Interroll ZoneControl Operating Manual Download

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INSPIRED BY EFFICIENCY

Operating Manual

Interroll ZoneControl

Summary of Contents for ZoneControl

Page 1: ...INSPIRED BY EFFICIENCY Operating Manual Interroll ZoneControl ...

Page 2: ...duct information at any time Copyright industrial property rights Text images graphics and similar elements as well as their arrangement are subject to copyright protection and other protective laws The reproduction alteration transfer or publication of this document in full or in part is prohibited in every form This document is solely for informational purposes and the intended use and does not ...

Page 3: ...persons 12 Electricity 12 Work environment 12 Faults in operation 12 Maintenance 12 Unintentional start up 12 2 6 Interface to other devices 13 2 7 Operating modes operating phases 13 Standard operation 13 Special operation 13 2 8 Applicable documentation 14 3 Product information 15 3 1 Product description 15 Functions 16 Speed settings 16 Feedback of energy Overvoltage protection 16 Temperature p...

Page 4: ...ensors 29 5 6 Inputs and outputs 30 RollerDrive connection 8 mm snap in 5 pin pin location in accordance with DIN EN 61076 2 30 Start sensor connector WAGO 733 103 mating plug 30 Zone sensor connector WAGO 733 103 mating plug 31 Upstream peer to peer connection RJ45 socket 8 pin Molex 43860 31 Power supply connector WAGO 734 102 mating plug 32 Inputs outputs connector WAGO 733 108 mating plug 32 D...

Page 5: ... of a conveyor 43 7 Maintenance and cleaning 44 7 1 Maintenance 44 Checking the ZoneControl 44 Replacing the ZoneControl 44 7 2 Cleaning 45 8 Troubleshooting 46 8 1 Troubleshooting 46 8 2 Deviations in the conveying process 48 Removing a package from the detection area of the zone sensor 48 Time out when leaving the zone sensor 48 Time out when reaching the zone sensor 48 9 Decommissioning and dis...

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Page 7: ...information and advice in this operating manual has been compiled with respect to applicable standards and regulations as well as the current state of the art To ensure safe and faultless operation and to fulfil any warranty claims that may apply read this operating manual first and observe its instructions Keep this operating manual within close reach of the ZoneControl Pass this operating manual...

Page 8: ...ce Measure s for avoiding hazard Signal words indicate the type and severity of the consequences if measures to avoid the hazard are not observed DANGER Denotes an imminent hazard If measures to avoid the hazard are not observed death or severe injury will occur Preventive measures WARNING Denotes a potentially hazardous situation If measures to avoid the hazard are not observed death or severe in...

Page 9: ...damage Preventive measures 1 3 Symbols This symbol indicates useful and important information ü This symbol indicates a requirement that must be fulfilled before carrying out assembly or repair work This symbol indicates general information relating to safety This symbol indicates an action that needs to be performed This symbol indicates a listed item ...

Page 10: ...rols an Interroll RollerDrive and must be integrated into a conveyor unit or conveyor system before commissioning 2 3 Improper use Any use that goes beyond the proper use is considered improper unless this has been authorised by Interroll Engineering GmbH where applicable The equipment must not be installed in areas in which substances could form explosive atmospheres dust atmospheres or for appli...

Page 11: ...rators Operators are trained in how to operate and clean the Interroll ZoneControl unit and follow the safety regulations Service engineers The service engineers have a specialist technical education or have successfully completed a training course from the manufacturer They carry out repair and maintenance work Qualified electricians Qualified electricians have a specialist technical education Mo...

Page 12: ...re that it cannot be unintentionally switched on again Work environment Remove any materials and objects that are not required from the working area Wear safety shoes Stipulate that the material to be conveyed must be set down carefully and monitor this to ensure it is carried out correctly Faults in operation Regularly check the ZoneControl for visible damage If smoke develops immediately switch ...

