24 VDC for Material. Handling Industries

24 VDC for Material Handling Industries 24 VDC for Material Handling Industries Energy efficiency, compact design and long service time, are growing to decisive and carefully evaluated questions in the Material Handling Industry. Interroll RollerDrive and DriveControl are the answer. Designed for the highest performance with the best efficiency, RollerDrive represents a perfect combination of newest drive technology and proven Interroll Roller know-how. That helps to meet the highest demands of today s conveyor manufacturers. Latest motor and controls technology was applied to design a product which is ready to bring the integrator to the next level. The focus shifted away from the single conveyor component to a market driven and customer oriented solution which incorporates a well adjusted set of components like Roller- Drives, DriveControls and Rollers. All from one supplier: Interroll. The total cost of ownership calculation for RollerDrive compared to conventional drive systems, like line shaft or flat belt driven conveyors shows significant benefits: Very less energy consumption due to high efficiency drives and demand related running times Less installation cost due to simplicity of the concept Maintenance free operation Less safety costs due to 24VDC low voltage technology With its wide product portfolio Interroll is the ideal partner for the Material Handling Industry in supplying products as a one stop shop. That proves the basic strategy of the Interroll Business Unit Drives & Rollers, being word wide supplier of premium components, to help the customer to achieve their goals in the global market. 1

Portrait of the Interroll Group Interroll Group products play a pivotal role in helping a variety of companies meet new challenges in material handling. The debut of 24 VDC RollerDrive and DriveControl products in the market has revolutionized the automated conveyor industry. Interroll RollerDrive and rivecontrol provide a comprehensive product offering with individual components available to be integrated to meet a multitude of needs for customized customer control. Conveyor solutions are provided on the basis of careful calculations to include the size, shape, weight, contents, shelf-life, vulnerability and other variables of material handled by customers. As a result, the material handling of fragile strawberries, heavy conduit, content sensitive computers, oversized tires and only refrigerators are all managed by Interroll RollerDrive and DriveControl. Globalization has brought about substantial changes when it comes to the handling and delivery of goods with far-reaching consequences for companies logistical processes. Internet fulfilment has forced companies to seamlessly meet the demands of immediate with no dash following response, customer-oriented flexibility and greater performance. As the world becomes smaller the vital importance of specified details needed to handle tailor-made customer solutions has become more complex. The dynamic, smooth flow of highly diversified products requires the highlevel technology incorporated in Interroll s RollerDrive products to provide the same integrity and delicate handling given when moving large or small, fragile or bulky, and temperature and time sensitive materials. Consequently, complex procurement and distribution networks are easily managed in an innovative global market. Each configuration of Interroll RollerDrive systems ensures a factor of critical success for each cycle of movement for sales, inventory and storage movement against the backdrop of shorter rotation requirements, more complicated manufacturing processes and new channels of distribution faced by customers. Material handling systems powered by Inter roll RollerDrives are configured systems free of external drive units, chains, drive shafting and expensive guard covers for safe, quiet and efficient operation. With Interroll RollerDrive, control engineers and technicians have designed and assembled sophisticated conveyor that have set new standards. Interroll Drives & Rollers, A Business Unit of the Interroll Worldwide Group. 2

Portrait of the Interroll Group 3

RollerDrive The design ruts of RollerDrive go back to the Universal Conveyor Roller Platform 1700. All basic dimensions are the same, which enables the user to design a conveyor free of any external drives and exposed motor stations. This gives the Designer more freedom in creating flexible conveyor solutions, then using conventional AC technology. All known advantages of the Interroll Universal Conveyor Roller, like silent run thru polymer components and vibration insulation, can be also found in the RollerDrive design. The soft and hard ware design of DriveControl also supports the general flexi bility of conveyors using RollerDrive. There is a good quantity of digital I/Os to integrate RollerDrive in each new or retrofitted system. Electronic and mechanical commutated motors are the core of RollerDrive. Following ergonomically principles each RollerDrive is operating at an extraordinary low noise level. To achieve that a high sophisticated vibration decoupling of motor and gear box is used. Thus the gear box is also protected against shock loads which increases the operation time and minimizes wear. The motor is attached to a one to three stages planetary gear box, which transmits its torque via a non slip drive assembly to the tube. The RollerDrive is supported by two bearing houses sitting in the opposed end of the tube. Both are derivative from long proven Interroll standard housings. 4

RollerDrive In the conception stage of a RollerDrive application it is important to answer following points most accurate: Load Speed Cycles per minute Geometry of the box Material of the box, specifically the bottom Maximum allowable after run Existing controls to be connected to RollerDrive Environment in regards to specific protection rate Basically all RollerDrives are protected according to Industrial Protection rate IP54. However there are special versions available how exceed that and reach IP66. All bearing houses are made of electro conductive techno polymer. That prevents the typical conveyor problem of electro static charged boxes and rollers. The energy can flow easy and uncritical thru the housing and bearing to the side frame of the conveyor. It is important that the side frames all are grounded very good. 5

Customer Benefit on the spot Low total cost of owner ship Significant low energy consumption Low installation cost due to quick and easy installation Maintenance free operation Safe low voltage technology Quick return on invest On-hand easy concept of conveyor components Throughout customer oriented design Excellent matching components for best application fit Easy control thru digital I/O World wide after sales service Enhanced work environment Worker friendly low noise emission Space saving design Good looking appearance High efficiency due to energy conservative drive technology. 6

Customer Benefit on the spot 7

Technical Information for all RollerDrive Selecting the conveying speed RollerDrive is following the principle of keeping the motor speed constant and selecting the conveying speed by having different gear box reductions available. Details are described which each of the RollerDrive products. Load capacity of RollerDrive Without thru going shaft the RollerDrive is seen as roller without shaft, comparable to a flow storage roller. However there is one specific point to be noticed, the motor end is always fixed with the side frame of the conveyor. The non driven end is with the most popular version, the 11 mm hex spring loaded shaft, only a loose fit in a hex hole. That fact is compensated by having it equipped with a double bearing configuration. Thus the whole RollerDrive can be seen as roller without shaft but with fixed stub shafts. In an application it is important that in minimum always three rollers including the RollerDrive are located underneath the box. In most of the applications the torque not the load will be the minimum factor to size the unit. For detailed calculations of the maximum load in relation to the roller length, the Roller Calculation Program is ready for download on the Interroll Web Page. Using the program the shaft type must be entered as Round and the shaft location as Stub Axle. 8

