INSPIRED BY EFFICIENCY

Operating manual

RollerDrive EC5000 AI/BI
24 V/48 V DC, analogue interface/bus interface

Manufacturer details
Interroll Engineering GmbH
Höferhof 16
42929 Wermelskirchen, Germany
Tel.: (+49-21) 93-230
Fax: (+49-21) 932-022
www.interroll.com

Content
We strive for the accuracy, timeliness and completeness of the information and have carefully prepared the contents
in this document. Regardless of this, errors and changes are expressly reserved.
Copyright/industrial property rights
Any texts, images, graphics and the like, as well as their arrangement, are subject to protection under copyright andother laws of protection. The reproduction, modification, transmission or publication of any part of this document or of
the entire document in any form is prohibited.
The document serves the exclusive purposes of information and of operation in accordance with the regulations anddoes not justify any counterfeiting of the products concerned.
All signs contained in this document (protected marks, such as logos and trade names) are the property of Interroll
Holding AG, CH or of third parties and must not be used, copied or distributed without prior written consent.
Online version – only suitable for colour printing!

Contents

1

About this document

7

1.1

Information about this operating manual

7

1.2

Warning notices in this document

8

1.3

Symbols2

Safety-related information

10

2.1

State of the art

10

2.2

Proper useApplication field

9

10
10

2.3

Improper use

11

2.4

Qualification of personnel

11

2.5

Dangers
Injury to persons1212Electricity12
Rotating parts

12Heat12Work environment

12

Faults in operation

12

Maintenance13
Unintentional start-up

13

2.6

Interface to other devices

13

2.7

Operating modes/operating phases13Standard operation

13

Special operation

13

2.8

Applicable documentation

14

3

Product information

15

3.1

Components
Colour rings on the connectors

3.2

Product description
Overload protection

3.3

15
15
16
16

RollerDrive EC5000 BI with CAN bus

18

Service life indicator lights

18

Health indicator lights

19

Various operating modes

20

3.4

Rating plate

21

3.5

RollerDrive EC5000 as a replacement for RollerDrive EC310

22

3.6

Product identification

23

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Contents

3.7

3.8

Technical specifications24

EC5000 20 W – AI/BI – 24 V DC

24

EC5000 35 W – AI/BI – 24 V DC

25

EC5000 50 W – AI/BI – 24 V DC

26

EC5000 20 W – AI/BI – 48 V DC

27

EC5000 35 W – AI/BI – 48 V DC

28

EC5000 50 W – AI/BI – 48 V DC

29

Performance data

30

Explanation of terms

30

EC5000 20 W – 24 V DC/48 V DC

31

EC5000 35 W – 24 V DC/48 V DC

31

EC5000 50 W – 24 V DC/48 V DC

32

3.9

Control systems for the RollerDrive EC5000

33

3.10

RollerDrive connector AI

34

3.11

RollerDrive connector BI

35

3.12

Dimensions of the motor shaft

36

3.13

Drive axle dimensions36

50 mm IP54

36

50 mm IP66

38

60 mm IP54 - only 50 W

39

3.14

Tapered RollerDrive (for curves)

40

3.15

Crowned RollerDrive (drive for belt conveyors)

43

Belt43
Belt conveyors

43

Permissible applications45

Dimensions46
Form and diameter progression of the tube

46

4Transport and storage

47

4.1

Transport

47

4.2

Storage47

5

Assembly and installation

48

5.1

Warning notices for installation

48

5.2

Installing the RollerDrive

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49

Installing the attachment shaft

49

Attaching the non-cable side

50

Securing the RollerDrive in the side profile51
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5.3

Installation tool (accessory)

52

The Interroll Interlock (accessory)

53

5.4

Warning notices for electrical installation

54

5.5

Electrical installation

54

6Start-up and operation

55

6.1

Warning notices for start-up and operation

55

6.2

Start-up
Check before the initial start-up

6.3

Operation
Check before every start-up

55
55
56
56

6.4

Procedure in the event of accidents or faults

56

7

Maintenance and cleaning

57

7.1

Maintenance

57

Checking the RollerDrive

57

Replacing the RollerDrive

57

7.2

Cleaning

58

8

Assistance in the event of faults

58

8.1

Troubleshooting58

9

Decommissioning and disposal

59

9.1

Decommissioning

59

9.2

Disposal

59

10

Appendix

60

10.1

Accessories

60Interroll control systems

60Interroll High Performance power supply unit

60

RollerDrive extension cable

60

PolyVee belt

61

PolyVee clamping aid61

PolyVee finger guard (50 mm roller only)

61

Tool61
10.2

Translation of the original Declaration of Conformity

62

10.3

UKCA Declaration of Conformity

63

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About this document

1

About this document

1.1

Information about this operating manualThis operating manual covers the following Interroll motor rollers:• RollerDrive EC5000 AI with analogue interface, 24 V DC and 48 V DC
• RollerDrive EC5000 BI with digital CANopen bus interface, 24 V DC and 48 V DC
in three different power levels (see „Product description“ auf Seite 16).
In the course of this manual, the term ‘RollerDrive’ will sometimes be used, or alternatively the type designation‘EC5000’.
The operating manual is a component of the product and contains important advice and information regarding thedifferent operating phases of the RollerDrive. It describes the RollerDrive at the time of shipping from Interroll.
The currently applicable version of this operating manual can be found online at:www.interroll.com
All the information and advice in this operating manual has been compiled with respect to applicable standards andregulations as well as the current state of the art.
For special versions, in addition to this operating manual, particular contractual arrangements and technicaldocuments apply.
¾

To ensure safe and faultless operation and to fulfil any warranty claims that may apply, read this operating
manual first and observe its instructions.

¾

Keep this operating manual within close reach of the RollerDrive.

¾

Pass this operating manual onto every subsequent owner or user.
The manufacturer assumes no liability for damage and malfunctions that occur as a result of noncompliance with this operating manual.
Should you still have any unanswered questions after reading this operating manual, please contact Interroll
customer service. Contact details for your region can be found online at www.interroll.com
Please direct any comments and suggestions regarding our operating manuals to manuals@interroll.com

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About this document

1.2

Warning notices in this document

Warning notices are provided in the context in which danger can occur and describe the nature of the danger inquestion. They are structured according to the following examples:

SIGNAL WORD
Type and source of hazard
Consequence(s) in the event of non-compliance¾

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.
¾

Preventive measures

WARNING
Denotes a potentially hazardous situation.
If measures to avoid the hazard are not observed, death or severe injury may occur.
¾

Preventive measures

CAUTION
Denotes the possibility of a hazardous situation.
If measures to avoid the hazard are not observed, minor or moderate injury may occur.
¾

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Preventive measures

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NOTE
Denotes a situation that can lead to material damage.
¾

Preventive measures

1.3

Symbols
This symbol indicates useful and important information.

üThis 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.

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Safety-related information2

Safety-related information

2.1

State of the art

The RollerDrive EC5000 has been constructed with respect to applicable standards and the current state of the art
and has been delivered in a condition that is safe to operate. Nevertheless, hazards can occur as a result of use.
Non-compliance with the instructions in this operating manual can result in life-threatening injuries.
In addition, the applicable local accident prevention regulations for the area of application and general safety
regulations must be adhered to.

2.2

Proper use

The RollerDrive may only be used in an industrial environment for industrial purposes within the stipulated
performance limits that are given in the technical specifications.
It must be integrated into a conveyor unit or conveyor system before commissioning.
The RollerDrive may only be used horizontally, with a maximum incline of 2.5°.

Application field
Drive for unit load conveyor technology, such as for the transportation of cardboard boxes, containers, barrels,
workpiece carriers or tyres.
The RollerDrive is suitable for:
• Zero-pressure roller conveyors• Entry conveyors• Roller conveyor curves• Belt conveyors
Depending on the area of application of the RollerDrive, PolyVee, round or toothed belts as well as chains can beused for the power transmission.