Page 13: ...system must be checked for any new potential hazards that may be present before the conveyor is switched on 2 7 Operating modes operating phases Standard operation Operation in the installed condition at the end customer as a component in a conveyor in an overall system Special operation Special operation encompasses all operating modes operating phases that are necessary to guarantee and maintain...

Page 14: ...e documentation In order to ensure proper use of the RollerDrive additional operating manuals documentation relating to the following must be consulted Power supply unit RollerDrive Description of the conveyor system unit Also ensure that you adhere to the information given in the operating manuals of the connected devices ...

Page 15: ... so that no accumulation pressure occurs Schematic diagram three zones controlled by ZoneControl 1 Zone 1 6 Zone sensor 2 Zone 2 7 RollerDrive 3 Zone 3 8 Power supply 4 Direction of travel 9 Peer to peer connection 5 ZoneControl 10 Package The sensor in zone 1 has detected a package The ZoneControl in zone 1 sends a request to zone 2 to ask whether the package can continue to be conveyed Since zon...

Page 16: ...Internally at eight levels by means of three DIP switches Externally continuously via the analog input SPEED is handled with priority and enables more fine tuned adjustment The speed setting is converted to an analog control voltage by the ZoneControl and output by the RollerDrive as a reference setting This reference setting is independent of the RollerDrive gears and their diameter Speed setting...

Page 17: ...itches are protected by the firmware to guarantee operation in the event of edge unstable and bouncing input levels This means that after a signal status change there is a time gap of 20 ms in which no additional status change is accepted The sample applies to the sensor inputs where signal status changes are only processed 50 ms after a signal modification 1 Signal with effect and start of the lo...

Page 18: ...P switches 4 RollerDrive connector 10 Marker changeable 5 Mounting link with hole for countersunk screw 11 Red and green LED 6 Power supply connector 1 PTP Peer to peer connection 3 3 Scope of delivery The ZoneControl contains the following components ZoneControl Mating plug for power supply WAGO 734 102 xxx xxx Mating plug for power supply WAGO 734 102 xxx xxx Spare tool for power supply mating p...

Page 19: ...ow voltage PELV Voltage range 19 bis 26 V DC no polarity protection 1 Current consumption with RollerDrive 3 to 5 A without RollerDrive 0 08 to 0 5 A Protection classification IP 20 Cooling Convection Ambient temperature in operation 0 C to 40 C Ambient temperature during transport and storage 20 C to 70 C Air humidity 5 to 95 condensation not permissible condensation not permissible Max 1000 m 1 ...

Page 20: ...gnment On steady Off ZoneControl ready for operation Stop Flashing 1 Off RollerDrive receives start signal Rotates On steady Flashes once 1 RollerDrive faulty or not connected Stop On steady Flashes twice 1 Fault in conveyor process for instance jammed package Stop On steady Flashes three times 1 Shutdown due to excessive temperature in chopper resistance Stop Off Flashes four times 1 System error...

Page 21: ...page 40 EPA BA Train release mode BA 1 Singulated release EPA 1 DIR RollerDrive rotates in an anticlockwise direction 2 RollerDrive rotates in a clockwise direction 2 PNP NPN Signals are emitted in accordance with NPN logic Signals are emitted in accordance with PNP logic 1 see Product description page 15 2 The direction of rotation is seen from the connecting cable side if the external input DIR_...

Page 22: ...y zone The ZONE_STATUS signal gets in active when A package initially standing is conveyed into the following zone When the zone sensor becomes free the ZONE_ STATUS gets in active providing no further package is following If a package does not reach the zone sensor the system assumes after 5 seconds that the package has been manually removed and the ZONE_STATUS signal gets in active If a standing...

Page 23: ...ing transport Check each ZoneControl after transport for any visible damage If any damage has been identified photograph the damaged parts In the event that damage has been incurred during transport inform the shipping agent or Interroll immediately to ensure that you do not lose any potential damage claims Do not expose the ZoneControl to any strong fluctuations in temperature since this can lead...

