Drive elements: Some drive elements are better suited for moistapplications. PolyVee belts are much better suited than roundbelts which are guided via grooves in the tube. The round beltscould slip in the groove that is slippery due to moisture.

Drives: The RollerDrive already has a high degree of protectionwith protection rating of IP54. If water jets can be expected in theapplication, Interroll recommends the design with protectionrating IP66.

Bearing: All rollers with precision ball bearings are wellprotected against moisture and dust. For systems with constanthumidity or moisture, Interroll offers designs with stainless steelball bearings.

Applications in deep freeze areaApplications with an ambient temperature of approx. –18 °F areparticularly prevalent in the food processing sector. Many itemsmust be taken into account in the so-called deep freeze area:

· Changed starting torque of conveyor rollers and drives.· Increased viscosity of greases, e.g. in ball bearings or gear

boxes.

· Possibly frozen and, therefore, less flexible components, such asdrive elements.

· Functional safety of all components through differentcontraction of various materials.

The solutions from Interroll

Materials: For various products, Interroll offers variants that areparticularly suited for deep freeze applications. The taperedelements for conveyor rollers and RollerDrive are manufacturedimpact-resistant. Conventional materials used are often brittleand break easily. The bearing housings of series 1700 aredesigned as high impact-resistant for deep freeze applications.

Drives: The RollerDrive EC5000 is available in a deep freezedesign (starting with Series EC5000). The special design with oiledball bearing offers a restart for many gear stages, even afterextended downtime.

Drive elements: Before using a drive element, its suitability fordeep freeze applications should be checked. It should also beensured that the friction at temperatures below zero is sufficientand the drive elements cannot freeze since frozen drive elementscould pose unplanned torque requirements for the drive. ThePolyVee belts offered by Interroll are suitable for deep freezeapplication (see page 60).

Bearing: The precision ball bearings used also work in deepfreeze conditions. However, the startup of the roller is higher inthis case than at an ambient temperature of 68 °F. RollerDriveare either designed for this higher startup, or oiled ball bearingsare being used. The oiled bearings run significantly smoother attemperatures below zero.

Under deep freeze conditions, materials such as steel andpolymer contract in different ways. For functional reliability, aPolyVee drive head for a RollerDrive is not only pressed into thesteel tube, but it is also flanged. Additional security is provided bya metal star. This star, which is being produced with laser cutting,is engaged in the drive head and channels itself into the insidewall of the tube. This innovative solution inside the tube allowsavoiding interfering edges on the outside contour of the tube.This solution is available as an option for various designs series3500 and 3500KXO.

Drive conceptsWith respect to drives, Interroll distinguishes between drives (suchas round belts, PolyVee belts, chains, etc.) and the actual drive.Different drives are used in conveyor systems, such as drummotors, gear motors, motor rollers, etc. Furthermore, the potentialenergy of conveying good, e.g. on gravity conveyors, is alsobeing utilized.

PLANNING BASICSDRIVE CONCEPTS

69© 06 | 2020 Interroll

Gravity conveyorsA gravity conveyor differs significantly from the other concepts. Itis not horizontally aligned, but always mounted at an incline.There are driven and non-driven gravity conveyors. Drivengravity conveyors can be driven with RollerDrive. If theRollerDrive and, as such, the conveyor is stopped, the conveyinggoods remain in place and do not slide downward. The EC5000holds its position with a certain torque which prevents anydownward sliding. The different gear boxes and powers offerdifferent continuous blocking torques. It must be ensured thatconveying goods do not slide over standing rollers; if necessary,friction must be increased, e.g. with PVC sleeve on rollers and RD.Gravity conveyors use the potential energy of conveying goods.This means that other technology must first move the conveyinggood to a corresponding spatial height.

The conveying good rolls without additional drive as a result ofthe potential energy up to the end of the conveyor or up to thepreceding conveying good. The speed and the restart capabilityof conveying goods is heavily influenced by:

· The incline of the conveyor· The already existing speed of a conveying good when placed

upon the gravity conveyor· The ease of movement of the rollers· The conveyor length· The condition of the underside of a conveying good· The weight of the conveying good· Other properties

On the one hand, the conveying good must reach the end of theconveyor. It must not stop because its weight is too low to startmoving rollers at rest. If many conveying goods are already on agravity conveyor and, as a result, a piece of conveying goodstops in the last section of the conveyor, then it must be ensuredthat the last item will start again and reach the end of the gravityconveyor after the first conveying goods have been conveyed.

On the other hand, the speed of the conveying goods must notbe or get too high. There is the risk that a conveying good hitsanother jammed conveying good or the end stop at the end ofthe conveyor. This creates an injury risk for employees who maywant to remove the conveying good by hand, as well as the riskof damaging the conveying good.

Establishing the matching properties of a gravity conveyorbecomes a challenge if different conveying goods have to bemoved. Generally, the conveying goods on a gravity conveyordiffer by at least one of the following properties: Weight, size,material and base condition. A mixture of different conveyinggoods can also be transported by a gravity conveyor withrespect to personnel and conveying good safety as well asprocess reliability. Interroll offers different products for thispurpose. The rollers of series 1100 are designed for use ingravity conveyors.

The magnetic speed controller MSC 50 enables the restart ofconveying goods starting at 1.1 lbs and reliably deceleratesconveying goods up to 77 lbs depending on the properties of theconveyor. If conveying goods are lighter than 1.1 lbs or heavierthan 77 lbs, it is also possible to use the RollerDrive seriesEC5000.