Technical Information Rolling resistance and performance When a box is conveyed on a roller lane, there a the following forces to be overcome: Static friction Rolling friction A box is moving with constant speed on a conveyor, following equation is valid: F = m * g * µ F: Tangential force in Newton m: Mass in kg g: Acceleration of gravity 9,81 m/sec µ: see table below for factors related to box material Material Steel 0.03 Polymer, flat 0.04 Polymer, uneven 0.05 Wood 0.05 Carton, hard 0.06 Carton, soft 0.08 Friction coefficient Example: Load: 30 kg Box material: Techno Polymer, friction coefficient µ 0.04 Speed: 0,5 m/sec Necessary tangential force: 11.77 N At a radius of 25 mm the required torque is 0.3 Nm That leads to a mechanical performance of 3.5 Watt Table of friction coefficient The performance which is needed to convey a box at constant speed on a roller conveyor is primary determined by the shape and the material of the bottom surface of the box. Less performance is needed for a flat and hard surface, like a steel box. But steel also has the tendency to slip on the rollers which results in longer acceleration and deceleration times. A rule of thumb is about 3 % of the load is needed as tangential force for hard box material. Using carton boxes on roller conveyors needs more performance. The friction coefficient is about 8 %. The difference to steel boxes is used to deform the bottom surface when running on a roller conveyor. Thus, this energy is not available for transportation. One cycle in a conveyor consists from acceleration to constant conveying to deceleration. Due to that, for performance calculations the acceleration is a critical phase which must be determined carefully. In the acceleration phase static friction has to be overcome and is replaced by the very less rolling friction. That explains 9

Technical Information for all RollerDrive the characteristic currant peak at the beginning of each conveying cycle. Due to the complexity of each application it is recommended to consult an Interroll RollerDrive Expert and the RollerDrive Calculation Program to find out what is the right product for each application. RollerDrive Calculation Program The RollerDrive Calculation Program is part of the RollerDrive Catalogue and contains all application and performance knowledge to select the right product for each application. It also indicates the maximum number of cycles according to current and heat calculations under given load and speed. The maximum continuous currant is calculated to select the right power supply for the application. Belts, Torque Transmissions A conveyor driven by RollerDrive needs a certain type of torque transmission from roller to roller. There are several ways to accomplish that: Friction drive Round belt running in grooves or grooved drive heads PolyVee belt running in special drive heads From fit drive Tooth belt 3/8" Chain To select the right torque transmission, it is important to know the size of a box in relation to the size of the conveyor zone. If the box comes to a stop always with one RollerDrive underneath, the belts are relived strongly. In the phase of acceleration most of the start torque is directly transferred from the RollerDrive tube to the box. If there is any possibility that a box can come to a stop without having a RollerDrive directly in contact to its bottom surface, it is important to select a torque transmission which is able to transmit high start up torques properly throughout the entire life of the application. Round Belt: Applications up to 0.6 m/sec and 40 kg. It is important, that the box always comes to a stop directly on the RollerDrive. Maximum number of idler rollers is 10. 10

Technical Information PolyVee Belt: There are several advantages compared to round belts. Due to a 300 % higher ability to transmit torque, all rollers in a zone are powered very even and smooth. That helps to reduce acceleration and deceleration distances. Boxes do not slide any more over the RollerDrive due to the fact that all idler rollers are much better linked to the RollerDrive. Applications with incline and decline conveyors are optimal equipped with PolyVee belts and PVC sleeved rollers and RollerDrives. The torque is transmitted very even throughout the entire zone and the PVC sleeve increases the friction between rollers and box. PolyVee belts are flexible to accepted center to center tolerances; they also need not tension device to work in the conveyor. Conveyor with more then 15 PolyVee rollers will see a RPM-drop of about one RPM per roller. The reason for that is a transmission effect which is caused by shifting the neutral phase of the belt under load. Available versions of PolyVee belt: Flexible Type PJ; ISO 9981; DIN 7867 Pitch 2.34 mm Maximum 4 ribs per belt, 2 x 4 ribs and one groove in the hub as gap Available belt length for center to center distances: 60, 73, 94, 100, 105, 120, 133, 160 mm Basically there are two version used for conveyors: 2-rib PolyVee belt: Applications up to 2 m/sec and 50 kg. The box must not come to a stop on the RollerDrive. The belt is able to handle the start up torques. 3-rib PolyVee belt: Heavy loads, using full performance of RollerDrives. Long conveyors for straight-thru applications according to the RollerDrive Calculation program. Tooth Belt: Form fit drive, very robust but with less efficiency due to strong belt material. Center to center distance tolerance is critical for longevity of the belt. Chain: Rare used torque transmission for RollerDrive due to the fact that the chain is not maintenance-free, which contradicts the concept of a RollerDrive conveyor. 11

RollerDrive Technology Technical Data Basically there are two different types of RollerDrive, mechanical commutated BT (brush type) and electronic commutated EC. The EC RollerDrives are subdivided in regards to the location of the controller, inside (EC200 and EC300) or outside (EC100 and EC110) of the RollerDrive. All RollerDrives are differentiated by their mechanical performance which is available at the tube for conveying goods. For that the tangential force at the tube is multiplied by the speed at maximum continuous currant. Resulting performance values are the base for choosing the right RollerDrive and reflecting in relation to the electrical input performance the efficiency. 12

