- Interroll
Contents
1. INTERROLL Product information Dimensions ra 6 96 in 177 mm v 5 69 in 144 mm EAS n 2 Speed Aaoal Baosl RE E l DITERROLE E 5 Hybrid Gentrel for RellerBrive E o A E e c o LE 8 S X E 4 A o o N m 878633522204350571 o Dd a o EE USA o N N Z axial com CE o 9 E 3 11 in 79 mm os in 5 6 mm 98 in 25 mm The following mounting hardware is supplied 2x button head screw 10 32 UNF x 0 5 2xnut with captive star washer 10 32 UNF ZPA technology ZPA is short for zero pressure accumulation The 9007 provides true zero pressure accumulation and other control options to a conveyor system Each 9007 controls a RollerDrive unit which in turn drives idler rollers using O rings or other belts The 9007 the RollerDrive and the idler rollers with associated sensors and switches are assembled into a short conveyor section a zone Zero pressure accumulation occurs as zones hold packages until the next downstream zone clears its sensor When accumulation2. ______________ to upstream ZPA card 24 VDC 24 VDC GND l GND i A smart I O based handshake is required at the interface DIP switch 5 must be OFF to make this zone into an exit zone Jog and reverse are enabled only if DIP switch 4 is ON T A EXIT ZONE TRANSPORT ZONE TRANSPORT ZONE ENTRY ZONE d e oA 0 EN A A A eno iion El E PLC j Eh amp b El op dr amp J Li J Ww se l D al 0 Q D o iB ip i mdi Q o Bg miii o o O O oO o a o o In ol i 12 1 2 S5 4 amp 6 7 l1 4 mE x 1 2 X 4 5 B 7 2 53 456 r7 Switch settings for f PLC at exit zone to control release Key Start sensor at ent
3. qm as Zone Hybrid Control a d E Smart Pn ol B Sensor in 24 VDC E S H to downstream ZPA card to upstream ZPA card amp m E e Smar 1 in H e N S GND Hz 4 E 24 VDC a El D Dependent Hybrid Controls iamo DIERRE E Smart in EN F pa ew 183 4 E 24 VDC El El 24 VDC 24 VDC GND GND A reverse command to the Zone 9007 will not be communicated to the dependent 9007 cards Dependent 9007 DIP switch settings e SW1 Must have the same switch setting as zone 9007 logic mode NPN or PNP Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive Version 1 1 11 2011 en Original language INTERROLL Product information 9007 as motor control board w DC O LLI l ER Direction of travel Q Smart1 in FWD command tome ME Vo gt for NPN GND in z amp pemo Sis gt for PNP 24 VDC in H A Finca wina o REV command _ z gt q TTD E gt for NPN GND in GND ES gt for PNP 24 VDC in 24 VDC a 2 E 24 VDC GND Start options s FWD connected to 24 VDC causes cew rotation REV connected to 24 VDC causes cw rotation FWD and REV connected to 24 VDC causes coast mode 27 9007 Hybrid Control for RollerDrive 28
4. Standard singulate mode SW3 Motor running counter clockwise SW2 All NPN inputs and outputs SW1 i DIP switch settings are read at reset power up only FUTURE ON OFF aud T 7 SW7 RollerDrive selection See chart See chart SW7 OFF ON ON OFF te SWE RollerDrive selection See chart See chart SW6 OFF OFF ON ON 0I SW5 Downstream Jog Rev ON Standard SW4 Upstream Jog Rev ON Standard Op H SW3 Singulation Enhanced Standard r SW2 Rotation CW CCW li o SW1 Logic PNP NPN The following table shows the switch position for different situations DIP switch ON up position SW5 Jog Rev ON the downstream Downstream peer to peer cable is connected to another 9007 and the jog reverse signal is transmitted OFF down position Standard the jog reverse signal is not transmitted SW4 Jog Rev ON the upstream Standard the jog reverse Upstream peer to peer cable is connected signal is not transmitted to another 9007 and the jog reverse signal is transmitted SW3 Enhanced enhanced Standard singulated release Singulation singulated release see Glossary page 47 is needed see Glossary page 47 is needed SW2 Clockwise rotation of the Counter clockwise rotation Rotation RollerDrive seen from the cable ofthe RollerDrive seen from end the cable end SW1 PNP all external inputs NPN all external inputs
5. FWD in DIP switch settings If SW5 is ON direction setting is transferred downstream If SW4 is ON direction setting is transferred upstream SW1 ON Start options FWD connected to 24 VDC at PNP mode causes ccw rotation REV connected to 24 VDC at PNP mode causes cw rotation FWD and REV connected to 24 VDC at PNP mode causes coast mode i FWD signal acts like a jog signal disregarding ZPA functionality and photoeye signals REV signal reverses motor and logic direction upstream becomes downstream and C sensor becomes B sensor Version 1 1 11 2011 en 23 Original language 9007 Hybrid Control for RollerDrive 24 INTERROLL Product information External direction set in NPN mode u x Q x Es Direction of travel zl o a Reverse direction of travel Mm cdam ee n amp fo SE Smart 1 Fwd in S 3 Revin e 2 Ii GND a 2 lt B Sense in 24 VDC e Soc o to downstream ZPA card _______________ to upstream ZPA card 24 VDC GND REV in FWD in DIP switch settings If SW5 is ON direction setting is transferred downstream If SW4 is ON direction setting is transferred upstream SW1 OFF Start options FWD connected to GND at NPN mode causes ccw rotation REV c
6. rotated by outside forces A segment of conveyor typically comprised of one RollerDrive and multiple idler rollers interconnected by O rings or some other device for driving the idlers Zero pressure accumulation The process of moving packages on a conveyor in such a manner that they do not touch each other also see ZPA technology page 7 Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Version 1 1 11 2011 en Original language Appendix Manufacturer s declaration in terms of the EC Machine Directive 98 37 EC and its amendment 98 79 EC Annex II B The manufacturer Interroll Corporation 3000 Corporate Drive Wilmington NC 28405 USA hereby declares with sole responsibility that the product range 9007 Hybrid Control for RollerDrive is not a ready to use assembly in terms of the EC Machine Directive and therefore does not fully comply with the requirements of this directive It must not be put into service until the machinery into which it is to be incorporated has been declared to conform with the provisions of the Machine Directive Applied EC Directives Machine Directive 98 37 EC and its amendment 98 79 EC Low Voltage Directive 2006 95 EC EMC Directive 2004 108 EC RoHS Directive 2002 95 EC Applied harmonized norms EN ISO 12100 Part1 and Part2 Wilmington NC December 20 2010 Richard Keely Vice President of Manufacturing This declaration ca
7. 7 7 13 6 42 6 6 7 12 5 36 5 5 6 10 4 30 4 4 5 8 3 23 3 3 5 4 T 2 17 2 3 3 5 1 10 1 2 2 3 0 4 0 1 1 2 15 9007 Hybrid Control for RollerDrive INTERROLL Product information Meaning of the LEDs The LEDs provide motor sensor and jam diagnostics as well as power fuse and temperature status The following table shows the meaning of the LEDs flashes are Y second on and 74 second off in a fixed 4 second time period LED Color Status Meaning Fuse red on steady all other Fuse blown LEDs are off Power green on steady Power ok Fault red on steady Stalled motor Jam at or between sensors Peer to peer cable unplugged flashing once Motor or motor cable open or disconnected flashing twice Over voltage detection 29 VDC x 0 2 VDC will cease normal operation flashing three times Under voltage detection 19 VDC x 0 2 VDC will cease normal operation flashing four times 9007 severe temperature shut down will cease normal operation until cool flashing five times Motor severe temperature shut down will cease normal operation until cool flashing six times Low gain or bad sensor sensor with fault output connected Warning amber on steady Motor current is limited to maximum continuous current due to motor over temperature flashing four times Motor current is limited to maximum continuous current due to card over temperature There is no error output if the amber LED is flashing Ve