Page 24: ... ZoneControl is not tensioned during the assembly process no bending or torsional load Do not drill any additional mount holes into the housing and do not enlarge any existing holes Ensure that the permitted operating temperature is under no circumstances exceeded as a result of external heat sources 5 2 Assembling the ZoneControl Look for level surfaces that are suitable for mounting the ZoneCont...

Page 25: ...n the operating voltages when all cables are connected Note Improper electrical installation can result in damage to the ZoneControl Observe national regulations for electrical installation Only operate the ZoneControl with a protective extra low voltage PELV of 24 V or 48 V Never operate the ZoneControl with an alternating voltage Ensure that the polarity of the power supply is correct Ensure tha...

Page 26: ...on which the RollerDrive cable is located All of the connections should be routed to one side of the conveyor to simplify cabling The cabling of the PTP connection must always following the direction of the conveyor that is to say that the PTP downstream connection of the upstream zone must be connected to the PTP upstream connection of the downstream zone etc This also applies if one several Zone...

Page 27: ...g plug using the yellow tool see Inputs and outputs page 30 Insert the power supply wires into the mating plug with the black spare tool Insert the mating plug into the ZoneControl Ensure that all of the ZoneControl are connected to a common ground Adjust the SPEED A SPEED B SPEED C EPA BA and DIR DIP switches according to requirements see Operation page 39 Adjust the PNP NPN DIP switch according ...

Page 28: ...RT ZONE_SENS_ IN PNP DIP OFF active 24 V 24 V 24 V 24 V 24 V in active NPN DIP ON active GND GND GND GND GND in active Signal status of outputs PNP NPN Status ZONE_STATUS ERROR EXT_ON PNP DIP OFF active 24 V 24 V 24 V in active NPN DIP ON active GND GND GND in active Schematics of all outputs With PNP logic With NPN logic UB Operating voltage RS Internal overload protection GND Ground ...

Page 29: ...Closer Logical Output Light beam Switch symbol Elektrical Output Package detected Swit ched on Volt age PNP Light barrier with reflector Dark switching Closer normally open No not interrupted No Yes interrupted Yes 24 V Light scanner Light switching Closer normally open No interrupted No Yes not interrupted Yes 24 V NPN Light barrier with reflector Dark switching Closer normally open No not interr...

Page 30: ... 5 6 Inputs and outputs RollerDrive connection 8 mm snap in 5 pin pin location in accordance with DIN EN 61076 2 1 24 V DC 4 Fault input 2 Output for direction of rotation 5 Speed output 3 Ground Start sensor connector WAGO 733 103 mating plug 1 24 V DC 3 Ground 2 START_SENS_IN input for start sensor signal ...

Page 31: ...ting manual 31 von 54 Assembly and installation Zone sensor connector WAGO 733 103 mating plug 1 24 V DC 3 Ground 2 ZONE_SENS_IN input for zone sensor signal Upstream peer to peer connection RJ45 socket 8 pin Molex 43860 Mating plug pre manufactured patch cable ...

Page 32: ...connector WAGO 733 108 mating plug 1 EXT_ON Output for additional start signal 5 ERROR Output for error signal 2 CLEAR Input for clear signal 6 ZONE_STATUS Output for zone status signal 3 SPEED Input for speed setting 7 ZONE_START Input for start signal 4 DIR_RET Input for change of transport direction and only effective when there is an active signal at CLEAR 8 ZONE_STOP Input for stop signal ...

Page 33: ...ing manual 33 von 54 Assembly and installation Downstream peer to peer connector RJ45 socket 8 pin Molex 43860 Mating plug pre manufactured patch cable The electrical data for each connection is specified in the appendix see Electrical data of connectors page 50 ...

