INSPIRED BY EFFICIENCYCATALOGROLLERDRIVECONTROLS
POWER SUPPLIESPRODUCT LOCATOR

Products
Voltage

InterfacePower

DiameterProtection
rate

Suitable fordeep freeze
areas

page

24 V

48 V

AI

BI

20 W

35 W

50 W

1.9"

2.36"

l

l

l

l

l

l

l

l

–

IP54

–

10

l

l

l

l

–

l

l

l

–

IP54

l

22

l

l

l

l

–

l

l

1.97"

–

IP66

–

30

l

l

l

l

–

–

l

–

l

IP54

–

26

l

l

l

l

l

l

l

l

–

IP54

–

16

DriveControl 20

l

–

l

–

l

l

–

IP20

–

34

DriveControl 54

l

–

l

–

l

l

–

IP54

l

36

DriveControl 2048

l

l

l

–

l

l

l

IP20

–

38

ZoneControl

l

–

l

–

l

l

–

IP20

–

40

MultiControl AI

l

l

l

–

l

l

l

IP54

l

44

MultiControl BI

l

l

–

l

l

l

l

IP54

l

48

HP5424

l

–

l

l

l

l

l

IP54

l

52

HP5448

–

l

l

l

l

l

l

IP54

l

56

RollerDrive EC5000

For straight sections

For curves
Controls

Switching power supplies

l = suitable– = not suitable© 06 | 2020 Interroll

Symbols

Contents

Suitable for deep freeze area

24V
48V

Voltage 24 V
Voltage 48 V

20W

Power 20 W

35W

Power 35 W

50W

Power 50 W

AI

Analog interfaceBI

Bus interface (CANopen)

The Interroll Group

4

Interroll DC Platform

6

Product overview

8

RollerDrive

10

Controls

34

Switching power supplies

52

Accessories

60

Planning basics

66

Index

80

www.interroll.com© 06 | 2020 Interroll

3

THE INTERROLL GROUP

The Interroll Group is a globally leading
supplier of high-quality key products andservices for internal logistics. The
company, which is listed on the stock
exchange and has its headquarters in
Switzerland, employs some 2300 people
in 32 companies around the globe.

The solutions for our customers' daily
logistical challenges are based on Interroll
key products that are built on a worldwide
common platform.

Conveyor Rollers

Drives and Controls

Interroll is the worldwide leading provider of conveyor rollers that can befound in a multitude of applications in internal logistics. For the roller
production, we merge quality, flexibility and speed. More than 13 million
rollers in 60,000 variants leave our plants worldwide every year. Our
production is always order-driven, even for the smallest order quantities and,
if desired, even with a delivery time of 24 hours. Proven.

Interroll is a leading manufacturer in the segment of DC motor rollers anddrum motors.
Interroll RollerDrive and their controls are used in automated conveyor
technology. Energy-efficient DC drives are installed in decentralized
conveyor systems and, as a result, optimize energy demand and material
handling. The bus interface enables integrating the zero pressure
accumulation conveyor technology into Industry 4.0 systems.
Interroll Drum Motors are designed for use in belt conveyors and conveyor
systems. These robust, high-quality belt drives enable the construction ofmaintenance-free, energy-efficient conveyor belt systems for the majority ofindustrial applications as well as for food processing, baggage handling andsupermarket checkouts.

4© 06 | 2020 Interroll

THE INTERROLL GROUP

HoldingGlobal Competence Centers

Sales, Production & Service

Regional Competence Centers

Conveyors & Sorters

Pallet & Carton Flow

The Modular Conveyor Platform (MCP) from Interroll offers highest flexibility:
a broad spectrum of modules, consisting of roller conveyors, belt conveyors
as well as key products such as transfer, high-performance diverts or spirallifts, covers all requirements of the material handling.
The Interroll crossbelt sorters were developed with an eye on precision forfast and precise sorting of goods of all types from 2 oz to 77 lbs. More than
300 Interroll sorters are used every day by the largest CEP players and Ecommerce enterprises worldwide.
The brand-new modular pallet conveyor platform (MPP) offers roller andchain conveyors as well as special conveyors such as transfers and turntables
to create a fully integrated, robust, space-saving and energy-saving solution
for high throughput handling of pallets.

Interroll Pallet Flow and Carton Flow are the first choice when it comes torapid turnarounds and optimizing the storage and commissioning process.
Thanks to its efficiency and robustness, Pallet Flow ensures long-term
availability and more flexibility for peaks in orders. The compact design
reduces space requirements by up to 50 percent compared to conventional
solutions. The integrated TimePlus Separator as well as the Magnetic Speed
Controller increase the safety of the work environment and significantly
reduce the risk of damages to goods.
The Interroll Carton Flow solutions are efficient as well as ergonomic, andwere developed to improve the commissioning output.

© 06 | 2020 Interroll

5

INTERROLL DC PLATFORM

Smart solutions
With the market launch of its new DC platform, Interroll is once
again setting standards in material handling technology. The
range of perfectly matched RollerDrive, control systems andpower supplies enables system integrators and machine builders

to provide an even better fit for their customers’ needs – fromstandard applications to equipment with Industry 4.0
functionality. The new DC platform has a solution to match every
challenge.

6© 06 | 2020 Interroll

INTERROLL DC PLATFORM

Technology at a glance
48-V technology
A 48-V voltage supply allows reducing the numberof power supplies depending on the application. In
addition, the risk of functional issues due to voltage
drop on the line will be reduced significantly. It alsomeans that longer cabling, or alternatively cables
with a minimized cross section, can be used.

Choice of three power levels
The RollerDrive EC5000 is available in 20, 35 and50 watt versions. This enables zero pressure
accumulation conveyors that are the perfect fit for
both heavy and lightweight conveying goods.

Bus interface
A large variety of operating data can be read out
via the bus interface of the new RollerDrive
EC5000. Not only can they be used for the analysisof the RollerDrive, but rather for optimizing theentire conveyor line as defined by Industry 4.0. The
service life indication, for example, allows
purposeful preventive maintenance. The
cooperation of PLC and Interroll MultiControl also
allows for ultra-precise positioning of conveying
goods, e.g., for the support of robotics applications.

Control systems for every application
Alongside DriveControl 2048 for standard
applications with few RollerDrive, MultiControl – afour-zone control compatible with multiple
protocols – offers the right solution for both simple
and demanding applications, from autonomousconveyors with integrated logic to conveyors withcustomized PLC programming via fieldbus
communication.

New switching power supplies
The new power supplies do not need to be installedin the control cabinet. Instead, the robust devices
with protection rating IP54 can be mounted directly
where the extra-low voltage is needed. This
enables much shorter cable lengths. Automatic
power limitation and selectable circuit protection
are integrated, as is status evaluation via LED or
signal lines to the PLC.

Everything from a single source
Control systems, power supplies, different cabling,
and other accessory parts. For Interroll, it isextremely important that the products not only
work together, but actually complement each other.
The company always has the right experts on handto answer any questions that arise.

Simple detection
In addition to the nameplate, the different design
variants of EC5000 can also be identified by acolor ring on the connector. Color assignment:····© 06 | 2020 Interroll

White - 24 V, analog interface
Gray - 24 V, bus interface
Black - 48 V, analog interface
Yellow - 48 V, bus interface

7

PRODUCT OVERVIEW

RollerDrive EC5000

ø 1.9", cylindrical, IP54,
for 32 to 104 °F
page 10

ø 1.9", tapered, IP54,
for 32 to 104 °F
page 16

ø 2.36", cylindrical, IP54,
for 32 to 104 °F
page 26

ø 1.97", cylindrical, IP66,
for 32 to 104 °F
page 30

ø 1.9", cylindrical, IP54,
for –22 to +32 °F
page 22

Controls

DriveControl 20
page 34

DriveControl 54
page 36

MultiControl AI
page 44

MultiControl BI
page 48

8

DriveControl 2048
page 38

ZoneControl
page 40© 06 | 2020 Interroll

PRODUCT OVERVIEW

Switching power
supplies

HP5424page 52

HP5448page 56

Accessories

PolyVee belt
page 60

RollerDrive fastening socket
page 61

RollerDrive counter wrench
page 62

RollerDrive EC5000 extension
cable
page 62

Voltage supply flat cablepage 62

MultiControl communication
cable
page 63

MultiControl Y-cablepage 63

Magnetic key
page 65© 06 | 2020 Interroll

9

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for 32 to 104 °F

24V

48V

20W

Application area
Drive for unit handling conveyor
systems, such as transporting
cardboard cartons, containers,
platens or tires at normal ambient
temperature. Suitable for straightconveyors, small belt conveyors
and especially zero-pressure
accumulation conveyors. Also
usable in shuttle systems, aligningconveyor segments or transfers toother "conveyor system branches".

Compact design
The motor integrated in the tube allows a very compact design of the conveyor system.
Very energy-efficient
The brushless drive features energy recovery when braking. The conveyor system can operate
without pneumatics or conventional drives, which must be operated continually.

AI

Flexible possible applications
RollerDrive is available in many variations, allowing it to be used in all types of different
conveyor systems. For the user, this translates into a single interface instead of many. Dependingon the application area, PolyVee, round or toothed belts can be used for the transmission offorce. Nine gear ratios allow selecting the perfect pairing between speed and torque. The
electronic holding brake (Zero-Motion-Hold) holds conveying goods in position, even on gravity
conveyors.

BI

Low-noise
The use of decoupling elements achieves particularly low-noise running.

35W
50W

Maintenance-free and installation-friendly
The drive with internal commutation electronics does not require any maintenance. It features anoverload protection that prevents damages due to overtemperature or blockage. It is connected
securely without complex screw connection by using a motor cable with 5-pin snap-in plug.