8. DIP switch 4 and 5 RollerDrive EC1xx is not in braking mode without any packages on the conveyor system This is not an error It is a power saving feature The RollerDrive EC1xx is in coast mode until it is commanded to run or accumulate Version 1 1 11 2011 en Original language 43 9007 Hybrid Control for RollerDrive INTERROLL Symptom Motor is in brake mode red fault LED flashes once and error output is active No fault output is active Troubleshooting The following errors are reported by illuminated LEDs also see Meaning of the LEDs page 16 Possible cause Invalid state of motor hall effect sensor Broken wire Failed hall effect sensor Help Replace the RollerDrive Voltage over or under limits Power supply fluctuations failure or overload condition Check the power supply On a decline motor is in brake mode momentarily Red fault LED flashes twice No fault output is active or power supply shutdown or fuse blown on card Overvoltage detection caused by over speed or excessive back EMF decline angle too high package weight too high Reduce decline angle Use brake roller to keep speed low Motor overrun overset speed e Package enters zone at a higher than anticipated speed Reduce the package entry speed Red fault LED flashes six times and error output is active No fault output is active Low gain signal from sensor Dir
9. Logic photoeye inputs and outputs photoeye inputs and outputs are active high 24 VDC are active low 0 VDC ground This excludes the No fault output which is always active high 24 VDC when in either NPN or PNP mode Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Speed CO v wt O iv ES AY Se Position 100 G hh OQ E O1 O Oo 0 JI U O UO rm m Oo e Version 1 1 11 2011 en Original language of full Speed All motors Product information Local jog and reverse are always enabled but upstream and downstream propagation are controlled by DIP switch 4 and DIP switch 5 respectively Itis now simple to use DIP switch 4 and DIP switch 5 to define jog reverse groups or to defeat jog and reverse completely recommended whenever not in use Ifthe RollerDrive is mounted with the cable exiting the opposite side of the conveyor frame switch SW2 has to be set in the opposte position to maintain equal direction of travel e For special cases see Setting options and wiring diagrams page 20 Rotary switches 16 position Accel Decel v C La eCo lt T LY NN o Vi 5 WP 96 v V 9 9 p er Position of full Accel Position of full Decel 96 of full Decel 96 of full Decel All motors EC100 EC110 EC120 F 100 F 100 100 100 E 94 E 35 40 67 D 87 D 17 20 33 C 81 C 14 16 26 B 74 B 11 12 20 A 68 A 10 11 18 9 61 9 9 10 17 8 55 8 8 9 15 7 48
10. Power input and I O terminal and Sensor connection are cage clamp terminals To actuate the cage clamp use the supplied tool or insert a small screwdriver Plugin the RollerDrive connector Plugin the peer to peer connection cable if applicable Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Initial startup and operation Initial startup Inspections before initial startup Ensure that all bolts are tightened according to the specifications Ensure that no additional dangerous areas arise due to interfaces with other components Ensure that the wiring is in accordance with specifications and legal guidelines Check all protection devices Ensure that no bystanders are in dangerous areas around the conveyor Operation NOTICE Damage to the 9007 or the motor of the RollerDrive due to induction Do not push items along the roller conveyor by hand Inspections before every startup Changing settings Do not spin the RollerDrive manually Check the position of the DIP switches see DIP switches page 14 Check the speed settings at the speed rotary switch It is recommended to run the RollerDrive at maximum speed Check the 9007 for visible damage Check all protection devices Ensure that no bystanders are in dangerous areas around the conveyor Clearly specify and monitor the way goo
11. VDC power supply on the 9007 The 5 VDC power is delivered by a converter on the board which converts the 24 VDC power that the board receives into 5 VDC for the internal logic and peer to peer board communications For communication cable hardware see Accessories page 46 OQOO99 COOCOO Downstream peer to peer Upstream peer to peer Jog I O left Jog I O right Reverse I O Reverse I O GE Accumulation I O GQ Accumulation I O B sensor OUT C sensor IN Ground amp NPN IN O NPN IN right Ground left i While different segments of a system may operate at different input voltages the DC ground for each system must be held at the same potential 0 VDC to ensure good operation and clean signals In other words when multiple power supplies are used the DC grounds must always be connected together i When a peer to peer port is connected to another ZPA product the NPN in signal is pulled low except for the case where a 9007 is upstream Version 1 1 11 2011 en 13 Original language 9007 Hybrid Control for RollerDrive INTERROLL 14 Product information DIP switches The DIP switches allow the selection of various types of control operations The default DIP switch settings are all OFF This would provide RollerDrive selection of an EC100 SW6 SW7 Standard 9007 connectivity upstream and downstream SW4 SW5
12. is too slow Calculate the speed and the distance to ensure the time limit is not exceeded Reset Learn Mode see Learn Mode Reset page 30 Jammed package Remove jammed packages Jammed roller Remove the cause of the jam or replace the roller Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Symptom Troubleshooting Possible cause Package coasts into the next zone Package is heavy or has a low Help Move the photoeye further back into the instead of stopping immediately coefficient of friction zone Apply a coating that increases the friction between the rollers and the packages Zone does not reverse Communication cable to upstream zone is miswired Replace the communication cable Signal has not been sent and received properly Check the output of the upstream 9007 and the input to the 9007 Different ground of the zones Check that a common ground exists between both zones System turns off when several zones are in use at the same time Power supply is not sufficient Ensure that the 24 VDC power supply has adequate power for the system requirements Check that the AC voltage source and DC voltage power supply are installed correctly 9007 does not recognize the start sensor Sensor and reflector are not aligned properly Check the alignment of the sensor and reflector Check the settings of
13. maximum CW so it will not affect the external speed setting for the wiring diagrams see page 19 Sensor out Mimics the Sensor 1 input signal from pin 4 on the sensor connection Unchanged by zone type see sensor connections page 12 Smart 1 FWD input Has various functions depending on zone type n entry zone acts as a start signal for the handshake with previous machines or conveyors In exit zone acts as a start signal to discharge the conveyor as handshake to following systems n transport zone acts as jog signal for the specific zone or the whole conveyor depending on the DIP switch settings n dependent zone acts as jog command to run the motor This input is PNP NPN selectable with DIP switch 1 REV input Invokes the system reverse function causing all interconnected controls to operate in reverse transport mode while the signal is active When in dependent mode the motor will simply run in reverse while this signal is active This input is PNP NPN selectable with DIP switch 1 No fault output Active high 24 VDC when either in NPN or PNP mode Signal goes low only when system faults occur Smart 1 output Has various functions depending on zone type n entry zone reflects the status of the zone occupied or free for handshake with previous systems n exit zone reflects the status of the zone occupied or free for handshake with following systems ntransport zone is the conn
14. occurs a low signal is passed upstream until each consecutive zone is occupied Packages never push each other and no line pressure occurs A logic controlled zero pressure conveyor is created when a number of zones are connected together and a simple six wire phone cable links each 9007 electronically The RollerDrives only operate when a package is detected by a photoeye If the downstream zone is empty the package moves forward 9007 Hybrid Control for RollerDrive INTERROLL Product information Principle of zones i lt A C B A O A m A A oy O e oro Te T8 j PAT o l Typical ZPA conveyor configuration D Zone 8 Photoeye 2 Direction of travel 6 9007 8 Load 7 Peer to peer communication cable E RollerDrive 24 VDC GND Zone A has a package at the photoeye The 9007 of zone A recognizes its presence checks zone B for availability and requests permission to transfer the package to zone B Since zone B has also a package its 9007 denies the permission until this package has been tra