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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.
Any modification by conversion to the RollerDrive or attachment to the RollerDrive is prohibited!
The equipment must not be installed in areas in which substances could form explosive atmospheres/dust atmospheresor for application in the medical/pharmaceutical sector.
The use of the RollerDrive in applications in which sea water is used is prohibited.
It is considered improper use to install the equipment in exposed spaces that are open to potentially adverse weather
conditions, or areas in which the technology would suffer from the prevailing climactic conditions and could potentiallymalfunction as a result.
The RollerDrive is not intended for use by private end users. The equipment must not be used in a residential
environment without further examination and without the use of EMC protective measures that have been adapted
accordingly.
The RollerDrive is not suitable for transporting people.
It must not be used as a safety-relevant component or for performing safety-relevant functions.

2.4

Qualification of personnel

Non-qualified personnel are unable to identify risks and are therefore exposed to higher levels of danger.
¾

Only qualified personnel may be assigned with the tasks outlined in this operating manual.

¾

The operating company is responsible for ensuring that personnel adhere to the locally valid rules andregulations for working in a safe and risk-aware manner.

This operating manual is intended for the following target audiences:
Operators
Operators are trained in how to operate and clean the Interroll RollerDrive 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. Moreover, due to their knowledge and experience as wellas knowledge of applicable regulations, they are able to carry out work on electrical equipment in an appropriatemanner. They are able to identify hazards independently and prevent electrical damage to persons and property.
All work on electrical equipment must generally only be performed by a qualified electrician.

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Safety-related information

2.5

Dangers
Here, you will find information about the different types of dangers or damage that can occur in connection
with the operation of the RollerDrive.

Injury to persons¾

Maintenance, installation and repair work on the unit must only be carried out by authorised technicalpersonnel in compliance with the applicable provisions.

¾

Before switching on the RollerDrive, ensure that no unauthorised personnel are situated in the vicinity of theconveyor/conveying system.

Electricity¾

Installation and repair work must only be carried out when the system has been disconnected from the power
supply.

¾

Switch off the power to the RollerDrive and ensure that it cannot be unintentionally switched on again.

Rotating parts¾

Keep fingers and hair away from moving parts.

¾

Persons with long hair should wear a hair net.

¾

Close-fitting work clothing should be worn.

¾

Do not wear items of jewellery such as necklaces or bands.

Heat¾

Do not touch the RollerDrive during operation. In applications with high switching cycles, the temperature of the
tube can reach up to 60°C.

Work environment¾

Remove any materials and objects that are not required from the working area.

Faults in operation¾

Regularly check the RollerDrive for visible damage.

¾

In the event that smoke begins to form, unusual sounds are heard or the material to be conveyed becomesjammed or develops defects, switch off the power to the RollerDrive immediately and ensure that it cannot be
unintentionally switched on again.

¾

Immediately contact specialist personnel to determine the cause of the malfunction.

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Maintenance¾

Since the product in question requires no maintenance, it is sufficient to simply examine the RollerDrive forvisible damage on a regular basis.

¾

Never open up the RollerDrive.

Unintentional start-up¾

Ensure that the RollerDrive cannot be switched on unintentionally, particularly during assembly andmaintenance work or in the event of a fault.

2.6Interface to other devices

The integration of the RollerDrive into a conveyor system can create additional potential hazards. Such potential
hazards are not covered by this operating manual and must be analysed during the development, installation andcommissioning of the conveyor system as a whole.
¾

Following the integration of the RollerDrive into a conveyor system, the entire system must be checked for any
new potential hazards that may be present before the conveyor is switched on.

2.7

Operating modes/operating phasesStandard 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 maintainsafe standard operation.
Special operating mode

Comments

Transport/storage-

Assembly/commissioning

In de-energised state

Cleaning

In de-energised state

Maintenance/repair

In de-energised state

Fault location-

Troubleshooting

In de-energised state

Decommissioning

In de-energised state

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Safety-related information

2.8

Applicable documentation

The RollerDrive EC5000 is part of the Interroll DC Platform, consisting of:• Interroll High Performance power supply unit HP5424 or HP 5448 (24 V DC/48 V DC)• Interroll MultiControl AI/BI• RollerDrive EC5000 AI/BI (24 V DC/48 V DC)• Interroll DriveControl 20/54/2048
Also ensure that you adhere to the information given in the operating manuals of the connected devices.

Further notes on operating and programming the RollerDrive can be found in the ‘Interroll RollerDrive EC5000 BI Interface Description’ supplement.
The latest version of this supplement can be found online at: www.interroll.com

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3

Product information

3.1

Components

1 Roller

4 Bearing seat with rating plate

2 Motor5 Motor shaft

3 Bearing

6 Motor connector with colour ring and cable (500 mm)

Colour rings on the connectors
The motor connector features a colour ring in order to make the various versions of the RollerDrive EC5000 easily
distinguishable from one another.
Colour ring

RollerDrive version

White

Analogue interface, 24 V DC

Grey

Bus interface, 24 V DC

Black

Analogue interface, 48 V DC

Yellow

Bus interface, 48 V DC

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Product information

3.2

Product description

The RollerDrive EC5000 can be used in both straight and curved sections and ensures a constant conveyor speed.
Motors, motor electronics and gears are installed in the RollerDrive.
Both interface versions (analogue/CAN bus) of the RollerDrive EC5000 are available in three different power levels:• 20 W• 35 W• 50 W

Overload protection
The EC5000 has multiple overload protection systems:
Blockage detection (only in velocity mode)
If the RollerDrive is blocked, it tries to overcome the blockage with 2.5 times the nominal torque.
If this does not succeed, an error signal is set after 20 seconds and the RollerDrive goes into freewheeling mode.
The error signal is automatically reset after 10 seconds.
Behaviour of the EC5000 AI: If the setpoint is still present, the RollerDrive tries to start again.
Behaviour of the EC5000 BI: The RollerDrive is ready to be acknowledged.
Heavy running detection
If the RollerDrive rotates more slowly than specified, it tries to overcome the heavy running with 2.5 times the nominal
torque.
If this does not succeed, an error signal is set after 50 seconds and the RollerDrive goes into freewheel mode.
The error signal is automatically reset after 10 seconds.
Behaviour of the EC5000 AI: If the setpoint is still present, the RollerDrive tries to start again.
Behaviour of the EC5000 BI: The RollerDrive is ready to be acknowledged.
At a temperature of the internal motor electronics <70°C and a motor speed of <300 rpm, the blockage
detection and heavy running detection are additionally pulsed for 1 second with four times the nominal
torque and for 2 seconds with 2.5 times the nominal torque.

WARNING
Crushing hazard
From a torque of 3.75 Nm (roller diameter 50 mm) or 4.5 Nm (60 mm) static forces > 150 N occur.
(see tables on pages 31 to 32)

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Temperature monitoring
The temperature of the motor installed in the RollerDrive is monitored in addition to the temperature of the motor
electronics. If the maximum permitted temperature is exceeded, the RollerDrive is switched off and an error signal isissued. Once the overheated components have cooled down, the error signal will be reset.
Behaviour of the EC5000 AI: If the setpoint is still present, the RollerDrive tries to start again.
Behaviour of the EC5000 BI: The RollerDrive is ready to be acknowledged.

WARNING
How the EC5000 AI behaves with overload protection:
The signals from the overload protection functions are automatically reset. If the target value is still applied, theRollerDrive may start up again unintentionally.
¾

Troubleshooting must be carried out via the control system.

Holding brake (zero motion hold)
The RollerDrive EC5000 is equipped with an electronic holding brake that allows it to be used in sloped andascending conveyors.
EC5000 AI:
Holding brake active when no start signal is present.
EC5000 BI:
Holding brake active in ‘Operational’ mode and target value ‘0’.
If the power supply system fails, the holding brake will no longer take effect as the brake is not mechanical.
Energy recovery system
The RollerDrive recovers energy when braking the conveyed material. This results in the motor and motor electronics
heating up less and improves the energy balance of the system. The Interroll control systems are equipped with acircuit that prevents an increase of voltage in the power supply.
If motor control systems are used without a voltage limiter (brake chopper), it must be ensured that thepower supply units used are suitable for energy recovery (up to 35 V/60 V).
We recommend using the Interroll High Performance power supply units.