Page 34: ...r to peer Connection ZoneControl within the conveyor section 1 Zone sensor This ZoneControl can be located at any position between the start and end zone This switch enables zero pressure accumulation conveying without additional functions The ZoneControl is connected to the adjacent ZoneControls via the Peer to Peer cable The zone sensor is fed with operating voltage via the sensor connector ...

Page 35: ... upstream conveyor section The zone status occupied or free can be queried via the signal ZONE_ STATUS see ZONE_STATUS page 22 The first zone of the ZoneControl conveyor can be started in the following ways Start sensor button A is not needed External signal at the ZONE_START input symbolised by switch A start sensor not needed The function of the switch can be provided using any switching element...

Page 36: ... must be given at the ZONE_START input of the last zone to discharge This can be a switch refer to the example in the diagram above or an external control PLC The signal can be switched in NPN or PNP mode The status of the last zone is given by the ZONE_STATUS output If there is no package in the relevant zone sensor s detection range and the ZONE_START signal is active the RollerDrive does not ro...

Page 37: ... SPEED signal can be connected to control the speed of the whole conveyor externally The signal should only be connected to one ZoneControl as it is transmitted via the PTP connection to all other ZoneControl The position of the ZoneControl within the conveyor and the cable length of the PTP connection is immaterial The voltage range for the SPEED signal is between 0 and 10 V DC with a maximum cur...

Page 38: ...Common GND of the DriveControl 20 If possible use the same power supply for the ZoneControl and DriveControl 20 Preselect a speed that is comparable to that of the ZoneControl on the DriveControl 20 using DIP switches SPEED A to D If the function DIR_RET is to be used in the application connect the DIR input of the DriveControl 20 to the DIR_RET signal of the ZoneControl and on the DriveControl 20...

Page 39: ...ion devices Clearly specify and monitor the way goods are placed on the conveyor Ensure that the RollerDrive is not blocked Ensure that no personnel stand in hazardous areas near the conveyor 6 2 Operation Caution Accidental start up of the RollerDrive Danger of crushing of limbs and damage to goods Ensure that no unauthorised persons are near the conveyor before switching on the operating voltage...

Page 40: ...0 26 0 19 0 15 0 10 off on on 0 80 0 60 0 45 0 36 0 30 0 20 0 15 0 11 0 07 off on off 0 56 0 42 0 32 0 25 0 21 0 14 0 11 0 08 0 05 off off on 0 32 0 24 0 18 0 15 0 12 0 08 0 06 0 05 0 03 off off off 0 09 0 07 0 05 0 04 0 03 0 02 0 02 0 01 0 01 Nominal values at an ambient temperature of 20 C Setting of the SPEED DIP switches on the ZoneControl Speed at gear ratio for RollerDrive EC5000 AI m s A B ...

Page 41: ...o all zones of the ZoneControl conveyor 6 4 External influence on zero pressure accumulation conveying The ZoneControl has two control signals to specifically influence the otherwise automatic conveyor process ZONE_START ZONE_STOPP These signals enable the current conveyor logic of a zone to be interfered with to the extent that locally generated START STOP processes can be integrated easily and s...

Page 42: ...PA or sensor status Caution Risk of collision If the signal gets inactive the zone again follows the rules of zero pressure accumulation conveying No initialisation takes place Connected to the last zone If the last zone is occupied by a package it is conveyed out of this zone If no further package follows the RollerDrive stops after 4 seconds run on If a further package is following then it is al...

Page 43: ...takes It causes forced conveyance All RollerDrive rotate simultaneously at the respectively preset speed and in the preset direction without taking the zone sensors into consideration Any CLEAR signal connected to an intermediate zone is ineffective CLEAR cannot be active while the ERROR signal is activated As soon as the CLEAR signal is inactive again the conveyor goes through an initialisation c...

Page 44: ...that maintenance or cleaning work is being carried out 7 1 Maintenance Checking the ZoneControl The ZoneControl itself requires no maintenance However in order to prevent faults from occurring the connections and fixings must be examined on a regular basis In the course of regular inspection and maintenance work on the conveyor ensure that the screws of the ZoneControl are still tight that the cab...