10© 06 | 2020 Interroll

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for 32 to 104 °F

Technical data
Rated voltage

24 V

24 V

24 V

48 V

48 V

48 V

Power

20 W

35 W

50 W

20 W

35 W

50 W

Rated current

1.4 A

2.4 A

3.4 A

0.7 A

1.2 A

1.7 A

Starting current

3.0 A

5.5 A

7.5 A

1.5 A

2.8 A

3.8 A

55 dB (A), application-dependent

Length of motor cable

19.6"

Max. reference length59"

Ambient temperature in operation

Controls

Max. noise emission (installed)

32 to 104 °F
Stainless steel, 7/16" HEX, thread M12 x 1

Anti-static version

Yes (< 10⁶ Ω)

Tube wall thickness

ø 1.9": 0.065"

Tube material

Zinc-plated steel, stainless steel

Tube sleeving

PVC sleeve 0.08"
PU sleeve 0.063", 0.125"

Switching power supplies

Motor shaft

Maximum static load capacity
The maximum load capacity of the RollerDrive EC5000 depends on the drive head and the length of the RollerDrive.

Length of RollerDrive

≤ 39"

43"

47"

51"

55"

59"

Maximum load capacity per RollerDrive without
drive head

242 lbs

203 lbs

165 lbs

143 lbs

121 lbs

104 lbs

76 lbsPlanning basics

Accessories

Maximum load capacity per RollerDrive with drive
head (PolyVee, round or toothed belt)© 06 | 2020 Interroll

11

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for 32 to 104 °F

24V

48V

20W
35W
50W

AI
BI

Design versions
20 W
Gear ratio

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

9:1

382

18

2.2

5.5

5.5

13:1

264

12

3.18

8.0

8.0

18:1

190

8

4.4

11.1

11.1

21:1

163

8

5.2

13.0

13.0

30:1

114

6

7.5

18.8

18.8

42:1

82

4

10.4

26.1

26.1

49:1

70

4

12.1

30.4

30.4

78:1

42

2

17.8

48.0

48.0

108:1

32

2

24.9

67.0

67.0

Gear ratio

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

9:1

382

18

3.89

9.8

9.8

13:1

264

12

5.6

14.1

14.1

18:1

190

8

7.8

19.6

19.6

21:1

163

8

9.2

22.9

22.9

30:1

114

6

13.1

33.1

33.1

42:1

82

4

18.3

45.8

45.8

49:1

70

4

21.4

53.4

53.4

78:1

42

2

31.4

84.4

84.4

108:1

32

2

43.8

115.0

115.0

35 W

12

© 06 | 2020 Interroll

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for 32 to 104 °F

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

9:1

382

18

5.5

13.98

13.98

13:1

264

12

8.0

20.2

20.2

18:1

190

8

11.2

28.0

28.0

21:1

163

8

13.0

32.7

32.7

30:1

114

6

18.8

47.2

47.2

42:1

82

4

26.1

65.4

65.4

49:1

70

4

30.5

76.3

76.3

78:1

42

2

44.8

115.0

115.0

108:1

32

2

62.5

115.0

115.0

Before the run-in, the values may differ up to ±20 %. After a run-in phase, the values vary only in the range of ±10 % for 95 % of all
RollerDrive used.

Dimensions
The minimum reference length depends on the gear box variant, the grooves in the tube and the drive or the bearing assembly. A
sufficient axial play is already taken into account, so that the actual clear width between side profiles is required.
When using the tapered hexagon spring shaft, it must be ensured that the design of the axial play is not too high. If the RollerDrive
selected is too short, the shaft may have play in the hexagon hole. A hexagon hole with a size of at least 0.44" is recommended. If theRollerDrive is installed obliquely, the fastening hole must be designed larger accordingly.
RL
EL

Switching power supplies

Gear ratio

Controls

50 W= Reference length/ordering length= Installation length

0.52"

0.2"

0.16"

Ø 1.9" x 0.065"

19.69"

Accessories

5/16"-18 or M8 female thread, without grooves

RL

Planning basics

EL=RL+0.35"© 06 | 2020 Interroll

13

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for 32 to 104 °F

24V

Hexagon spring shaft, without grooves
19.69"

0.52"

0.2"

0.18"

0.61"

Ø 1.9" x 0.065"

48V

20W
35W

RL
EL=RL+0.38"

50W

AI

5/16"-18 or M8 female thread, with grooves
C

BI

D
0.52"

0.2"

0.16"

Ø 1.50"Ø 1.9" x 0.065"

19.69"RL
EL=RL+0.35"

Hexagon spring shaft, with grooves
C
0.52"

D

0.2"

0.18"
0.61"

Ø 1.50"Ø 1.9" x 0.065"

19.69"RL
EL=RL+0.38"

PolyVee drive head with M8 female thread
0.52"

0.2"

1.19"

Ø 1.69"

Ø 1.9" x 0.065"

19.69"RL
EL=RL+1.39"

14© 06 | 2020 Interroll

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for 32 to 104 °F

PolyVee drive head with 7/16" hexagon spring shaft
0.52"

0.2"

1.21" 0.56"

Ø 1.69"

Ø 1.9" x 0.065"

19.69"RL
EL=RL+1.41"

0.52"

0.2"

1.19"

Ø 1.49"

Ø 1.9" x 0.065"

19.69"

Controls

Round belt drive head with M8 female thread

RL

Switching power supplies

EL=RL+1.39"

Round belt drive head with 7/16" hexagon spring shaft
0.52"

0.2"

1.21" 0.53"

Ø 1.49"

Ø 1.9" x 0.065"

19.69"

RL

Planning basics

Accessories

EL=RL+1.41"© 06 | 2020 Interroll

15

ROLLERDRIVESERIES EC5000
Based on ø 1.9", tapered, IP54, for 32 to 104 °F

24V

48V

20W
35W

Application area
Drive for unit handling conveyor
systems, such as transporting
cardboard cartons, containers,
platens or tires at normal ambient
temperature. Suitable for roller/
belt curves as well as constantly
driven or zero pressure
accumulation conveyor technology.

50W

Compact design
The drive integrated in the tube allows a very compact design of the curve.
Very energy-efficient
The brushless drive features energy recovery when braking. The conveyor system can operate
without pneumatics or conventional drives, which must be operated continually.
Robust design
In contrast to conventional designs, the tapered elements (gray and black) are secured against
axial shifting. This safeguard prevents the tapered elements from shifting on the tube, similar to
the matching conveyor rollers.
Flexible possible applications
RollerDrive is available in many variations, allowing it to be used in all types of different
conveyor systems. For the user, this translates into a single interface instead of many. Dependingon the application area, PolyVee or round belts can be used for the transmission of force. Nine
gear ratios allow selecting the perfect pairing between speed and torque.

AI
BI

Low-noise
The use of decoupling elements achieves particularly low-noise running.
Maintenance-free and installation-friendly
The drive with internal commutation electronics does not require any maintenance. It features anoverload protection that prevents damages due to overtemperature or blockage. It is connected
securely without complex screw connection by using a motor cable with 5-pin snap-in plug.

16© 06 | 2020 Interroll

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
Based on ø 1.9", tapered, IP54, for 32 to 104 °F

Technical data
Rated voltage

24 V

24 V

24 V

48 V

48 V

48 V

Power

20 W

35 W

50 W

20 W

35 W

50 W

Rated current

1.4 A

2.4 A

3.4 A

0.7 A

1.2 A

1.7 A

Starting current

3.0 A

5.5 A

7.5 A

1.5 A

2.8 A

3.8 A

55 dB (A), application-dependent

Length of motor cable

19.6"

Max. reference length40"

Ambient temperature in operation

Controls

Max. noise emission (installed)

32 to 104 °F

Maximum load capacity per RollerDrive without
drive head

104 lbs

Max. load capacity per RollerDrive with drive head
(PolyVee or round belt)

76 lbsStainless steel, 7/16" HEX, thread M12 x 1

Anti-static version

No

Tube wall thickness

0.065"

Tube material

Zinc-plated steel, stainless steel

Tapered cones

1.8° in black (not antistatic)

Switching power supplies

Motor shaft

Design versions

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

9:1

382

18

2.2

5.5

5.5

13:1

264

12

3.18

8.0

8.0

18:1

190

8

4.4

11.1

11.1

21:1

163

8

5.2

13.0

13.0

30:1

114

6

7.5

18.8

18.8

42:1

82

4

10.4

26.1

26.1

49:1

70

4

12.1

30.4

30.4

78:1

42

2

17.8

48.0

48.0

108:1

32

2

24.9

67.0

67.0

© 06 | 2020 Interroll

Planning basics

Gear ratio

Accessories

20 W

17

ROLLERDRIVESERIES EC5000
Based on ø 1.9", tapered, IP54, for 32 to 104 °F

24V

48V

35 W
Gear ratio

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

9:1

382

18

3.89

9.8

9.8

13:1

264

12

5.6

14.1

14.1

18:1

190

8

7.8

19.6

19.6

21:1

163

8

9.2

22.9

22.9

30:1

114

6

13.1

33.1

33.1

42:1

82

4

18.3

45.8

45.8

49:1

70

4

21.4

53.4

53.4

78:1

42

2

31.4

84.4

84.4

108:1

32

2

43.8

115.0

115.0

Gear ratio

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

9:1

382

18

5.5

13.98

13.98

13:1

264

12

8.0

20.2

20.2

18:1

190

8

11.2

28.0

28.0

21:1

163

8

13.0

32.7

32.7

30:1

114

6

18.8

47.2

47.2

42:1

82

4

26.1

65.4

65.4

49:1

70

4

30.5

76.3

76.3

78:1

42

2

44.8

115.0

115.0

108:1

32

2

62.5

115.0

115.0

20W
35W
50W

AI
BI

50 W

Before the run-in, the values may differ up to ±20 %. After a run-in phase, the values vary only in the range of ±10 % for 95 % of all
RollerDrive used.