15. 0 322 Fax 44 1536 748 515 gb sales interroll com Central Europe Germany Interroll F rdertechnik GmbH H ferhof 16 D 42929 Wermelskirchen Tel 49 2193 23 0 Fax 49 2193 20 22 d sales interroll com Austria Tel 49 2193 23 187 Fax 49 2193 23 164 Belgium Tel 49 2193 23 131 Fax 49 2193 23 164 Luxembourg Tel 49 2193 23 190 Fax 49 2193 23 164 Netherlands Tel 49 2193 23 151 Fax 49 2193 23 164 Switzerland Tel 49 2193 23 190 Fax 49 2193 23 164 Eastern Europe Czech Republic Interroll CZ s r o Na Radku 7 3172 CZ 69002 Breclav Tel 420 519 330 210 Fax 420 519 330 211 cz sales interroll com Hungary Tel 36 23 337 891 Fax 36 23 337 892 Poland Interroll Polska Sp z 0 0 ul Plochocinska 85 PL 03 044 Warszawa Tel 48 22 741 741 0 Fax 48 22 741 741 1 pl sales interroll com Slovakia Tel 421 2 4363 8102 Fax 421 2 4342 7294 Slovenia Tel 386 1 56 56 370 Fax 386 1 56 56 372 Turkey Rol er Makina San Ve Tic Ltd Sti Pembegul Sok Dostlar Apt No 12 D 10 Suadiye 347 40 Istanbul Turkiye Tel 90 216 386 37 75 Fax 90 216 386 38 22 tr sales interroll com Near East Israel ComTrans Tech Ltd P O B 17433 Tel Aviv 61174 Israel Tel 972 54 4 27 27 47 Fax 972 3 7 44 08 64 il sales interroll com Africa South Africa Interroll SA Pty Ltd P O Box 327 Isando 1600 37 Director Road Spartan Ext 2 1619 South Africa Tel 27 11 281 9900
16. 11 2011 en Original language 9007 Hybrid Control for RollerDrive 9007 is exit zone Version 1 1 11 2011 en Original language INTERROLL Product information Upstream device 9007 Downstream device DIP switch 4 Off On Off On DIP switch 5 Off On On Off Upstream peer to peer jog Disabled Functional Disabled Functional reverse Downstream peer to peer Disabled Functional Functional Disabled jog reverse Zone type Smart I O ZPA mode ZPA mode Smart I O exit exit Smart 1 in Perm Jog Jog Perm Reverse in System System System System reverse reverse reverse reverse Smart 1 out Request Motor run Motor run Request Sensor 2 Another Another Another Another C sensor C sensor C sensor C sensor Standard configuration with Smart in GND 24 VDC Smart 1 IN start command Direction of travel pu D DDD DUDUDU INTERROL MA etre er Belt A mooo ROLLERDRIVE Sensor in GND 24 VDC 24 VDC GND L to upstream ZPA card GND 24 VDC DIP switch settings SW5 ON OFF specifies if this zone is a transport or exit zone Smart 1 IN signal by PLC or photoeye Start signal for PNP 24 VDC Start signal for NPN GND 29 9007 Hybrid Control for RollerDrive INTERR
17. 229 1134 Japan Tel 81 42 764 2677 Fax 81 42 764 2678 jpn sales interroll com Korea Interroll Korea Corporation Room 301 Dongsan Bldg 333 60 Shindang Dong Choong ku Seoul Korea Tel 822 2 231 1900 Fax 822 2 254 36 83 kr sales interroll com Singapore Interroll Asia Pte Ltd 386 Jalan Ibrahim 629156 Singapore Republic of Singapore Tel 65 6266 6322 Fax 65 6266 6849 sgp sales interroll com Thailand Interroll Thailand Co Ltd 41 6 Moo 6 Bangchalong Bangplee Samutprakarn 10540 Thailand Tel 66 2 337 0188 91 Fax 66 2 337 01 92 th sales interroll com India Interroll Drives and Rollers India Private Limited SF 12 KSSIDC Building 3rd Stage Peenya Bangalore Bangalore 560058 Kamataka India Tel 91 80 2359 5904 Fax 91 80 2349 5241 in drummotors interroll com Australia amp New Zealand Australia Conveyor Solutions Australia Pty Ltd 70 Keon Parade Thomastown VIC 3073 Australia Tel 61 3 9460 2155 Fax 61 3 9460 2029 aus sales interroll com New Zealand Automation Equipment NZ Ltd 45 Colombo Street Frankton Hamilton New Zealand Tel 64 7847 2082 Fax 64 7847 7160 nz sales interroll com For other countries please see contacts at
18. Appendix Accessories Part Power and I O plug Description 8 pin cage clamp type connector Wago part 231 308 026 004 Wire diameter Minimum 0 08 mm AGW 28 Maximum 2 5 mm AGW 12 Sensor plug 6 pin cage clamp type connector Wago part 734 106 000 004 Wire diameter Minimum 0 08 mm AGW 28 Maximum 1 5 mm AGW 14 Peer to peer cable parts Cable 6 pos flat cable Digikey part A0063R Two plugs 6 pos modular connector plug Digikey part A9093 ND Conductor Size AWG 26 Assembly tool AMP part 2 231652 8 Peer to peer cable preassembled Complete cable 6 pos flat cable with 2 6 pin modular plugs Digikey part A1663R 03 ND 03 3 foot length www digikey com Motor plug The motor plug for the RollerDrive consists of a plug and terminal pins Plug AMP part 175778 8 Terminal pins AMP part 1 175102 1 Crimping tool AMP part 9184381 Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Back EMF B sensor C sensor Coast mode DIP switch 4 DIP switch 5 Downstream Dynamic braking EC1xx Edge full Enhanced Singulated release Foldback current Version 1 1 11 2011 en Original language Appendix Glossary Electromotive force voltage generated by a package arriving at high speed at a powered RollerDrive under no load prior to the package s arrival EMF is a counter volta
19. Fax 27 11 252 9083 za sales interroll com North amp South America USA Interroll Corporation 3000 Corporate Drive USA Wilmington NC 28405 Tel 1 910 799 11 00 Fax 1 910 392 38 22 usa sales interroll com Canada Interroll Components Canada Ltd 8900 Keele Street Unit 2 amp 3 Concord Ontario L4K 2N2 Canada Tel 1 905 660 4426 Fax 1 905 660 4159 cdn sales interroll com Interroll Canada Ltd Drives amp Rollers Canada 1201 Gorham Street Newmarket Ontario L3Y 8Y2 Canada Tel 1 905 727 3399 Fax 1 905 727 3299 cdn sales interroll com Brasil Interroll Logistica Elementos para Sistemas Transportadores Ltda Av Alexandrina das Chagas Moreira 945 Bairro Distrito Industrial Pindamonhangaba SP Brasil CEP 12412 800 Tel 55 12 3648 8021 Fax 55 12 3648 8164 sa sales interroll com For other countries in South America please contact Interroll Espafia S A Parc Teconol gic del Vall s C Dels Argenters 5 Edificio 1 m dulos Bp y Cp E 08290 Cerdanyola del Vall s Tel 34 90 211 0860 Fax 34 93 586 4895 e sales interroll com INTERROLL Asia China Interroll Suzhou Co Ltd Unit 10B Modern Industrial Square No 333 Xing Pu Road Suzhou Industrial Park Suzhou Jiangsu Province People s Republic of China Postal Code 215126 Tel 86 512 6256 0383 Fax 86 512 6256 0385 cn sales interroll com Japan Interroll Japan Co Ltd 302 1 Shimokuzawa Sagamihara shi Kanagawa
20. INTERROLL WE MAKE THE WORLD MOVE User Manual Interroll 9007 Hybrid Control for RollerDrive EC100 EC110 EC120 future Manufacturer Interroll Corporation 3000 Corporate Drive Wilmington NC 28405 Tel 800 830 9680 Fax 800 830 9679 www interroll us Copyright The copyright of this manual remains with Interroll Corporation This manual includes regulations and technical drawings which may not be copied or duplicated either in whole or in part Unauthorized use publication or application of this document is prohibited Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Table of contents Introduction Handling of the user manual llli ce eee eee 2 Warnings in this manual eh 2 Further symbols llle 3 Safety General safety instructions llli 4 Irnitended use euren bo dee eben ie add TAR dame e eMac SLE de sn a 4 Unintended use liliis nh 4 Qualified persons 0000 cee en 5 alc PTT 5 Interfaces sc eves e ur PEATE uum uud XR AR REQUE d See 5 Product information Comporients ih aa dew RE Yea S Peau dd mE PES EEG un 6 DIMENSIONS 22 LT 7 ZPA technology 1 2 isle hs 7 Product description l l 9 Incline and decline applications llle 10 Inputs and outputs s eiia pat a e eee 11 Peer to peer communication lees 13 DIP switches zie pc ge e a Die je E tak Ree A 14 Meaning of the LEDS 000020 e ce
21. INTERROLL Product information 9007 is entry zone Upstream device Downstream device 9007 DIP switch 4 Off On Off On DIP switch 5 Off On On Off Upstream peer to peer jog Disabled Functional Disabled Functional reverse Downstream peer to peer Disabled Functional Functional Disabled jog reverse Zone type Smart I O ZPA mode Smart I O ZPA mode entry entry Smart 1 in Request Jog Request Jog Reverse in System System System System reverse reverse reverse reverse Smart 1 out Perm Motor run Perm Motor run Sensor 2 Not used Another Not used Another smart I O C sensor Smart lO C sensor Standard configuration with PLC or photoeye start command UU a a a uy pan 9 Direction of travel amp E Baum a c BE tem SE E 5 3 TON B Sensor2 in o D GND 2 7 O quom eH Sensor in op GND 24 VDC EJ o 424 VDC o o T GND 24 VDC to downstream ZPA card DIP switch settings e SW4 ON OFF specifies if this zone is a transport or entry zone if sensor 2 IN is used SW4 must be set to ON Sensor 2 IN start signal by PLC or photoeye Start signal for PNP 24 VDC Start signal for NPN GND If you are using a photoeye as a starting signal connect sensor 2 IN with the photoeye Version 1 1