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Product information

3.3

RollerDrive EC5000 BI with CAN bus

The CAN bus communication of the EC5000 BI is based on the following CAN/CANopen standards:• ISO 11898-1 Road vehicles – Controller area network (CAN) – Part 1: Data link layer and physical signalling• ISO 11898-2 Controller area network (CAN) – Part 2: High-speed medium access unit
• EN 50325 Industrial communications subsystem based on ISO 11898 (CAN) for controller-device interfaces –Part 1: General requirements• CiA 402 CANopen device profile for drives and motion control
CAN bus communication enables, among other things, the actual values of the RollerDrive to be read out (monitoring),
including:• Number of starts/stops• Operating hours (ready for operation)• Runtime (time during which motor is rotating)• Minimum temperature• Maximum temperature• Actual temperature• Number of quick stops• Average power• Number of revolutions
So-called health indicator lights and service life indicator lights have also been integrated, which can be evaluated via
the connected Interroll MultiControl BI or a connected PLC.

Service life indicator lights
In accordance with statistically determined reference values, a signal is output when the RollerDrive reaches a service
life at which a replacement is recommended.
This is not a fixed value that decreases with the runtime.
The expected service life increases or decreases depending on the load on the RollerDrive.
The service life indicator lights have two statuses:
GreenThe RollerDrive has not yet reached its expected service life.

Yellow

The RollerDrive has reached its expected service life. Replacement is recommended.

Red

This status is not used.

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Health indicator lights
So-called health or status indicator lights are used to monitor the current values of the RollerDrive.
Health indicator lights are used to check the• Temperature• Power• Frequency of errors
Temperature
Green

RollerDrive temperature OK.

Yellow

The temperature of the RollerDrive has reached the warning limit.

Red

The temperature of the RollerDrive has exceeded a critical value.

Power
Green

The RollerDrive is working within the specified power limits.

Yellow

The rated power of the RollerDrive has been exceeded.

Red

The power of the RollerDrive is >120% of the rated power.

Frequency of errors
The frequency of the following errors is monitored within a specified time frame:• Heavy running• Stall timing• Overvoltage• Undervoltage
Green

Status of the RollerDrive OK.

Yellow

The number of errors within the specified time frame has reached the warning limit.

Red

The number of errors within the specified time frame has reached a critical limit.
The indicator lights are used purely for information purposes and do not result in the shutdown of theRollerDrive.
The signals can be evaluated and processed via the connected control system.

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Product information

Various operating modes
The RollerDrive EC5000 BI can be operated in either speed or positioning mode.
This enables the RollerDrive to be moved with millimetre precision in certain applications.
For the positioning mode, the direction of rotation ‘clockwise’ (default setting) must be selected in the default
settings!
CAN bus default settings
Node ID: 127 (LSS mode for dynamic address assignment)
Baud rate: 250 kbps
Default acceleration values for the RollerDrive EC5000 BI (also applies to EC5000 AI)
The EC5000 BI/AI is supplied with the following acceleration values for an optimum acceleration ramp.
Gear

9:1

13:1

18:1

21:1

30:1

42:1

49:1

78:1

108:1

Acceleration value in mm/s2

13215

9149

6608

5664

3965

2832

2427

1525

1101

Deceleration value in mm/s

0

0

0

0

0

2832

2427

1525

1101

2907

2013

1454

1246

872

623

534

335

242

2

Max. acceleration/deceleration value inpositioning mode mm/s2

These values define the fastest possible acceleration/deceleration and are entered in the RollerDrive in the SDO
object ‘6083h/6084h’.
Object
ID

Sub
index

Name

Data
type

Acc

6083h

00h

Profile acceleration

UINT326084h

00h

Profile deceleration

UINT32

Min.

Max.

Default

Mappablerw

Geardependent

RM

rw

0

RM

Further information on the CAN bus can be found in the ‘Interroll MultiControl BI’ operating manual and the‘Interroll RollerDrive EC5000 BI - Interface Description’ supplement.
The supplement document can be found in the download area at www.interroll.com

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3.4

Rating plate

The information on the rating plate allows the RollerDrive to be identified. This is essential to be able to use theRollerDrive as intended.
ERROLL
INT
Ro

|
18
6/

I|

2345678DE1©

000 DF |
e EC5
20W
riv
rD
|A
lle

| 24VDC | 2A | IP
65
8:1
10
|4

14
13
12
11
10
9
8

1
2
3
4
5
6
7

Rating plate
1 Manufacturer

8 Electrical connected loads

2 Designation

9 Protection rate*

3 Type designation

10 Calendar week/year of manufacture

4 DF = Deep Frost (optional)

11 Serial number with country code

5 Mechanical power

12 CE marking

6 Interface type

13 UL marking (optional)

7 Gear ratio

14 Note on the NFC chip in the label*For the option with UL marking, the type rating 2 is printed instead of the IP classDue to space limitations, it is not possible to place the UKCA mark on the label.
We certify the conformity of the product by means of the declaration of conformity or the declaration ofincorporation in accordance with the relevant UK directives in the appendix (see “10.3 UKCA Declaration ofConformity” on page 63).
Product-specific data can be read out via the Interroll Product App and the NFC chip integrated into the type plate.
The Interroll Product App is available in all well-known app stores:

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Product information

3.5

RollerDrive EC5000 as a replacement for RollerDrive EC310

The RollerDrive EC5000 24 V DC 20 W AI and EC5000 24 V DC 35 W AI are suitable as a replacement for
RollerDrive EC310 without further modifications or accessories.

NOTE
Overload of the existing extension cable with RollerDrive EC5000 24 V DC 50 W AI¾

When using the RollerDrive EC5000 24 V DC 50 W AI as a replacement for the RollerDrive EC310, any
extension cables used must be replaced.
Note the different speeds as a result of the different rated speeds of the installed motors and different gear
ratios.

Motor rated speed
Gear stages

1)

RollerDrive EC310

RollerDrive EC5000

6000 rpm

6900 rpm 1)

9:1

9:1

12:1

13:1

16:1

18:1

20:1

21:1

24:1

30.1

36:1

42:1

48:1

49:1

64:1

78:1

96:1

108:1

If the EC5000 is operated below the rated voltage, a minimal speed reduction must be expected.

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3.6

Product identification

The following information is required to identify the RollerDrive:
Information

Possible value

RollerDrive

Motor type

Rating plate

Gear ratio

Own value

Serial number
Mechanical power
Supply voltage
Analogue/CAN bus
UL certified

Yes/noTube diameter

50 mm, 60 mm

Tube material

Stainless steel
Zinc-plated steel

Tube sleeve

PVC hose 2 mm, 5 mm
PU hose 2 mm
Rubber coating 2–5 mm
Tapered elements 1.8°, 2.2°

Installation length

Installation length

RollerDrive
Drive element on the non-cable side

PolyVee drive head
Round belt:
Two grooves
Round belt head
Toothed belt drive head
Sprocket drive head

Attachment on the non-cable side

Hexagonal spring shaft
Female thread attachment
Hexagonal spring shaft, conical(See „Drive axle dimensions“ aufSeite 36)

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Product information

3.7

Technical specifications

EC5000 20 W – AI/BI – 24 V DC
Rated voltage

24 V DC, protected extra-low voltage (PELV)

Voltage range

18 to 28 V DC

Rated current

1.2 A/1.4 A 1)

Starting current

3.0 A 2)

Switching threshold, signal input

Safe ‘High’: U >7 V DC

‘Rotational direction’

Safe ‘Low’: U <4 V DC

Maximum residual ripple of the power supply

3%

Maximum noise level

55 dB(A) 3)(mounted)
Protection rate

IP54 or IP66

UL type rating

Type rating 2 (optional)

Ambient temperature in operation

0°C to +40°C

Ambient temperature for transport and storage-30°C to +75°C

Altitude of installation site

Max. 1000 m 4)

All data applies for an ambient temperature of 20°C.
From 25°C, a derating factor must be taken into account.
1)

Higher rated current at gear ratios of 78:1 and 108:1 (three-stage rather than two-stage gear)2)T he actual current course is dependent on the circumstances of the application, such as conveyor weight, number ofconnected rollers and so on

3)

The value can vary depending on the installation condition, profile shapes and system resonance behaviour.