18© 06 | 2020 Interroll

Dimensions
The minimum reference length depends on the gear box variant, the grooves in the tube and the drive or the bearing assembly. A
sufficient axial play is already taken into account, so that the actual clear width between side profiles is required.
When using the tapered hexagon spring shaft, it must be ensured that the design of the axial play is not too high. If the RollerDrive
selected is too short, the shaft may have play in the hexagon hole. A hexagon hole with a size of at least 0.44" is recommended. If theRollerDrive is installed obliquely, the fastening hole must be designed larger accordingly.
RL
ELU

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
Based on ø 1.9", tapered, IP54, for 32 to 104 °F= Reference length= Installation length= Usable tube length: Length of tapered elements

Controls

Reference lengths with tapered elements

Max. Ø
[inch]

11.85

2.30

3.05

13.62

2.19

3.05

15.61

2.07

3.05

15.80

2.30

3.30

17.57

2.19

3.30

19.56

2.07

3.30

19.75

2.30

3.56

21.53

2.19

3.56

23.51

2.07

3.56

23.70

2.30

3.81

25.48

2.19

3.81

27.46

2.07

3.81

27.66

2.30

4.06

29.43

2.19

4.06

31.41

2.07

4.06

31.61

2.30

4.32

33.38

2.19

4.32

35.36

2.07

4.32

Accessories

Min. Ø
[inch]

Planning basics

Tapered rated length[inch]

Switching power supplies

Conicity: 1.8°, color: black (not antistatic)© 06 | 2020 Interroll

19

ROLLERDRIVESERIES EC5000
Based on ø 1.9", tapered, IP54, for 32 to 104 °F

24V

Hexagon spring shaft, without grooves
19.69"

0.52"

0.2"

0.18"

0.61"

Ø 1.9"X0.065"

48V

20W
35W
U

50W

RL
EL=RL+0.38"

AI
5/16"-18 or M8 female thread, with grooves

BI
C
D

0.16"

Ø 1.50"0.52" 0.2"

Ø 1.9X0.065

19.69"URL
EL=RL+0.35"

PolyVee drive head with M8 female thread
19.69" 0.52" 0.2"

Ø 1.9"X0.065"

Ø1.69"

1.19"

U
RL
EL=RL+1.39"

20© 06 | 2020 Interroll

Planning basics

Accessories

Switching power supplies

Controls

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
Based on ø 1.9", tapered, IP54, for 32 to 104 °F© 06 | 2020 Interroll

21

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for –22 to 32 °F

24V

48V

20W

Application area
Drive for unit handling conveyor
systems, such as transporting
cardboard cartons, containers orplatens in deep freeze conditions.
Suitable for straight conveyors andespecially zero-pressure
accumulation conveyors. Also
usable in shuttle systems, aligningconveyor segments or transfers toother "conveyor system branches".

Compact design
The motor integrated in the tube allows a very compact design of the conveyor system.
Very energy-efficient
The brushless drive features energy recovery when braking. The conveyor system can operate
without pneumatics or conventional drives, which must be operated continually.

AI

Flexible possible applications
RollerDrive is available in many variations, allowing it to be used in all types of different
conveyor systems. For the user, this translates into a single interface instead of many. Dependingon the application area, PolyVee, round or toothed belts can be used for the transmission offorce. Nine gear ratios allow selecting the perfect pairing between speed and torque. The
electronic holding brake (Zero-Motion-Hold) holds conveying goods in position, even on gravity
conveyors.

BI

Low-noise
The use of decoupling elements achieves particularly low-noise running.

35W
50W

Maintenance-free and installation-friendly
The drive with internal commutation electronics does not require any maintenance. It features anoverload protection that prevents damages due to overtemperature or blockage. It is connected
securely without complex screw connection by using a motor cable with 5-pin snap-in plug.

22© 06 | 2020 Interroll

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for –22 to 32 °F

Technical data
Rated voltage

24 V

24 V

48 V

48 V

Power

35 W

50 W

35 W

50 W

Rated current

2.2 A

3.4 A

1.1 A

1.7 A

Starting current

5.5 A

7.5 A

2.8 A

3.8 A

55 dB (A), application-dependent

Length of motor cable

19.6"

Max. reference length59"

Ambient temperature in operation

Controls

Max. noise emission (installed)–22 to 32 °F
Stainless steel, 7/16" HEX, thread M12 x 1

Anti-static version

Yes (< 10⁶ Ω)

Tube wall thickness

ø 1.9": 0.065"

Tube material

Zinc-plated steel, stainless steel

Tube sleeving

PVC sleeve 0.08"
PU sleeve 0.063", 0.125"

Switching power supplies

Motor shaft

Maximum static load capacity
The maximum load capacity of the RollerDrive EC5000 depends on the drive head and the length of the RollerDrive.

Length of RollerDrive

≤ 39"

43"

47"

51"

55"

59"

Maximum load capacity per RollerDrive without
drive head

242 lbs

203 lbs

165 lbs

143 lbs

121 lbs

104 lbs

76 lbsAccessories

Maximum load capacity per RollerDrive with drive
head (PolyVee, round or toothed belt)

Design versions

Gear ratio

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

30:1

114

6

13.1

33.1

33.1

42:1

82

4

18.3

45.8

45.8

49:1

70

4

21.4

53.4

53.4

© 06 | 2020 Interroll

Planning basics

35 W

23

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for –22 to 32 °F

24V

48V

50 W
Gear ratio

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

13:1

264

12

8.0

20.2

20.2

18:1

190

8

11.2

28.0

28.0

21:1

163

8

13.0

32.7

32.7

30:1

114

6

18.8

47.2

47.2

42:1

82

4

26.1

65.4

65.4

49:1

70

4

30.5

76.3

76.3

78:1

42

2

44.8

115.0

115.0

108:1

32

2

62.5

115.0

115.0

20W

50W

AI
BI

Before the run-in, the values may differ up to ±20 %. After a run-in phase, the values vary only in the range of ±10 % for 95 % of all
RollerDrive used.

Dimensions
The minimum reference length depends on the gear box variant, the grooves in the tube and the drive or the bearing assembly. A
sufficient axial play is already taken into account, so that the actual clear width between side profiles is required. A hexagon hole witha size of at least 0.44" is recommended. If the RollerDrive is installed obliquely, the fastening hole must be designed larger
accordingly.
RL
EL= Reference length/ordering length= Installation length

M8 female thread, without grooves
19.69"

0.52"

0.2"

0.16"

Ø 1.9" x 0.065"

35W

RL
EL=RL+0.35"

24© 06 | 2020 Interroll

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
ø 1.9", cylindrical, IP54, for –22 to 32 °F

M8 female thread, with grooves
C
D
0.52"

0.2"

0.16"

Ø 1.50"Ø 1.9" x 0.065"

19.69"

RL

Controls

EL=RL+0.35"

PolyVee drive head with M8 female thread
0.52"

0.2"

1.19"

Switching power supplies

Ø 1.69"

Ø 1.9" x 0.065"

19.69"RL
EL=RL+1.39"

PolyVee drive head with 7/16" hexagon spring shaft
0.52"

0.2"

1.21" 0.56"

Ø 1.69"

Ø 1.9" x 0.065"

19.69"

RL

Accessories

EL=RL+1.41"

Round belt drive head with M8 female thread
0.52"

0.2"

1.19"

Ø 1.49

Ø 1.9" x 0.065"

19.69"

Planning basics

RL
EL=RL+1.39"© 06 | 2020 Interroll

25

ROLLERDRIVESERIES EC5000
ø 2.36", cylindrical, IP54, for 32 to 104 °F

24V

48V

20W
35W
50W

Application area
Drive for unit handling conveyor
systems, such as transporting
cardboard cartons, containers,
platens, (truck) tires or lightweightpallets at normal ambient
temperature. Suitable for straightconveyors, small belt conveyors
and especially zero-pressure
accumulation conveyors. Also
usable in aligning conveyor
segments or transfers or other"conveyor system branches".

AI

Compact design
The motor integrated in the tube allows a very compact design of the conveyor system.
Very energy-efficient
The brushless drive features energy recovery when braking. The conveyor system can operate
without pneumatics or conventional drives, which must be operated continually.
Flexible possible applications
RollerDrive is available in many variations, allowing it to be used in all types of different
conveyor systems. For the user, this translates into a single interface instead of many. Nine gear
ratios allow selecting the perfect pairing between speed and torque. The electronic holding
brake (Zero-Motion-Hold) holds conveying goods in position, even on gravity conveyors.
Low-noise
The use of decoupling elements achieves particularly low-noise running.

BI

Maintenance-free and installation-friendly
The drive with internal commutation electronics does not require any maintenance. It features anoverload protection that prevents damages due to overtemperature or blockage. It is connected
securely without complex screw connection by using a motor cable with 5-pin snap-in plug.

26© 06 | 2020 Interroll

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
ø 2.36", cylindrical, IP54, for 32 to 104 °F

Technical data
Rated voltage

24 V

48 V

Power

50 W

50 W

Rated current

3.4 A

1.7 A

Starting current

7.5 A

3.8 A
55 dB (A), application-dependent

Length of motor cable

19.69"

Max. reference length59"

Ambient temperature in operation

Controls

Max. noise emission (installed)

32 to 104 °F

Max. load capacity per RollerDrive with PolyVee
drive head

123 lbs

Anti-static version

Yes (< 10⁶ Ω)

Tube wall thickness

0.079"

Tube material

Zinc-plated steel, stainless steel

Tube sleeving

PVC sleeve 0.079"
Lagging 0.079"

Switching power supplies

Stainless steel, 7/16" HEX, thread M12 x 1

Design versions

Gear ratio

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

9:1

474

23

5.5

13.9

13.9

13:1

328

18

8.0

20.2

20.2

18:1

236

12

11.2

28.0

28.0

21:1

202

10

13.0

32.7

32.7

30:1

141

6

18.8

47.2

47.2

42:1

102

6

26.1

65.4

65.4

49:1

86

6

30.5

76.3

76.3

78:1

55

2

44.8

115.0

115.0

108:1

39

2

62.5

115.0

115.0

Accessories

50 W

Before the run-in, the values may differ up to ±20 %. After a run-in phase, the values vary only in the range of ±10 % for 95 % of all
RollerDrive used.

© 06 | 2020 Interroll

27

Planning basics

Motor shaft

ROLLERDRIVESERIES EC5000
ø 2.36", cylindrical, IP54, for 32 to 104 °F

24V

Dimensions

48V

RL
EL

20W
35W

= Reference length/ordering length= Installation length, clear width between side profiles

The minimum reference length depends on the gear box variant and the drive or the bearing assembly. A sufficient axial play isalready taken into account, so that the actual clear width between side profiles is required. A hexagon hole with a size of at least
0.44" is recommended. If the RollerDrive is installed obliquely, the fastening hole must be designed larger accordingly.
Note: This model is available in metric sizes only (millimeters) as shown below.