RollerDrive Technology Electrical Data BT100 EC100 EC110 EC200 EC300 Nominal voltage 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC Voltage range 16 28 VDC 22 28 VDC 22 28 VDC 18 28 VDC 18 28 VDC No load current 0.6 A 0.6 A 0.6 A 0.4 A 0.4 A Maximum continuous current 1.3 A 1.8 A 2.5 A 2.1 A 3.5 A (13:1) 4 A (7.85:1) Maximum peak current 4.5 A 4.1 A 4.1 A 5.5 A 5.5 A Mechanical Performance 11 W 18 W 31 W 25 W 44 W (13:1) 52 W (7.85:1) System Efficiency (Drive) 36% 42% 52% 49% 54% Maximum ripple from power supply 5% 5% 5% 3% 3% Noise emission (mounted) 47 db(a) 55 db(a) 55 db(a) 55 db(a) 50 db(a) Lifetime under nominal conditions 6 000 h 15 000 h 15 000 h 15 000 h 20 000 h Maximum Start/Stop per minute 15 30 30 30 30 Protection classification IP54 (IP66) IP54 IP54 (IP66) IP54 (IP66) IP54 Gear ratio BT100 EC100 EC110 EC200 EC300 9 12 4 12 7,85 9R 16 9 16 13 21 24 12 36 30 36 16 48 37 48 24 64 37R 64 36 96 48 64 Additional Technical Data Ambient temperature 0 40 C Maximum roller length RL 1500 mm 13

RollerDrive Technology Shaft executions All shaft executions are available in carbon steel zinc plated or stainless steel. Shaft executions on motor end of RollerDrive All bearing houses of the RollerDrive on the motor end are made from electro conductive Techno Polymer material. That solves the problem of static charged conveyor rollers and prevents damages to electronic components in the RollerDrive or on the conveyor. However, it is essential to ground the conveyor frame in a proper manner. RollerDrive Motor end of RollerDrive M12 x 1 M12 x 1,5 11 mm 11 mm hexagonal hexagonal 11 mm hexagonal with M8 end drilled and tapped M12 x 1 with 10,5 mm key flat 11 mm solid hexagonal BT100 BT100 IP66 EC100 EC110 EC200 EC200 IP66 EC300 14

RollerDrive Technology M12 x 1.5 mm 19.5 mm 13.5 mm 5000 mm RL M12 x 1,5 or 1 on 11 mm hexagonal This is the most used standard execution for RollerDrive. The shaft can be mounded into 11 mm hexagonal or 12.5 mm round hole. The torque transmission to the conveyor side frame is given by two serrated lock washers and a counter nut. This version is also available for IP66 protection rate with BT100 and EC200. 6 mm RL Hexagonal 11 mm 21 mm 15 mm M12 x 1 mm 480 mm 6 mm Key flats 10.5 mm 17.5 mm 11.5 mm RL M12 on round shaft with 10,5 mm key flats This version is only available for EC300. The torque transmission to the conveyor side frame is given by given by two serrated lock washers and a counter nut. M12 x 1 mm 160 mm 6 mm 15

11 mm 25 mm 19 mm RL 11 mm solid hexagonal (no threads) Applied for high torques, this shaft execution is the optimal fit with a strong anti spin bracket which is mounted on the conveyor frame. The anti spin bracket clamps the shaft and realizes a reinforced form fit. This version is available for EC100 and EC110. 6 mm 5000 mm 13 mm AF16 mm 22.5 mm M8 end drilled and tapped Only available for RollerDrive BT100, allows that shaft execution the fixing of a RollerDrive in a 8.2 mm hole which is normally only foreseen for M8 end drilled and tapped idler rollers. That gives additional flexibility when placing the RollerDrive in the conveyor frame. Also available in protection rate IP66. 16

RollerDrive Technology Shaft executions on idler side of RollerDrive RollerDrive Idler side of RollerDrive 11 mm M8 end hexagonal drilled and spring tapped loaded stub axle Poly V 11 mm hexagonal spring loaded Poly V 11 mm end drilled and tapped M8 Round belt head 11 mm hexagonal spring loaded Round belt head 11 mm hexagonal end drilled and tapped M8 Timing belt/ 3/8" chain 11 mm hexagonal end drilled and tapped M8 BT100 BT100 IP66 EC100 EC110 EC200 EC200 IP66 EC300 RL 5 mm 15.5 mm 11 mm hexagonal spring loaded Double bearing end house with fully indentable hexagonal shaft. Universal and very stable design fits lots of applications. 17

RL 5 mm 8 mm end drilled and taped stub shaft Stub shaft fixed to the profile and axial free floating in the RollerDrive. RL 27 mm 4 mm 11 mm PolyVee head 11 mm spring loaded hexagonal shaft Double bearing design with fully indentable shaft. ø 43 mm RL 27 mm 5 mm PolyVee head with M8 end drilled and taped stub shaft Stub shaft fixed to the profile and axial free floating in the RollerDrive. ø 43 mm RL US 18

RollerDrive Technology RL 31 mm 4 mm 11 mm ø 38 mm PolyO head with 11 mm hexagonal shaft Double bearing design with fully indentable shaft. RL 13.5 mm 31 mm 13 mm 4 mm ø 38 mm PolyO head with M8 end drilled and taped stub shaft Stub shaft fixed to the profile and axial free floating in the RollerDrive. 19

RL 16.8 mm 9.5 mm 3/8" double chain sprocket with 11 mm hexagonal M8 end drilled and tapped shaft. RL 35 mm 27.5 mm Z20 T8 double timing belt sprocket with 11 mm hexagonal M8 end drilled and tapped shaft. ø 45.8 mm n 60.9 mm 35 mm 20

RollerDrive Technology RollerDrive Technology Protection rate of RollerDrive As a general standard, all RollerDrive are protected at the IP54 rate. By that, they are protected against dust and lower grade spray water. RollerDrive BT100 and EC200 are available in protection rate IP66. They are sealed to withstand heavy spray water and dust. All protection rates are laboratory tested and certified. Tube executions The tube of the RollerDrive is ether from zinc plated carbon steel DIN2394 or from stainless steel DIN 2463. Both versions have an outer diameter of 50 mm and a wall thickness of 1.5 mm. The maximum concentricity deviation is 0.3 mm. 21