The driven RollerDrive ensures that every lightweight conveyinggood, regardless of its weight, can be moved or moved again.When decelerating heavy conveying goods, the energyrecovered by the RollerDrive must not be too high. If one orseveral RollerDrive are used within a gravity conveyor, it alsoprovides the advantage of accumulation pressure reduction. If aRollerDrive, which may be connected with additional rollers viadrive elements, is stopped, then the conveying goods stop. Thisallows reducing the pressure on conveying goods that arealready on the conveyor or on the stop at the end of theconveyor. On long gravity conveyors, it may be advisable to useseveral RollerDrive in order to reduce the accumulation pressureeven further. If the incline is so high that conveying goods slideover the steel tube of stopped RollerDrive or rollers, then thefriction may be increased with a PVC sleeve on the tube.

In principle, it is recommended to test every gravity conveyordesign under original conditions.

Fixed drive conveyorIf a conveying good moves in harmony with the drive, then it isgenerally a fixed or constantly driven conveyor. The drive headof the rollers used is permanently connected with the tube. If thefixed drive heads are replaced with friction drive heads, theycreate a friction conveyor. Many different types of fixed driveconveyors are possible. They generally differ with respect to theselected drive element, such as chains, PolyVee belts, round belts,etc., and the drives used.

For all current fixed drive conveyors, Interroll offers matchingconveyor rollers, with the RollerDrive EC5000, the Pallet Driveand PolyVee belt even drives and drive elements. When using aRollerDrive as drive, it is recommended to place it in the middle ofthe driven conveyor rollers (for information about the PalletDrive, see the separate product documents). If many rollers haveto be driven, then PolyVee belts offer advantages over roundbelts. The use of PolyVee belts reduces the number of rollerrevolutions with increasing distance to the RollerDrive.

Zero pressure accumulation conveyorThe zero pressure accumulation conveying is often abbreviatedas ZPA. A ZPA conveyor is generally divided into zones. The zonelength is based on the length of the conveying good or thelongest conveying good. Each zone features an option ofidentifying conveying goods, e.g. via a photo cell. In addition,every zone can be switched on and off. The zones are driven indifferent ways, see the examples below.

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PLANNING BASICSDRIVE ELEMENTS

70 © 06 | 2020 Interroll

One option consists of a central drive, often a gear motor, thatdrives a flat belt. The flat belt is pressed onto the rollers using aswitchable unit or guided past them. In the case of bypassing, therollers are also often decelerated. It is feasible that the flat belt ispressed onto only a few rollers of a zone and the remainingrollers are connected with them by means of other driveelements. In many cases, this switching unit consists of pneumaticvalves. They frequently cause an undesired noise level. A highlevel of energy can be expected for this ZPA solution since thepowerful gear motor must also be powered if, for example, onlyone conveying good has to be moved on a 40-zone section.

Another option always presses the flat belt against a section of aroller in every zone. The remaining portion of the roller isswitched in or out via a coupling. The remaining rollers of everyzone are connected with the driven roller via other driveelements.

Another concept is the use of decentral drives. Motor rollers areoften used for this purpose. In this case, drives which are directlydriving the respective rollers, are installed in one or severalrollers of a zone. A drive element connecting the entire conveyoris redundant. The remaining rollers of a zone are generallyconnected with the motor roller(s) using PolyVee or round belts.The zones can be activated or deactivated by purposefullyswitching the motor rollers on or off.

Depending on the length of the conveyor, the design with centraldrive usually falls below the investment costs of a solution withmotor rollers. However, the operating costs tend to be higher dueto the constant turning of the drive, even when nothing may beconveyed at the time. For most solutions with motor rollers, higherinvestment costs are possibly amortized after a short time.

Not only the lower energy consumption speaks in favor of asolution with motor rollers, but also the compact design. Themotor is installed in a roller and does not have to be placed nextto or below the conveyor.

Compared to gear motors, motor rollers are maintenance-free,they do not have to be greased and generally offer a highersafety level with a protected extra-low voltage.

But solutions with motor rollers can also have disadvantages. Forsolutions with many motor rollers per zone, the availabilitydecreases – the more motors are being used, the higher theprobability that a motor roller fails.

For this reason, Interroll recommends the use of the RollerDriveEC5000. In this case, one RollerDrive per zone is generallysufficient, and flexible control concepts are available.Furthermore, the controls offer many other options, such aschange of direction of rotation or start and stop ramps which arenot being offered by conventional ZPA conveyors.

Drive elementsWith respect to drives, Interroll distinguishes between the actualdrive, such as RollerDrive, drum motor, Pallet Drive, gear motor,etc. and the drive elements. Drive elements refers to differenttypes of the torque transmission. Only the following driveelements are considered in this chapter:

· Toothed belt· PolyVee belt· Round belt

Toothed beltThe share of toothed belts as drive element in roller conveyorsystems is declining. Toothed belts are generally used from rollerto roller and are unable to negotiate curves. Compared to roundor PolyVee belts, the power requirement of a toothed belt issignificantly higher because of its design. This must be taken intoaccount in the selection of the drive. Toothed belts pose a highdemand on the tolerance of the roller pitch since the toothengagement is form-fit with the profile of the drive head. Interrollrecommends obtaining the tolerances to be followed from themanufacturer of the selected toothed belt.