50W
PolyVee drive head with female thread

AI

500

31

5

Ø 43

Ø 60x2

BI

13.1

RL
EL=RL+36

28© 06 | 2020 Interroll

Planning basics

Accessories

Switching power supplies

Controls

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
ø 2.36", cylindrical, IP54, for 32 to 104 °F© 06 | 2020 Interroll

29

ROLLERDRIVESERIES EC5000
ø 1.97", cylindrical, IP66, for 32 to 104 °F

24V

48V

20W
35W
50W

Application area
Drive for unit handling conveyor
systems, such as transporting
cardboard cartons, containers orplatens at normal ambient
temperature. Suitable for straightconveyors and especially zeropressure accumulation conveyors.
Often used at locations forcleaning with water jets due to thehigh protection rating.

AI

Compact design
The motor integrated in the tube allows a very compact design of the conveyor system.
Very energy-efficient
The brushless drive features energy recovery when braking. The conveyor system can operate
without pneumatics or conventional drives, which must be operated continually.
Flexible possible applications
RollerDrive is available in many variations, allowing it to be used in all types of different
conveyor systems. For the user, this translates into a single interface instead of many. Dependingon the application area, PolyVee or round belts can be used for the transmission of force. The
many gear ratios allow selecting the perfect pairing between speed and torque.
Low-noise
The use of decoupling elements achieves particularly low-noise running.

BI

Maintenance-free and installation-friendly
The drive with internal commutation electronics does not require any maintenance. It features anoverload protection that prevents damages due to overtemperature or blockage. It is connected
securely without complex screw connection by using a motor cable with 5-pin snap-in plug.

30© 06 | 2020 Interroll

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
ø 1.97", cylindrical, IP66, for 32 to 104 °F

Technical data
Rated voltage

24 V

24 V

48 V

48 V

Power

35 W

50 W

35 W

50 W

Rated current

2.4 A

3.4 A

1.2 A

1.7 A

Starting current

5.5 A

7.5 A

2.8 A

3.8 A

55 dB (A), application-dependent

Length of motor cable

19.69"

Max. reference length59"

Ambient temperature in operation

Controls

Max. noise emission (installed)

32 to 104 °F
Stainless steel, 7/16" HEX, thread M12 x 1

Anti-static version

Yes (< 10⁶ Ω)

Tube wall thickness

ø 1.97": 0.059"

Tube material

Stainless steel

Tube sleeving

PVC sleeve 0.08", 0.19"
PU sleeve 0.08"
Lagging 0.08" to 0.19"

Switching power supplies

Motor shaft

Maximum static load capacity
The maximum load capacity of the RollerDrive EC5000 depends on the drive head and the length of the RollerDrive.

Length of RollerDrive

≤ 39"

43"

47"

51"

55"

59"

Maximum load capacity per RollerDrive without
drive head

242 lbs

203 lbs

165 lbs

143 lbs

121 lbs

104 lbs

76 lbsPlanning basics

Accessories

Maximum load capacity per RollerDrive with drive
head (PolyVee, round or toothed belt)© 06 | 2020 Interroll

31

ROLLERDRIVESERIES EC5000
ø 1.97", cylindrical, IP66, for 32 to 104 °F

24V

48V

20W
35W
50W

AI
BI

Design versions
35 W
Gear ratio

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

18:1

196

8

7.8

19.6

19.6

21:1

169

8

9.2

22.9

22.9

30:1

118

6

13.1

33.1

33.1

42:1

84

4

18.3

45.8

45.8

49:1

72

4

21.4

53.4

53.4

78:1

45

2

31.4

84.4

84.4

108:1

33

2

43.8

115.0

115.0

Gear ratio

Max. conveying
speed
[fpm]

Min. conveying
speed
[fpm]

Rated torque[in-lbs]

Acceleration torque[in-lbs]

Continuous blocking
torque[in-lbs]

18:1

196

8

11.2

28.0

28.0

21:1

169

8

13.0

32.7

32.7

30:1

118

6

18.8

47.2

47.2

42:1

84

4

26.1

65.4

65.4

49:1

72

4

30.5

76.3

76.3

78:1

45

2

44.8

115.0

115.0

108:1

33

2

62.5

115.0

115.0

50 W

Before the run-in, the values may differ up to ±20 %. After a run-in phase, the values vary only in the range of ±10 % for 95 % of all
RollerDrive used.

32© 06 | 2020 Interroll

Dimensions
The minimum reference length depends on the gear box variant, the grooves in the tube and the drive or the bearing assembly. A
sufficient axial play is already taken into account, so that the actual clear width between side profiles is required. A hexagon hole witha size of at least 0.44" is recommended. If the RollerDrive is installed obliquely, the fastening hole must be designed larger
accordingly.
RL
EL

RollerDrive EC5000

ROLLERDRIVESERIES EC5000
ø 1.97", cylindrical, IP66, for 32 to 104 °F= Reference length/ordering length= Installation length, clear width between side profiles

The female thread solution for the IP66 designs consists of a shaft bolt using a floating bearing. Ball bearings are not used.

Controls

Note: This model is available in metric sizes only (millimeters) as shown below.
Female thread, without grooves
13.3

4

10

Switching power suppliesØ 50x1.5500

RL
EL=RL+14

Female thread, with grooves
C
13.3

D

4

10

Ø 38.4

Ø 50x1.5

500

Accessories

RL
EL=RL+14

PolyVee drive head with female thread
31

4

Ø 43

Planning basics

13.3

Ø 50x1.5500

RL
EL=RL+35© 06 | 2020 Interroll

33

CONTROLSDRIVECONTROL 20
For EC5000, 24 V
20 W, 35 W, with analog interface

24V

48V

20W
35W

Application area
Control of RollerDrive EC5000 in
applications without start-stop
operation, e.g. in roller curves.
Mechanical engineering
applications. Applications with PLC,
but without fieldbus. Small
applications with max. ten
RollerDrive.

Product description
The DriveControl 20 is a simple control for the RollerDrive EC5000. It does not contain any logic(e.g. for zero-pressure accumulation conveying) and requires external signals.
DIP switches can be used to set the direction of rotation, a start and braking ramp and the speed
in 15 increments. Digital inputs and outputs serve as interface to a higher-level control. Signals
allow adjusting the direction of rotation and the speed in seven increments. The braking energyof the RollerDrive EC5000 is fed back into the DC supply system. The voltage fed back from theRollerDrive EC5000 is limited at 30 V by means of the integral brake chopper (voltagedependently switched load resistance).

50W
Functions· Speed setting (DIP switches 15x, digital input 7x)· Selection of direction of rotation (via DIP switches or digital input)· Error signal output· Status display with LEDs
· Voltage limitation via brake chopper

AI
BI

34

© 06 | 2020 Interroll

RollerDrive EC5000

CONTROLS
DRIVECONTROL 20
For EC5000, 24 V
20 W, 35 W, with analog interface

Technical data
Electrical data
Rated voltage

24 V DC

Voltage range

19 to 26 V DC

Current consumption

DriveControl: approx. 0.5 A + current of RollerDrive EC5000*

Fuse

Present, non-replaceable

Protection rate

IP20

Controls

Ambient conditions
Ambient temperature in operation

32 to 104 °F

Ambient temperature during transportand storage–40 to 176 °F

Max. installation height above sea level3280 ft (at higher altitudes, a reduction of performance values is possible)

Power supply

Fine-wired, 1.5 mm² (AWG 16)

Inputs/outputs (I/O)

Fine-wired, 0.08 to 0.5 mm² (AWG 28 to 20)* The power of EC5000 depends on the application, e.g., conveying good weight, conveying speed, acceleration ramp, and on the EC5000 used (refer to thecorresponding chapter).

Dimensions
5.12“

0.1“

0.24“

Ø 0.2

Accessories(0.26“)

1.65“(0.26“)

2.17“

4.65“

4“

(0.24“)Switching power supplies

Cable cross-sections

4.25“

0.95“

Planning basics

Accessories· RollerDrive EC5000 extension cable, page 62· Switching power supply HP5424, page 52

Ordering information· Article number: S-1001415· Scope of supply: 2 plugs for voltage supply, 1 plug for inputs and outputs, polymer tool for cabling© 06 | 2020 Interroll

35

CONTROLSDRIVECONTROL 54
For EC5000 24 V
20 W, 35 W, with analog interface

24V

48V

20W
35W
50W

Application area
Control of RollerDrive EC5000 in
applications without start-stop
operation, e.g. in roller curves.
Mechanical engineering
applications. Applications with PLC,
but without fieldbus. Small
applications with max. ten
RollerDrive. Applications withsplashing water (e.g. Sprinkler
systems) or applications in deep
freeze area.

AI

Product description
The DriveControl 54 is a simple control for the RollerDrive EC5000. It does not contain any logic(e.g. for zero-pressure accumulation conveying) and requires external signals. The DriveControl
54 has a protection rating of IP54 and, as a result, is suitable for use in wet environments or
deep freeze conditions.
DIP switches can be used to set the direction of rotation, a start and braking ramp and the speed
in 15 increments. Digital inputs and outputs serve as interface to a higher-level control. Signals
allow adjusting the direction of rotation and the speed in seven increments. The braking energyof the RollerDrive EC5000 is fed back into the DC supply system. The voltage fed back from theRollerDrive EC5000 is limited at 30 V by means of the integral brake chopper (voltagedependently switched load resistance).
Functions· Speed setting (DIP switches 15x, digital input 7x)· Selection of direction of rotation (via DIP switches or digital input)· Error signal output· Status display with LEDs
· Voltage limitation via brake chopperBI

36© 06 | 2020 Interroll

RollerDrive EC5000

CONTROLS
DRIVECONTROL 54
For EC5000 24 V
20 W, 35 W, with analog interface

Technical data
Electrical data
Rated voltage

24 V DC

Voltage range

19 to 26 V DC

Current consumption

DriveControl: approx. 0.5 A + current of RollerDrive EC5000*

Fuse

Present, non-replaceable

Protection rate

IP54

Controls

Ambient conditions
Ambient temperature in operation–18 to 104 °F

Ambient temperature during transportand storage–40 to 176 °F

Max. installation height above sea level3280 ft (at higher altitudes, a reduction of performance values is possible)

Power supply

Fine-wired, 1.5 mm² (AWG 16)

Inputs/outputs (I/O)

Fine-wired, 0.08 to 0.5 mm² (AWG 28 to 20)* The power of EC5000 depends on the application, e.g., conveying good weight, conveying speed, acceleration ramp, and on the EC5000 used (refer to thecorresponding chapter).