1.8º RollerDrive Technology L Ta Non-driven roller curves The nominal dimension of the curve inside radius Ri is 800 mm for roller lengths (RL) of 300, 400, 500 mm, etc. and 850 mm for roller lengths of 250, 350, 450 mm etc. The curve inside radius is measured from the inner edge of the inside supporting profile (i.e. from the beginning of install at - ion length EL). W Ti Driven curves with RollerDrive For driven roller curves, RollerDrive has proven itself the most inexpensive and elegant solution of all well-known drive types. These curves are quiet, compact and exhibit a modern, straightforward construction. As overdimensioned components, standard O-rings are preferably used in combination with the fixed drive roller series 3500 with drive head. Due to the proj ec t - ing end of the drive head (RL=EL-36), inner curve radii of Ri 770 mm and 820 mm result. In the dimensioning of the RollerDrive, it is important to use the mean diameter of the tapered elements for calculating the required torque and the conveyor speed. The installation length should be calculated so that the conveyed items do not contact the side profiles during transport. Calculation of the minimum outer radius Ra or the minimum EL. Ra = (Ri + W) 2 + (L/2) 2 +50 EL min. = Ra-Ri 90º EL Ri Ra 22

RollerDrive Technology Adapting of the EL min. to the standard length (next larger size in 50 mm increments) 286, 336, 386 936 mm (250, 300, 350 900 mm for gravity rollers) Calculation of actual Ra with selected standard EL Ra = EL+Ri The roller pitch is generally dependent upon the properties and condition of the conveyed item and should be selected so that safe transport is ensured. In selecting the smallest possible roller pitch (Ti), the diameter of the tapered elements must be taken into account so that these do not contact each other. Otherwise, any Ti value can be selected. The only restriction to observe is that the first or last roller has a ratio to the total angle of the curve of approx. Ti/2 and that any standard belts lengths are also consided. Roller pitch Ta, measured at the inner edge of the outer profile, can be calculat ed with the following formula: Ti x Ra Ta = Ri A overview of all tapered tubes available, is located on page 56. Tube coating All RollerDrives can be sleeved with grey PVC sleeve of 2 and 5 mm wall thickness. With a hardness of 58+5 Shore (A), the friction between the boxes and the rollers is increased very positive. The sleeve fulfills the RoHS requirements. Zinc plating of tubes All carbon steel tubes are electro zinc plated and passivated according to DIN 2394. The coating thickness is between 8 and 15 µm. All materials for the zinc plating process are according to RoHS requirements. The zinc plated and passivated tube surface is sensitive to scratching and rubbing loads. White rust will be a result of damaged passivation and shows the selective destruction of the protection system. However, there is no derogation to the function of the RollerDrive. Larger temperature deviations should also be avoided, they can cause cracks in the passivation, which will result also in white rust. However, the protection system zinc plating and passivation for carbon steel tubes, is an adequate and proven method which gives cost optimal corrosion protection for RollerDrive. For applications in harbors or near to the sea in salty environment, also in tropical areas or for the transport of wet goods it is recommended to use stainless steel tubes and shafts for RollerDrive. 23

RollerDrive BT100 Basic information With a mechanical performance of 11 Watt and a mechanical commutated motor the RollerDrive BT100 is the optimal solution for application with lower throughputs and less weight. Due to the simplicity of connecting only two wires, BT100 can be controlled and integrated very easy. There is no specific controller or current limiter needed. With a minimum operational life time of 6000 h, BT100 can convey up to 14 Million boxes. Operating at a noise level of 47 db(a), BT100 is the most silent 24VDC drive in the market. RollerDrive BT100 is less electrical noise emitting, fulfilling the requirements of DIN EN 60034-1:1998/A11: 2002. 11 Watts mechanical performance Integral overheat protection 6 different gear ratios available 6000 hours minimum operational time Protection rate IP54 or IP66 47 db(a) mounted in a conveyor frame 5 m cable length Open cable termination or plug for use with Z-Card BT 24

13.5 EL = RL + 36 RL 27 M 12 x 1.5 SK 11 RollerDrive BT100 cable length 5000 mm SW 19 IG M 8 13.5 M 12 x 1.5 SK 11 EL = RL + 11 RL max. 120 min. 30 min. 30 RollerDrive BT100 cable length 5000 mm SW 13 IG M 8 Performance Data Gear ratio Nominal Speed Nominal Torque (1.3 A) Peak Torque (4.5 A) m/s Nm Nm 9 0.90 0.45 1.9 9R 0.70 0.70 2.6 21 0.40 0.84 3.0 30 0.30 1.28 4.4 37 0.20 1.64 6.6 37R 0.10 2.50 6.4 Maximum loads are depending on speed and cycle time and must be calculated by using the RollerDrive Calculation Program. Speeds are very dependent on the amount of load, due to the fact that BT100 is a not controlled drive running on its natural motor curve. R means reduced motor RPM. 25

RollerDrive BT100 Minimum RL Cartridge Tube Idler bearing Min RL 9:1 to 9:1 red. 11 mm hexagonal end drilled and tapped M8 203 11 mm hexagonal spring loaded 246 PolyVee end drilled and tapped M8 228 PolyVee 11 mm hexagonal spring loaded 239 Timing belt/3/8" chain end drilled and tapped 220 Groove 30 60 11 mm hexagonal end drilled and tapped M8 246 Groove 50 80 11 mm hexagonal spring loaded 262 21:1 to 37:1 red. 11 mm hexagonal end drilled and tapped M8 221 11 mm hexagonal spring loaded 264 PolyVee end drilled and tapped M8 246 PolyVee 11 mm hexagonal spring loaded 257 Timing belt/3/8" chain end drilled and tapped 238 Groove 30 60 11 mm hexagonal end drilled and tapped M8 264 Groove 50 80 11 mm hexagonal spring loaded 280 9:1 und 9:1 red. 11 mm hexagonal end drilled and tapped M8 203 IP66 version Groove 30 60 11 mm hexagonal end drilled and tapped M8 246 21:1 to 37:1 red. IP66 version Groove 30 60 11 mm hexagonal end drilled and tapped M8 11 mm hexagonal end drilled and tapped M8 218 261 The minimum RL is determinate by the idler bearing and grooves. Maximum RL: 1500 mm. 26