22. ND a b e S Sensor in 24 VDC out for PNP GND for NPN done el SND oc GND 24 VDC to downstream ZPA card i A smart I O based handshake is required at the interface DIP switch 4 must be OFF to make this zone into an entry zone Jog and reverse are enabled only if DIP switch 5 is ON e T T EXIT ZONE TRANSPORT ZONE TRANSPORT ZONE ENTRY ZONE 6 o o A A A Nas E D ri PLC o Omp Eh o ep o egt O E C C ye l e ON ON ON ON a D D o miu oO a C D iD lo lol lo a B O lo lo lo lo a iC iD ID old lo 12 34 56 7 1 2 3 4 5 6 1 2 8 4 5 6 7 12 34 56 7 Switch settings for Stop at exit zone of conveyor Key PLC start at entry zone 0 Zone 8 Photoeye Singulated release Direction of travel 9007 CCW direction Load 7j Peer to peer communication cable NPN 4j RollerDrive 24 VDC GND SW5 ON will let product continue past the exit zone sensor Version 1 1 11 2011 en 33 Original language 9007 Hybrid Control for RollerDrive INTERROLL Product information 9007 before PLC handshake exit zone ROLLERDRIVE Direction of travel pu Smart IN downstream permission 24 VDC IN for PNP GND for NPN Smart1 OUT downstream request Sensor in 24 VDC OUT for PNP GND for NPN AUD HHDH THH A 0000 24 VDC
23. OLL Product information Learn Mode Reset At startup Learn Mode automatically sets the zone length and saves it simply by running an object from the upstream sensor to the downstream sensor If the sensor positioning or zone length should change after startup you must reset the learn mode Simply remove the two screws from the cover to reveal the two pin header shown below Carefully short these two pins together until you see the LED s flash Immediately remove the short You are now ready to run an object from the upstream sensor to the downstream sensor to re learn the zone length Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL this page intentionally left blank Version 1 1 11 2011 en 31 Original language 9007 Hybrid Control for RollerDrive INTERROLL Product information 9007 in conjunction with PLC handshakes 9007 after 9007 before 9007 PLC handshake entry zone PLC handshake exit zone between PLC handshakes Upstream device PLC PLC 9007 9007 PLC Downstream device 9007 9007 PLC PLC PLC DIP switch 4 Off Off Off On Off DIP switch 5 Off On Off Off Off Upstream peer to peer jog reverse Disabled Disabled Disabled Functional Disabled Downstream peer to peer jog Disabled Functional Disabled Disabled Disabled reverse Zone type Smart I O Smart I O Smart I O Smart I O Smart I O entry entry exit exit dependent Smart 1
24. and diagrams the warning and safety instructions in this manual the system specific regulations and requirements national or local regulations and requirements for safety and accident prevention Risks The following list informs you about the various types of danger or damage that may occur while working with the 9007 Maintenance or repair work mustonly be executed by authorized and qualified persons in accordance with the applicable regulations Before using the 9007 ensure that no unauthorized persons are near the conveyor v Only perform installation and maintenance work after you have switched off the power Ensure that the power cannot be turned on accidentally Do not use the 9007 in explosive atmospheres Remove equipment or material which is not required from the workspace Regularly check the 9007 for visible damage In case of fumes turn off the power at once and ensure that it cannot be turned on accidentally Contact qualified personnel immediately to find the source the malfunction VV VY Y Y As the product is maintenance free you only need to check regularly for visible damage and that all leads and screws are still tightened Interfaces By assembling the 9007 in a conveyor module potential hazards may occur These are not described in this manual andhave to be analyzed during the design installation and startup of the conveyor module gt After assembling the 9007 in a conveyor
25. ards to achieve multiple RollerDrives in a single zone This signal can also be used by a PLC as a motor running status input Smart braking Depending on upstream and downstream zone occupancy the RollerDrive will brake if needed and coast if no braking is required This saves on power heat and vibration in the RollerDrive and ultimately in the system When no photoeyes are blocked in the system all RollerDrives are in coast mode Dynamic braking RollerDrive acts like a generator and the 9007 feeds back current into the RollerDrive windings Zero motion hold When the 9007 has no start signal the RollerDrive will be held in place Advanced braking The combination of dynamic braking followed by zero motion hold provides superior braking and holding for many applications Operation modes The operation modes of a RollerDrive conveyor with 9007 Hybrid Controls include Version 1 1 11 2011 en Original language Standby The RollerDrives are turned off if the zone is empty Accept When a load reaches the sensor at the upstream end of the zone the RollerDrives turn on to accept it Transfer The RollerDrives continue to run to ensure that the load entering the upstream end of the zone is transferred to the downstream end This creates a smooth transition and high throughput Discharge The RollerDrives in the zone continue running to discharge the load if no accumulation command is received from the downstream zone 9007 Hybri
26. cks during transport Check each 9007 visually for damage after transport In case of damage take photos of the damaged parts To maintain the warranty instantly report any damage caused during transport to the transport company and to Interroll Do not transfer the 9007 between warm and cold environments as this may cause condensing water Y NY NY NY Y Y v Storage AA CAUTION Risk of injury due to improper storage Do not stack more than four carton boxes gt Check each 9007 for damage after storage Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Assembly Warning notices concerning assembly NOTICE Risk of damage leading to failure or shortened life expectancy of the 9007 gt Observe the following notices Do not drop or mishandle the 9007 to avoid internal damage gt Check each 9007 visually for damage before assembly Warning notices concerning the electrical installation NOTICE Risk of damage to the 9007 gt Observe the following notices gt The electrical installation may only be executed by qualified and authorized persons gt Disconnect the power before installing removing or rewiring the 9007 Do not apply AC current to the RollerDrive or 9007 device at any time as this will cause irreparable damage Do notapply too much stress to the connector pins Bending the wires at the connector can cause damage to the insulat
27. d Control for RollerDrive INTERROLL 10 Safety and stall functions Product information There are different levels of over temperature or stall related functions Jam protection If the 9007 detects a jam or obstruction at the downstream end of the zone it sends an accumulation signal to the upstream zone preventing a build up of accumulation pressure that could cause product damage or personal injury Motor temperature foldback At a motor temperature of 80 C 176 F the 9007 will fold back peak current down to continuous current This is indicated by the amber LED lighting up constantly When the RollerDrive cools down the amber LED extinguishes and the maximum peak current is now possible again The motor can run at this reduced current limit indefinitely without harming the 9007 or the motor Motor temperature shutdown At a motor temperature of 100 C 212 F the 9007 will shut down the motor and the motor will go into dynamic braking This is indicated by the red led flashing five times When the RollerDrive cools back down the red LED stops flashing and motor operation will resume Motor stall current limiting When the motor is stalled the current will fold back to 1 4 A until the stall is cleared 9007 temperature foldback At acard temperature of 70 C 158 F the 9007 will foldback peak current downto continuous current This is indicated by the amber LED lighting up constantly When the 9007 cools dow