One advantage of the toothed belt compared to round andPolyVee belts, is the fact that it passes movements withoutslipping when used properly. On top of that, toothed belts arelow-noise and maintenance-free, lubricating or retensioning is notrequired.

The drive length of a conveyor with toothed belt drive should bedimensioned so that the overall load of 2697 lbs conveying goodbeing conveyed at the same time is not being exceeded.

For the roller series 3500 and the RollerDrive EC5000, amaximum toothed belt width of 0.47" and a Poly-Chain GTgearing is recommended.

PolyVee beltPolyVee belts are ribbed V-belts that are generally used for thetorque transmission from roller to roller in roller conveyorsystems. The belts must feature a flexible tension member whichrenders them significantly less flexible than most round belts.Nevertheless, they can accept tolerances within the roller pitchbecause of their flexibility and used as drive elements in curves.For the installation of PolyVee belts, Interroll recommends the useof a PolyVee tensioning device.

Compared to round belts, PolyVee belts can transfer a highertorque of up to 300 %, the service life is longer and, when usedproperly, a PolyVee belt does not slip over the drive head. Instart-stop operation, the rollers can be stopped more preciselyand, compared to round belts, a higher number of conveyorrollers can be driven because of the high torque transmission.

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Due to the design of the PolyVee drive head and the small widthof the belts, they can be placed very close to the side profile. Thisleads to an optimal tube utilization for conveying goods. With thesmall diameter of the PolyVee drive head, any contact of PolyVeebelt and conveying good is generally ruled out.

In container conveyor systems, 2-rib and 3-rib PolyVee belts aregenerally used. Interroll offers PolyVee belts for these designs forthe most common roller pitches, see PolyVee belt. The 9-rib drivehead also allows using 4-rib belts. The ability of high torquetransmission also carries with it a high demand on safety. Injuries,such as jammed fingers between PolyVee belt and drive head,must be avoided. Interroll offers a finger guard for the mostcommon roller pitches. It does not have to be fastened to the sideprofile and, for this reason, can be used for almost all sideprofiles.

Round beltRound belts, also referred to as O-rings, are available in differentmaterials, colors and diameters. They are often used for thetorque transmission from roller to roller. Round belts are cost-effective with respect to their purchase, are very flexible and canbe installed with ease. The disadvantage is a relatively poorpower transmission and relatively short service life. For thisreason, the use of PolyVee belts predominates in conveyorsystems.

The round belt guides with the RollerDrive EC5000 can becarried out via grooves in the tube or a round belt drive head.The drive head made from polyamide offers the advantage thatthe round belts can be guided closer at the end of the RollerDriveor at the side profile of the conveyor. In this case, it is more likelyto separate torque transmission and running surface of conveyinggoods. Furthermore, the concentric precision is increased since nomechanical change of the tube occurs compared to grooves inthe tube.

The round belt drive head offers a higher conveyance for mostbelts because of its material. This significant advantage must betaken into account if acceleration and deceleration for start-stopoperation are so high that the belt briefly slips and wears outbecause of it. The better the conveyance from the guide, thehigher the wear in this case. Groove solutions in tubes and alsothe round belt drive head offer 0.39" wide grooves. This allowsusing round belts with a maximum diameter of 0.23". In case ofhigher round belt diameters, there is the risk of two contact pointsof the round belt – at the bottom and at the side of the groove.In this case, the belt is subjected to two different speeds andexperiences above average wear.

Roller curves

How to build a curve?It is possible to build roller curves with cylindrical rollers. Withsuch a design, conveying goods are not conveyed in the center ofthe curve, but alongside a required side guide. This requires moreenergy and it poses the risk of damage to the side guide orconveying good. For this reason, the design with taperedconveyor rollers is recommended.

The diameter of the tapered rollers increases towards thedirection of the outside curve diameter. With the increasingdiameter, the circumferential speed increases. This allowsconveying goods to be transported through the curve withoutlosing their orientation. With the usual speeds (max. 157 fpm)and ideal curve design, a side guide is not required.

Interroll offers different curve-capable rollers that feature thedesignation KXO. These are rollers with cylindrical steel tube ontowhich tapered elements are pressed. Compared to conventionalcurve rollers/curve motor rollers, the Interroll products areadditionally secured against shifting on the steel tube by meansof a form fit. This safety mechanism is not visible from the outsideso that no interfering edges are being created.

Installing the rollers/RollerDrive

1,8˚

For the curve construction, it must be taken into account that thetop side of the curve RollerDrive is level. Hence, the fasteningshaft is not horizontal. As a result, vertically arranged sideprofiles do not have a 90° angle. For this reason, Interrollrecommends an angle compensation so that the fastening shaftdoes not experience any warping. The EC3500 with protectionrating IP54 is exclusively available for installation in the curve.

The installation length of curved sections must be longer than thatof straight sections to ensure that the conveying good does nottouch the side guide in the curve. Please select the next largerinstallation length grid.

DriveThe RollerDrive has established itself as the drive for poweredroller curves. It allows implementing a cost-efficient, compact andquiet curve. RollerDrive in conjunction with PolyVee belts as driveelement are the simplest solution for torque transmission in

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curves. Such curves can be constructed and set up in an easy way– for constantly rotating as well as for curves for start-stopoperation.

Drive elementRound belts and PolyVee belts are suitable as drive element.