4)

Estimated derating: 5% from 1500 m, 10% from 2000 m.

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EC5000 35 W – AI/BI – 24 V DC
Rated voltage

24 V DC, protected extra-low voltage (PELV)

Voltage range

18 to 28 V DC

Rated current

2.2 A/2.4 A 1)

Starting current

5.5 A 2)

Switching threshold, signal input

Safe ‘High’: U >7 V DC

‘Rotational direction’

Safe ‘Low’: U <4 V DC

Maximum residual ripple of the power supply

3%

Maximum noise level

55 dB(A) 3)(mounted)
Protection rate

IP54 or IP66 4)

UL type rating

Type rating 2 (optional)

Ambient temperature in operation

0°C to +40°C (30:1, 42:1, 49:1 = -30°C to +40°C)

Ambient temperature for transport and storage-30°C to +75°C

Altitude of installation site

Max. 1000 m 5)

All data applies for an ambient temperature of 20°C.
From 25°C, a derating factor must be taken into account.
1)

Higher rated current at gear ratios of 78:1 and 108:1 (three-stage rather than two-stage gear)2)The actual current course is dependent on the circumstances of the application, such as conveyor weight, number ofconnected rollers and so on

3)

The value can vary depending on the installation condition, profile shapes and system resonance behaviour.

4)

IP66 not for Deep Freeze applications

5)

Estimated derating: 5% from 1500 m, 10% from 2000 m.

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EC5000 50 W – AI/BI – 24 V DC
Rated voltage

24 V DC, protected extra-low voltage (PELV)

Voltage range

18 to 28 V DC

Rated current

3.0 A/3.4 A 1)

Starting current

7.5 A 2)

Switching threshold, signal input ‘Rotational direction’

Safe ‘High’: U >7 V DC
Safe ‘Low’: U <4 V DC

Maximum residual ripple of the power supply

3%

Maximum noise level (mounted)

55 dB(A) 3)

Protection rate

IP54 or IP66 4)

UL type rating

Type rating 2 (optional)

Ambient temperature in operation-30°C to +40°C

Ambient temperature for-30°C to +75°C

transport and storage
Altitude of installation site

Max. 1000 m 5)

All data applies for an ambient temperature of 20°C.
From 25°C, a derating factor must be taken into account.
1)

Higher rated current at gear ratios of 78:1 and 108:1 (three-stage rather than two-stage gear)2)T he actual current course is dependent on the circumstances of the application, such as conveyor weight, number ofconnected rollers and so on

3)

The value can vary depending on the installation condition, profile shapes and system resonance behaviour.

4)

IP66 not for Deep Freeze applications

5)

Estimated derating: 5% from 1500 m, 10% from 2000 m.

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EC5000 20 W – AI/BI – 48 V DC
Rated voltage

48 V DC, protected extra-low voltage (PELV)

Voltage range

36 to 56 V DC

Rated current

0.6 A/0.7 A 1)

Starting current

1.5 A 2)

Switching threshold, signal input ‘Rotational direction’

Safe ‘High’: U >7 V DC
Safe ‘Low’: U <4 V DC

Maximum residual ripple of the power supply

3%

Maximum noise level

55 dB(A) 3)(mounted)
Protection rate

IP54 or IP66

UL type rating

Type rating 2 (optional)

Ambient temperature in operation

0°C to +40°C

Ambient temperature for transport and storage-30°C to +75°C

Altitude of installation site

Max. 1000 m 4)

All data applies for an ambient temperature of 20°C.
From 25°C, a derating factor must be taken into account.
1)

Higher rated current at gear ratios of 78:1 and 108:1 (three-stage rather than two-stage gear)2)The actual current course is dependent on the circumstances of the application, such as conveyor weight, number ofconnected rollers and so on

3)

The value can vary depending on the installation condition, profile shapes and system resonance behaviour.

4)

Estimated derating: 5% from 1500 m, 10% from 2000 m.

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EC5000 35 W – AI/BI – 48 V DC
Rated voltage

48 V DC, protected extra-low voltage (PELV)

Voltage range

36 to 56 V DC

Rated current

1.1 A/1.2 A 1)

Starting current

2.8 A 2)

Switching threshold, signal input ‘Rotational direction’

Safe ‘High’: U >7 V DC
Safe ‘Low’: U <4 V DC

Maximum residual ripple of the power supply

3%

Maximum noise level (mounted)

55 dB(A) 3)

Protection rate

IP54 or IP66 4)

UL type rating

Type rating 2 (optional)

Ambient temperature in operation

0°C to +40°C (30:1, 42:1, 49:1 = -30°C to +40°C)

Ambient temperature for transport and storage-30°C to +75°C

Altitude of installation site

Max. 1000 m 5)

All data applies for an ambient temperature of 20°C.
From 25°C, a derating factor must be taken into account.
1)

Higher rated current at gear ratios of 78:1 and 108:1 (three-stage rather than two-stage gear)2)T he actual current course is dependent on the circumstances of the application, such as conveyor weight, number ofconnected rollers and so on

3)

The value can vary depending on the installation condition, profile shapes and system resonance behaviour.

4)

IP66 not for Deep Freeze applications

5)

Estimated derating: 5% from 1500 m, 10% from 2000 m.

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EC5000 50 W – AI/BI – 48 V DC
Rated voltage

48 V DC, protected extra-low voltage (PELV)

Voltage range

36 to 56 V DC

Rated current

1.5 A/1.7 A 1)

Starting current

3.8 A 2)

Switching threshold, signal input ‘Rotational direction’

Safe ‘High’: U >7 V DC
Safe ‘Low’: U <4 V DC

Maximum residual ripple of the power supply

3%

Maximum noise level (mounted)

55 dB(A) 3)

Protection rate

IP54 or IP66 4)

UL type rating

Type rating 2 (optional)

Ambient temperature in operation-30°C to +40°C

Ambient temperature for transport and storage-30°C to +75°C

Altitude of installation site

Max. 1000 m 5)

All data applies for an ambient temperature of 20°C.
From 25°C, a derating factor must be taken into account.
1)

Higher rated current at gear ratios of 78:1 and 108:1 (three-stage rather than two-stage gear)2)The actual current course is dependent on the circumstances of the application, such as conveyor weight, number ofconnected rollers and so on

3)

The value can vary depending on the installation condition, profile shapes and system resonance behaviour.

4)

IP66 not for Deep Freeze applications

5)

Estimated derating: 5% from 1500 m, 10% from 2000 m.

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3.8

Performance data

Explanation of terms
Rated torque
Torque that the RollerDrive can deliver at an ambient temperature of 20°C and at the rated speed during continuous
operation.
Acceleration torque
Torque available to the RollerDrive during operation to counteract a load.
Acceleration torque = rated torque x 2.5.
The acceleration torque cannot be greater than 13 Nm.
Holding torque (zero motion hold)Holding torque = Acceleration torque.
Breakaway torque
The breakaway torque is available at a motor speed of <350 rpm and a motor temperature of <70°C.
The breakaway torque is available in the frequency 1 s - 4 x MRated/2 s - 2.5 x MRated.
The breakaway torque cannot be greater than 13 Nm.

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EC5000 20 W – 24 V DC/48 V DC
Gear ratio

Conveyor speed
50 mm roller [m/s]

Rated torque[Nm] 1)

Acceleration
torque[Nm] 1)

Holding torque[Nm] 1)

Breakaway
torque[Nm] 1)

Max.

Min.

