Interroll 9006 Manual de usuario
User Manual
Interroll
9006 Hybrid Control for RollerDrive
EC100
EC110
EC120 (future)
Version 1.1 (11/2011) en
Original language
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.
1
Version 1.1 (11/2011) en
Original language
9006 Hybrid Control for RollerDrive
Table of contents
Table of contents
Introduction
Handling of the user manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Further symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety
General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unintended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Qualified persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product information
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ZPA technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Incline and decline applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Peer-to-peer communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIP switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Meaning of the LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9006 label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Speed settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting options and wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transport and storage
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Assembly
Warning notices concerning assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Warning notices concerning the electrical installation . . . . . . . . . . . . . . . . 37
Installing the 9006 in a conveyor system . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Initial startup and operation
Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Procedure in case of accident or malfunction . . . . . . . . . . . . . . . . . . . . . . 39
Maintenance and cleaning
Warnings concerning maintenance and cleaning. . . . . . . . . . . . . . . . . . . . 40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Troubleshooting
Error search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Abandonment and disposal
Abandonment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Manufacturer's declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2Version 1.1 (11/2011) en
Original language
Introduction
9006 Hybrid Control for RollerDrive
Introduction
Handling of the user manual
In this manual the 9006 Hybrid Control for RollerDrive for the EC100, EC110,
EC120 is referred to as 9006.
Content of the manual This manual contains important advice, notes, and information about the
9006 in all phases of its lifecycle:
• Transport, assembly, and commissioning
• Safe operation, maintenance, troubleshooting, and disposal
• Accessories
Validity of the manual The manual describes the 9006 as it is delivered by Interroll.
Special application designs require validation from Interroll and additional
technical instructions.
This manual is part of the
product
For trouble-free, safe operation and warranty claims, read this manual and
follow the instructions before handling the 9006.
Keep this manual near to the 9006.
Pass this manual on to any subsequent operator or occupant of the
9006.
Interroll does not accept any liability for malfunctions or defects due to non-
observance of this manual.
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
9006. 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
Structure of warnings
Signal word Meaning
Danger Indicates a hazardous situation which, if not
avoided, 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.
Nature and source of the hazard
Possible consequence of non-observance
Information about how to avoid the hazard.
DANGER
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Version 1.1 (11/2011) en
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9006 Hybrid Control for RollerDrive
Introduction
Further symbols
This symbol marks the steps that have to be carried out.
This symbol identifies possible material damage.
Information about how to avoid damage.
Important
This symbol displays safety instructions.
Hint
This symbol marks useful and important information.
4Version 1.1 (11/2011) en
Original language
Safety
9006 Hybrid Control for RollerDrive
Safety
General safety instructions
The 9006 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 9006 and other material.
Always read the entire operating and safety instructions before starting to
work with the 9006 and follow the information contained herein in full.
Only instructed and qualified persons may work with the 9006.
Always keep this user manual at hand when working on the 9006 so
that you can consult it quickly if required.
Always comply with relevant national safety regulations.
If 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 9006 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 9006 is only allowed in the areas described under product
information.
Any changes that affect the safety of the product are not allowed.
The 9006 may only be used within the given operation limits.
Unintended use
Applications not according to the intended use of the 9006 require
approval from Interroll.
Important
Disregarding the warnings in this manual may lead to serious injury.
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Version 1.1 (11/2011) en
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9006 Hybrid Control for RollerDrive
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 9006, taking the
following into account:
• the relevant manuals 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
Persons Maintenance or repair work must only be executed by authorized and qualified
persons in accordance with the applicable regulations.
Before using the 9006, ensure that no unauthorized persons are near
the conveyor.
Electricity Only perform installation and maintenance work after you have switched off
the power. Ensure that the power cannot be turned on accidentally.
Working environment Do not use the 9006 in explosive atmospheres.
Remove equipment or material which is not required from the workspace.
Avoiding malfunctions in
operation
Regularly check the 9006 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.
Maintenance 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 9006 in a conveyor module, potential hazards may
occur. These are not described in this manual and have to be analyzed during the
design, installation, and startup of the conveyor module.
After assembling the 9006 in a conveyor module, check the whole
system for any new potential dangerous condition prior to turning on the
conveyor.
Important
The following list informs you about the various types of danger or damage that
may occur while working with the 9006.
6Version 1.1 (11/2011) en
Original language
Product information
9006 Hybrid Control for RollerDrive
ProdThe ybridControl 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.uct infor
The 9006 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
7
Version 1.1 (11/2011) en
Original language
9006 Hybrid Control for RollerDrive
Product information
Dimensions
Mounting hardware The following mounting hardware is supplied:
• 2x button head screw 10-32 UNF x 0.5"
• 2x nut with captive star washer 10-32 UNF
ZPA technology
ZPA is short for zero pressure accumulation. The 9006 provides true
zero pressure accumulation and other control options to a conveyor system.
Each 9006 controls a RollerDrive unit, which in turn drives idler rollers
using O-rings or other belts. The 9006, 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 accumulation 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
9006 electronically. The RollerDrives only operate when a package is
detected by a photoeye. If the downstream zone is empty, the package moves
forward.
8Version 1.1 (11/2011) en
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Product information
9006 Hybrid Control for RollerDrive
Principle of zones
Zone A has a package at the photoeye. The 9006 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
9006 denies the permission until this package has been transfered 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 9006 of zone A will only start to operate the RollerDrives in its
zone after it gets permission from the 9006 of zone B.
1Zone
2Direction of travel
3Load
4RollerDrive
5Photoeye
6HC-DriveControl
7Peer-to-peer communication cable
8+24 VDC / GND
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