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Interroll 9006 User Manual

Hybrid control for rollerdrive ec100, ec110, ec120 (future)
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User Manual
Interroll
9006 Hybrid Control for RollerDrive
EC100
EC110
EC120 (future)

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Summary of Contents for Interroll 9006

  • Page 1 User Manual Interroll 9006 Hybrid Control for RollerDrive EC100 EC110 EC120 (future)
  • Page 2 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.

  • Page 3: Table Of Contents

    Warning notices concerning the electrical installation ....37 Installing the 9006 in a conveyor system ......38 Electrical installation .

  • Page 4: Handling Of The User Manual

    Introduction Handling of the user manual Introduction 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: •...

  • Page 5: Further Symbols

    9006 Hybrid Control for RollerDrive Introduction Further symbols 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.  This symbol marks the steps that have to be carried out.

  • Page 6: Safety

    9006 Hybrid Control for RollerDrive Safety General safety instructions Safety 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.

  • Page 7: Qualified Persons

    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, •...

  • Page 8: Product Information

    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.

  • Page 9: Dimensions

    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 –...
  • Page 10 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. Zone...

  • Page 11: Product Description

    • Learn Mode: During system startup, the 9006 will automatically set the zone length and save it, simply by running an object from the upstream photoeye to the downstream photoeye.

  • Page 12: Incline And Decline Applications

    • 9006 temperature shutdown: At a 9006 temperature of 90 °C (194 °F) the 9006 will shutdown the motor and the motor will go into dynamic braking. This is indicated by the red LED flashing four times. When the 9006 cools back down the red LED stops flashing and motor and 9006 operation will resume.

  • Page 13: Inputs And Outputs

    9006 Hybrid Control for RollerDrive Product information Inputs and outputs Power input and I/O connections Speed analog input: External speed control down to approximately 33% of the maximum speed. When using a 10 kΩ external potentiometer, the wiper must be connected here. The on-board rotary switch should be set to maximum (CW) so it will not affect the external speed setting (for the wiring diagrams see page 19).
  • Page 14 Sensor connection Accum (L-stop) input: An active signal (NPN/PNP switchable) on this terminal input will cause the 9006 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).

  • Page 15: Peer-To-Peer Communication

    All logic operates from a regulated and filtered 5 VDC power supply on the 9006. 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).

  • Page 16: 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 9006 connectivity upstream and downstream (SW4, SW5) • Standard singulate mode (SW3) • Motor running counter clockwise (SW2) •...
  • Page 17 9006 Hybrid Control for RollerDrive 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. • It is 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).

  • Page 18: Meaning Of The Leds

    9006 Hybrid Control for RollerDrive 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 ¼ second on, and ¼ second off, in a fixed 4 second time period):...

  • Page 19: 9006 Label

    9006 Hybrid Control for RollerDrive Product information 9006 label The specifications on the 9006 label are used to identify the 9006. This is required to use the 9006 as intended. Technical data Version 1.1 (11/2011) en Original language...

  • Page 20: Speed Settings

    EC100, EC110, and EC120) by the rotary switch marked "speed" on the 9006. Default setting is maximum. Hint If more than one 9006 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).
  • Page 21 9006 Hybrid Control for RollerDrive Product information External speed setting Apart from the rotary switch on the 9006, there are other ways to set the speed. HintF For the meaning of the settings see "DIP switches", page 14. Version 1.1 (11/2011) en...

  • Page 22: Setting Options And Wiring Diagrams

    9006 Hybrid Control for RollerDrive Product information Setting options and wiring diagrams This chapter explains the DIP switch settings for different application Hint 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).
  • Page 23 9006 Hybrid Control for RollerDrive Product information DIP switch settings: • SW1: ON Version 1.1 (11/2011) en Original language...
  • Page 24 9006 Hybrid Control for RollerDrive Product information DIP switch settings: • SW1: OFF Version 1.1 (11/2011) en Original language...
  • Page 25 9006 Hybrid Control for RollerDrive Product information 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.
  • Page 26 9006 Hybrid Control for RollerDrive Product information 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.
  • Page 27 9006 Hybrid Control for RollerDrive Product information Works like a standard configuration, only the 9006 is turned upsidedown. Version 1.1 (11/2011) en Original language...
  • Page 28 9006 Hybrid Control for RollerDrive Product information Hint A reverse command to the Zone 9006 will not be communicated to the dependent 9006 cards. Dependent 9006 DIP switch settings: • SW1: Must have the same switch setting as zone 9006 (logic mode NPN or PNP).
  • Page 29 9006 Hybrid Control for RollerDrive Product information Start options: • FWD connected to 24 VDC causes ccw rotation. • REV connected to 24 VDC causes cw rotation. • FWD and REV connected to 24 VDC causes coast mode. Version 1.1 (11/2011) en...
  • Page 30 9006 Hybrid Control for RollerDrive Product information 9006 is entry zone Upstream device Downstream device 9006 DIP switch 4 DIP switch 5 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...
  • Page 31 9006 Hybrid Control for RollerDrive Product information 9006 is exit zone 9006 Upstream device Downstream device DIP switch 4 DIP switch 5 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...
  • Page 32 9006 Hybrid Control for RollerDrive 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.
  • Page 33 9006 Hybrid Control for RollerDrive (this page intentionally left blank) Version 1.1 (11/2011) en Original language...
  • Page 34 9006 Hybrid Control for RollerDrive Product information 9006 in conjunction with PLC- handshakes 9006 after 9006 before 9006 PLC-handshake (entry zone) PLC-handshake (exit zone) between PLC- handshakes Upstream device 9006 9006 Downstream device 9006 9006 DIP switch 4 DIP switch 5...
  • Page 35 9006 Hybrid Control for RollerDrive Product information • 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 Version 1.1 (11/2011) en...
  • Page 36 9006 Hybrid Control for RollerDrive Product information • 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 Version 1.1 (11/2011) en...
  • Page 37 9006 Hybrid Control for RollerDrive Product information • A smart I/O based handshake is required at both interfaces • 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...