9:1

2.01

0.09 2)

0.25

0.63

0.63

1.01

13:1

1.39

0.06

2)

0.36

0.91

0.91

1.46

18:1

1.00

0.04 2)

0.50

1.26

1.26

2.02

21:1

0.86

0.04 2)

0.59

1.47

1.47

2.36

30:1

0.60

0.03

2)

0.85

2.13

2.13

3.40

42:1

0.43

0.02 2)

1.18

2.95

2.95

4.71

49:1

0.37

0.02

2)

1.37

3.44

3.44

5.50

78:1

0.23

0.01 2)

2.02

5.43

5.43

8.68

108:1

0.17

0.01

2.82

7.57

7.57

12.12

Rated torque[Nm] 1)

Acceleration
torque[Nm] 1)

Holding torque[Nm] 1)

Breakaway
torque[Nm] 1)2)EC5000 35 W – 24 V DC/48 V DC
Gear ratio

Conveyor speed
50 mm roller [m/s]
Max.

Min.

9:1

2.01

0.09 2)

0.44

1.11

1.11

1.77

13:1

1.39

0.06 2)

0.64

1.60

1.60

2.56

18:1

1.00

0.04

2)

0.89

2.22

2.22

3.55

21:1

0.86

0.04

2)

1.04

2.59

2.59

4.14

30:1

0.60

0.03 2)

1.49

3.74

3.74

5.98

42:1

0.43

0.02

2)

2.07

5.18

5.18

8.28

49:1

0.37

0.02 2)

2.42

6.04

6.04

9.66

78:1

0.23

0.01

2)

3.55

9.54

9.54

13.00

108:1

0.17

0.01 2)

4.95

13.00

13.00

13.00

All data applies for an ambient temperature of 20°C.
1)

Before the run-in, the values can vary by up to ±20%. After the run-in phase, the values for 95% of all RollerDrives
used vary only in the range of ±10%.

2)Due to tolerances and/or voltage drop on cables, it is possible that the RollerDrive does not turn. In this case,increase the setpoint.

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EC5000 50 W – 24 V DC/48 V DC
Gear ratio

Conveyor speed
50 mm roller [m/s]

Rated torque[Nm] 1)

Acceleration
torque[Nm] 1)

Holding torque[Nm] 1)

Breakaway
torque[Nm] 1)

Max.

Min.

9:1

2.01

0.09 2)

0.63

1.58

1.58

2.54

13:1

1.39

0.06

2)

0.91

2.29

2.29

3.66

18:1

1.00

0.04 2)

1.27

3.17

3.17

5.07

21:1

0.86

0.04 2)

1.48

3.70

3.70

5.92

30:1

0.60

0.03

2)

2.13

5.34

5.34

8.54

42:1

0.43

0.02 2)

2.96

7.40

7.40

11.83

49:1

0.37

0.02

2)

3.45

8.63

8.63

13.00

78:1

0.23

0.01 2)

5.07

13.00

13.00

13.00

108:1

0.17

0.01

7.07

13.00

13.00

13.00

Gear ratio

Conveyor speed
60 mm roller [m/s]

Rated torque[Nm] 1)

Acceleration
torque[Nm] 1)

Holding torque[Nm] 1)

Breakaway
torque[Nm] 1)

2)

Max.

Min.

9:1

2.41

0.12 2)

0.63

1.58

1.58

2.54

13:1

1.67

0.09 2)

0.91

2.29

2.29

3.66

18:1

1.20

0.06

2)

1.27

3.17

3.17

5.07

21:1

1.03

0.05 2)

1.48

3.70

3.70

5.92

30:1

0.72

0.03

2)

2.13

5.34

5.34

8.54

42:1

0.52

0.03 2)

2.96

7.40

7.40

11.83

49:1

0.44

0.03

2)

3.45

8.63

8.63

13.00

78:1

0.28

0.01 2)

5.07

13.00

13.00

13.00

108:1

0.20

0.01

7.07

13.00

13.00

13.00

2)

All data applies for an ambient temperature of 20°C.
1)

B efore the run-in, the values can vary by up to ±20%. After the run-in phase, the values for 95% of all RollerDrives
used vary only in the range of ±10%.

2) ue to tolerances and/or voltage drop on cables, it is possible that the RollerDrive does not turn. In this case,D
increase the setpoint.

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3.9

Control systems for the RollerDrive EC5000

Interroll recommends that the RollerDrive EC5000 is operated in conjunction with the different Interroll control
systems:
Analogue interface
24 V
Control system

20
W

35
W

DriveControl 20/DriveControl 54

X

X

DriveControl 2048

X

X

ZoneControl

X

X

MultiControl AI

X

XMultiControl BI

Bus interface

48 V

24 V

50
W

20
W

35
W

50
W

X

X

X

X

X

X

X

X

48 V

20
W

35
W

50
W

20
W

35
W

50
W

X

X

X

X

X

X

More detailed information on the controls can be found in the corresponding operating manual, in theInterroll DC Platform catalogue or at www.interroll.com

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3.10

RollerDrive connector AI

5
3

5

3

4

4

1
2

1
2

Pin

ColourFunction

Value

1

Brown

Input of the power supply(+)

Rated voltage:

24 V DC

48 V DC

Voltage range:

18 to 28 V DC

36 to 56 V DC

Input of the rotational
direction as seen from theend of the cable of theRollerDrive‘Low’ = anti-clockwise

2

White

‘High’ = clockwise

3

Blue

Earth for power supply andsignal (-)

Earth

4

Black

Error output

Open collector
UCESAT = 0.5 V DC at IC = 5 mA
UMAX = 30 V DC
ICMAX = 5 mA
Error: ‘High’ signal
No error: ‘Low’ signal

5

Grey

Analogue speed/startsignalSee table ‘Analogue speed/start signal (pin 5)’

NOTE
Incorrect connected loads can destroy the RollerDrive.
¾

Do not attempt to operate a RollerDrive EC5000 24 V DC at 48 V DC. This will destroy the motor
electronics.

¾

Check the colour ring on the motor connector before connecting (see “Colour rings on the connectors” onpage 15).

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Analogue speed/start signal (pin 5)
Voltage range

0 to 24 V DC

Stop (zero motion hold)0 to 2.3 V DC

Speed

2.3 V DC to 10 V DC
2.3 V = Minimum speed = 300 rpm
10 V = Maximum speed = 6900 rpm

Max. speed

10 V DC to 24 V DC

The conveyor speed results from the gear ratio and the voltage rating of the analogue speed signal.

3.11

RollerDrive connector BI

5
3

5

3

4

4

1
2

1
2

Pin

ColourFunction

Value

1

Brown

Input of the power supply(+)

Rated voltage:

24 V DC

48 V DC

Voltage range:

18 to 28 V DC

36 to 56 V DC

2

White

CAN High

3

Blue

Earth for power supply andsignal (-)

4

Black

CAN Low5

GreyService manufacturer

Earth

NOTE
Connecting/disconnecting under voltage can destroy the RollerDrive EC5000 with bus interface¾

The RollerDrive EC5000 BI is not hot-plug-compatible. Disconnect the power supply to connect/disconnect
the RollerDrive EC5000 BI.

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3.12

Dimensions of the motor shaft
Version with degree of protection IP54
5

Version with degree of protection IP66
500

13.3

4

Ø 50

13.1

Ø

500

RL

RL

EL

EL

Ø = 50 mm or 60 mm
RL = Reference length/order length
EL = Installation length, clearance between the side profiles

3.13

Drive axle dimensions

50 mm IP54
M8 female thread, without grooves

Hexagon spring shaft, without grooves

5

5

RL

RL

EL = RL + 10

EL = RL + 10

M8 female thread, with grooves

Hexagon spring shaft, with grooves

C

C

5

D

5 15.5

Ø 38.4

Ø 38.4D

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15.5

RL

RL

EL = RL + 10

EL = RL + 10

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PolyVee drive head with M8 female thread

PolyVee drive head with hexagon spring shaft
31

11

Ø 43

Ø 43

31

RL

RL

EL = RL + 36

EL = RL + 36

Round belt drive head with M8 female thread

Round belt drive head with hexagon spring shaft
31

RL

RL

EL = RL + 36

EL = RL + 36

Toothed belt drive head with M8 female thread11

Ø 37.8

Ø 37.831

Sprocket drive head with M8 female thread35
16.8 9.1
5.2

Ø 45.8

Ø 60.09

27,5

RL

35

EL = RL + 40

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EL = RL + 40

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50 mm IP66
M8 female thread, without grooves

M8 female thread, with grooves
C

10

10

Ø 38.4D

RL

RL

EL = RL + 14

EL = RL + 14

PolyVee drive head with M8 female thread

Ø 43

31

RL
EL = RL + 35

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60 mm IP54 - only 50 W
Polyamide PolyVee drive head with M8 female thread

M8 female thread, without grooves
5

Ø 43

31

RL

RL

EL = RL + 36

EL = RL + 10

Welded steel PolyVee drive head, 9 rib, with M8 female
threadWelded steel double sprocket drive head, 5/8” Z13,
with M8 female thread
57
26

31

18

RL
EL = RL + 62

Ø 72.5Ø 45

RL
EL = RL + 36

Ø 66.34

Ø 56

8.9

We recommend using the steel PolyVee drive head for using four-rib PolyVee belts.