Page 45: ...refore ensure dirty environments are cleaned regularly to prevent short circuits that could damage the ZoneControl NOTE The ZoneControl can be damaged if it is cleaned improperly Never immerse the ZoneControl in fluids If necessary vacuum any dust or dust that is present To clean the ZoneControl more thoroughly disconnect it from the power supply detach it and wipe it with a damp cloth ...

Page 46: ...s page 21 ZoneControl faulty or damaged Internal fuse triggered or faulty Replace the ZoneControl RollerDrive is not working RollerDrive is faulty or no power supply Check whether the output voltage of the power supply is within the specified voltage range Check the connections and correct if necessary The ERROR signal is automatically reset after elimination of the fault and the ZoneControl immed...

Page 47: ...reinitialisation of the affected zone PTP cable disconnection Check all of the PTP cable connections Systemfehler PTP cable disconnection Switch operating voltage off and on to reinitialise the conveyor system The error signal is active in the event of the following faults RollerDrive fault RollerDrive not connected Fuse faulty Upper and lower levels of permitted operating voltage transgressed Ope...

Page 48: ...llerDrive has started the occupied zone sensor must become free after 5 seconds If the sensor is still occupied at the end of this time period the RollerDrive stops The ERROR output becomes active and the next ZoneControl displays an error by means of the error LED An assumption is made that the package is blocking the conveyor The time period of 5 seconds can result in long packages not being abl...

Page 49: ...om the power supply Switch off the power to the ZoneControl and ensure that it cannot be unintentionally switched on again 9 1 Decommissioning Remove all cables from the ZoneControl Loosen the screws that have been used to attach the ZoneControl to the conveyor frame Remove the ZoneControl from the conveyor frame 9 2 Disposal The operating company is responsible for disposing of the ZoneControl ac...

Page 50: ...C Overvoltage protection max 30 V DC Permanent free of harmonic waves Logic level low 0 to 5 V DC npn active Input current low max 3 mA Logic level high 15 to 28 V DC pnp active Input current high max 4 5 mA Response time for repeated signal change min 20 ms Outputs ZONE_STATUS ERROR RD_EXT_ON Porperties not short circuit proof Output current 50 to 100 mA At an operating voltage of 30 V max 500 ms...

Page 51: ... factor 19 Return electric strength max 35 V DC absence of harmonic waves max 500 ms after 500 ms the reserve voltage must be 30 V duty factor max 27 Direction of rotation output Pin 2 Properties not electrically isolated short circuit proof infeed of external voltage not permitted Overvoltage protection max 30 V DC Clockwise direction of rotation max 4 V logical 0 Output current low max 1 mA Load...

Page 52: ...30 V DC Logic level 1 H error Residual current high Max 0 01 mA Speed output Pin 5 Properties Not galvanically separated Speed setting range for motor control voltage 2 3 to 10 V DC RollerDrive rotates Stop range 0 to 2 V DC RollerDrive does not rotate Accuracy of motor control voltage 5 Motor control voltage between 2 3 and 10 V DC at 21 C Ripple of motor control voltage 250 mVPP 50 Ω Max load fo...

Page 53: ...ssociated CE marking in accordance with the aforementioned Directives List of the coordinated standards that have been applied EN 60947 5 3 1999 A1 2005 EN 61000 6 2 2005 AC 2005 EN 61000 6 3 2007 A1 2011 AC 2012 EN 60204 1 2006 AC 2010 Authorised for compiling technical documentation Interroll Engineering GmbH Höferhof 16 42929 Wermelskirchen Germany Jörg Schiffler Product Compliance Officer Inte...

Page 54: ...INSPIREDBY EFFICIENCYEN 04 2019 Version 2 0 2019 INTERROLL ...

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