INSPIRED BY EFFICIENCY

Operating manualHigh Performance power supply unit
HP5424 (24 V DC, 40 A), HP5448 (48 V DC, 20 A)

Manufacturer details
Interroll Software & Electronics GmbHIm Südpark 183
4030 Linz
AUSTRIAwww.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 color 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

10

2.3

Improper use

10

2.4

Qualification of personnel

11

2.5

Dangers
Injury to persons

9

12
12

Electricity12Work environment

12

Faults in operation

12

Maintenance12
Unintentional start-up

12

2.6

Interface to other devices

13

2.7

Operating modes/operating phases13Standard operation

13

Special operation

13

2.8

Applicable documentation

13

2.9

Product information via the Interroll Product App

14

3

Product information

14

3.1

Product description

14

3.2

Components

Energy recovery / Overvoltage protection / Brake chopper

14
15

Overview (HP5424 exploded drawing)

15

DC on/off switch

16

HP5424/HP5448 status LED

17

Power LED flashing cycle

18

3.3

Rating plate

18

3.4

Technical specifications

19

3.5

Dimensions

20

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Contents

4

Transport and storage

21

4.1

Transport

21

4.2

Storage21

5

Assembly and installation

22

5.1

Warning notices for installation

22

5.2

Installation location

22

5.3

Connections and settings

The following installation locations are permitted:

5.4

23
24

(1) Connection to earth26(2) Connection block 1 – 24/48 V AC

26(3) Connection block 2 – 24 V AC

26(4) Signal connection (Transistor outputs)

27(6) UDC setting potentiometer

27(7) Jumper setting, DC cable protection

28(5) Connection block 3 – 400 V AC

28(8) Connection block 4 – 400 V AC

28

Electrical installation

29

Application notes

30

Mains-side connection and protection

30

Load-side connection and protection

30

Conveyors with multiple Interroll power supply units

31Electrical connection

31

6Start-up and operation

32

6.1

Start-up

32

6.2

Operation

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

32
33
33

6.3

Procedure in the event of accidents or faults

33

7

Maintenance and cleaning

34

7.1

Maintenance

34

7.2

Cleaning

34

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8

Assistance in the event of faults

8.1

Troubleshooting

35
35

9

Decommissioning and disposal

36

9.1

Decommissioning

36

9.2

Disposal

36

10

Appendix

37

10.1

Accessories

37

10.2

Translation of the original Declaration of Conformity

38

10.3

UKCA Declaration of Conformity

39

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6 of 40

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1

About this document

1.1

Information about this operating manualThis operating manual covers the following Interroll power supply units:• HP 5424• HP 5448
Throughout this manual, the term "power supply unit" is used in the singular. Unless otherwise specified, theinformation in this operating manual refers to both variants.
The operating manual is a component of the product and contains important advice and information regarding thedifferent operating phases of the power supply unit. It describes the power supply unit at the time of shipping fromInterroll.
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.
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 power supply unit.

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.
Gender-appropriate language is not used in these instructions for better legibility.
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 warns of hot surfaces.

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 Interroll power supply units have been constructed with respect to applicable standards and the current state of
the art and have been delivered in a condition that is safe to operate. Nevertheless, hazards can occur as a result ofuse.
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 power supply unit 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 for supplying power to the Interroll RollerDrive before
commissioning.
Only indoor use is allowed.

2.3

Improper use

Any use that goes beyond the proper use is considered improper, unless this has been authorised by Interroll
Engineering GmbH where applicable.
The equipment must not be installed in areas in which substances could form explosive atmospheres/dust atmospheresor for application in the medical/pharmaceutical sector.
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 power supply unit 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.
It must not be used as a safety-relevant component or for performing safety-relevant functions.
The Interroll power supplies HP5424 and HP5448 are not AS-Interface power supplies!

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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:
Operating personnel
Operating personnel have been instructed 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 power supply unit.

Injury to persons


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



Before switching on the power supply unit, ensure that no unauthorised personnel are situated in the vicinity of
the conveyor/conveying system.