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3.14

Tapered RollerDrive (for curves)

Ø 50 mm, tapered, IP54 grey (not anti-static), -30°C to+40°C

Ø 50 mm, tapered, IP54 black (anti-static), -30°C to+40°C

Tapered RollerDrive for deep freezing range -30 °C to 0 °C are exclusively available in 50 W.

RL = Reference length/order length
EL = Installation length, clearance between the side profiles
U = Usable tube length: Length of tapered elements

Hexagon spring shaft without grooves

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M8 female thread with grooves (alternatively also with round belt drive head)

PolyVee drive head with M8 female thread

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If the tube protrudes over the tapered elements, other reference lengths can be obtained. The specified minimum
diameters relate to the smallest diameter of the first tapered element. The reference lengths of 150 mm and 200 mm
as well as 950 mm and 1000 mm do not include a protective cap.
Conicity: 1.8°, colour: grey
(not anti-static)

Conicity: 1.8°, colour: black(anti-static)

Tapered nominal length [mm] Min. Ø[mm]Max. Ø
[mm]

Tapered nominal length [mm] Min. Ø[mm]Max. Ø
[mm]

150

55.6

64.8

150

55.6

64.8

200

52.5

64.8

200

52.5

64.8

250

55.6

71.2

250

55.6

71.2

300

52.5

71.2

300

52.5

71.2

350

55.6

77.6

350

55.6

77.6

400

52.5

77.6

400

52.5

77.6

450

55.6

84.0

450

55.6

84.0

500

52.5

84.0

500

52.5

84.0

550

55.6

90.4

550

55.6

90.4

600

52.5

90.4

600

52.5

90.4

650

55.6

96.8

650

55.6

96.8

700

52.5

96.8

700

52.5

96.8

750

55.6

103.2

750

55.6

103.2

800

52.5

103.2

800

52.5

103.2

850

55.6

109.9

-

-

-

900

52.5

109.9

-

-

-

950

55.6

116.0

-

-

-

1000

52.5

116.0

-

-

-

Tapered nominal length [mm] Min. Ø[mm]Max. Ø
[mm]

Tapered nominal length [mm] Min. Ø[mm]Max. Ø
[mm]

190

56.0

70.6

440

56.0

89.8

240

56.0

74.4

540

56.0

97.5

290

56.0

78.3

640

56.0

105.2

340

56.0

82.1

740

56.0

112.8

Conicity: 2.2°, colour: grey
(not anti-static)

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3.15

Crowned RollerDrive (drive for belt conveyors)

Crowned RollerDrive are exclusively available in 35 W and 50 W.

Belt
Max. permissible belt elongation

8%

Max. tensile force for 1% elongation

175 Nm/mm

Permissible temperature range

0°C to +40°C

Belt conveyors
Max. length

2000 mm

Ratio of length to width

A random length-width ratio can be selected; the width of the belt
conveyor must not exceed the length.

Belt divert

Exclusively rolling, not gliding

The max. permissible belt tension for your application can be calculated with the following formula:Max. Belt tension [N] = belt width [mm] · tensile force for 1% elongation [N/mm] · Factor by which the actual belt
elongation is above 1% (maximum of 8, as the maximum belt elongation is 8%) · 2 (Factor, as carrying and return
section have to be taken into account) · 1.2 (Suggestion for a safety factor of 20%).
The calculated max. belt tension must not exceed the following maximum permissible belt tension for EC5000:
Gear stage

Max. permissible belt tension

18:1

2120 N

21:1

2230 N

30:1

2510 N

42:1

2810 N

49:1

2950 N

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Belt tensile force
The following formula can be used to calculate the belt tensile force (F). It is used for selecting the suitable power level,
gear stage and possible weight of goods to be conveyed.
F = F0 + F1 + F2 + safety factor
We recommend a safety factor of 20%.

F0= 0.04·g·L·(2 Pn+Ppr)
Force without load
F1=0.04·g·L·Pm1
Force to convey goods horizontally
F2=g·H·Pm1*

Force to convey goods on inclines
Pn in kg/m

= Belt weight per metre

Ppr in kg/m

= Weight of rotating parts of the belt conveyor per metre length

Pm1 in kg/m

= Weight of goods to be conveyed

L in m= Centre -to-centre length

H in m= Height difference in conveyor

F0 to F2 in N

= Belt tensile force components for operating conditions showng in m/s²= 9.81

The following formula can be used to calculate the required rated torque (M) using the belt tensile force (F): M [Nm]=0.026 · F

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Permissible applications
Extensive tests have been conducted with the EC5000 as the belt drive. The following information
represents the results of such tests and is based on an ambient temperature of 20°C and a belt tension
of 4%. Despite the test results, we recommend testing your application, as each application case featuresindividual properties.
A roller of the 1700 Heavy series with a diameter of 51 mm and a wall thickness of 2 mm should be used
for belt deflection.
Horizontal belt conveyors
Tested mechanical power level

50 W

Max. permissible weight per conveyor

50 kg (for all available gear stages)

Max. number of conveyed goods per
minute (start-stop operation)

40 (18:1 gears, depending on the pause time and zone length)

Higher gear ratios

Reduced number due to lower speed

Belt conveyor tilted 10°
Tested mechanical power level

50 W

Max. permissible weight per conveyor

10 kg (18:1 gears)
15 kg (21:1 gears)
25 kg (30:1 gears)
35 kg (42:1 gears)
40 kg (49:1 gears)

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Product information

Dimensions
RL = Reference length/order length
EL = Installation length, clearance between the side profiles
Crowned tube with M8 female thread

Form and diameter progression of the tube

Cylindrical tube end 10 to
60 mm

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1/3 tapered Ø 52
to 51.5 mm

1/3 cylindrical Ø
52 mm

1/3 tapered Ø 52
to 51.5 mm

Cylindrical tube
end 10 to 60 mm

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4

Transport and storage

4.1

Transport
CAUTION

Risk of injury from improper transport.
¾

Transport operations must only be carried out by authorised, qualified personnel.

Please note the following:¾

Avoid heavy impacts during transport.

¾

Check each RollerDrive after transport for any visible damage.

¾

If any damage has been identified, photograph the damaged parts.

¾

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.

¾

Do not expose the RollerDrive to any strong fluctuations in temperature, since this can lead to condensation
forming.

4.2

Storage
CAUTION

Risk of injury due to improper storage.
¾

Ensure that the RollerDrive is stored safely.

Please note the following:¾

Do not stack pallets on top of one another.

¾

Check each RollerDrive after storage for any visible damage.

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Assembly and installation

5

Assembly and installation

5.1

Warning notices for installation
WARNING

Risk of electric shock!
When using the RollerDrive EC5000 48 V DC, it is possible that in generator operation (motor revolution
14,500 RPM-1/gear reduction) the permissible contact voltage of 60 V DC at the open connector is exceeded.
¾

Do not drive unconnected RollerDrive from the outside.
For the RollerDrive EC5000 24 V DC, exceeding the permissible contact voltage is only theoreticallypossible.

CAUTION
Risk of crushing due to rotating parts.
¾

Do not place your fingers between the RollerDrive and the round belt/PolyVee belt.