RollerDrive BT100 RollerDrive BT100 Electrical Data Nominal voltage Voltage range No load current Maximum continuous current Maximum peak current Mechanical Performance 24 VDC 16 28 VDC 0.6 A 1.3 A 4.5 A 11 W System Efficiency (Drive) 36% Maximum ripple from power supply 5% Noise emission (mounted) 47 db(a) Applications RollerDrive BT100 is often used for empty tote return, zero pressure accumulation conveyors with lower throughput and commissioning zones. Due to the protection rate of IP66 BT100 is applied in high moisture environment. With a very low noise emission, it is the optimal fit for conveyors which are located in assembly areas were the RollerDrive is the only mechanical part in motion. Specifically applied with Z-Card BT, BT100 is a very smart and cost effective solution for zero pressure accumulation conveyors. 27

RollerDrive EC100 Basic information RollerDrive EC100 is the first choice for medium to heavy applications. With external commutation electronic and mechanical performance of 18 Watts, EC100 is a proven and stable solution for many different types of conveyors. Speed selection takes place by picking one of the seven available gear ratios. On the external control board it is also possible to fine adjust the speed via a potentio meter. There will be no loss of torque because EC100 uses a closed loop controller. For decline conveyor applications the EC100 is equipped with a zero motion hold electronic brake. This keeps the packages on decline conveyors in place and prevents drifting. 18 Watt continuous mechanical performance External commutation electronic 7 gear ratios After run reducing motor stop function Zero motion hold for declines 15.000 hours minimum operation time Protection rate IP54 55 db(a) noise emission mounted in conveyor 800 mm cable length 8 pole Tyco connector 28

15 EL = RL + 36 RL 27 M 12 x 1.5 SK 11 SW 19 IG M 8 800 mm cable length 15 EL = RL + 11 RL max. 120 min. 30 min. 30 RollerDrive EC100 M 12 x 1.5 SK 11 RollerDrive EC100 SW 13 IG M 8 800 mm cable length Performance Data Gear Ratio Speed Range Nominal Torque Peak Torque with DC-EC100 (1.8 A) with HC-EC100 (4.1 A) m/s Nm Nm 12 1.32 0.44 0.37 1.4 16 1.03 0.34 0.48 1.8 24 0.69 0.22 0.75 2.8 36 0.44 0.15 1.17 3.8 48 0.35 0.12 1.24 5.0 64 0.25 0.08 1.82 6.1 96 0.17 0.06 3.00 11.3 Maximum loads are depending on speed and cycle time and must be calculated by using the RollerDrive Calculation Program. 29

RollerDrive EC100 Minimum RL Cartridge Tube Idler bearing Min RL 12:1 to 24:1 11 mm hexagonal end drilled and tapped M8 233 11 mm hexagonal spring loaded 276 PolyVee end drilled and tapped M8 258 PolyVee 11 mm hexagonal spring loaded 269 Timing belt/3/8" chain end drilled and tapped 250 Groove 30 60 11 mm hexagonal end drilled and tapped M8 276 Groove 50 80 11 mm hexagonal spring loaded 292 36:1 to 96:1 11 mm hexagonal end drilled and tapped M8 242 11 mm hexagonal spring loaded 285 PolyVee end drilled and tapped M8 267 PolyVee 11 mm hexagonal spring loaded 278 Timing belt/3/8" chain end drilled and tapped 259 Groove 30 60 11 mm hexagonal end drilled and tapped M8 285 Groove 50 80 11 mm hexagonal spring loaded 301 The minimum RL is determinate by the idler bearing and grooves. Maximum RL: 1500 mm. 30

RollerDrive EC100 RollerDrive EC100 Electrical Data Nominal voltage Voltage range No load current Maximum continuous current Maximum peak current Mechanical Performance 24 VDC 22 28 VDC 0.6 A 1.8 A 4.1 A 18 W System Efficiency (Drive) 42% Maximum ripple from power supply 5% Noise emission (mounted) 55 db(a) Applications Refrigerators, light pallets or in picking areas, everywhere an external commu - tation electronic is applicable, RollerDrive EC100 is used extensively. It is the optimal and most cost effective solution for an easy plug and play zero pressure accumulation (ZPA) conveyor with the Hybrid Control HC-EC100. There is no need for upper level controls to get a smart ZPA. 31

RollerDrive EC110 Basic information RollerDrive EC110 has the most torque in the whole product line. It was developed specifically under the aspect of increased efficiency, to enable 24 VDC conveyor systems to work with less energy since ever. Based on the design of the EC100 there are eight different gear ratios to chose from. Even heaviest loads can be moved reliably with a mechanical performance of 31 Watts. 31 Watt continuous mechanical performance External commutation electronic 8 gear ratios After run reducing motor stop function Zero motion hold for declines 15.000 hours minimum operation time Protection rate IP54 55 db(a) noise emission mounted in conveyor 1000 mm cable length 8 pole Tyco connector 32

15 EL = RL + 36 RL 27 M 12 x 1.5 SK 11 SW 19 IG M 8 1000 mm cable length 15 EL = RL + 11 RL max. 120 min. 30 min. 30 RollerDrive EC110 M 12 x 1.5 SK 11 SW 13 IG M 8 RollerDrive EC110 1000 mm cable length Performance Data Gear Ratio Speed Range Nominal Torque (2.5 A) Peak Torque with HC-EC110 (4.1 A) m/s Nm Nm 4 2.41 0.80 0.3 1.2 9 1.07 0.36 0.8 2.6 12 0.80 0.26 1.0 3.5 16 0.60 0.20 1.5 4.2 24 0.40 0.13 2.2 5.8 36 0.27 0.09 2.9 9.2 48 0.20 0.07 3.4 11.5 64 0.15 0.05 4.3 13.2 Maximum loads are depending on speed and cycle time and must be calculated by using the RollerDrive Calculation Program. 33