Electricity


Installation and repair work must only be carried out when the system has been disconnected from the power
supply. Switch off the power to the power supply unit and ensure that it cannot be unintentionally switched on
again.

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

Faults in operation
Regularly check the power supply unit for visible damage.



If smoke develops, immediately switch off the power to the power supply unit and ensure that it cannot be
unintentionally switched on again.

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

Maintenance

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



Never open the power supply unit.

Unintentional start-upEnsure that the power supply unit cannot be switched on unintentionally, particularly during assembly andmaintenance work or in the event of a fault.
Use a padlock to prevent the isolating switch of the power supply unit from being switched back on.
Remove the key and keep it on your person until maintenance or repair work is complete.

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2.6

Interface to other devices

The integration of the power supply unit 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 and commissioning of the conveyor system as a whole.
¾

Following the integration of the power supply unit 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

Disposal-

2.8

Applicable documentation

Power supply units HP5424 and HP5448 are 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.

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Product information

2.9

Product information via the Interroll Product App

Product-specific data can be read out via the Interroll Product App and the QR code or the NFC chip on the
nameplate. The Interroll Product App is available in all well-known app stores:

3

Product information

3.1

Product description

The Interroll DC Platform comprises a RollerDrive with 24 V or 48 V rated voltage.
The Interroll power supply unit converts the three-phase 400 V alternating input voltage into 24 V or 48 V direct
voltage for supplying power to the connected Interroll RollerDrive:• HP5424 – output voltage 24 V DC, output current 40 A continuous,• HP5448 – output voltage 48 V DC, output current 20 A continuous.
Further distinguishing features include ease of operation, minimal configuration effort ("plug and play") and simple
replacement in the event of a defect.
The integrated DC on/off switch enables the connected RollerDrive to be disconnected from the power supply.
The switch can be locked in the Off position to prevent it from being unintentionally switched on again.

Energy recovery / Overvoltage protection / Brake chopper
If the connected RollerDrives are stopped or their speed is abruptly reduced, the kinetic energy of the conveyedmaterial in the RollerDrive is converted into electrical energy, akin to a generator. This energy is fed back into thesystem, where it can either be used by other RollerDrives or converted into heat by the braking resistor integrated in
the power supply unit.
The chopper is activated when the output voltage set by the potentiometer is exceeded by 1 V (HP5424) / 2 V(HP5448) as a result of the energy recovery process. This prevents excessively high voltages within the system.

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3.2

Components

Overview (HP5424 exploded drawing)

1 Terminal compartment cover

6 Jumper output current limitation

2 Terminal compartment

7 M25 cable glands

3 M20/M12 cable glands

8 Status LED

4 Housing cover

9 DC on/off switch (lockable)

5 Rating plate

10 Housing base with heat sink

Opening the terminal compartment cover possible with a suitable flat-head screwdriver.

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Product information

DC on/off switch

WARNING
Risk of death due to electric shock.
The DC on/off switch on the power supply unit is not a mains isolation device according to STOP category 0.
The on/off switch only switches off the DC supply voltage to the connected RollerDrive.
¾

Electrical work must only be carried out by a qualified electrician.

¾

When working on the 400 V power supply, disconnect the conveyor system from the mains and ensure thatit cannot be unintentionally switched on again.

A contactless switching element is used as the control system.
The isolating switch can be locked in the Off position to prevent the power supply unit from being unintentionallyswitched on again.

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HP5424/HP5448 status LED

Error 1

Error 2Error 3

Power

Error 2Error 4

Error 1

HP5448Power

HP5424

ON

OFF

OFF

OFF

OFF

ON

OFF

OFF

DC output voltage switched off

1 Hz

OFF

OFF

OFF

Shutdown by error condition

Flashes
n*
times

OFF

1 Hz

OFF

OFF

ON

ON

Flashes
n*
times

ON

ON

ON

ON

Warning (DC output remains active)