¾

Install protective equipment (Interroll PolyVee finger guard, for example) to prevent fingers from gettingcaught in the PolyVee belt or round belt.

¾

Affix suitable warning notices/pictograms to the conveyor.

NOTE
An improper approach to installing the RollerDrive can lead to material damage or reduce the service life of theRollerDrive.
¾

To preserve the interior of the RollerDrive, do not allow the RollerDrive to fall or for it to be used in an
improper fashion.

¾

Check each RollerDrive before assembly for any visible damage.

¾

To prevent the inner connections from being damaged, do not hold, carry or secure the RollerDrive by thecable.

¾

Do not use force to insert the RollerDrive into the side profile. It must be inserted gently into the side profile.

¾

Pay attention to the correct tightening torque of the RollerDrive hexagonal nut to prevent the shaft in theside profile from rotating and the RollerDrive cable from twisting (see „Securing the RollerDrive in the side
profile“ auf Seite 51).

¾

Do not twist the RollerDrive cable.

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5.2

Installing the RollerDrive

Installing the attachment shaft

NOTE
Internal parts of the RollerDrive can be damaged through improper handling.
¾

Do not fit the fastening nut yet¾

Ensure correct equipotential bonding of all metallic elements of the conveyor unit (RollerDrive, side profile,
supporting structure and so on). Improper earthing can lead to a build-up of static charge, which can resultin a malfunction or premature failure of the RollerDrive and/or the connected control system.

¾

Remove packaging material and transport protection from the RollerDrive.
To guarantee safe equipotential bonding of the RollerDrive, the fastening nut must be in direct contact withthe metallic surface of the earthed side profile.

¾

If necessary, remove the coating of the side profile in the area of the fastening nut.

¾

Insert the RollerDrive cable and attachment shaft into the hex hole provided (min. 11.2 mm) or round hole (min.
12.2 mm) of the side profile.

¾

Position one or two round belts of 4 mm (max. 5 mm) or PolyVee belts.

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Assembly and installation

Attaching the non-cable side
Two examples are provided:
Inserting the hexagonal spring shaft¾

Press the spring shaft inwards and align the shaft so that it corresponds to the opening in the side profile.

¾

Release the hexagonal spring shaft so that it springs into the opening of the side profile.

Inserting the female thread shaft pin¾

Place a washer on a M8x20 screw.

¾

Align the RollerDrive with the opening in the side profile and insert the M8 screw with the washer into the
opening. Secure the shaft pin with an open-ended spanner to prevent it from twisting (depending on theversion of the shaft pin, the width across flats will be 13 mm or 19 mm).

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Tighten the screw using a torque spanner with a tightening torque of 20 Nm.
If the parts used for attaching the RollerDrive are not the parts that have been supplied by Interroll, it isimportant to ensure that the attachment is secure enough that it will not twist.

Securing the RollerDrive in the side profile
A nut is located close to the bearing housing on the attachment shaft. This inner nut is pre-fitted and secured in thecorrect position.
Do not twist the inner nut.

¾

Secure the inner nut with a flattened counter ratchet with a 17 mm width across flats (accessory) to prevent itfrom twisting.

¾

Slide the nut included in the scope of delivery over the RollerDrive line and screw it onto the attachment shaft.

¾

Tighten the nut using a torque spanner with a tightening torque of 70 Nm.
For installing a RollerDrive with tapered elements, the attachment shaft is positioned at an angle of 1.8°
or 2.2° to the side profile. To prevent bending forces from acting on the attachment shaft, an appropriate
angle compensator must be provided for the attachment. This is not included in the scope of delivery.

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Assembly and installation

5.3

Installation tool (accessory)
For the installation of the PolyVee belt, we recommend using the PolyVee clamping aid, which is available asan accessory.

¾

Attach the first roller.

¾

Position the PolyVee clamping aid between the attached roller and the roller/RollerDrive that has not yet been
attached.

¾

Rotate the PolyVee clamping aid by 90° so that the rollers are positioned in the cut-outs intended for them.

¾

The belt is optimally tensioned and a roller/RollerDrive is properly aligned horizontally and vertically. A female
thread attachment is consequently aligned with the attachment hole in the side profile.

The PolyVee clamping aid is intended for the 75 mm and 100 mm roller pitches and designed for rollers
and RollerDrives with a diameter of 50 mm.

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The Interroll Interlock (accessory)
The Interroll Interlock is slipped over the cable of the RollerDrive and attached to the conveyor frame.

2

1
Ø22

45

62,5

M5 x 16

10
Ø
5,3
34
48

3

4



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Assembly and installation

5.4

Warning notices for electrical installation
WARNING

Risk of crushing from uncontrolled start-up of the RollerDrive.
¾

Before connecting the RollerDrive, switch off the power to the conveyor system and ensure that it cannot be
unintentionally switched on again.

NOTE
Possible signal interference in the bus communication!
¾

When laying the RollerDrive cable/extension cable, pay attention to the laying guidelines! Lay the cables ata sufficient distance from power lines (400 V) and frequency converters and their cables.

5.5

Electrical installation
NOTE

Risk of material damage to the RollerDrive and/or the RollerDrive cables.
¾

Never operate the RollerDrive with an alternating current (AC), as this can result in irreparable damage tothe device.

¾

Do not expose the RollerDrive connector to excessively high tensile or pressure loads. Bending theRollerDrive cables or sliding the attachment nut on too forcefully can damage the insulation of the cables,
which can lead to the failure of the RollerDrive.

¾

Permissible bending radii: Simple bending 15 mm, multiple bending 50 mm.

¾

Connect the RollerDrive connector to the corresponding connection of the Interroll control system.
If no Interroll control system is used, an adapter cable must be used to connect the RollerDrive to the control
system (for pin assignment, see „RollerDrive connector AI“ auf Seite 34/35). Cutting off the RollerDrive
connector will void the warranty!
When using an extension cable to connect the RollerDrive, a max. length of 10 m must not be exceeded.

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6

Start-up and operation

6.1

Warning notices for start-up and operation
WARNING

Risk of crushing and potential hazards from rotating parts due to uncontrolled start-up of the RollerDrive.
¾

Do not reach between RollerDrive and drive media with your fingers.

¾

Do not remove the protective equipment.

¾

Keep fingers, hair and loose clothing away from the RollerDrive.

NOTE
Possible damage to the RollerDrive through induction.
¾

Do not slide any objects over the roller conveyor by hand.

¾

Do not turn the RollerDrive by hand.

6.2

Start-up

Check before the initial start-up¾

Ensure that there are no points of contact between objects and rotating/moving parts.

¾

Ensure that all screws have been tightened according to the specifications.

¾

Ensure that no additional hazards are formed through the interfaces to other components.

¾

Ensure that the wiring conforms to specifications and legal provisions.

¾

Ensure that no persons are in the hazardous areas by the conveyor system.

¾

Check all protective equipment.

Information on start-up can be found in the operating manual for the Interroll control system or motor
control system that is used.

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Start-up and operation

6.3

Operation

Check before every start-up¾

Ensure that no persons are in the hazardous areas by the conveyor system.

¾

Ensure that the RollerDrive is not jammed.

¾

Check the RollerDrive for any visible damage.

¾

Check all protective equipment.

¾

Specify in detail how the material to be conveyed should be set down on the conveyor and monitor this toensure it is carried out correctly.
Take the ambient conditions into account during operation (see „Technical specifications“ auf Seite 24).

6.4

Procedure in the event of accidents or faults¾

Stop the conveyor system immediately, switch off the power supply and ensure that it cannot be unintentionallyswitched on again.

¾

In the event of an accident: Perform first aid and call for the emergency services.

¾

Inform the relevant supervisor.

¾

Have specialist personnel rectify the fault.

¾

Only resume operating the conveyor system once this has been approved by the specialist personnel.

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Maintenance and cleaning

7

Maintenance and cleaning
WARNING

Risk of injury from following incorrect procedure.
¾

Maintenance and repair work must only be carried out by authorised and trained (specialist) personnel.