Round belts can be guided via grooves which are located in thearea of a tube projection. As an alternative, round belts can alsobe guided via a drive head at the inside radius.

PolyVee belts are exclusively guided via a drive head, also at theinside radius.

The most frequent solution is the PolyVee belt. For use in curves,2-rib and 3-rib flexible belts are suitable. The belts must occupythe first grooves from the direction of the inner curve radius. Adistance of one groove is required between the two belts.

Length of tapered elements1.8° elements: The first tapered element has a length of 1.77"or 3.74". All additional elements have a length of 3.94". The totallength of the tapered elements can be selected in increments of1.97". The different lengths of the first tapered elements result in2 different inside curve radii.

2.2° elements: The length of the first tapered is always 5.51".Hence, the inner curve radius does not vary.

RadiiDifferent inside curve radii can be created with the differenttapered elements. A conveying good will be conveyed perfectlythrough a curve only if the radii are being maintained.

Inside curve radii for RollerDrive with PolyVee or round beltdrive head

Inner curve radius Conicity Reference lengths

25.98" 2.2° 7.48", 9.44", 11.41",13.38", 17.32", 21.25",25.19", 29.13"

32.28" 1.8° 5.9", 9.84", 13.77",17.71", 21.65", 25.59",29.52", 33.46", 37.4"

30.31" 1.8° 7.87", 11.81", 15.75",19.68", 23.62", 27.55",31.5", 35.43", 39.36"

Roller pitchThe roller pitch depends on the selected drive element.

PolyVee belt: For example, if a PolyVee belt is used in the curvefor a roller pitch of 2.95", then a hole pitch of 2.9" must beplanned at the inside radius. The roller pitch at the outside radiuscan be calculated using the following formula:

Po =

Ro

Pi

Pi ∙

Po = Roller pitch on the outside diameterPi = Roller pitch on the inside diameterRo = Outside radius of the curve

Interroll recommends an angle of 5° between two rollers. Theangle must not be greater than 5.5°.

Round belts: Any length can be used here. To ensure a sufficientdistance of the rollers,Interroll recommends not to plan more than22 rollers in a 90° curve. This also applies to non-driven curves.

Number of rollersThe calculation or determination of the roller pitch and the angleof the roller curve result in the number of rollers to be used,which is not always an even number. In this case, the value mustbe rounded up or down.If a PolyVee belt is used in the curve for a roller pitch of2.87" (based on a straight conveyor line), it results in an evenroller count for the following curve angles:

Angle Number of rollers

30° 6

45° 9

90° 18

180° 36

SpeedFor a conveying good to be conveyed perfectly through thecurve, the speed of the curve and the adjacent straight conveyorlines must be identical. The curve speed refers to the averagespeed, see the following sample calculation. If the speeds ofstraight and curve are different, the conveying good can loose itsorientation and, as a result, reach the side guide.

Sample calculation of average diameter

First, the average diameter of the tapered rollers is to becalculated. When tapered elements with an angle of 1.8° and alength of 17.71" are used, the starting diameter is 2.19" and theending diameter 3.3", see page 19.

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(Ømin + Ømax) 2.18“ + 3.3“ 2

ØØ = = = 2.74“

2

ØØ = Average diameter of tapered elementsØmin. = Starting diameterØmax. = Ending diameter

Sample calculation of same speed

Let us assume that the straight section before and after the curveis equipped with 1.97" diameter rollers and runs at a speed of157 fpm. The speed in the curve is to be of the same value andmust be converted to the average diameter of 2.74".

SStrai. 157 FPM

ØØ

SRD

= = 2.74“

· 1.97“ = 112 FPM∙ ØStrai.

SRD = Speed to be set of the RollerDriveSStrai. = Required speed on the straight lineØØ = Average diameter of tapered elementsØStrai. = Diameter of rollers on the straight line

Interroll recommends using different gear stages for the straightline sections and curves. A gear stage of 30:1 would be ideal forthe calculated curve example. Based on a diameter of 1.97", amaximum speed of 118 fpm can be calculated. Based on anaverage diameter of 2.74", a RollerDrive with this gear box couldalso be set to 157 fpm. For sections with cylindrical rollers andRollerDrive before and after the curve, a gear stage of 21:1would present itself. In general, the gear stage 21:1 could also beused in both parts of the system. The recommendation of the gearstage 30:1 for the curve is based on the fact that it has a highertorque and a higher torque is often required in curves. Inprinciple, we recommend using the powerful 50-W version foruse in curves.

Different forces occur in a curve. If the centrifugal force is greaterthan the static friction force, conveying goods will almost alwaysloose their orientation. This occurs at speeds over approx. 157fpm. At that point, conveying goods will no longer be conveyedthrough the center of the curve and come into contact with theside guide at the outside radius. Besides the conveying speed, thisalso depends on, e.g. material and condition of the underside ofthe conveying good. Corresponding factors must also be takeninto consideration when planning the curves.

Deep freezingRoller curves can also be operated in the deep freeze area. Anideal drive is the RollerDrive EC5000 in deep freeze design.Driven rollers should feature oiled ball bearings so that therequired drive power is not increased unnecessarily. Interroll

recommends PolyVee belts as drive element. They have to bewatched for suitability for deep freezing and that the belt tensionis not too high.

RollerDrive variant selection

Mechanical output powerThe RollerDrive EC5000 is available in three power designs: 20,35 and 50 W. It can be identified via the label imprint.