28. ds are placed on the conveyor To reduce the speed manually turn the rotary switch counterclockwise with a small screwdriver To increase the speed manually turn the rotary switch clockwise with a small screwdriver To set the DIP switches carefully use a small screwdriver Procedure in case of accident or malfunction Y NY NY Y Y Version 1 1 11 2011 en Original language Stop the conveyor at once and ensure that it cannot be started accidentally In case of an accident Provide first aid and call for emergency assistance Inform responsible persons Have the malfunction repaired by qualified persons Start the conveyor only after this has been approved by qualified persons 39 9007 Hybrid Control for RollerDrive INTERROLL Checking the 9007 Replacing the 9007 Replacing fuse Maintenance and cleaning Warnings concerning maintenance and cleaning CAUTION Risk of injury due to improper handling or accidental motor starts Maintenance work and cleaning may only be executed by qualified and authorized persons Only perform maintenance work after switching off the power Ensure that the 9007 cannot be turned on accidentally Set up signs indicating maintenance work Maintenance The 9007 must be checked at regular intervals to avoid malfunctions Monthly check the 9007 and its leads for visible damage Annually ensure that the screws of the 9007 are still tight and that the cables are st
29. e ee eee 16 9007 label needa Reh i ne Redeem eeu tmd dai RR hen 17 Technical data cee eee 17 Speed settings 0020200 18 Setting options and wiring diagrams ee 20 Transport and storage Transpoft ewe ee whe ae eee eren SPREE GS ue ee eee Ss 36 SLOAN cT TP 36 Assembly Warning notices concerning assembly 0 000 eee eaee 37 Warning notices concerning the electrical installation 37 Installing the 9007 in a conveyor system 0 0000 e eee eee 38 Electrical installation llle 38 Initial startup and operation Initial startup llle RII I I A 39 Operation 2 0 2235 00 65 22a anise BE aged Sad AA NL Ode RR a dos eke 39 Procedure in case of accident or malfunction 39 Maintenance and cleaning Warnings concerning maintenance and cleaning 40 Maintenance invidentes Boro EON E ERE 40 Cleaning Eee ile Eee 40 Troubleshooting Error search occum AREE e bes Ire uh 41 Abandonment and disposal Abandonment llle eee 45 DISPOSal scammer tae PETERET 45 Appendix ACCOSSONGS ne outta E or A aware ee een Rake eee oe OR L 46 GIOSSAlY MC 47 Manufacturer s declaration 00 cee eee eee eee 49 Version 1 1 11 2011 en 1 Original language 9007 Hybrid Control for RollerDrive INTERROLL Content of the manual Validity of the manual This manual is part of the product Structure of warnings Introduction Handli
30. ection to control a second RollerDrive in the zone by interfacing with Smart 1 IN of the dependent zone n dependent zone reflects the status of the sensor This output is PNP NPN selectable with DIP switch 1 Common ground input Must be connect to the main power ground O 24 VDC input Main power supply 24 VDC voltage range see Technical data page 17 11 INTERROLL 9007 Hybrid Control for RollerDrive INTERROLL Product information i The 9007 is protected against reverse polarity but the power supply must provide a short circuit or over current protection and a voltage ripple tolerance of less than 5 Sensor connection M l oa as 8 Accum L stop input 8 Sensor 2 input 4 Sensor 1 input 3 Motor run 2 Sensor common ground output Sensor 24 VDC output ooooo00Q0 Accum L stop input An active signal NPN PNP switchable on this terminal input will cause the 9007 to accumulate in this zone until the signal is removed A manual switch or a PLC controller can provide the signal referenced to a common DC ground NPN or 24 VDC PNP This input is PNP NPN selectable with DIP switch 1 Sensor 2 input Used as a start sensor It is located at the upstream edge of the zone and tells the first zone in a conveyor to run Th
31. f travel g q Bees E 3 d Eu Accum in L stop ER Rum EB Sensor in 24 VDC 3 Serr EH SND DC to downstream ZPA card E at to upstream ZPA card 24 VDC 24 VDC GND i GND DIP switch settings SW1 ON Version 1 1 11 2011 en 21 Original language 9007 Hybrid Control for RollerDrive INTERROLL 22 Product information Accumulation L stop in NPN mode Direction of travel ROLLERDRIVE pi deze o6 Huuuuu GND 24 VDC a ITERROLe DT Accum in L stop oe Sensor in 24 VOC to upstream ZPA card to downstream ZPA card DE 24 VDC 1 GND 24 VDC i GND DIP switch settings e SW1 OFF Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Product information External direction set in PNP mode m a a x x Direction of travel a o a Reverse direction of travel A gt amp IE IO OO SE Smart 1 Fwd in SE Revin a R q a o E GND E 2 nm e B Sensor in 24 VDC al o gt S SND IG o to downstream ZPA card _______________ to upstream ZPA card T 24 VDC GND REVin
32. ge phenomenon that is always present in a motor Excessive back EMF can cause a current backlash that may damage the 9007 or power supply Care should be taken to minimize excessive back EMF by minimizing the speed differences between the gravity conveyor and or different zones of powered conveyor sections Downstream edge presence sensor of own zone Downstream edge presence sensor of upstream zone The RollerDrive is running freely without power or braking Affects upstream peer to peer propagation of speed jog and reverse signals for certain scenarios Affects downstream peer to peer propagation of speed jog and reverse signals for certain scenarios Normally this is the zone to the left of another given zone The reference is always that packages move from upstream to downstream For DC motors dynamic braking is a method of stopping a motor by applying a resistive load across the motor winding leads after disconnection from the DC supply The motor operates as a generator By its nature dynamic braking has no holding power by itself i e the motor can still be rotated by outside forces Interroll has added zero motion hold to achieve this Short form for Interroll 24 VDC brushless RollerDrive versions EC100 EC110 e EC120 Also referred to as product waiting It indicates that an upstream zone has a product at its downstream edge sensor waiting to be moved into the next downstream zone Edge full is a signal transmitted acros
33. ground is shared by all supplies System reverses or jogs without prompting Fuse is blown If DIP switch 4 and 5 are ON for all cards a blown fuse or loss of power in one 9007 sends a reverse jog command to all 9007 cards in the system Check the fuses in all 9007 cards of the system and replace the blown one see Replacing fuse page 40 Miswired communication cable Check the communication cables in the entry zone of the system Replace the miswired cables Zone stops when package arrives Zone does not accept package Zone receives the accumulate signal Check that the zone is not receiving the accumulate signal from the downstream zone Ensure that there is no jumper installed from ground to the Accum L stop input terminal on the 9007 of the zone where the package stops If a switch is used instead of a jumper check that the switch is off Communication cable to or between the zones is miswired Check the communication cables and replace them if they are miswired No power supply of the 9007 Check the power input to 9007 No power supply of the RollerDrive EC1xx Verify that the motor wires are terminated properly Communication cable is miswired between the zone that is operating and the zone that is not Replace the cable Package stops within a zone 42 Photoeye is not aligned properly Check the alignment of the photoeye Speed of the RollerDrive EC1xx