RollerDrive EC110 Minimum RL Cartridge Tube Idler bearing Min RL 4:1 to 24:1 11 mm hexagonal end drilled and tapped M8 249 11 mm hexagonal spring loaded 292 PolyVee end drilled and tapped M8 274 PolyVee 11 mm hexagonal spring loaded 285 Timing belt/3/8" chain end drilled and tapped 266 Groove 30 60 11 mm hexagonal end drilled and tapped M8 292 Groove 50 80 11 mm hexagonal spring loaded 308 36:1 to 64:1 11 mm hexagonal end drilled and tapped M8 258 11 mm hexagonal spring loaded 301 PolyVee end drilled and tapped M8 283 PolyVee 11 mm hexagonal spring loaded 294 Timing belt/3/8" chain end drilled and tapped 275 Groove 30 60 11 mm hexagonal end drilled and tapped M8 301 Groove 50 80 11 mm hexagonal spring loaded 317 The minimum RL is determinate by the idler bearing and grooves. Maximum RL: 1500 mm. 34

RollerDrive EC110 Electrical Data RollerDrive EC110 Nominal voltage Voltage range No load current Maximum continuous current Maximum peak current Mechanical Performance 24 VDC 22-28 VDC 0.6 A 2.5 A 4.1 A 31 W System Efficiency (Drive) 52 % Maximum ripple from power supply 5 % Noise emission (mounted) 55 db(a) Applications Long straight or incline conveyors, any application were high torque is needed; RollerDrive EC110 is the best fit. With its high performance and the use of PolyVee belts it is possible to compete against mechanical systems for long line conveyors. Coated with PVC sleeve, incline conveyor do not need belt-overroller any more. That makes a cost effective solution for applications RollerDrive was not able to handle before. High number of cycles beyond 30 per minute can be secure realized with EC110. For details, please consult the RollerDrive Calculation Program. 35

RollerDrive EC200 Basic information RollerDrive EC200 is equipped with an integral motor control which fulfills all required commutation- and safety functions. Independent from load on the conveyor, EC200 runs always with the same speed featuring a true four-quadrant- motion controller. EC200 can be used with out any external control electronic. By using a combined analog Signal (0-10V), speed and start is set. This input is valid up to 28 V, which makes it very easy to control the EC200 with a simple relay, so that it runs at full speed. There is also a compact interface box available, to simplify the speed setting and decouple the signals. 25 Watts continuous mechanical performance Integral commutation electronic Constant conveyor speed After run reducing motor stop function 15.000 hours minimum operation time Protection rate IP54 or IP66 55 db(a) noise emission mounted in conveyor 450 mm cable length 5 pole Fixcon connector 36

M 12 x 1 SK 11 15 EL = RL + 36 RL 27 480 mm cable length incl. Fixcon connector SW 19 IG M 8 EL = RL + 11 RL 15 max. 120 min. 30 min. 30 M 12 x 1 SK 11 RollerDrive EC200 SW 13 IG M 8 480 mm cable length incl. Fixcon connector Performance Data RollerDrive EC200 Gear Ratio Speed Range Nominal Torque Peak Torque m/s Nm Nm 12 0.98 0.14 0.7 1.2 16 0.74 0.11 0.9 1.8 36 0.33 0.05 1.7 3.6 48 0.25 0.04 2.3 5.4 64 0.18 0.03 3.6 8.0 Maximum loads are depending on speed and cycle time and must be calculated by using the RollerDrive Calculation Program. 37

RollerDrive EC200 Minimum RL Cartridge Tube Idler bearing Min RL 12:1 to 16:1 11 mm hexagonal end drilled and tapped M8 266 11 mm hexagonal spring loaded 309 PolyVee end drilled and tapped M8 291 PolyVee 11 mm hexagonal spring loaded 302 Timing belt/3/8" chain end drilled and tapped 283 Groove 30 60 11 mm hexagonal end drilled and tapped M8 309 Groove 50 80 11 mm hexagonal spring loaded 325 12:1 to 16:1 11 mm hexagonal end drilled and tapped M8 262 IP66 version Groove 30 60 11 mm hexagonal end drilled and tapped M8 305 36:1 to 48:1 11 mm hexagonal end drilled and tapped M8 256 11 mm hexagonal spring loaded 299 PolyVee end drilled and tapped M8 281 PolyVee 11 mm hexagonal spring loaded 292 Timing belt/3/8" chain end drilled and tapped 273 Groove 30 60 11 mm hexagonal end drilled and tapped M8 299 Groove 50 80 11 mm hexagonal spring loaded 315 36:1 to 48:1 IP66 version Groove 30 60 11 mm hexagonal end drilled and tapped M8 11 mm hexagonal end drilled and tapped M8 250 293 The minimum RL is determinate by the idler bearing and grooves. Maximum RL: 1500 mm. 38

RollerDrive EC200 Electrical Data Nominal voltage 24 VDC Voltage range No load current Maximum continuous current Maximum peak current Mechanical Performance 18 28 VDC 0.4 A 2.1 A 5.5 A 25 W RollerDrive EC200 System Efficiency (Drive) 49% Maximum ripple from power supply 3% Noise emission (mounted) 55 db(a) Applications RollerDrive EC200 is used in applications were an external controller does not fit into the general concept. With its performance of 25 Watts there are a wide variety of applications up to medium pallet handling possible. 39