20WInterroll recommends the cost-effective 20-W power stage forconveying empty containers or conveying good weights of nomore than 33 lbs.

35WThe allrounder of the power stages is the EC5000 with 35 W. It isrecommended to use this power stage for conveying goodweights of up to 110 lbs. This classic for zero pressureaccumulation conveyor systems is the perfect solution betweenacceleration and cost effectiveness.

50WThe 50-W version should be used for conveying good weights ofup to 550 lbs. This highest-torque design is suitable for thecontainer conveyor system (ø 1.97") as well as for light palletconveyor system (ø 2.36"). With the enormous acceleration,conveying goods reach their target speeds the fastest, which hasa very positive effect on the demands of the throughput.

InterfaceThe RollerDrive EC5000 is available with two different interfaces– analog and bus. Its identification is possible via label imprintand a color ring at the connector.

Analog interfaceThe analog interface (AI) is a very cost-effective solution. With ananalog voltage, it allows the speed setting within the rangespecified by the gear box. It also allows influencing start and/orbraking ramps. The direction of rotation can be predefined andthe error status can be read. The motor commutation technologyintegrated in the tube allows for a flexible control of theRollerDrive. If not start signal (at the same time speedspecification) is active, the RollerDrive holds its position. Hence, itis also suitable for incline and decline conveyors. The AI isavailable with voltages of 24 and 48 V, with power stages of 20,35 and 50 W, as well as tube diameters of 1.97" and 2.36".

Bus interfaceThe bus interface (BI) enables the data exchange betweenRollerDrive and a control system via CANopen. It allows for thefollowing specifications:

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· Speed specification within the range specified by the gear box· Exact specification of start and/or braking ramps· Specification of direction of rotation· Toggling between “Hold position” and “Free-running”· Exact positioning (when switching to the speed mode)· Specification of the motor temperature warning threshold· Activating a derating mode

Many data can be read out – including:

· Error cause (e.g. temperature, blocking or overvoltage)· System status indicators (high temperature of RollerDrive, high

torque demand and an above-average high number of errormessages)

· Service life indicator (information about statistical end ofservice life)

· Operating data – for example:– Operating hours– Stand-by hours– Number of start cycles– Current motor temperature– Maximum motor temperature reached– Current torque– Current speed– Serial number– Date of manufacture

Compared to the AI, the BI enables an exact error analysis and,as a result, an easier cause analysis or avoidance of error causes.When the three system status indicators are evaluated, thecauses analyzed and remedied, it allows for reaching the optimalservice life. The service life indicator enables a preventivemaintenance of conveyor lines with a very high availabilityrequirement. Last, but not least, the operating data with the useof the BI enable the implementation of an Industry 4.0 conveyorsystem. Not only do they reading out the operating state of everyRollerDrive, but also exact conclusions on the conveyor system.Regardless of whether the RollerDrive was manufactured inChine, Germany or the United States, it features a unique serialnumber. It can be read on the label or read out electronically. If aRollerDrive was damaged, the transmission of the serial number issufficient to manufacture an identical spare part.

The EC5000 with BI can be controlled with MultiControl. In thiscase, an automatic addressing of up to four connectible EC5000takes place. MultiControl is capable of reading out RollerDrivedata, such as the diameter.

The BI is available with voltages of 24 and 48 V, with powerstages of 20, 35 and 50 W, as well as tube diameters of 1.97"and 2.36".

VoltageThe RollerDrive EC5000 is available in two operating voltagedesigns: 24 V DC and 48 V DC. It can be identified via the labelimprint, a color ring at the connector or electronically when usingan EC5000 BI.

24 V DC voltage supplyRollerDrive with a voltage supply of 24 V DC have establishedthemselves worldwide for many decades now. The extra-lowvoltage allows a high flexibility for installation and cabling as wellas a high level of safety during operation. The RollerDrive isfrequently found adjacent to sensors, PLCs and other electronicproducts that are operated with a voltage of 24 V DC. Theuniform voltage enables the exclusive use of 24-V DC switchingpower supplies. The 24 V DC EC5000 is available for bothinterfaces with power stages of 20, 35 and 50 W as well asdiameters of 1.97" and 2.36".

48 V DC voltage supplyInterroll introduced the 48-V DC voltage supply for RollerDrive in2019 – motivated by customer requests, the automotive industryand many 48-V DC motors that were already in use in otherareas of conveyor technology. The extra-low voltage allows ahigh flexibility for installation and cabling as well as a high levelof safety during operation. Sensors and other electronic productsadjacent to the RollerDrive continue to be supplied with 24 V DCand the comparatively more power-intensive RollerDrive with 48V DC. The 48-V DC voltage is a very cost-effective supply option.In most cases, fewer switching power supplies are needed. Thistranslates in cost savings as a result of fewer units, more cost-effective power supplies and less planning, installation andcabling. Not least, the flexibility in cabling due to longer linelengths, cost savings by using smaller line cross sections or lowererror risk from voltage drop on lines speak in favor of a supplywith 48 V DC. The 48-V DC design is available for bothinterfaces with power stages of 20, 35 and 50 W as well asdiameters of 1.97" and 2.36".

Tube materialVarious aspects must be taken into account when selecting thecorrect tube material.