Dimensions
4.72“(0.31“)

2.75“

Accessories

Ø

8“
0.1

2.12“

0.31“

0.31“

Switching power supplies

Cable cross-sections

4.09“(0.31“)

1.06“

Planning basics

Accessories· RollerDrive EC5000 extension cable, page 62· Switching power supply HP5424, page 52

Ordering information
Article number: S-1001416© 06 | 2020 Interroll

37

CONTROLSDRIVECONTROL 2048
For EC5000 24 V, 48 V
20 W, 35 W, 50 W, with analog interface

24V

48V

20W
35W

Application area
Control of RollerDrive EC5000 in
applications without start-stop
operation, e.g. in roller curves.
Mechanical engineering
applications. Applications with PLC,
but without fieldbus. Small
applications with max. ten
RollerDrive.

Product description
The DriveControl 2048 is a simple control for the RollerDrive EC5000. It does not contain any
logic (e.g. for zero-pressure accumulation conveying) and requires external signals.
2 rotary coding switches can be used to set the direction of rotation, 8 different start andbraking ramps and the speed in 15 increments. Digital inputs and outputs serve as interface to ahigher-level control. Signals allow adjusting the direction of rotation and the speed in sevenincrements. The braking energy of the RollerDrive EC5000 is fed back into the DC supply system.
The voltage fed back from the RollerDrive EC5000 is limited at 30 V by means of the integral
brake chopper (voltage-dependently switched load resistance).

50W
Functions· Speed setting (rotary coding switch 15x, digital input 7x)· Selection of direction of rotation (via rotary coding switch or digital input)· Adjustment of acceleration and braking ramp (rotary coding switch 8x)· Status display with LEDs
· Voltage limitation via brake chopper

AI
BI

38

© 06 | 2020 Interroll

RollerDrive EC5000

CONTROLS
DRIVECONTROL 2048
For EC5000 24 V, 48 V
20 W, 35 W, 50 W, with analog interface

Technical data
Electrical data
Rated voltage

24 or 48 V DC

Voltage range

24 V DC: 19 to 28 V DC 48 V DC: 38 to 56 V DC

Current consumption

DriveControl: approx. 0.5 A + current of RollerDrive EC5000*

Fuse

Present, non-replaceable

Protection rate

IP20

Controls

Ambient conditions
Ambient temperature in operation

32 to 104 °F

Ambient temperature during transportand storage–40 to 176 °F

Max. installation height above sea level3280 ft (at higher altitudes, a reduction of performance values is possible)

Power supply

Fine-wired, 1.5 mm² (AWG 16)

Inputs/outputs (I/O)

Fine-wired, 0.08 to 0.5 mm² (AWG 28 to 20)* The power of EC5000 depends on the application, e.g., conveying good weight, conveying speed, acceleration ramp, and on the EC5000 used (refer to thecorresponding chapter).

Dimensions
5.12“Accessories

1.65“

2.17“

0.24“

(0.26“)

4.65“

“

.24

(0.26“)

Ø0

0.1“

Switching power supplies

Cable cross-sections(0.24“)

0.95“

4.25“

Accessories
Planning basics· RollerDrive EC5000 extension cable, page 62· Switching power supply HP5424, page 52· Switching power supply HP5448, page 56

Ordering information· Article number: S-1113898· Scope of supply: 2 plugs for voltage supply, 1 plug for inputs and outputs, polymer tool for cabling© 06 | 2020 Interroll

39

CONTROLSZONECONTROLFor EC5000 24 V
20 W, 35 W, with analog interface

24V

48V

20W

Application area
Zero-pressure accumulation (ZPA)
conveying for systems with medium
to high number of conveyor zones.
Applications with or without PLC,
but without fieldbus.

Product description
The ZoneControl is a single-zone control for a RollerDrive EC5000 and a zone sensor. The
ZoneControl can be used to create stand-alone, zero-pressure accumulation conveyors which
require no higher-level control (PLC). Additional functions and communication to upstream anddownstream conveyors can be implemented via digital inputs and outputs (I/Os).
The advantage is that the ZPA logic is contained in the ZoneControl and does not have to be
programmed within a PLC. DIP switches can be used to set the RollerDrive speed and direction ofrotation as well as the logic (single or train release). For all ZoneControl connected with eachother, the speed can also be changed with an analog signal and a cumulative error signal canbe read out.

35W
50W

The wiring of the voltage supply is done via switching wire and communication using commercial
CAT5 patch cables (Ethernet cable). The ZoneControl is only partially suited when a tracking of
conveying goods or the control of the RollerDrive with start and brake ramps is being planned
or a large number of additional functions is to be used.

AI
BI

The ZoneControl shows its strength in the fact that it does not have to be addressed, whichmakes an exchange in case of a failure extremely easy, and it can easily be configured with DIP
switches.

40© 06 | 2020 Interroll

RollerDrive EC5000

CONTROLSZONECONTROLFor EC5000 24 V
20 W, 35 W, with analog interface

Functions
Logic for zero-pressure accumulation conveying incl. initialization
Communication with upstream and downstream zones via peer-to-peer connection
Speed setting in 8 increments via DIP switches or analog signal
Direction of rotation setting via DIP switches or external digital signal
Connection of a zone sensor
Connection of a start sensor for the start of the conveyor line
Determination of NPN or PNP switching logic
Switching a second RollerDrive into the zone
Additional functions: Running the conveyor empty, error signaling of all connected zones, external start or stop signal
Voltage limitation via brake chopper

Controls

·
·
·
·
·
·
·
·
·
·

Technical data

Rated voltage

24 V DC

Voltage range

19 to 26 V DC

Current consumption

ZoneControl with sensor: approx. 0.5 A + current of RollerDrive EC5000*

Fuse

Present, non-replaceable

Protection rate

IP20

Switching power supplies

Electrical data

Ambient conditions
Ambient temperature in operation

32 to 104 °F

Ambient temperature during transportand storage–40 to 176 °F

Max. installation height above sea level3280 ft (at higher altitudes, a reduction of performance values is possible)

Power supply

Fine-wired, 1.5 mm² (AWG 16)

Inputs/outputs (I/O)

Fine-wired, 0.08 to 0.5 mm² (AWG 28 to 20)

Planning basics* The power of EC5000 depends on the application, e.g., conveying good weight, conveying speed, acceleration ramp, and on the EC5000 used (refer to thecorresponding chapter).

Accessories

Cable cross-sections© 06 | 2020 Interroll

41

CONTROLSZONECONTROLFor EC5000 24 V
20 W, 35 W, with analog interface

24V

Dimensions

48V

5.12“
4.65“

0.24“

1.65“

35W
50W

(0.26“)

Ø 0.2

AI

2.17“

(0.26“)

20W

4“(0.24“)

0.1“
4.25“

BI

0.95“

Accessories· RollerDrive EC5000 extension cable, page 62· Switching power supply HP5424, page 52

Ordering information· Article number: S-1101459· Scope of supply: Plug for voltage supply, plug for inputs and outputs, one plug each for start and zone sensor, polymer tool forcabling42© 06 | 2020 Interroll

Planning basics

Accessories

Switching power supplies

Controls

RollerDrive EC5000

CONTROLSZONECONTROLFor EC5000 24 V
20 W, 35 W, with analog interface© 06 | 2020 Interroll

43

CONTROLS
MULTICONTROL AI
For EC5000 24 V, 48 V
20 W, 35 W, 50 W with analog interface

24V

48V

20W
35W

Application area
Zero-pressure accumulation
conveying (ZPA) for systems withmedium to high number ofconveyor zones. Control of theInterroll Transfer and High
Performance Divert as well as
Interroll Pallet Drive (via Pallet
Control).

50W

AI

Product description
The MultiControl is a four-zone control. This means that up to four RollerDrive EC5000 AI andfour zone sensors can be connected. The use of Y-cables enables connecting four additional
inputs or outputs. The connections can be configured individually.
MultiControl is multi-protocol-capable. PROFINET, EtherNet/IP and EtherCat can be used via
simple switching.
With help of the MultiControl, sensors and RollerDrive are directly integrated into the field bus
level. An additional sensor/actuator level and, as a result, additional communication lines or agateway become redundant. A standard flat cable is used for power supply. They can simply be
cut to the desired length and can be connected very quickly using the piercing technology ofMultiControl.
The separate voltage supply allows a safe power-off of the RollerDrive while the bus
communication and sensors can continue to be used.

BI

Addressing and naming is done over PLC software, a web user interface, or with the Interroll
teach-In method. With the Teach-In method, automatic addressing and configuration of all
MultiControl is possible. In addition, the sequence of all MultiControls in the conveyor line can be
determined. This saves time during the commissioning on site.