RollerDrive EC300 Basic information RollerDrive EC300 is the flag ship product complete line and it is unique in its performance density. With a mechanical performance of 44 Watts (EC300 13:1) and 52 Watts (EC300 7,85:1) there are high speed and high cycle applications possible. Using a helical planetary steel/polymer gear box, the product achieves minimum operational life of 20.000 hour even under hardest conditions. 44 Watts continuous mechanical performance (13:1) 52 Watts continuous mechanical performance (7,85:1) Integral commutation electronic Constant conveyor speed After run reducing motor stop function 20.000 hours minimum operation time Protection rate IP54 55 db(a) noise emission mounted in conveyor 160 mm cable length 5 pole Fixcon connector 40

11,5 M 12 x 1 SW 10.35 EL = RL + 36 RL 27 160 mm cable length incl. Fixcon connector SW 19 IG M 8 11,5 M 12 x 1 SW 10.5 EL = RL + 11 RL max. 120 min. 30 min. 30 RollerDrive EC300 SW 13 IG M 8 160 mm cable length incl. Fixcon connector Performance Data Gear Ratio Speed Range Nominal Torque Peak Torque m/s Nm Nm 7.85 2.0 1.02 0.70 1.0 13 1.27 0.12 0.90 1.6 Maximum loads are depending on speed and cycle time and must be calculated by using the RollerDrive Calculation Program. RollerDrive EC300 41

RollerDrive EC300 Minimum RL Cartridge Tube Idler bearing Min RL 7.85:1 und 13:1 11 mm hexagonal end drilled and tapped M8 224 11 mm hexagonal spring loaded 267 PolyVee end drilled and tapped M8 249 PolyVee 11 mm hexagonal spring loaded 260 Timing belt/3/8" chain end drilled and tapped 241 Groove 30 60 11 mm hexagonal end drilled and tapped M8 267 Groove 50 80 11 mm hexagonal spring loaded 283 The minimum RL is determinate by the idler bearing and grooves. Maximum RL: 1500 mm. 42

RollerDrive EC300 Electrical Data Nominal voltage Voltage range No load current 24 VDC 18 28 VDC 0.4 A Maximum continuous current 3.5 A (13:1) 4 A (7.85:1) Maximum peak current 5.5 A Mechanical Performance 44 W (13:1) 52 W (7.85:1) System Efficiency (Drive) 54% Maximum ripple from power supply 3% Noise emission (mounted) 50 db(a) RollerDrive EC300 Applications RollerDrive EC300 has proven its reliability in lot of continuous duty applications with high speed. It is also first choice for conveyor with high throughput with exceeds significantly 30 cycles per minute. For details please consult the RollerDrive Calculation Program. 43

137 mm 102 mm 69 mm 52 mm 62 mm 22 mm 6 mm 79 mm DriveControl DC-EC100 Basic information The DriveControl DC-EC100 fulfills all commutation- and safety function which are required to install RollerDrive EC100 into a wide variety of applications. Utilizing a heat model of the motor, the currant is monitored at any time to prevent overheating or damage in stall conditions. By using an external analog signal (0-5 V) the speed can be adjusted from a PLC. It is also possible to fine adjust the speed by using the on board potentiometer. All signals for the DC-EC100 require common ground. Functions Commutation electronic for RollerDrive EC100 Overload protection of motor Speed controller Interface to upper level controls Direction setting with two inputs Failure output Logic conversion NPN PNP Sensor power supply and Protection rate IP20 44

161 mm 124 mm HybridControl HC-EC100/110 Basic information HC-EC100/110 is the only control option for RollerDrive EC110. DriveControl and ZPA-logic are combined in one card. Using HC-EC100/110 it is very easy to realize stand alone ZPA conveyors which do not require upper level controls. At the same time upstream and downstream machines or conveyors can interface very easy due to defined digital I/O points. Functions Zero pressure accumulation control Single zone control concept with communication up- and downstream Direct connection of start sensor Interface to upper level controls Commutation electronic for EC100/110 Overload protection of motor Direction setting with two inputs Failure output Logic conversion NPN PNP Sensor power supply and Protection rate IP20 Applications Everywhere a quick, easy to install and reliably ZPA controller is needed, HC-EC100/110 is used. DC-EC100 HC-EC100/110 69 mm 55 mm 62 mm 22 mm 79 mm 5.6 mm 45

8 9 7 6 5 C 4 3 F 2 0 1 50 mm 28 mm A B D E 8 7 6 5 4 3 2 1 12 mm 74 mm 51 mm 41 mm 51 mm 7 mm DriveControl DC-EC200/300 Basic information DriveControl DC-EC200/300 is designed as an easy to use interface for an optimal integration of RollerDrive EC200/300. By using the on board 16-positon rotary switch, speed and direction can be selected. This allows speed changes in different areas of the application even the RollerDrive is installed. To interface with upper level controls, all digital I/Os are optical isolated. Functions Speed setting Direction setting Start signal input (optical isolated) Direction signal input (optical isolated) Failure output (optical isolated) Status LEDs Logic conversion NPN/PNP Protection rate IP20 Applications If there is no analog signal for direct interface available to control RollerDrive EC200/300, DriveControl DC-EC200/300 is used as a universal interface. 46

35 mm 20 mm 205 mm 35 mm 37 mm Z-Card Basic information As a four zone controller the Z-Card allows the setup of a high flexible zero pressure accumulation conveyor system with RollerDrive EC200/300 or BT100 in a through going protection rate of IP54. Z-Card comes with all necessary cables and plugs go connect RollerDrive, sensors and power supply. There are two different versions of Z-Card: Z-Card BT, RollerDrive BT100 with a special cable version which includes a plug is directly connected. A very convenient and proven solution for conveyors with fewer throughputs. (BT100 with Z-Card BT only with M12 on 11 mm hexagonal on motor side, no end drill and tapped, due to preas - sembled connector) DC-EC200/300 Z-Card 86 mm 53 mm 20 mm 9 mm 10 mm 47