If the conveying good or the environment is moist, if water is usedfor cleaning, or if there is a risk that a sprinkler system could beactivated, then a tube with a high corrosion protection should beselected. A tube made of stainless steel is recommended.Furthermore, it must be checked whether protection rating IP54 issufficient or whether the design should be used in IP66.

The RollerDrive and also adjacent rollers must be capable ofreliably moving the conveying good. In many cases, this alsoincludes stopping and starting the conveying good without lettingit slide on the tubes. This is particularly important for conveyorswith an incline. For many conveying goods, the friction to themetal tube of the RollerDrive is sufficient, e.g. tires. For otherconveying goods, a suitable sleeve or a lagging of the tube isrequired. It is recommended to fit the tube with a PU sleeve. It ismore robust than a PVC sleeve and more cost-effective than alagging. However, it is indispensable to adjust the friction of theRollerDrive to the application properties.

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FastenerOn the conducting side, the RollerDrive is fastened via a hexagonshaft in the side profile. The hexagon features an M12 malethread, an M12 fastening nut is supplied as standard. This nutfeatures ribs on the contact surface to the side profile whichprevents a loosening of the nut in almost all side profiles due tovibration. The ribs are also intended to enable electrical contactbetween RollerDrive shaft and powder-coated side profiles. Theelectrical connection and, as a result, the possibility of staticdischarge must be checked in principle. This very simple fasteningsolution prevents the shaft from turning inside the fastening holeand damaging the connecting cable. The nut must be tightenedwith a torque of 51.6 ft-lbs. A fastening socket for a torquewrench with opening for the RollerDrive connecting cable issuitable for this purpose, see page 61.

On the opposite side, the RollerDrive can be fastened in differentways. An M8 screw can be screwed into a shaft pin with femalethread. For the IP66 variant, the shaft bolt sits in a slide bearing.For the conventional variant with protection rating IP54, it sits ina ball bearing. The fastening is also possible for a spring-loadedshaft solution. In combination with a drive head, e.g. a PolyVeedrive head, the spring-loaded shaft is designed as hexagon.Without drive head, e.g. if round belts are guided via grooves,the spring-loaded shaft is designed as tapered hexagon. With thissolution, the hexagon slides so far into the fastening hole until it isbacklash-free. This solution reduces the noise level and possiblewear.

RollerDrive with tapered elements require an angle compensationduring fastening.

Protection rateThe RollerDrive has a protection rating of IP54. If this should notbe sufficient due to moisture or dirt, a design with protectionrating of IP66 is available.

Temperature rangeThe RollerDrive is designed for a temperature range from 32 to104 °F. For deep freeze applications up to –22 °F, Interrollrecommends the use of a corresponding deep freeze variant, seestarting from page 22.

Drive elementSeveral drive heads are available, and grooves can also be fittedin the tube. Interroll recommends the use of PolyVee belts sincethey are suitable for almost all applications (straight, curve,gravity, etc.).

Speed/torqueThe RollerDrive EC5000 covers all common speeds for ZPAconveyors. 9 gear stages are available to meet the requirementsof different applications. The gear stage should be selected with

respect to the required speed and the required torque. For thispurpose, the RollerDrive can be varied with respect to speed. Forexample, the gear ratio 18 : 1 can turn with a maximum speed of196 fpm, but also with every lower speed up to 8 fpm.

Compared with some drive solutions without gear box, theRollerDrive allows implementing a broad spectrum of applicationswith different torque requirements. It is sufficient to use the samedrive with the same interface and control at all times, but employdifferent gear stages.

RollerDrive planningFor safe and reliable conveyance, at least one RollerDrive andtwo conveyor rollers have to be located under the conveyinggood. It is recommended to place the RollerDrive in the center ofthe conveyor zone that it is driving.

If the conveying good is to be moved on a conveyorperpendicular to the direction of the roller shaft, that is free oftransverse force, then the static friction and rolling friction haveto be overcome.

The following equation applies to conveying goods, which aremoved at a constant speed along a conveyor track:

F = m · g · μ

F = Required tangential force in Nm = Mass in kgg = Max. gravitational acceleration 9.81 m/sµ = Coefficient of friction

Sample calculationIf the weight of the conveying good is 30 kg and the coefficientof friction is 0.04, the resulting required tangential force is11.8 N.

With a roller radius of 25 mm, the required torque(force × distance) is 0.3 Nm. The required mechanical power at aspeed of 0.5 m/s (force × speed) measures 5.9 W.

Coefficients of friction for different container materials whenusing rollers with steel tubes:

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Material Coefficient of friction µ

Steel 0.03

Polymer, smooth 0.04

Polymer, profiled 0.05

Wood 0.05

Cardboard carton 0.06

During zero-pressure accumulation conveying, the RollerDrive isstarted and stopped many times. The RollerDrive is designed for ahigh number of cycles. The previously described calculations areused for checking to what extent a RollerDrive is capable ofconveying certain conveying goods. On top of that, the cyclecount, i.e. how often the RollerDrive switches off and on per timeunit, also plays a decisive role. The higher the cycle count, thehigher the motor temperature. The motor temperature is alsoaffected by the turning time per time unit. The less the standstilltime of the motor, the less cooling time for the motor. With cycletimes that are too high and standstill times that are too low, theRollerDrive switches to a temperature protection function and canno longer be operated until is has cooled off. This must be takeninto account for the planning.

The required drive force to convey an item at a constant speedalong a roller conveyor depends on the condition of theunderside of the conveying good. A minimal force has to beexerted for a rigid, difficult to deform underside, such as a steelcontainer.