44© 06 | 2020 Interroll

RollerDrive EC5000

CONTROLS
MULTICONTROL AI
For EC5000 24 V, 48 V
20 W, 35 W, 50 W with analog interface

Functions

·
·
·
·
·
·

Controls·

Easy handling – One control card for PROFINET, EtherNet/IP and EtherCat (simple toggling of bus protocols)
Independent power supply for RollerDrive
Plug & Play in case of replacements – no addressing or configuration required
Status display with LEDs for all functions and I/Os
Integrated logic for zero-pressure accumulation conveying incl. initialization
Secure communication with the use of certificates: PROFINET Conformance Class B, EtherNet/IP ODVA Conformance, EtherCat
Conformance
Configuration via PLC, web browser menu and via teach-In method of:– Speed, direction of rotation, start and stop ramp of RollerDrive– Sensor properties– Timer– Error handling– Logic (single/train release)
UL-listed
Voltage limitation via brake chopper
Variable process images for optimizing the data volumes transferred between MultiControl and PLC
Functional ground connection for shield of communication line
Polarity reversal protection of voltage supply
Short circuit-proof design of voltage supply of inputs and outputs

Switching power supplies

·
·
·
·
·
·

Possible applications
Function of a PLC

Function of MultiControl

No• None• Implementation of ZPA logic

Yes• Influencing the ZPA logic• Tracking of conveying goods• Error diagnostics• Implementation of ZPA logic• Implementation of PLC specifications

Yes• The PLC must be programmed and controls all connected
RollerDrive via this program• Tracking of conveying goods and error diagnostics• Function as input/output card
• Transmits the status of all sensors, RollerDrive and, if
necessary, error information to the PLC

Planning basics

Accessories

Use of a PLC© 06 | 2020 Interroll

45

CONTROLS
MULTICONTROL AI
For EC5000 24 V, 48 V
20 W, 35 W, 50 W with analog interface

24V

48V

Technical data
Electrical data
Rated voltage

24 or 48 V DC

Voltage range

24 V DC: 22 to 28 V DC 48 V DC: 44 to 56 V DC (voltage supply of RollerDrive only)

Current consumption

Logic supply voltage:
MultiControl: max. 0.2 A + connected sensors/actuators = max. 1.6 A+ current of RollerDrive EC5000*

Fuses– For logic– For RollerDrive– For sensors and I/Os, can be reset

Protection rate

IP54

20W
35W
50W

AI
Ambient conditions
Ambient temperature in operation–22 to 104 °F

Ambient temperature during transportand storage–40 to 176 °F

Max. installation height above sea level3280 ft*** The power of EC5000 depends on the application, e.g., conveying good weight, conveying speed, acceleration ramp, and on the EC5000 used (refer to thecorresponding chapter).
** The installation in systems at an altitude above 3280 ft is possible. However, this can lead to a reduction of the performance values.

Dimensions
MultiControl
8.35“

2.76“

BI

1.69“

46

0.45“

7.28“

0.45“

© 06 | 2020 Interroll

RollerDrive EC5000

CONTROLS
MULTICONTROL AI
For EC5000 24 V, 48 V
20 W, 35 W, 50 W with analog interface

Base plate
6.42“
5.95“
0.59“

3.54“

0.59“

Controls

2.36“

1.28“

1.28“

To be able to position the magnetic key, the distance from the top edge of MultiControl to adjacent components must be at least 0.4".

Accessories
Flat cable for voltage supply, page 62
Magnetic key, page 65
MultiControl dummy plug, page 64
RollerDrive EC5000 extension cable, page 62
MultiControl communication cable, page 63
MultiControl Y-cable, page 63
Switching power supply HP5424, page 52
Switching power supply HP5448, page 56
Cable distribution, page 63
Shield connection cable, page 64

Accessories

·
·
·
·
·
·
·
·
·
·

Switching power supplies

6“
0.2
Ø

.26
“
Ø0

Ø

0.2
6“

1.02“

0.26“

0.16“

2.76“

0.26“

Ordering information

Planning basics· Article number: S-1103563· Scope of supply: Base plate© 06 | 2020 Interroll

47

CONTROLS
MULTICONTROL BI
For EC5000 24 V, 48 V
20 W, 35 W, 50 W, with bus interface (CANopen)

24V

48V

20W
35W
50W

Application area
Zero-pressure accumulation
conveying (ZPA) for systems withmedium to high number ofconveyor zones. Control of theInterroll Transfer and High
Performance Divert as well as
Interroll Pallet Drive (via Pallet
Control). Control of RollerDrive
EC5000 BI in applications withpositioning demand.

AI

Product description
The MultiControl is a four-zone control. This means that up to four RollerDrive EC5000 BI andfour zone sensors can be connected. The use of Y-cables enables connecting four additional
inputs or outputs. The connections can be configured individually.
MultiControl is multi-protocol-capable. PROFINET, EtherNet/IP and EtherCat can be used via
simple switching.
With help of the MultiControl, sensors and RollerDrive are directly integrated into the field bus
level. An additional sensor/actuator level and, as a result, additional communication lines or agateway become redundant. A standard flat cable is used for power supply. They can simply be
cut to the desired length and can be connected very quickly using the piercing technology ofMultiControl.
The separate voltage supply allows a safe power-off of the RollerDrive while the bus
communication and sensors can continue to be used.

BI

Addressing and naming is done over PLC software, a web user interface, or with the Interroll
Teach-In method. With the Teach-In method, automatic addressing and configuration of all
MultiControl is possible. In addition, the sequence of all MultiControls in the conveyor line can be
determined. This saves time during the commissioning on site.

48© 06 | 2020 Interroll

RollerDrive EC5000

CONTROLS
MULTICONTROL BI
For EC5000 24 V, 48 V
20 W, 35 W, 50 W, with bus interface (CANopen)

Functions

·
·
·
·
·
·
·
·
·
·
·

Controls·

Easy handling – One control card for PROFINET, EtherNet/IP and EtherCat (simple toggling of bus protocols)
Independent power supply for RollerDrive
Plug & Play in case of replacements – no addressing or configuration required
Status display with LEDs for all functions and I/Os
Integrated logic for zero-pressure accumulation conveying incl. initialization
Secure communication with the use of certificates: PROFINET Conformance Class B, EtherNet/IP ODVA Conformance, EtherCat
Conformance
Configuration via PLC, web browser menu and via teach-In method of:– Speed, direction of rotation, start and stop ramp of RollerDrive– Sensor properties– Timer– Error handling– Logic (single/train release)
UL-listed
Voltage limitation via brake chopper
Variable process images for optimizing the data volumes transferred between MultiControl and PLC
Functional ground connection for shield of communication line
Polarity reversal protection of voltage supply
Short circuit-proof design of voltage supply of inputs and outputs
Precise error diagnostics of EC5000 – Analysis via web browser menu and PLC
Automatic addressing of all connected EC5000s
Test operation without previous configuration or connection of a PLC
Positioning the connected EC5000 together with a PLC
Analysis of various RollerDrive data via web browser menu and PLC:
– Operating hours– Throughput– Temperature of EC5000– System status indicators– Life cycle indicator (allows preventive maintenance, resulting in increased availability)

Switching power supplies

·
·
·
·
·
·

Function of a PLC

Function of MultiControl

No• None• Implementation of ZPA logic• Visualization of EC5000 data

Yes

• Influencing the ZPA logic• Tracking of conveying goods• Error diagnostics• Implementation of ZPA logic• Implementation of PLC specifications

Yes• The PLC must be programmed and controls all connected
RollerDrive via this program• Tracking of conveying goods and error diagnostics• Specification of target position in positioning mode

• Function as input/output card
• Transmits the status of all sensors, RollerDrive and, if
necessary, error information to the PLC

Planning basics

Use of a PLC

Accessories

Possible applications© 06 | 2020 Interroll

49

CONTROLS
MULTICONTROL BI
For EC5000 24 V, 48 V
20 W, 35 W, 50 W, with bus interface (CANopen)

24V

48V

Technical data
Electrical data
Rated voltage

24 or 48 V DC

Voltage range

24 V DC: 22 to 28 V DC 48 V DC: 44 to 56 V DC (voltage supply of RollerDrive only)

Current consumption

Logic supply voltage:
MultiControl: max. 0.2 A + connected sensors/actuators = max. 1.6 A+ current of RollerDrive EC5000*

Fuses– For logic– For RollerDrive– For sensors and I/Os, can be reset

Protection rate

IP54

20W
35W
50W

AI
Ambient conditions
Ambient temperature in operation–22 to 104 °F

Ambient temperature during transportand storage–40 to 176 °F

Max. installation height above sea level3280 ft*** The power of EC5000 depends on the application, e.g., conveying good weight, conveying speed, acceleration ramp, and on the EC5000 used (refer to thecorresponding chapter).
** The installation in systems at an altitude above 3280 ft is possible. However, this can lead to a reduction of the performance values.

Dimensions
MultiControl

2.76“

BI

1.69“

50

0.45“

7.28“

0.45“

© 06 | 2020 Interroll

RollerDrive EC5000

CONTROLS
MULTICONTROL BI
For EC5000 24 V, 48 V
20 W, 35 W, 50 W, with bus interface (CANopen)

Base plate
6.42“
5.95“
0.59“

3.54“

0.59“

Controls

2.36“

1.28“

1.28“

To be able to position the magnetic key, the distance from the top edge of MultiControl to adjacent components must be at least 0.4".

Accessories
Flat cable for voltage supply, page 62
Magnetic key, page 65
MultiControl dummy plug, page 64
RollerDrive EC5000 extension cable, page 62
MultiControl communication cable, page 63
MultiControl Y-cable, page 63
Switching power supply HP5424, page 52
Switching power supply HP5448, page 56
Cable distribution, page 63
Shield connection cable, page 64

Accessories

·
·
·
·
·
·
·
·
·
·

Switching power supplies

6“
0.2
Ø

.26
“
Ø0

Ø

0.2
6“

1.02“

0.26“

0.16“

2.76“

0.26“

Ordering information

Planning basics· Article number: S-1103564· Scope of supply: Base plate© 06 | 2020 Interroll

51

SWITCHING POWER SUPPLIESSWITCHING POWER SUPPLY HP5424

24V

48V

20W

Application area
Voltage supply of MultiControl orConveyorControl system via flat
cable. Voltage supply of
DriveControl or ZoneControl via
round cable. Basic voltage supplyof 24-V DC products.

Product description
The Interroll switching power supply HP5424 is a three-phase power supply for providing 24-V
DC voltage. The robust housing achieves a protection rating of IP54. This allows placement in theimmediate vicinity of the products to be supplied with 24 V DC, such as Interroll MultiControl.
The central voltage supply saves costs for control cabinets and allows very short lines which, inturn, lead to cost savings and error reduction with respect to voltage drops on the line.
The HP5424 is immediately operational, all required functions, such as circuit protection or
maintenance switches, are already present. Given its high level of overload capability, the power
supply is perfectly adjusted to the current requirements of the RollerDrive EC5000. This ensures
the power supply of several RollerDrive starting at the same time.