Flashes
n*
times

OFF

OFF

OFF

OFF

Flashes
n*
times

OFF

OFF

Overcurrent, DC 1

Flashes
7 times

ON

OFF

OFF

OFF

Flashes
7 timesON

OFF

Overcurrent, DC 2

Flashes
7 times

OFF

ON

OFF

OFF

Flashes
7 timesOFF

ON

Overcurrent, DC 3

Flashes
7 times

OFF

OFF

ON

OFF

Overcurrent, DC 4

Flashes
7 times

OFF

OFF

OFF

ON

System error, overcurrent

Flashes
7 times

ON

ON

ON

ON

Flashes
7 timesON

ON

Normal operation* n = see table on the next page

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Product information

Power LED flashing cycle
Number n of times
power LED flashes

Description1

Device protection: Critical condition (e.g. overcurrent in the power section)2

Device protection: Rated power exceeded for too long3

Device protection: Overload – 1.5 x rated power exceeded

4

Device protection: Excessive temperature

5

Failure of one phase detected

6

Device protection: Chopper resistor overload

7

Overcurrent protection on the output side

Wherever possible, statuses are output as a warning. This enables the DC outputs to remain active. Criticalstatuses are output as errors and result in the DC outputs being switched off.

3.3

Rating plate

The information on the rating plate allows the power supply unit to be identified. This is essential to be able to use thepower supply unit as intended.

1 Article number

5 Serial number

2 Connection values Output

6 Connection values Input 1)

3 Manufacturer

7 CE- / UL-Marking / Warning symbols

4 Week/year of production∑ ≤13 A - When looping through the supply line to a maximum of eight power supplies expected maximum total
current.
1)

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3.4

Technical specifications
HP5424

Connection values

HP5448

380Y/220 V - 480Y/277 V ±10%; 3~+PE; 1,625 A (∑ ≤13 A)

Required mains-side protection

3 x 16 A

Leakage current~1 mA

Network configurations

TT network
TN-C-S network

Mains frequency
Maximum inrush current

50–60 Hz, ± 6%
4,4 A 400 V / 50 Hz

5,3 A 480 V / 60 Hz

Rated output voltage

24 V DC

48 V DC

Control range output voltage(potentiometer)

24–28 V

48–54 V

Output voltage tolerance± 0.5% when idle

Residual ripple (peak – peak)

Vpp ≤ 600 mV1)

Vpp ≤ 400 mV 1)

Rated output current at 380–480
V AC

40 A at 24 V DC

20 A at 48 V DC

Nominal Power

960 W

Boost mode
Performance chopper resistance

1440 W for 4 s
Continuous power 30 W, peak power 200 W - pulse-resistant version

Energy recovery capacity

up to 35 V

up to 60 V

Efficiency

≥ 92%

≥ 92%

Overvoltage category

III

Protection rate

IP54

Degree of contamination

2

Ambient temperature in operation-30 °C to +40 °C 2)

Ambient temperature duringtransport and storage-40 °C to +85 °C

Altitude of installation site

Max. 1000 m 3)

All data applies to a temperature of 20 °C.
Value in accordance with Interroll Measurement rule Residual ripple in accordance with standards IEEE 1515-2000
and JEITA-RC9131A.
2)
The cable feedthroughs used can only carry a static load at temperatures below -20 °C.
1)

3)

From 1000 m, a significant derating is to be expected.

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Product information

3.5

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Dimensions

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4

Transport and storage

4.1

Transport
WARNING

Danger to life due to damage to the housing!
¾

Check each power supply unit 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.

CAUTION
Risk of injury from improper transport.
¾

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

Please note the following:¾

Do not stack pallets on top of one another.

¾

Prior to transport, check whether the Interroll power supply units are correctly attached.

¾

Avoid heavy impacts during transport.

¾

Do not expose the power supply units to any strong fluctuations in temperature, since this can lead tocondensation forming.

4.2

Storage
CAUTION

Risk of injury due to improper storage.
¾

Ensure that the power supply units are stored safely.

Please note the following:¾

Do not stack pallets on top of one another.

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Assembly and installation

5

Assembly and installation

5.1

Warning notices for installation
WARNING

Danger to life due to damage to the housing!
¾

Check each power supply unit before assembly for any visible damage.