¾

Maintenance and repair work must only be carried out when the system has been disconnected from thepower supply. Switch off the power to the RollerDrive and ensure that it cannot be unintentionally switchedon again.

¾

Put up signs to indicate that maintenance or cleaning work is being carried out.

7.1

Maintenance
WARNING

Risk of injury due to uncontrolled movements!
Damage to the RollerDrive cable can lead to uncontrolled behaviour (start-up, wrong direction of rotation and soon)!
¾

Check RollerDrive cable/extension cable weekly for visible damage.

Checking the RollerDrive
If the RollerDrive is not secured according to the installation instructions (see „Installing the RollerDrive“ auf Seite49), it may rotate in the side profile. This means that the RollerDrive cable may twist and become damaged.
¾

One month after the RollerDrive has been installed, check to ensure it is still firmly seated in the side profile andtighten it with a torque spanner if necessary.

¾

Check the RollerDrive every month for any visible damage.

¾

Once a year, ensure that the shaft of the RollerDrive is still correctly secured in the side profile.

Replacing the RollerDrive
If a RollerDrive is damaged or defective, it must be replaced.
Do not attempt to open the RollerDrive!

¾

Install a new RollerDrive (see „Decommissioning“ auf Seite 59 and „Installing the RollerDrive“ auf Seite
49).

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Assistance in the event of faults

7.2

Cleaning¾

Remove any foreign bodies and coarse impurities from the surface of the roller.

¾

Minor impurities can be removed using a damp cloth.

¾

Do not use any sharp-edged tools to clean the RollerDrive.

8

Assistance in the event of faults
WARNING

Risk of injury from following incorrect procedure.
¾

Troubleshooting must only be carried out by authorised, qualified personnel.

¾

Troubleshooting must only be carried out when the system has been disconnected from the power supply.

¾

Switch off the power to the RollerDrive and ensure that it cannot be unintentionally switched on again.

8.1

Troubleshooting

Fault

Possible cause

RemedyRollerDrive does not run.

No/wrong supply voltage.

Check the 24 V DC/48 V DC power
supply.

RollerDrive connector is notconnected correctly.

Check the cable connection.

Wrong interface selection AI/BI

Connect correct RollerDrive

Settings for speed and rotational
direction are incorrect.

Change the settings for the Interroll
control system.

Incorrect voltage set point for
rotational speed, should theRollerDrive not be operated with an
Interroll control system.

Check the voltage set point.

Unusual noises can be heard fromthe RollerDrive.

Motor or gears are damaged.

Replace the RollerDrive.

Operation of the RollerDrive isinterrupted.

RollerDrive cable is damaged.

Check the RollerDrive cable fordamage. If the cable is defective,
replace the RollerDrive.

RollerDrive is overloaded.

See „Overload protection“ auf Seite
16.

RollerDrive turns in the wrong
direction or at the wrong speed.

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9

Decommissioning and disposal
CAUTION

Risk of injury from following incorrect procedure.
¾

Decommissioning must only be carried out by authorised, qualified personnel.

¾

Only decommission the RollerDrive when the system has been disconnected from the power supply.

¾

Switch off the power to the RollerDrive and ensure that it cannot be unintentionally switched on again.

9.1

Decommissioning¾

Disconnect the RollerDrive cable from the control system.

¾

Remove the outer nut from the motor shaft.

¾

If the RollerDrive is fitted with an female thread shaft pin, remove the screw on the shaft.

¾

Remove the RollerDrive from the side profile.

9.2

Disposal
In principle, the operator is responsible for the professional and environmentally friendly disposal of the
products.
The implementation of the WEEE Directive 2012/19/EU in national laws must be observed.
Alternatively, Interroll offers to take back the products.
Contact:
de10_customerservice@interroll.com

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Appendix

10

Appendix

10.1

Accessories

Interroll control systems
Product

Product number

DriveControl 20

S-1001415

DriveControl 54

S-1001416

DriveControl 2048

S-1113898

ZoneControl

S-1004023

MultiControl AI

S-1103563

MultiControl BI

S-1103564

Interroll High Performance power supply unit
Product

Product number

HP5424

S-1113899

HP5448

S-1113900

RollerDrive extension cable
Product

Product number

Extension cable EC5000 (2 m)

S-1113897

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PolyVee belt
Numberof ribs

Rollerpitches+/-1 mmMax. weight ofmaterial to beconveyed (kg)

Product number

Belt designation

2

60

50

S-1111211

256

2

75

S-1111217

286

2

90

S-1111220

314

2

100

S-1111222

336

2

120

S-1111224

376

3

60

S-1111216

256

3

75

S-1111219

286

3

90

S-1111221

314

3

100

S-1111223

336

3

120

S-1111225

376

300

PolyVee clamping aid
Product

Product number

PolyVee clamping aid

S-1101272

PolyVee finger guard (50 mm roller only)
Product

Product number

Roller pitch 75 mm

S-8863

Roller pitch 100 mm

S-8864Tool
Product

Product number

Attachment nut

S-1101248

Counter ratchet width across flats 13 mm/17 mm

S-1132933

InterlockS-1120484

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Appendix

10.2

Translation of the original Declaration of Conformity

EU Declaration of conformity
EMC Directive 2014/30/EU
RoHS Directive 2011/65/EU
The manufacturer
Interroll Engineering GmbH
Höferhof 16
42929 Wermelskirchen, Germany
Germany
hereby declares that the ‘incomplete machine’• RollerDrive EC5000
conforms to the applicable provisions and the associated CE marking in accordance with theaforementioned directives.
List of the coordinated standards that have been applied:
EN ISO 12100:2010
EN 61800-3:2004 + A1:2012
EN IEC 63000:2018

Declaration of incorporation
EC Machinery Directive 2006/42/EC
In addition to the information specified above, the manufacturer declares that:
The health and safety requirements have been applied in accordance with Annex I (1.1.2, 1.1.3, 1.1.5, 1.2.6, 1.3.7, 1.3.8,
1.5.1, 1.5.2, 1.5.4, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.6.1, 1.6.3, 1.7.2, 1.7.3, 1.7.4). The relevant technical documentation has
been compiled in accordance with Annex VII B and has been passed on to the relevant authorities where applicable.
The commissioning of the incomplete machine is prohibited until the conformity of the overallmachine/system in which it is installed with the EC Machinery Directive has been declared.
Authorised for compiling technical documentation:
Interroll Engineering GmbH, Höferhof 16, 42929 Wermelskirchen, Germany

Jörg Schiffler

Product Compliance Officer Interroll Engineering GmbH
Wermelskirchen, Germany, 24 January 2019

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10.3

UKCA Declaration of Conformity

Declaration of conformity
UK Electromagnetic Compatibility Regulations 2016
UK Restriction of the Use of Certain Hazardous Substances in Electrical andElectronic Equipment Regulations 2012
The manufacturer
Interroll Engineering GmbH
Höferhof 16
42929 Wermelskirchen
Germany

represented in the UK by

Interroll Limited
Unit 1a, Orion Way, Kettering, Northants
NN15 6NL
Englandhereby declares that the "incomplete machine"• RollerDrive EC5000
conforms to the applicable provisions and the associated UKCA marking in accordance with theaforementioned Directives.

Declaration of incorporation
UK Supply of Machinery (Safety) Regulations 2008
In addition to the information specified above, the manufacturer declares that:
The health and safety requirements have been applied in accordance with the EC Machinery Directive 2006/42/EC as listed
in the EC Declaration of incorporation. The relevant technical documentation has been compiled in accordance with Annex
VII B and has been passed on to the relevant authorities where applicable.
The commissioning of the incomplete machine is prohibited until the conformity of the overallmachine/system in which it is installed with the UK Supply of Machinery (Safety) Regulations 2008
has been declared.
Authorised for compiling technical documentation:
Interroll Engineering GmbH, Höferhof 16, 42929 Wermelskirchen, Germany

Jörg Schiffler

Product Compliance Officer Interroll Engineering GmbH
Wermelskirchen, 29th October 2021

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EN | 10/2022 | Version 4.0

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