35W
50W

Properties· No installation in switch cabinet required· Compact design using heat dissipation element· Very high peak output (150 %)· Adjustable circuit protection (jumper)· Overcurrent protection with resettable fuse
· Status signal· LED status display· 400 V AC can be looped through· 4 24-V DC outputs are available· Multiple terminal points, no special and expensive connectors required· Brake chopper for limiting feedback voltage – resulting in feedback capability· Lockable maintenance switch against reactivation· Screw for connecting/disconnecting ground potential of primary side with ground of
secondary side
· Maintenance-free· No power reduction (derating) over the entire operating temperature range

AI
BI

52

© 06 | 2020 Interroll

RollerDrive EC5000

SWITCHING POWER SUPPLIESSWITCHING POWER SUPPLY HP5424

Technical data

400 V AC, 3 phases

Supply system voltage range

380 to 480 V AC ± 10 %Supply system frequency

50 to 60 Hz ± 6 %Supply system power consumption

Typically 1.6 A per phase at 3 x 400 V AC

Rated output voltage

24 V DC

Rated output power

960 W

Rated peak power

Max. 1440 W at 24 V DC for 4 s,
repetition rate depends on duration and actual peak load

Maximum output current

60 A at 24 V DC for 4 s

Current limitation for each output

10, 16, 25 A

Efficiency

Min. 92 %Feedback resistance≤ 35 V DC

Brake chopper

30 W (briefly 200 W)

Switching power supplies

Rated supply voltage

Controls

Electrical data

Ambient conditions
Protection rate

IP54

Ambient temperature in operation–22 to 104 °F

Ambient temperature during transportand storage–40 to 176 °F

Max. installation height above sea level3280 ft*

Weight

9 lbs

Color

RAL9005 (black)

Accessories

Miscellaneous data

Planning basics* The installation in systems at an altitude above 3280 ft is possible. However, this can lead to a reduction of the performance values.

© 06 | 2020 Interroll

53

SWITCHING POWER SUPPLIESSWITCHING POWER SUPPLY HP5424

24V

Dimensions

48V

8.23“

1.84“

12.17“

9.06“

50W

SW24
10.95“

SW29

1.97“

35W

1.16“ 1.4“ 1.68“

20W

SW15

AI

5.51“

6.3“

Ø
0.
4

“

BI

10“

Accessories
Set of rubber seals for all cable screw connections· 24-V DC output for one flat cable, article number: S-1115406· 24-V DC output for two flat cables, article number: S-1115407· 24-V DC output for a round cable (ø 0.19" up to 0.51”), article number: S-1115405

Scope of delivery· Fit all cable screw connections (in the screwed-on condition) with dummy plugs. Jumper for current limitation of all cables.

54© 06 | 2020 Interroll

Planning basics

Accessories

Switching power supplies

Controls

RollerDrive EC5000

SWITCHING POWER SUPPLIESSWITCHING POWER SUPPLY HP5424© 06 | 2020 Interroll

55

SWITCHING POWER SUPPLIESSWITCHING POWER SUPPLY HP5448

24V

48V

20W

Application area
Voltage supply of MultiControl via
flat cable. Voltage supply of
DriveControl via round cable. Basic
voltage supply of 48-V DC
products.

Product description
The Interroll switching power supply HP5448 is a three-phase power supply for providing 48-V
DC voltage. The robust housing achieves a protection rating of IP54. This allows placement in theimmediate vicinity of the products to be supplied with 48 V DC, such as Interroll MultiControl.
The central voltage supply saves costs for control cabinets and allows very short lines which, inturn, lead to cost savings and error reduction with respect to voltage drops on the line.
The HP5448 is immediately operational, all required functions, such as circuit protection or
maintenance switches, are already present. Given its high level of overload capability, the power
supply is perfectly adjusted to the current requirements of the RollerDrive EC5000. This ensures
the power supply of several RollerDrive starting at the same time.

35W
50W

Properties· No installation in switch cabinet required· Compact design using heat dissipation element· Very high peak output (150 %)· Adjustable circuit protection (jumper)· Overcurrent protection with resettable fuse
· Status signal· LED status display· 400 V AC can be looped through· 2 48-V DC outputs are available· Multiple terminal points, no special and expensive connectors required· Brake chopper for limiting feedback voltage – resulting in feedback capability· Lockable maintenance switch against reactivation· Screw for connecting/disconnecting ground potential of primary side with ground of
secondary side
· Maintenance-free· No power reduction (derating) over the entire operating temperature range

AI
BI

56

© 06 | 2020 Interroll

RollerDrive EC5000

SWITCHING POWER SUPPLIESSWITCHING POWER SUPPLY HP5448

Technical data

400 V AC, 3 phases

Supply system voltage range

380 to 480 V AC ± 10 %Supply system frequency

50 to 60 Hz ± 6 %Supply system power consumption

Typically 1.6 A per phase at 3 x 400 V AC

Rated output voltage

48 V DC

Rated output power

960 W

Rated peak power

Max. 1440 W at 48 V DC for 4 s,
repetition rate depends on duration and actual peak load

Maximum output current

30 A at 48 V DC for 4 s

Current limitation for each output

10, 16, 20 A

Efficiency

Min. 92 %Feedback resistance≤ 60 V DC

Brake chopper

30 W (briefly 200 W)

Switching power supplies

Rated supply voltage

Controls

Electrical data

Ambient conditions
Protection rate

IP54

Ambient temperature in operation–22 to 104 °F

Ambient temperature during transportand storage–40 to 176 °F

Max. installation height above sea level3280 ft*

Weight

9 lbs

Color

RAL9005 (black)

Accessories

Miscellaneous data

Planning basics* The installation in systems at an altitude above 3280 ft is possible. However, this can lead to a reduction of the performance values.

© 06 | 2020 Interroll

57

SWITCHING POWER SUPPLIESSWITCHING POWER SUPPLY HP5448

24V

Dimensions

48V

8.23“

1.84“

SW15

AI

12.17“

9.06“

50W

SW24

10.95“

SW29

1.97“

35W

1.16“ 1.4“ 1.68“

20W

5.51“

6.3“

Ø

0.
4

“

BI

10“

Accessories· Set of rubber seals for all cable screw connections– 48-V DC output for one flat cable, article number: S-1115406– 48-V DC output for two flat cables, article number: S-1115407– 48-V DC output for a round cable (ø 0.19" up to 0.51”), article number: S-1115405

Scope of delivery· Fit all cable screw connections (in the screwed-on condition) with dummy plugs. Jumper for current limitation of all cables.

58© 06 | 2020 Interroll

Planning basics

Accessories

Switching power supplies

Controls

RollerDrive EC5000

SWITCHING POWER SUPPLIESSWITCHING POWER SUPPLY HP5448© 06 | 2020 Interroll

59

ACCESSORIESPolyVee belt

Product description· Elastic standard belt, 1 to 3 % pretension, for fixed shaft
distances· Significantly longer service life than round belts· Up to 300 % higher torque transmission than with comparable
round belts· Much better efficiency compared to toothed belts since muchless flexing work is required· Curve application: Use of 2-rib or 3-rib belts· Suitable for normal and deep freeze temperatures· Belts are antistaticTechnical data

A PolyVee belt is used for the drive from roller to roller orRollerDrive for straight sections and for curves.

· Temperature range: –22 to 104 °F (in operation)· Color: Black· Belt acc. to Type PJ; ISO 9982; DIN 7867

Design versions
Number of ribs

Roller pitches ±0.04"

Max. weight of conveying
good
[lbs]

Article number

2

3"

110

S-1001109

3

3"

660

S-1001113

Material specification
Standards

ISO 9982 (DIN 7867) PJ profile for 2-rib and 3-rib V-ribbed belts (PolyVee)

Material

Complies with the Directive 2011/65/EC (RoHS)
Contains only materials, which have been tested and registered to comply with the
REACH Directive (EC No. 1907/2006)
Silicon-free, PVC-free, flame-resistant

Hardness

Ribs 70 Shore A

Electrical conductivity< 7 MΩ (antistatic)

Temperature range–22 to 176 °F (transport and storage)

Dimensions

In accordance with ISO 9982 (DIN 7867), profile PJ

Please contact the relevant manufacturer for information on otherdrives.

60© 06 | 2020 Interroll

RollerDrive EC5000ACCESSORIES

Controls

Fastening socket

The fastening socket is used for tightening according to thetorque of the RollerDrive fastening nut using a torque wrench.
The socket features a lateral opening through which theRollerDrive connecting cable can be fed to the outside.

Switching power supplies

Article number: S-1101248

85 3

14

12

34

17

12.7 (1/2")

Dimensions

Accessories

Ø 23.5 2

Planning basics

Note: Measurements in mm.

© 06 | 2020 Interroll

61

ACCESSORIESCounter wrench

RollerDrive EC5000 extension cable

The connecting cable of the EC5000 can be extended easily witha plug connection by using the RollerDrive extension cable.
The RollerDrive has a glued-on ribbed nut that is located at thebearing housing. An additional nut is used to screw theRollerDrive in the side profile. Depending on the condition of theside profile, the glued-on nut must be secured with a counter
wrench while tightening the outside nut.
The counter wrench size 17 WAF fits perfectly between theflange of the ribbed nut and the bearing housing of theRollerDrive.
Article number: S-1101270
Dimensions

4

A-A ( 1 : 1 )Technical data
·
·
·
·
·
·
·
·
·
·

Temperature range: –22 to 104 °F
Color: Black
Length: 78.7"
Outside diameter: 0.2"
Plug connection: M8 snap-in plug and socket
Protection rate: IP67 in connected state
Cross sections: 3 x 0.14 mm² and 2 x 0.5 mm²Type designation of the cable: Li9Y11Y
Bending radius with fixed laying: > 5 * diameter of the cable
Bending radius with flexible application: > 10 * diameter of thecable· Properties: Halogen-free, UL-certified cable· Suitable for drag chains: Yes

1.5

12

Article number: S-1113897

A
A

17.5
24.5

Voltage supply flat cable

Note: Measurements in mm.

The flat cable is used for the voltage supply of ConveyorControl
and MultiControl. The outer contour of the line corresponds tothe standard of AS interface. The shell of the line covers holesthat were created by piercing contacts. This means that the cablemaintains the protection rating even after disconnecting a control.