¾

Do not mount damaged power supply units!

¾

In case of damage inform the supplier or Interroll immediately.

NOTE
An improper approach to installing the Interroll power supply unit can lead to material damage or reduce theservice life of the power supply unit.
¾

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

¾

Do not install the power supply unit above heat sources and ensure that natural air circulation is maintained
around the power supply unit.

¾

Do not drill any additional mount holes into the housing and do not enlarge any existing holes.

5.2

Installation location
To minimise cable losses, install the power supply unit close to Interroll control systems.
Install the power supply unit in the preferred installation location (see figure on the following page).
If installed in alternative installation locations, derating can be expected.

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The following installation locations are permitted:

Preferred installation location

Alternative installation locations (derating possible / not UL approved)¾

Install the Interroll power supply unit on a level surface of the conveyor frame.

¾

Ensure that the screws cannot come loose as a result of vibration or impact and make sure the housing has notbeen distorted.

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Assembly and installation

5.3

Connections and settings

HP 5424
1 Connection to earth

5 Connection block 3 – 400 V AC (max. 6 mm2)2 Connection block 1 – 24 V DC (max. 6 mm )6 Potentiometer 24 V DC

3 Connection block 2 – 24 V DC (max. 6 mm2)

7 Jumper output current limitation

4 Signal connection (max. 1,5 mm )8 Connection block 4 – 400 V AC (max. 6 mm2)22

If the jumper is not connected, an error message appears (overcurrent protection).

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HP 5448
1 Connection to earth

5 Connection block 3 – 400 V AC (max. 6 mm2)2 Connection block 1 – 48 V DC (max. 6 mm2)

6 Potentiometer 48 V DC
7 Jumper output current limitation

4 Signal connection (max. 1,5 mm2)

8 Connection block 4 – 400 V AC (max. 6 mm2)

If the jumper is not connected, an error message appears (overcurrent protection).

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Assembly and installation(1) Connection to earth
The screw marked with "A" establishes the PELV protective earth conductor connection for the DC power supply.
For the insulation test (secondary side to PE), the "A" screw must be removed. The screw must then be
reinserted.

NOTE
Malfunction of the integrated cable protection!
The screw labeled „A” already ensures the PELV protective conductor connection.
An additional connection of the „DC 1 - to DC 4 -” terminals to the protective conductor disables the integrated
cable protection and leads to malfunction of the monitoring electronics!
¾

The “DC 1 - to DC 4 -” terminals must not be connected to the protective conductor!

(2) Connection block 1 – 24/48 V AC

DC 1 +

HP5424

HP5448+ 24 V DC+ 48 V DC

DC 1 -0V

0V

DC 2 ++ 24 V DC+ 48 V DC

DC 2 -

0V

0V

HP5424To avoid overloading
the output terminals, werecommend arranging
the connected devices
symmetrically.

(3) Connection block 2 – 24 V AC

DC 3 ++ 24 V DC

DC 3 -

0V

DC 4 ++ 24 V DC

DC 4 -0V

NOTE
Loss of cable protection due to incorrect connection¾

The outputs must not be connected in series or parallel.

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Signal outputs for readiness of the DC power supply and a group error signal.
DC OK

ERROR

DC off; no error (possibly no supply)L

H

DC on; no error

H

H

DC on; warning (e.g. phase failure, etc.)

H

L

DC off; error (e.g. overcurrent, overload, etc.)

L

L

The ERROR output is fail-safe.
The 24 V control voltage must be routed separately.

(6) UDC setting potentiometer
Fine adjustment of the DC output voltage

Adjustment range

HP5424

HP544824–28 V DC

48–54 V DC

NOTE
Irreparable damage to the built-in potentiometer.
¾

Do not turn past the end position of the potentiometer (this is not an endless control potentiometer).

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Assembly and installation(7) Jumper setting, DC cable protection
The DC cable protection is adjusted to match the connected RollerDrive.

