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SMART ROLL SELECTION GUIDE
The Smart Roll needs to be used with a Smart Monitor, PLC, or similar device that can monitor the pulses and select a desired output .
Read the complete manual and understand all wiring, pulse selection, and mounting instructions prior to installation . Refer to the sections
Pulse Selection and Frequently Asked Questions of this manual . If necessary contact a PPI Applications Engineer .
The Smart Roll and Smart Monitor should be installed by trained personnel using appropriate safety practices per the National Electric
Code, including electrical disconnect and lockout practices reference ANSI Z244 .1 . This device is not intended for use in hazardous areas
as defined by the NEC articles 500-504 . Intrinsically Safe Smart Rolls and Smart Monitors are not presently available . Follow all procedures
for power disconnect, lockout-tagout, mechanical blocking, etc . to ensure safety .
SMART ROLL SELECTION GUIDE
SELECTING HOW MANY PULSES PER REVOLUTION
FOR THE SMART ROLL
The PPI Smart Roll is a preset sensor switch . As the roll rotates,
an electrical circuit is opened and closed to create pulses . It is
available in options of 1, 2, or 6 pulses per revolution . The most
commonly used is the 2 pulse option . Belt speed, roll diameter,
and electronics capabilities are selection considerations . Using
the lowest number of pulses per revolution will maximize the time
duration of each pulse . The Clean Side Return SAD5CSRSB-2PL4
is the most versatile and most commonly used Smart Roll . Table 1 .1
is based on using a Smart Monitor and the Clean Side Return Smart
Roll using a 5 inch diameter roll . The actual speed limitations may
differ from these limits depending on the roll diameter and electronics .
SELECTING THE SMART ROLL MOUNTING OPTION AND LOCATION
The Smart Roll is available in 4 mounting options, and can fit most locations on a conveyor .
1 . Clean Side Return (CSR) – Preferred
2 . Universal Mount – An 11 .125” long roll in a mounting bracket with two slots for mounting .
3 . Return Roll positions in CEMA C and D sizes . Belt widths from 24-60 inches .
4 . Troughing Idler (wing roll only) positions in CEMA C and D sizes . Belt widths from 24-60 inches .
In order for the Smart Roll to provide reliable feedback follow these guidelines:
• The roll must maintain belt contact at all times . Areas with high vibration should be avoided .
• Avoid areas where material can build up on the roll . This can increase the roll diameter
and cause errors .
• Select an area and location where the Smart Roll will be best protected from abuse .
• PPI typically recommends the Clean Side Return (CSR) mounting option .
• The next best option is typically the Universal Mount .
• Mounting the Smart Roll in a troughing frame or return position should be considered
as a last option .
• The CSR is the most commonly used Smart Roll (see picture) . This Operation and Maintenance
Manual uses this model when explaining the installation and wiring .
SELECTING WHICH SMART MONITOR TO USE
Several models of the Smart Monitor are available . The most commonly used is part number 37543
Smart Monitor 120VAC . This Operation and Maintenance Manual uses this model when explaining
the installation and wiring .
• 37543 Smart Monitor 120VAC; Relay Contacts
• 37545 Smart Monitor 120VAC 4-20mA output
• 47268 Smart Monitor 9-36 VDC; Relay Contacts
• 47269 Smart Monitor 220VAC 4-20mA output
Attention must be given to the location of the Smart Roll so that it is always in contact with the belt . Failure to mount properly may void
warranty and could cause damage to conveyor belt and other components .
# PULSES
SPEED FEET
PER MINUTE
MIN
SPEED
(FPM)
MAX
RANGE
APPLICATION
6
5
700
Low
Feeders/Metering
2
10
2000
Normal
Normal
1
20
4000
High
High Speed
TABLE 1 .1 – Smart Roll Speed Limitations