34. ill laid properly and connected to the terminals If a 9007 is damaged it has to be replaced Install a new 9007 see Abandonment page 45 and see Assembly page 37 Carefully use tweezers to remove and insert the fuse Ensure you do not damage the fuse holder the circuit board or its devices Cleaning Dust and dirt in combination with humidity may bridge the electric circuit Therefore in a dirty environment periodic cleaning will help to avoid short circuits which could damage the 9007 gt Regularly blow off dust and dirt by using low compressed air Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Symptom System is not operating Troubleshooting Error search When troubleshooting the conveyor system keep in mind that each 9007 controls a zone If a problem exists in a zone or a section of zones the symptoms might exist either in the zone or in the neighboring zone Keep in mind that information travels downstream The cause of most control problems can be found upstream Possible cause No power supply Help Check whether the output voltage of the power supply is within the specified voltage range Wrong polarity of the bus line inputs Verify the polarity of the bus line inputs to the 9007 see Inputs and outputs page 11 Wrong position of the DIP switch 1 Verify that the position of the DIP switch 1 Logic NPN or PNP matches
35. in Request Request Perm Perm Run Reverse in System System System System System reverse reverse reverse reverse reverse Smart 1 out Perm Perm Request Request B sensor Sensor 2 Not used Not used Another Another Not used smart I O smart I O C sensor C sensor 32 Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL 9007 after PL C handshake entry zone ii 2 ra a Y Lu d E Direction of travel 9 CIERRO Smart1 in upstream request T e mar mad 24 VDC in for PNP GND for NPN ele EE E Smart1 out upstream permission G
36. ion of the wires which could result in failure of the 9007 or the RollerDrive Ensure that the RollerDrive the 9007 and the 24 VDC power source are properly earthed through the frame or supporting structure in which the RollerDrive and the 9007 are installed Failure to do so could cause the buildup of static electricity or ground loops and can cause the motor or 9007 to malfunction or fail prematurely gt Do not spin the RollerDrive manually as this generates an induction voltage which could damage the 9007 Version 1 1 11 2011 en 37 Original language 9007 Hybrid Control for RollerDrive INTERROLL 38 Assembly Installing the 9007 Hybrid Control in a conveyor system Use the 9007 as a template and mark the center of the two mounting holes For the distance between the holes see Dimensions page 7 gt Drill two 5 6 6 mm 0 22 0 24 in mounting holes at the marked spots Insert the button head screws in the holes on the opposite side the 9007 is to be mounted Install the 9007 to the frame with the screws protruding through the mounting holes Slip the nuts to the screws and tighten Ensure thatthere is a ground path between the 9007 and the conveyor frame it is mounted to The 9007 and conveyor frame should be at the same potential referenced to earth ground Electrical installation The connector supplied with the RollerDrive EC1xx mates up with the header on the 9007 The connectors
37. is input is PNP NPN selectable with DIP switch 1 Sensor 1 input Located at the downstream edge of the zone This input is PNP NPN selectable with DIP switch 1 Motor run output Output to tell PLC that the motor is running Unchanged by zone type This input is PNP NPN selectable with DIP switch 1 Sensor common ground output Power ground connection for sensor 1 and sensor 2 Sensor 24 VDC output 24 VDC power supply for sensor 1 and sensor 2 oO GO OG i Only the sensors mentioned below may be chosen sensor supply current from the board is 50 mA max NPN retro reflective reflector required light operate normally open NO contact e NPN diffused no reflector dark operate normally closed NC contact PNP retro reflective reflector required light operate normally open NO contact e PNP diffused no reflector dark operate normally closed NC contact 12 Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Product information Peer to peer communication Even though all of the external inputs and outputs are NPN and PNP switchable the 9007 peer to peer communications always use NPN TTL logic This means that if a signal passing from board to board is high it is not in operation If it is low grounded it is either performing its designated function or sending the function signal to a nearby board All logic operates from a regulated and filtered 5
38. llers Permission Signal to upstream zone to discharge zone send load An ON OFF sensor that uses light to sense the presence of objects If the light beam is broken an object is present Usually the light is reflected back to the sensor via a reflector placed on the opposite side of the conveyor frame from the sensor itself The 9007 can use either NPN type or PNP type photoeyes NPN sensors indicate an active state by a grounded connection being made NPN mode or a 24 VDC connection being made PNP mode Request from upstream zone to discharge zone in downstream direction One of several types of DC powered rollers manufactured by Interroll Corporation A method of releasing packages where packages are allowed into downstream zone only after the trailing edge of the package currently occupying that downstream zone clears the zone s downstream edge sensor DIP switch 3 chooses either standard or enhanced singulation significant for all zone types except smart I O dependent The opposite of downstream see definition Typically the zone to the right of another zone For DC motors zero motion hold is a method of holding a motor by applying a small amount of current to the motor winding leads When the 9007 is commanded to stop and accumulate the braking action is twofold First the motor package is stopped using dynamic braking Second the motor is held in place by zero motion hold In this state the 9007 will resist being
39. module check the whole system for any new potential dangerous condition prior to turning on the conveyor 9007 Hybrid Control for RollerDrive INTERROLL Product information The 9007 has ZPA and motor control functionality on board If no peer to peer port is connected and DIP switches 4 and 5 are set to OFF it Switches automatically from ZPA mode to motor control mode only Components TS a Ir m Fel Waring U ER E El Doro Central fer RollerDaive E EM pese qu RENI E E Honinil voltug 24 VDC E Mindrum surent 4 1 A PIN 9006 Rev B H 43509 IH 1 g A fS 000001 060000000050 LL e Warning LED amber 2 Fault LED red Power LED green 4 Fuse LED red 5 DIP switches 6 Speed potentiometer T Acceleration potentiometer Deceleration potentiometer Label Motor cable of RollerDrive i Sensor connection 12 Upstream connection 13 Downstream connection Direction of travel 15 Power input and O terminal Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive Mounting hardware Version 1 1 11 2011 en Original language
40. n the amber LED extinguishes and the maximum peak current is now possible again The 9007 can run at this reduced current limit indefinitely without harming the 9007 or the motor 9007 temperature shutdown At a 9007 temperature of 90 C 194 F the 9007 will shutdown the motor and the motor will go into dynamic braking This is indicated by the red LED flashing four times When the 9007 cools back down the red LED stops flashing and motor and 9007 operation will resume Incline and decline applications Due to the zero motion hold and regenerative braking features the 9007 and RollerDrive EC1xx can be used for incline and decline applications up to an angle of 15 Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive Power input and I O connections Version 1 1 11 2011 en Original language Product information Inputs and outputs al El 2 Speed analog input Sensor out 7 Smart 1 FWD input REV input No fault output 4 Smart 1 output 3 Common ground input 2 24 VDC input D l El WERL p Speed analog input External speed control down to approximately 33 of the maximum speed When using a 10 kO external potentiometer the wiper must be connected here The on board rotary switch should be set to