Selection

HP5424

HP5448

10 A*/16 A/25 A

10 A*/16 A/20 A*Factory setting

NOTE
Overload on the connected RollerDrive.
¾

Ensure that the DC cable protection is adjusted correctly.
The DC cable protection features a common cutout element for all outputs. In the event of overcurrent oroverload on a single output, all outputs are switched off.

(5) Connection block 3 – 400 V AC
Input terminals for the 400 V power supply.
A four-wire connection cable without neutral conductor is sufficient when connecting Interroll power supply
units.

(8) Connection block 4 – 400 V AC
Output terminals for looping through the 400 V power supply to a further Interroll power supply unit.
To prevent incorrect routing between the DC and AC voltage range, a partition is installed in the terminal
compartment.

Type M25 cable glands are used for the supply cable and the cable for looping through the supply cable.
Manufacturer / Type: Jacob GmbH - Perfect 50.625 PA/SW UL-File: QCRV2.E140310
Type M20 cable glands are used for the cables to the Interroll control systems.
Manufacturer / Type: Jacob GmbH - Perfect 50.620 PA/SW UL-File: QCRV2.E140310
A type M12 cable gland is used for the signal cable.
Manufacturer / Type: Jacob GmbH - Perfect 50.612 PA/SW UL-File: QCRV2.E140310
All cable glands are sealed with a round stopper on delivery.

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5.4

Electrical installation
WARNING

Risk of death due to electric shock.
¾

Check each power supply unit before assembly for any visible damage.

¾

Do not mount damaged power supply units!

¾

In case of damage inform the supplier or Interroll immediately.

¾

Electrical installation work must only be carried out by a qualified electrician.

¾

Before installing, removing or connecting the Interroll power supply unit, switch off the power to theconveyor system and ensure that it cannot be unintentionally switched on again.

¾

Do not switch on the operating voltage until all cables are connected and the cover is fitted on the power
supply unit.

NOTE
Damage to the power supply unit.
¾

For the supply cable to the power supply unit, only use cables that are adequately dimensioned for the
specific operating conditions, particularly with regard to cross-section and insulation.

¾

Since the temperature in the terminal compartment can exceed 60 °C at nominal load, make sure that theconnection cables used are approved for temperatures > 80 °C.

¾

Ensure that no dust or dirt deposits can penetrate into the housing when it is opened.

¾

Ensure that all connected components are correctly earthed

NOTE
Professional installation!
¾

Before you can start connecting the cables, the device must be mounted on the intended mounting surface!

¾

The cables must be routed and secured in such a way that the cable glands or the electrical connection
points are not mechanically stressed!

¾

Use bunched conductors. These can be clamped directly without using ferrule terminals.

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Assembly and installation

Application notes
The following notes are designed to support the operator when using the Interroll power supply unit. These notes do
not claim to be exhaustive. The extent to which the specific operating conditions permit the notes to be followed must
be reviewed on a case-by-case basis. The safety and installation regulations applicable at the respective place of
operation take priority.

Mains-side connection and protection
The Interroll power supply unit does not contain any internal device fuses. Due to the operating principle of the power
supply unit, load-side overloads are not transferred to the mains connection. Mains-side protective devices would
therefore be ineffective.
Mains-side fuses can be dimensioned according to the cable protection.
To guarantee the full performance of the power supply unit, the use of phase monitoring or linked fuses isrecommended on the mains side.

NOTE
Professional installation!
¾

Extended/permanent operation of the power supply unit with just two phases is not permitted.

Load-side connection and protection
The power supply unit is equipped with electronic DC cable protection.
Depending on the jumper setting for output current limitation (see „Connections and settings“ on page 24), theoutput current and the total current are evaluated and, when the corresponding value is exceeded, a shutdown is
initiated.
The total power of 1 kW or an overload of 1.5 kW for 4 seconds is also independently monitored.
The shutdown interrupts the flow of energy.
The shutdown is monitored in the integrated controller. If the secondary-side flow of energy is not stopped within
the expected response time, a forced shutdown is initiated. This ensures that the defined response time for the safetyfunction is never exceeded.
The error is reset by switching the DC on/off switch off and back on.