However, a steel container tends to slide on the tube materialduring acceleration and deceleration. Approx. 3 % of theconveying good weight must be applied as propelling forceduring constant travel. μ is approx. 8 % with a cardboardcontainer. This can be explained by the soft and malleableunderside. With a cardboard container, the differential figure isapplied to the steel container for the deformation of theunderside of the container and is therefore no longer availablefor the forward motion.

As a conveyor cycle consists of acceleration, constant travel andbraking, acceleration is critical for assessing the output.

In the acceleration phase, the static friction is overcome and atransition to significantly lower roller friction takes place. For thisreason, a power surge can be measured at the start of everyconveyor cycle.

For zero-pressure accumulation conveying, the conveyor shouldbe divided into zones. As a rule, every zone is driven by aRollerDrive. The zone length must orient itself at the conveyinggood length or the longest conveying good. The zone length mustbe longer than the longest conveying good so that a gapprevents the conveying goods from contacting each other. Inmost cases, light barriers are used to detect conveying good inevery zone. The run-on depends on various factors, such asspeed or conveying good weight, but also the selected driveelement. The run-on describes the distance from the sensor to thefront edge of the stopped conveying good. In an ideal case, therun-on is very small, although the conveying good comes to astandstill later in most cases. The programming of the logic of thezero-pressure accumulation conveying does not have to becomplex, it is already contained in most Interroll controls. Apower surge can be measured at the switch-on time of theRollerDrive. This application-dependent current peak must betaken into account for the power supply dimensioning.

Power supply dimensioning

IntroductionThe Interroll RollerDrive is supplied with a voltage of 24 or48 V DC. Interroll offers the matching switching power supply forevery voltage. The power supplies are exactly dimensioned forthe requirements of the RollerDrive and its controls. The followingmust be observed if conventional power supplies are used:

· The rated and startup current of the RollerDrive must be takeninto account when dimensioning the power supply.

· The RollerDrive, and also its controls, feed back voltage, i.e. thepower supply must be feedback-capable.

· The Interroll RollerDrive controls each contain one brakechopper. This safety function is activated when the voltageexceeds a certain value (see the chapter of the respectivecontrol). This voltage may be elevated due to feedback of theRollerDrive or a supply voltage that has been set too high. Ifthe voltage is elevated over a period of a few seconds, thecontrol system will switch off for cooling purposes because of ahigh brake chopper temperature. For this reason, it isrecommended not to set the voltage of the power supply to theswitch-on threshold of the brake chopper.

· Long line lengths (particularly for 24 V) should be avoidedsince they could be accompanied by a high voltage drop.


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Basic informationThe RollerDrive EC5000 can be connected to the followingcontrols:

EC5000 24 V EC5000 48 V

DriveControl 20

DriveControl 54

DriveControl 2048 DriveControl 2048

ZoneControl

ConveyorControl

MultiControl AI MultiControl AI

MultiControl BI MultiControl BI

Each control (without connected RollerDrive or connected sensor)allows a current flow of approx. 0.5 A (generally significantlylower). This current is not taken into account for the power supplydimensioning in the following example. The same applies to thesensors. As a rule, they can be assumed to have a current flow of50 mA. If additional current-relevant inputs or outputs areswitched, they should be included in the dimensioning, but theyhave been omitted in the example.

Depending on the power and voltage version, the RollerDriveEC5000 has a different rated and startup current:

24 V DC 48 V DC

20 W 35 W 50 W 20 W 35 W 50 W

Ratedcurrent

1.4 A 2.4 A 3.4 A 0.7 A 1.2 A 1.7 A

Startingcurrent

3.0 A 5.5 A 7.5 A 1.5 A 2.8 A 3.8 A

The currents depend on different factors, e.g. The acceleration ofthe RollerDrive, the number of rollers connected with theRollerDrive, the weight of the conveying good, the speed of theRollerDrive, etc. In many applications, the currents are below thevalues listed here.

In general, several RollerDrive are supplied by one power supply.The RollerDrive are mostly used for zero-pressure accumulationconveying. In this case, not all RollerDrive are startedsimultaneously in the so-called single release. For this reason, asimultaneity factor must be taken into account for the powersupply dimensioning. If it is not clear how many RollerDrive could

start simultaneously, it is recommended to dimension the powersupply with the assumption that all RollerDrive will startsimultaneously.

Sample calculation/dimensioningThe calculation refers to the HP5448 switching power supply with20 A rated and 30 A peak current.

It must be checked with a calculation whether one power supplyis sufficient for 24 units of EC5000 48 V 20 W. Since noapplication currents were determined, the catalog current valuesare used for the calculation:

Rated current 0.7 AStartup current 1.5 A

Total rated current:It is assumed that up to 80 % of the RollerDrive can startsimultaneously.

INges = n · IN

Example: IRtot = 24 · 0.7 A = 16.8 A

Total startup current:

IAges = n · IA

Example: IStot = 24 · 1.5 A = 36 A

Total startup current80 %:

IA80% = n · 80% · IA

Example: IS 80% = 24 · 80 % · 1.5 A = 28.8 A

IR = rated current in AIRtot = total rated current in AIS = startup current in AIStot = total startup current in AIS80% = total startup current 80% in An = number of RollerDrive

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ExplanationsIf only the total rated current would be taken into account, all 24RollerDrive could be supplied with one power supply and startsimultaneously, since the power supply offers a current of up to20 A.