41. n be obtained at www interroll com if needed 49 Europe Nordic Denmark Interroll Nordic A S Hammerholmen 2 6 DK 2650 Hvidovre Denmark Tel 45 36 88 33 33 Fax 45 36 88 33 72 dk sales interroll com Interroll Service Islandsvej 5 DK 7900 Nyk bing M Tel 45 97 71 15 55 Fax 45 97 71 16 55 dk sales interroll com Iceland IBH ehf Dugguvogur 10 104 Reykjavik Iceland Tel 354 562 6858 Fax 354 562 6862 ingi ibh ehf is Finland Tel 358 9 54 94 94 00 Fax 358 9 54 94 94 16 Norway Tel 47 32 88 26 00 Fax 47 32 88 26 10 Sweden Tel 46 35 227077 Fax 46 35 227078 Western Southern Europe France Interroll S A S Z de Kerannou B P 34 F 29250 Saint Pol de L on Tel 33 298 24 41 00 Fax 33 298 24 41 02 f sales interroll com Italy Rulli Rulmeca S p A Via A Toscanini 1 1 24011 Alm Bg Tel 39 035 4300111 Fax 39 035 545523 i sales interroll com Portugal Rulmeca Interroll de Portugal Lda Apartado 69 Centro Civico P 6201 909 Covilha Tel 351 275 330 780 Fax 351 275 990 789 p sales interroll com Spain Interroll Espa a S A Parc Teconol gic del Vall s C Dels Argenters 5 Edificio 1 m dulos Bp y Cp E 08290 Cerdanyola del Vall s Tel 34 90 211 0860 Fax 34 93 586 4895 e sales interroll com Version 1 1 11 2011 en Original language United Kingdom Interroll Ltd Brunel Road Earlstrees Industrial Estate GB Corby Northants NN17 4UX Tel 44 1536 20
42. nfor mation Apart from the rotary switch on the 9007 there are other ways to set the speed For the meaning of the settings see DIP switches page 14 External speed set by potentiometer Speed analog input GND input 24 VDC input Direction of travel fumo Od uuuuu oooooooo S ROLLERDRIVE 20000 00 Sensor in ND 24 VDC to downstream ZPA card t LO upstream ZPA card T 24 VDC GND 10 kQ Pot at minimum equals 33 of rated speed for all motors External speed set by PLC u x a r4 ul Direction of travel 4 o a amp ES 0 mua Speed analog input EE re Gl a 43 lt E v I lt El Sensor in GND input Gl lt a o n 24 VDC input al al 2 GND a LI it to downstream ZPA card ______________ to upstream ZPA card 24 VDC 1 10 VDC GND PLC analog speed output 0 10 VDC 1 V 2 33 of rated speed for all motors 10 V 7 100 of rated speed GND 19 9007 Hybrid Control for RollerDrive 20 9007 is between two 9007 Cards Product information Setti
43. ng of the user manual In this manual the 9007 Hybrid Control for RollerDrive for the EC100 EC110 EC120 is referred to as 9007 This manual contains important advice notes and information about the 9007 in all phases of its lifecycle Transport assembly and commissioning Safe operation maintenance troubleshooting and disposal Accessories The manual describes the 9007 as it is delivered by Interroll Special application designs require validation from Interroll and additional technical instructions gt For trouble free safe operation and warranty claims read this manual and follow the instructions before handling the 9007 gt Keep this manual near to the 9007 gt Pass this manual on to any subsequent operator or occupant of the 9007 gt Interroll does not accept any liability for malfunctions or defects due to non observance of this manual gt If you have any questions after reading this user manual feel free to contact our customer service See the last page for contact information Warnings in this manual The warnings in this document refer to risks which may arise while using the 9007 For relevant warnings see Safety page 4 and the warnings at the beginning of each chapter There are three categories of danger The following signal words are used in the document as required Danger Warning Caution Signal word Meaning Danger Indicates a hazardous situation which if not a
44. ng options and wiring diagrams INTERROLL This chapter explains the DIP switch settings for different application When the DIP switch settings ON OFF are stated both settings are possible for the shown wiring for the meaning of the settings see DIP switches page 14 Upstream device Downstream device DIP switch 4 Off On DIP switch 5 On Off Upstream peer to peer jog Disabled Functional reverse Downstream peer to peer Functional Disabled jog reverse Zone type ZPA mode ZPA mode Smart 1 in Jog Jog Reverse in System System reverse reverse Smart 1 out Motor run Motor run Sensor 2 Another Another C sensor C sensor Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Product information Standard configuration u x Q va w l ME Direction of travel 2 amp fro e Ema E EF B nu 2 B pla baron E Sensor in 24 VOC al Eme E GND DC to downstream ZPA card L to upstream ZPA card 24 VDC 24 VDC GND L GND Accumulation L stop in PNP mode y m a a UU 2 Direction o
45. nsfered to zone C singulation mode or has at least started being transfered enhanced singulation mode The singulation method depends on the setting of DIP switch SW3 The 9007 of zone A will only start to operate the RollerDrives in its zone after it gets permission from the 9007 of zone B Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Product information Product description Features N Zone to zone communication Activities in upstream and downstream zones are monitored by photoeyes to permit control in various situations Learn Mode During system startup the 9007 will automatically set the zone length and save it simply by running an object from the upstream photoeye to the downstream photoeye Diagnostics LEDs provide motor sensor and jam diagnostics as well as power fuse and temperature status Reverse or jog entire system Switch settings and connections on the board allow the user to reverse the zone to zone logic jog the entire system or reverse or jog parts of the system or bypass those functions altogether default without the use of external cards NPN or PNP All inputs and outputs can be switched collectively for NPN or PNP with one switch Only No fault output is always active high failsafe function with 24 VDC in No fault status Multiple dependent RollerDrives in one zone Up to three RollerDrives can be run from one 9007 and two dependent c
46. onnected to GND at NPN mode causes cw rotation FWD and REV connected to GND at NPN mode causes coast mode FWD signal acts like ajog signal disregarding ZPA functionality and photoeye signals REV signal reverses motor and logic direction upstream becomes downstream and C sensor becomes B sensor Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Product information Left to right conveyor Direction of travel ROLLERDRIVE to upstream ZPA card to downstream ZPA card ENG EX mass e Sensor in B 3 firmat b E zi E GND GND 24 VDC 1 24 VDC i Works like a standard configuration only the 9007 is turned upsidedown Version 1 1 11 2011 en 25 Original language 9007 Hybrid Control for RollerDrive INTERROLL 26 Product information Multiple RollerDrives in one zone Direction of travel ROLLERDRIVE ROLLERDRIVE ROLLERDRIVE pu
47. or the EC100 EC110 and EC120 by the rotary switch marked speed on the 9007 Default setting is maximum Gear ratio Speed range EC100 9007 EC110 9007 EC110 9007 Future EC120 1 9 diameter 1 9 diameter 2 5 diameter 2 5 diameter 41 2 41 to 0 80 m s 475 to 157 fpm 9 1 1 07 to 0 36 m s 211 to 70 fpm 12 1 1 32 to 0 44 m s 0 8to 0 26 m s 1 05100 35 ms 260 to 86 fpm 158to52fpm 207 to 69 fpm 16 1 1 03 to 0 234 mis 0 6to 0 20 m s 0 78 to 0 26 ms 202 to 67 fpm 119to39fpm 154 to 51 fpm 24 1 0 69 to 0 23 m s 0 4 to 0 13 m s 0 52 to 0 17 ms 135 to 45 fpm 79 to 26 fpm 103 to 34 fpm 36 1 0 44t0 0 15 m s 0 27t0009m s 0 3510 0 12 ms 0 26to 0 09 m s 88 to 29 fpm 53 to 17 fpm 69 to 23 fpm 52 to 17 fpm 48 1 0 3510 0 11 m s 0 2to 0 07 m s 0 26 to 0 09 mss 0 20 to 0 07 m s 68 to 22 fpm 40 to 13 fpm 51 to 17 fpm 39 to 13 fpm 64 1 0 25t0 0 08 mis 0 15to0 05 mss 0 15to 0 05 m s 50 to 16 fpm 30 to 10 fpm 29 to 10 fpm 96 1 0 17 to 0 06 ms 0 10 to 0 04 m s 34 to 11 fpm 20 to 7 fpm If more than one 9007 has to run with reduced speed it is recommended to set the speed externally by PLC or external potentiometer see External speed setting page 19 Version 1 1 11 2011 en Original language INTERROLL 9007 Hybrid Control for RollerDrive INTERROLL External speed setting Version 1 1 11 2011 en Original language Product i
48. rsion 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Product information 9007 label The specifications on the 9007 label are used to identify the 9007 This is required to use the 9007 as intended C X0 v a RT SHG Control ror RollerDrive Ser N 123456 Production week year 00 0000 ominal voltage 24 VDC aximum current 4 1 A P N 9007 Rev 97863359222043850970 terroll Corporation Wilmington N C 28405 USA C e www nterroll com XS E Technical data Nominal voltage 24 VDC Voltage range 221026 VDC Voltage ripple tolerance 5 1 recommended Continuous current EC100 1 8A EC110 24A EC120 25A Peak current EC100 4 1 A EC110 5 1 A EC120 5 1 A Fuse 5 A slow blow Littelfuse 0452005 Protection dassification IP20 Ambient temperature for operation 0 C to 40 C 32 F to 104 F Ambient temperature for transport and 20 C to 75 C AF to 167 F storage max 1 K min 3 h two cycles Ambient temperature changes according to IEC 68 2 14 Ambient humidity max 90 not condensing Version 1 1 11 2011 en 17 Original language 9007 Hybrid Control for RollerDrive 18 On board speed setting Product information Speed settings The speed can be continuously adjusted between 100 and 33 f