Z-Card Z-Card EC, RollerDrive EC200/300 is directly connected with an extension cable. There is no need for DC-EC200/300. RollerDrive EC100/110 can also be connected; however the DC-EC100 or HC-EC110 is needed due to the external commutation setup. The configuration for different conveyer modes is done by a rotary- and slide switch. There are different parameters which must be set up: Number of RollerDrives/Zones connected Single- or train release Single release with PLC stop option Motor starter without any ZPA logic Functions Zero pressure accumulation control for up to four zones Speed control by rotary switch Interface to higher level controls by optical isolated I/Os Failure output Logic conversion NPN/PNP Protection rate IP54 Applications Z-Card is the best fit for lager conveyor systems with zero pressure accumulation logic. Due to the Protection rate of IP54, Z-Card can be installed everywhere in the system without the need for additional housing. Also the pre-manufactured cable set makes the installation very quick. Typical applications are postal- and package handling and similar distribution centers. 48

ANTI SPIN BRACKET FLAT UP ANTI SPIN BRACKET POINT UP 11.5 mm hex 9.4 mm 11.5 mm hex 61.5 mm 44.9 mm 6.4 mm 6.4 mm (2 x) 61.5 mm 44.9 mm 6.4 mm 6.4 mm (2 x) 18 mm 18 mm 34.6 mm 34.6 mm 47.3 mm 47.3 mm Accessory Anti Spinning Bracket Cable To prevent spinning of the shaft in the conveyor side frame under high torques, the use of an anti spinning bracket is mandatory for all RollerDrive with solid hexagonal shafts. Due to a reinforced form fit, the torque is optimal transmitted to the side frame. Mostly the anti spinning bracket is used with RollerDrive EC110. Do not use it with threaded 11 mm hexagonal shafts. Interroll offers a verity of cables for its different products: Extension cable for RollerDrive EC200/300 Protection rate IP66 Length 1600 mm Fixcon plugs on both sides Cable set for Z-Card All cables for Z-Card come with a rubber grommet for seal the Z-Card housing and pre-assembled plugs on both sides ready for installation: Communication cable for peer to peer Sensor connection cable for M8 or M12, both in length of 1000 and 2000 mm RollerDrive cable for EC200/300 in 1000 and 2000 mm Power supply cable with flying leads on one side in 1000 mm Z-Card Accessory All cables are on stock and available within a short delivery time. 49

Rollers Additionally to RollerDrive Interroll offers a wide verity of gravity conveyor rollers which will fit to virtually every application. On the next pages there is an overview about the gravity rollers. For details please have a look at the Interroll Conveyor Catalogue. 50

R5 min. 30 min. 30 min. 30 max. 120 RL EL = AGL Series 1700 with grooves Version for round belt drive Series 1700 with grooves To prevent electrostatic charges, an antistatic roller version is supplied as standard The load capacity per roller is limited to 300 N due to the driving force of the round belt. The actual load capacity of the roller with steel tube falls below this value only at lengths greater than 1400 mm It is advisable to select a type of spindle which is protected against torsion (e.g. female threaded spindle) Rollers 51

R5 13 13.5 Ø 37.8 4 27 RL = 31 EL = RL + 36 AGL = RL + 65 Series 3500 Plastic PolyO head with two grooves, R = 5 mm and tapered spindle shuttle In addition to the properties listed above, this version features further advantages for the user: This roller is ideal for all motor-driven applications, especially if low-noise is required simultaneously with high output. The spring-loaded tapered spindle shuttle allows the roller to be mounted free of play in conveyor profiles with 11 mm hexagonal holes. The roller is thus likewise fixed in position just as a screwed-in roller with female threaded spindle. Features: Spindle shuttle made of conductive material in order to disperse static charge Both spindle ends are inserted by pressing in Shuttles are aligned opposite to one another Installation costs same as standard spring-loaded spindles Very low-noise running due to tapered plastic shuttle No wear due to play-free seat of the shuttle in the profile Bearing version 6002 2Z, greased Max. roller length RL = 1000 mm Max. load of 350 N 52

R5 13 13.5 Ø 37.8 0.5 0.5 31 RL EL=AGL=RL+36 5 Series 3500 Plastic PolyO head with two grooves, R = 5 mm. The drive head is pressed directly into the tube with a correspondingly long press fit. Only fixed drive is therefore possible for this roller. Additional properties: The drive components work as close together as possible on the profile Spatially separated drive and conveying areas (important in the case of soiling by the conveyed items) Standard O-rings No deformation of the tubes due to grooves No shifting of lightweight conveyed items due to out-of-round O-rings Max. load of 350 N Rollers 53

Ø 43 0.5 (8.5) (18.7) 31 RL EL = AGL = RL + 36 5 0.5 Series 3500 Plastic V-ribbed belt head with 9 grooves The drive head is pressed directly into the tube with a correspondingly long press fit; therefore only fixed drive is possible for this roller. Additional properties: The drive components work as close together as possible on the profile Spatially separated drive and conveying areas (important in the case of soiling by the conveyed items) Flexible standard V-ribbed belts, initial tension 1-3 % Flexible PJ form; ISO 9981; DIN 7867; pitch 2.34 mm Belts with up to 4 ribs can be used (2 x 4 ribs + 1 groove spacing) Even when using elastic belts with only 2 ribs, a transfer of twice the amount of torque as that delivered by comparable round belts is possible Bearing version 6002 2Z, greased Max. load of 350 N 54

4 27.5 1 35 RL EL = AGL = RL + 40 Series 3500 The required motor power for toothed belt driven or V-ribbed belt driven con - veyors varies considerably depending on the belt design and the particular manufacturer. Please consult the belt manu factu rer for assistance in calculating the required motor power. Rollers Wirk-Ø 45.8 5 0.5 55

Series 3500-KXO 13.5 13 R 5 Ø 37.8 0.5 0,5 5 RL EL = AGL = RL + 36 31 Series 1700-KXO max.120 5 0.5 RL EL = AGL min. 30 min. 30 0.5 5 Inner radius of curve Tapered roller length (mm) (mm) 800 300 400 All RollerDrive can be ordered with tapered tubes to design driven roller curves. Interroll also offers tapered gravity rollers. 500 600 700 800 900 850 250 350 450 550 650 750 850 56