  • Page 38: Transport And Storage

     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 9006 between warm and cold environments as this may cause condensing water. Storage...

  • Page 39: Assembly

     Disconnect the power before installing, removing or rewiring the 9006.  Do not apply AC current to the RollerDrive or 9006 device at any time as this will cause irreparable damage.  Do not apply too much stress to the connector pins. Bending the wires at the connector can cause damage to the insulation of the wires, which could result in failure of the 9006 or the RollerDrive.

  • Page 40: Installing The 9006 In A Conveyor System

    Assembly Installing the 9006 Hybrid Control in a conveyor system  Use the 9006 as a template and mark the center of the two mounting holes. For the distance between the holes, see "Dimensions", page 7.  Drill two ø 5.6 - 6 mm (0.22 - 0.24 in) mounting holes at the marked spots.

  • Page 41: Initial Startup And Operation

     Check all protection devices.  Ensure that no bystanders are in dangerous areas around the conveyor. Operation Damage to the 9006 or the motor of the RollerDrive due to induction  Do not push items along the roller conveyor by hand.

  • Page 42: Maintenance And Cleaning

    The 9006 must be checked at regular intervals to avoid malfunctions.  Monthly check the 9006 and its leads for visible damage.  Annually ensure that the screws of the 9006 are still tight and that the cables are still laid properly and connected to the terminals.

  • Page 43: Troubleshooting

    Troubleshooting When troubleshooting the conveyor system, keep in mind that each 9006 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.
  • Page 44 System reverses or jogs without Fuse is blown Check the fuses in all 9006 cards of prompting If DIP switch 4 and 5 are ON for all the system and replace the blown one cards, a blown fuse or loss of power (see "Replacing fuse", page 40).
  • Page 45 Replace the communication cable. zone is miswired Signal has not been sent and Check the output of the upstream received properly 9006 and the input to the 9006. Different ground of the zones Check that a common ground exists between both zones.
  • Page 46 9006 Hybrid Control for RollerDrive Troubleshooting The following errors are reported by illuminated LEDs: (also see "Meaning of the LEDs", page 16) Symptom Possible cause Help Motor is in brake mode, red fault Invalid state of motor hall effect Replace the RollerDrive.

  • Page 47: Abandonment And Disposal

     Unscrew the screws attaching the 9006 to the conveyor frame.  Extract the 9006 from the conveyor frame. Disposal The operator is responsible for the proper disposal of the 9006. In doing so, industry-specific and local provisions must be observed for the disposal of the 9006 and its packaging.

  • Page 48: Appendix

    9006 Hybrid Control for RollerDrive Appendix Appendix Accessories Plugs and cables Part Description Power and I/O plug • 8-pin cage clamp type connector, Wago part # 231-308/026-004 • Wire diameter: – Minimum 0.08 mm (AGW 28) – Maximum 2.5 mm...

  • Page 49: Glossary

    RollerDrive under no load prior to the package’s arrival. EMF is a counter-voltage phenomenon that is always present in a motor. Excessive back EMF can cause a current backlash that may damage the 9006 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.
  • Page 50 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 9006 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).

  • Page 51: Manufacturer's Declaration

    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 can be obtained at www.interroll.com, if needed.) Version 1.1 (11/2011) en Original language...
  • Page 52 India Tel. +36 23 337 891 Tel. +1 905 727 3399 Rulli Rulmeca S.p.A. Interroll Drives and Rollers India Private Limited Fax +1 905 727 3299 Fax +36 23 337 892 Via A. Toscanini, 1 SF 12, KSSIDC Building 3rd Stage cdn-sales@interroll.com...

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