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Conveyors with multiple Interroll power supply units
If a conveyor requires a higher connected load than can be provided by an Interroll power supply unit, the conveyor
must be divided into supply areas. Each of these areas must be supplied by a separate power supply unit.
The loads of two or more power supply units may not be connected in seires or parallel.
If the conveyor is to be divided into supply areas, the required simultaneous activation of the areas must be taken into
account when designing the switching mechanism (see the notes in the operating manual for the connected Interroll
control system).
It is possible to loop through the mains connection to simplify installation. Every Interroll power supply unit has
an additional terminal point and an additional M20 cable gland for connecting a further power supply unit. The
requirements regarding the loading capacity of the supply cable, fuse protection and switching requirements must be
taken into account in the design.

Electrical connection¾

Replace the round stoppers in the cable glands to be used with suitable seal inserts.

¾

Guide the cable through the gland next to the respective terminal.

¾

Ensure that all glands are present and fitted with suitable seals.

¾

Strip the cables with a suitable tool and remove the insulation to a sufficient length.

¾

Connect the cables according to the terminal diagram (see „Connections and settings“ on page 24).
The supply cable of the Interroll power supply unit does not require a clockwise rotating field. To make theconnections easier to identify, however, we recommend using the corresponding wire colour.

NOTE
Do not open the housing.
¾

With the exception of the terminal compartment, the housing must not be opened. Opening the housing
renders the test certificate null and void and also, therefore, the Interroll warranty.

¾

The looping of the supply line is limited to a maximum of eight power supplies!

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Start-up and operation

6

Start-up and operation

6.1

Start-up

Check before the initial start-up¾

Ensure that the power supply unit has been correctly attached to the conveyor frame and that all screws havebeen properly tightened.

¾

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

¾

Ensure that the wiring conforms to the specifications and legal provisions.

¾

Check all protective equipment.

¾

Carry out insulation tests.

NOTE
Damage to the power supply unit.
¾

As the power supply unit features varistors on the housing, an insulation test (primary side PE) in the system
must be performed with no more than 500 V.

The PELV switching status must be disabled during an insulation test. The operator is responsible for ensuringthat the correct switching status is restored once the test is complete (see „Connections and settings“ onpage 24).
¾

If necessary, carry out further tests after assembly and installation and before switching the system on for the
first time in accordance with the regulations applicable at the place of operation.

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6.2

Operation
WARNING

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

Before switching on the operating voltage, ensure that no persons are present in the hazardous areas
surrounding the conveyor.

CAUTION
Risk of burns!
¾

Depending on the load and the ambient temperature, temperatures > 65 °C are possible on the heat sinkof the power supply unit.

Check before every start-up¾

Check the power supply unit for any visible damage.

WARNING
Danger to life due to damage to the housing!
¾

Immediately switch off damaged power supply units and secure against being switched on again!

¾

Inform responsible supervisor and electrician.

¾

Check all protective equipment.
Take the ambient conditions into account during operation (see „Technical specifications“ on page 19).

¾

6.3

Switch on the DC power supply for the Interroll RollerDrive by turning the DC on/off switch to position "I".

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 power supply unit and ensure that it cannot be unintentionallyswitched on again.

¾

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

CAUTION
Risk of burns!
¾

Depending on the load and the ambient temperature, temperatures > 65 °C are possible on the heat sinkof the power supply unit.

7.1

Maintenance

The power supply unit itself requires no maintenance.
¾

Check connections and fixings regularly (visual inspection).

¾

Check that all components are generally intact (visual inspection).

A check of the insulation and DC cable protection can be carried out if necessary.
The housing must be cleaned if necessary.
Do not attempt to open the power supply unit (with the exception of the terminal compartment).

7.2

Cleaning¾

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

¾

Minor impurities can be removed using a cloth.

¾

Do not use any sharp-edged tools to clean the power supply unit.

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Assistance in the event of faults

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 power supply unit and ensure that it cannot be unintentionally switched on
again.