However, the startup must also be taken into account. With 36 A,it is significantly higher than the maximum current of the powersupply (30 A). As such, a second power supply would have to beused or it must be avoided to switch on all RollerDrive at thesame time.

If it can be ensured that no more than 80 % of the RollerDrivewill start at the same time, the total startup current 80 % can betaken into account. In the example, this current is 28.8 A. Hence,all 24 RollerDrive could be supplied with one power supply.

If calculations are made with current values below the catalogvalues and/or with a simultaneity factor (like the 80% in theexample), these values should be validated through field tests.

In principle, it is recommended to position the power supply in themiddle of the RollerDrive or control systems to be supplied so thata cable can be routed to the left and to the right. This reducesthe total cable length and, as a result, the risk of excessive linevoltage drop.

If train release is used instead of single release, it must beassumed for conventional logic programs that all RollerDrive startsimultaneously. The Interroll controls avoid a cumulative highstartup current of all RollerDrive:

· ZoneControl: The control has a permanently set delay time of125 ms in the train release program. After an enabling signal,the first RollerDrive starts. The next RollerDrive starts 125 mslater, etc.

· ConveyorControl: The delay time is adjustable, functionidentical to ZoneControl.

· MultiControl: The delay time is adjustable, function identical toZoneControl.

INDEXInterroll from A to Z

80 © 06 | 2020 Interroll

Numeric24-V switching power supply 52, 76

48-V switching power supply 56, 76

CCable bridge 65

Cable distribution 63

Chain 70

Communication cable 63

Control 44, 48

Controls 34, 36, 38, 40

Conveying good 66

Counter wrench 62

Curve 71

DDrive concepts 68

DriveControl 20 34

DriveControl 2048 38

DriveControl 54 36

Dummy plug 64

EEC5000 10, 16, 22, 26, 30

EtherCat 44, 48

EtherNet/IP 44, 48

Extension cable 62

FFastening socket 61

Flat belt 70

Flat cable 62

HHP5424 (24-V power supply) 52

HP5448 (48-V power supply) 56

IInterroll Group 4

IP54 10, 16, 22, 26

IP66 30

MMagnetic key 65

Motor roller 10, 16, 22, 26, 30

MultiControl 44, 48

MultiControl dummy plug 64

MultiControl Y-cable 63

PPolyVee belt 60, 70

Power supply HP5424 (24 V) 52, 76

Power supply HP5448 (48 V) 56, 76

Product locator 8

Profinet 44, 48

Protected against water jets 30

RRoller pitch 67, 70, 71

RollerDrive 10, 16, 22, 26, 30

RollerDrive controls 34, 36, 38, 40, 44, 48

RollerDrive counter wrench 62

RollerDrive extension cable 62

RollerDrive fastening socket 61


81© 06 | 2020 Interroll

SSealing inserts (power supply) 64

Shield connection cable 64

Sprocket 70

Suitable for deep freeze application 22

YY-cable 63

ZZero-pressure accumulation conveying 68

ZoneControl 40

COMPETENCE CENTER

The Interroll Center of Excellence in Wermelskirchen (nearCologne, Germany) concentrates on conveyor rollers, RollerDriveand controls, used as key products in roller conveyors forcontainer transport and other internal logistics systems.In this product sector, the company certified in compliance withISO 9001 is responsible within the global Interroll Group for alltechnical concerns ranging from development and applicationengineering to production and support for local Interrollcompanies. With an annual production volume of several millionunits, Interroll is currently seen in the logistics sector as the world‘slargest specialist manufacturer of conveyor rollers.

Interroll Engineering GmbHHöferhof 16 | 42929 Wermelskirchen |Germany Tel.: +49 2193 23-0

LEGAL NOTICES

ContentsWe strive for the information presented to be correct, up to date andcomplete. We have carefully developed the contents of this document.Nevertheless, errors and changes are expressly subject to change.

Copyright/intellectual property rightText, images, graphics and the like, as well as their arrangement, areprotected by copyright and other protective legislation. Reproduction,modification, transfer or publication of any part or the entire content ofthis document in any form is prohibited. This document is intendedexclusively for informational purposes and for intended use and does not

authorize replication of the corresponding products. All identificationsymbols used in this document (protected trademarks, such as logos andcommercial designations) are the property of Interroll AG or theirrespective owners and may not be used, copied or disseminated withoutprior written permission.

About InterrollThe Interroll Group is a globally leading provider of solutions formaterial handling. The company was founded in 1959 and hasbeen listed on the SIX Swiss Exchange since 1997. Interrollsupplies system integrators and machine builders with a broadproduct range of platform-based products and services in thecategories "Rollers" (conveyor rollers), "Drives" (motors anddrives for conveyor systems), "Conveyors & Sorters“ as well as"Pallet & Carton Flow” (flow storage systems). Solutions fromInterroll are used by express and postal services, in e-commerce,in airports and in the areas of food & beverage, fashion,automotive and other industries. The company counts leadingbrands, such as Amazon, Bosch, Coca-Cola, DHL, Nestlé, Procter& Gamble, Siemens, Walmart, or Zalando, among its users.Interroll, with its headquarters in Switzerland, features a globalnetwork of 34 companies with annual revenues of roughly 559.7million francs and 2,400 employees (2019).

interroll.com

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