49. ry zone of conveyor o Zone Sj Photoeye Singulated release 2 Direction of travel 6 9007 CCW direction 8 Load 7 Peer to peer communication cable ollerDrive NPN 4 RollerD 24 VDC GND Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL 9007 between two PLC handshakes ij z rd a rd LU d od Direction of travel 9 Smart in run signal S S B c 24 VDC in for PNP and GND for NEN 5 El Smartt out downstream edge presence sensor GND E aum E Sensor in 24 VDC out for PNP and GND for NPN 424 VDC al gt meu e We E GND d 24 VDC 24 VDC GND i e A smart I O based handshake is required at both interfaces s DIP switch 4 and DIP switch 5 must both be OFF to make this zone into a dependent zone Version 1 1 11 2011 en 35 Original language 9007 Hybrid Control for RollerDrive INTERROLL 36 Transport and storage Transport Each 9007 is packed in its own carton case ZA CAUTION Risk of injury due to improper transport Transport may only be carried out by qualified and authorized persons gt Observe the following notices Do not stack more than four carton boxes Check the fixation of the 9007 before transport Avoid hard sho
50. s the peer to peer cable used by the 9007 for zone to zone communication Also called wave release A method of release which allows the upstream release of a package as soon as the downstream package blocks the photoeye of the downstream zone with its leading edge This dramatically increases throughput over singulated release but can sometimes result in lost packages There is also a short delay that is propagated upstream to eliminate all packages starting at the exact same time Maximum allowable current is decreased by the 9007 47 9007 Hybrid Control for RollerDrive INTERROLL Idler rollers Jam protection Jog N C NPN override O rings Perm Photoeye Req RollerDrive Singulated release Singulation Upstream Zero motion hold Zone ZPA 48 Appendix Non powered rollers attached to a RollerDrive typically via O rings or multi rip belts A method of protecting packages that are possibly jammed in a zone If the 9007 detects a jam or obstruction at the downstream end of the zone it sends an accumulation signal to the upstream zone preventing a buildup of accumulation pressure RollerDrive runs continuously as long as the command is set If jog mode is activated the 9007 disregards ZPA or photoeye signals No care affects nothing DIP switch 4 is for upstream DIP switch 5 is for downstream O rings made of materials such as polyurethane that connect RollerDrives to their associated idler ro
51. the sensor type see DIP switches page 14 Fuse is blown Replace the fuse see Replacing fuse page 40 Zone runs without package Version 1 1 11 2011 en Original language Wrong sensor output Check the type of sensor output see Sensor connection page 12 Wrong alignment of sensors Verify the alignment of the sensors Align the photoeyes to see the conveyor field only no overhead lights side frames etc Jog command by an inadvertently grounded Smart 1 FWD input command Check the connection of Smart 1 FWD input Communication cable is twisted or defective Check the communication cable upstream Photoeye is not connected properly Check the connection of the photoeye to 9007 Verify the photoeye pin assignment see Sensor connection page 12 Photoeye is damaged Replace the photoeye If the zone continues to run without any communication cables connected and no photoeye input 9007 is damaged Replace 9007 Assembly of the 9007 see Assembly page 37 41 9007 Hybrid Control for RollerDrive INTERROLL Symptom Multiple zones run continuously Troubleshooting Possible cause Communication cable is defective sending a jog command Help Find the farthest zone in the upstream direction that is running continuously Check the communication cables of this zone Different ground of a multiple power supply Verify that a common
52. ty sensor lens or misaligned Clean the sensor lens and align the sensor Current folds back to maximum continuous current amber fault LED is on Card or motor over temperature Excessive load or duty cycle Reduce the load of packages or throughput of the zone Current folds back to approximately 1 5 A while applying consistent torque Red fault LED is onand error output is active No fault output is active 44 Motor stall condition Obstruction or load too heavy to be conveyed Once the stall condition is removed the RollerDrive will resume normal operation Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Version 1 1 11 2011 en Original language Abandonment and disposal Abandonment AA CAUTION Risk of injury due to improper handling Abandonment may only be executed by qualified and authorized persons Only abandon the 9007 after switching off the power Ensure that the 9007 cannot be turned on accidentally Disconnect all cables from the 9007 Unscrew the screws attaching the 9007 to the conveyor frame Extract the 9007 from the conveyor frame Disposal The operator is responsible for the proper disposal of the 9007 In doing so industry specific and local provisions must be observed for the disposal of the 9007 and its packaging 45 9007 Hybrid Control for RollerDrive INTERROLL 46 Plugs and cables
53. voided will result in death or serious injury Warning Indicates a hazardous situation which if not avoided could result in death or serious injury Caution Indicates a hazardous situation which if not avoided may result in minor or moderate injury A DANGER Nature and source of the hazard Possible consequence of non observance gt Information about how to avoid the hazard Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL Version 1 1 11 2011 en Original language ep Introduction Further symbols NOTICE This symbol identifies possible material damage gt Information about how to avoid damage This symbol displays safety instructions This symbol marks useful and important information This symbol marks the steps that have to be carried out 9007 Hybrid Control for RollerDrive INTERROLL Safety General safety instructions The 9007 is designed according to the technical state of the art and is reliable in operation once distributed However risks may still arise Risks of physical injury to the user or bystanders Adverse effects of the 9007 and other material Disregarding the warnings in this manual may lead to serious injury Always read the entire operating and safety instructions before starting to work with the 9007 and follow the information contained herein in full Only instructed and qualified persons may work
54. with the 9007 Always keep this user manual at hand when working on the 9007 so that you can consult it quickly if required Always comply with relevant national safety regulations gt f you have any questions after reading this user manual feel free to contact our customer service See the last page for contact information Intended use The 9007 may only be used for industrial applications and in an industrial environment to control a RollerDrive EC1xx It must be integrated in a conveyor module or a conveying system Any other use is considered inappropriate Use of the 9007 is only allowed in the areas described under product information Any changes that affect the safety of the product are not allowed The 9007 may only be used within the given operation limits Unintended use Applications not according to the intended use of the 9007 require approval from Interroll Version 1 1 11 2011 en Original language 9007 Hybrid Control for RollerDrive INTERROLL A Persons Electricity Working environment Avoiding malfunctions in operation Maintenance Version 1 1 11 2011 en Original language Safety Qualified persons Qualified persons are persons who read and understand the manual and taking national regulations into account can competently execute incidental work Only instructed and qualified persons may work with the 9007 taking the following into account the relevant manuals
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