CAUTION
Risk of burns!
¾

8.1

Depending on the load and the ambient temperature, temperatures > 65 °C are possible on the heat sinkof the power supply unit.

Troubleshooting¾

For a description of the status LEDs, see „HP5424/HP5448 status LED“ on page 17.

¾

See also table „(4) Signal connection“ on page 27.

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Decommissioning and disposal

9

Decommissioning and disposal
WARNING

Risk of injury from following incorrect procedure.
¾

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

¾

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

¾

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

CAUTION
Risk of burns!
¾

Depending on the load and the ambient temperature, temperatures > 65 °C are possible on the heat sinkof the power supply unit.

9.1

Decommissioning¾

Switch off the DC power supply for the Interroll control systems by turning the DC on/off switch to position "0".

¾

Disconnect all cables from the power supply unit.

¾

Loosen the screws that have been used to attach the power supply unit to the conveyor frame.

¾

Remove the power supply unit from the conveyor frame.

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:
atse.customerservice@interroll.com

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10

Appendix

10.1

Accessories

ArticleArticle number

Ribbon cable for power supply (25 m)

S-1004030

Sealing inserts for power supply unit – accessories kit, round*

S-1115405

Sealing inserts for power supply unit – accessories kit, for one ASI-cable*

S-1115406

Sealing inserts for power supply unit – accessories kit, for two ASI-cables*

S-1115407* Cable diameter in connection with the associated sealing inserts of the company Jacob GmbH:
Cable Ø [mm]Sealing insert

VDE / ENUL

M12 Sealing insert „WJ-RD 7”

2-5

3,1 - 5

M20 Sealing insert „WJ-RDM 20/T”

5 - 13

9 - 13

M25 Sealing insert „WJ-RDM 25/T”

8 - 17

11 - 17

1 x ASI 2,5 mm2 „WJ-DM 20/ASI/1”

For one ribbon cable 2 x 2,5mm2

2 x ASI 2,5 mm2 „WJ-DM 20/ASI/2”

For two ribbon cables 2 x 2,5mm2

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Appendix

10.2

Translation of the original Declaration of Conformity

EU Declaration of Conformity
Low Voltage Directive 2014/35/EU
EMC Directive 2014/30/EU
RoHS Directive 2011/65/EU
The manufacturer
Interroll Software & Electronics GmbHIm Südpark 183
4030 Linz
AUSTRIA
hereby declares that the• Interroll High Performance power supply units HP5424 – model number
1113899, 1137434• Interroll High Performance power supply units HP5448 – model number
1113900, 1137435
conform to the applicable provisions and the associated CE marking
in accordance with the aforementioned Directives.
List of the coordinated standards that have been applied:
EN 61010-2-201:2013 / AC: 2013
EN 61326-1:2013
EN IEC 63000:2018
Authorised for compiling technical documentation:
Interroll Software & Electronics GmbH, Im Südpark 183, 4030 Linz

Andreas Eglseer

Managing Director, Interroll Software & Electronics GmbH
Linz, 01.07.2023

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10.3

UKCA Declaration of Conformity

Declaration of conformity
UK Electrical Equipment (Safety) Regulations 2016
UK Electromagnetic Compatibility Regulations 2016
UK Restriction of the Use of Certain Hazardous Substances inElectrical and Electronic Equipment Regulations 2012
The manufacturer
Interroll Software & Electronics GmbHIm Südpark 183
4030 Linz
AUSTRIA
hereby declares that the• Interroll High Performance power supply units HP5424 – model number
1113899, 1137434• Interroll High Performance power supply units HP5448 – model number
1113900, 1137435
conform to the applicable provisions and the associated UKCA marking
in accordance with the aforementioned Directives.

Authorised for compiling technical documentation:
Interroll Software & Electronics GmbH, Im Südpark 183, 4030 Linz

Andreas Eglseer

Managing Director, Interroll Software & Electronics GmbH
Linz, 01.07.2023

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EN | 07/2023 | Version 2.3

INSPIRED BY
EFFICIENCY© 2023 INTERROLL