62© 06 | 2020 Interroll

Article number: S-1004030

Technical data

Technical data
·
·
·
·
·
·
·
·

RollerDrive EC5000ACCESSORIES

Temperature range: –18 to 104 °F
Strand insulation: Brown for voltage, blue for ground
Length: 164 ft
Cross section of braids: 2.5 mm²Maximum voltage: 60 V DC
Protection rate: IP54 in contacted state
Halogen-free

·
·
·
·
·
·
·
·

Temperature range: –22 to 104 °F
Color: Green
Length: 118"
Outside diameter: 0.26"
Plug connection: M12, straight on M12, straightProtection rate: IP67 in contacted state
Line: Cat5, shielded
UL1581

MultiControl Y-cable
Controls

Dimensions

3.6
The Y-cable with M8 plugs enables the use of an additional input
or output at the MultiControl.

6.5
9Article number: S-1104460

Switching power supplies

4

2

10

Note: Measurements in mm.

MultiControl communication cable

·
·
·
·
·

Temperature range: –22 to 104 °F
Color: Black
Length: 11.81" (+ plug)
Outside diameter: 0.2"
Plug connection with single connector: M8, straight, screwed, 4pin, for connecting to a MultiControl· Plug connection with dual connector: A) M8, straight, screwed,
4-pin, for connecting to a zone sensorB) M8, straight, screwed, 4-pin, for connecting to an input or
output· Protection rate: IP67 in contacted state

Accessories

Technical data

The prefabricated Ethernet cable is used for communication with
MultiControl. The cable allows connecting one MultiControl withanother MultiControl, another bus node, a switch or a PLC.
Article number: S-1104438© 06 | 2020 Interroll

The cable distribution allows splitting a flat cable. MultiControl in
its initial design (article number S-1101834) allowed connecting asecond flat cable as an option for the voltage supply of
connected RollerDrive. MultiControl in its new design (article
number S-1103563) requires two voltage supplies in principle. If
the new design of MultiControl is to be used as spare part in asystem that features only flat cables for voltage supply, the cabledistribution can be used.

63

Planning basics

Cable distribution

ACCESSORIESThe cable distribution includes two end caps for left and rightdesign to protect the cable ends and to maintain the system
protection rating of IP54.

such cases, then it is necessary to close the open connections. The
dummy plug package contains as many plugs as needed if theMultiControl has only the minimum connections.

Article number: S-1115717

Article number: S-1104466

Dimensions

21

Dummy plug package

18.3

MultiControl
connection

Dummy plug
size

Use

Dummy plugs
included

RollerDrive

M8

Insert3

Sensor or I/O

M8

Screws3

Communication

M12

Screws1

14.5
The dummy plugs are delivered prefabricated for the requiredconnections.

48.4
2.7

29.5

10

4.3

Technical data

Note: Measurements in mm.

Shield connection cable
To reduce the risk of interference effects on the communicationline of MultiControl, the shield of the cable can be grounded.
Both sides of the MultiControl feature a contact that is connectedwith the shield of the respective communication cable. The shieldconnection cable can be used to connect the contact withfunctional ground or to connect the two contacts of MultiControl
with each other. The shield connection cable is 13" long andfeatures a cable lug at each end. The cable lugs allow connecting
the cable to one or both contacts of the MultiControl. The
required screws and toothed washers are part of the scope ofdelivery.
Article number: S-1113876

MultiControl dummy plug

· Temperature range: –22 to 104 °F· Color: Black

Sealing insert for switching power supplies
The Interroll switching power supplies feature different cablegrommets sealed with dummy plugs. Three different sets ofsealing inserts are available for the line connection. For line
connection, they ensure maintaining protection rating IP54 andproviding cable relief.
Design versions
Three different sets of sealing inserts are available:
Set 1

Set 2

Set 3

400-VACconnections

2 pieces M25 sealing inserts for round cableø0.31" to 0.67”

Error
connection

1 piece M12 sealing insert for round cableø0.08" to 0.2”

24/48-VDC
connections

2 pieces M20
sealing inserts
for round cableø0.2" to 0.51”

2 pieces M20
sealing inserts
for a flat cable2 pieces M20
sealing inserts
for two flat
cables

Article number

S-1115405

S-1115406

S-1115407

Every power supply is delivered with a matching set. The sets canalso be ordered individually.

The MultiControl features 4 RollerDrive, 2 communication and 4
sensor or I/O connections. If all connections are occupied, thenthe MultiControl has a protection rating of IP54. Based on theapplication, it is also possible that not all connections areoccupied. If the protection rating of IP54 is to be maintained in

64© 06 | 2020 Interroll

RollerDrive EC5000ACCESSORIES

Cable bridge for flat cable
The cable bridge allows electrically combining two flat cables andchanging the position of one flat cable. The ends of both flat
cables have to point in the same direction.

Controls

Article number: S-1004028

Conveyor
SegmentControl or ComControl
Cable bridge
Obstacle (wall, column or similar)

Switching power supplies

1
2
3
4

Technical data
· Temperature range: –22 to 104 °F· Protection rate: IP54
· Suitable for the communication cable of the ConveyorControl
system· Suitable for the voltage line of the ConveyorControl system or
the MultiControl: can be loaded up to 6 A

Planning basics

Accessories

Magnetic key

The magnetic key with a high-quality neodyme magnet offers
many functions. For the MultiControl, it enables switching the bus
protocol or the use of the Teach-In method. For theConveyorControl, it enables addressing or, for example,
performing a self-test.
Article number: S-64100210© 06 | 2020 Interroll

65

PLANNING BASICS
CONVEYING GOOD

Conveying good
This chapter is intended to provide support in the planning of
conveyor systems and the selection of matching products.
The properties of the conveying good, the requirements withregards the conveyor system and the ambient conditions are thebasis for the planning of the system.

Length and width of conveying good

· Minimize the roller pitch as much as possible to ensure that the
products are conveyed smoothly with as large a base surface
as possible.
· Avoid rapid acceleration and harsh braking. Use MultiControl
or ConveyorControl as far as possible for controlling EC5000.
These control systems allow for purposeful matching ofacceleration and deceleration of the RollerDrive.
· With inclined conveyor tracks, determine the center of gravityof the conveying good and check whether there is a risk of it
tipping.

The length and width of the conveying good have an effect onseveral factors:

Weight and weight distribution of the conveying
goodStraight running: The higher the ratio of length to width, themore stable will be the straight running of your items. With
smaller length to width ratios, it may be necessary to put in place
additional measures to stabilize the straight running of theconveying goods.

The weight of the conveying good must be distributed on anumber of conveyor rollers so that the maximum load capacity of
the individual conveyor roller and RollerDrive is not exceeded.
This may mean that more than three conveyor rollers must
support the conveying good.

Reference length: As a rule, the reference length corresponds tothe conveyor width +1.97" or for large conveying goods, such as
pallets, +3.94". In curves, Interroll recommends the use oftapered conveyor rollers and RollerDrive whose length must be
calculated separately (see Curve dimensioning).

In principle the weight of the conveying good should be
distributed as evenly as possible. The more uneven the weight
distribution is, the more difficult a reliable conveyance is.

Roller pitch: To transport the conveying good without problems,
the roller pitch must be selected so that the conveying good is
carried by three conveyor rollers at any given time.
Surface pressure: The different Interroll conveyor rollers andRollerDrive can be loaded with different forces. The static load
capacity can be taken from the respective chapter. The values
are based on the assumption that a conveying good rests on thecomplete usable tube length and not just on a part of it. If aconveying good has contact with less than approx. 50 % of theusable tube length, please have the application checked byInterroll beforehand.
Very long conveying goods generally do not rest on all conveyor
rollers and RollerDrive that are located under them. If, forexample, 20 conveyor rollers are under a piece of conveying
good, but the conveying good contacts only 15 conveyor rollers,then the load capacity of a roller must be greater than onefifteenth of the conveying good weight. For very long conveying
goods, the tolerance of the roller fastening height for conveyor
rollers and RollerDrive should be kept as low as possible so thatas many conveyor rollers as possible can carry the conveying
good.

Height of conveying good
The greater the height of the conveying good in relation to its
bottom area, the higher is the risk of it tipping over whentraveling on the conveyor. The following must be taken into
consideration:

66

If the weight of the goods is mostly at the front, then it is very
likely that the rollers at the end of the load carrier support only
very little weight. In the worst case scenario, the rollers at thestart of the load carrier could be overloaded.
The load capacity increases with larger tube diameter. For heavy
conveying goods, RollerDrive with a diameter of 2.36" should be
used instead. The load capacity is increased by rollers withthreaded shafts. In addition, the shafts reinforce the conveyor
and act as a cross tie.
Drive elements, such as round belts or toothed belts, must also be
selected while taking the conveying good weight into
consideration. Interroll recommends PolyVee belts for conveying
containers and cardboard cartons. Their service life and torquetransmission is significantly higher compared to round belts.

Material of conveying good
The material, and especially the condition of the base, has aneffect on the rolling and starting resistance.
Hard materials, such as polymer containers, feature lower rollingand starting resistances than soft materials, such as cardboard
cartons. This has a direct impact on the required drive output andmust be included in its calculation. The softer the underside of theconveying good, the higher is the drive output required for a
product with the same weight but with a hard underside. In
principle, the softer the conveying good, the smaller the roller
pitch needs to be.

© 06 | 2020 Interroll

RollerDrive EC5000

PLANNING BASICS
CONVEYOR REQUIREMENTS

Conveyor requirements
The following fundamental parameters determine theconfiguration of the conveyor:

13%

24%

13%

The topic of environmental conditions is discussed below.

Static charging
In principle, conveyance via rollers creates electrostatic charging
which, among other things, depends on the properties of theconveying good and the tube material.
To prevent electrostatic charging from occurring or dissipate it
immediately and without creating sparks, Interroll offers antistatic
versions for rollers with steel tube. RollerDrive feature anantistatic design in principle. Sleeves, lagging and gray tapered
elements do not feature an antistatic design. For this reason,
Interroll recommends the use of black tapered elements forcurves.
Antistatic conveyor rollers and RollerDrive require the proper
manufacturing and check of the conducting connection between
shaft and side profile and the grounding of the side profile by thesystem manufacturer.

Controls

When checking whether a roller has sufficient load capacity for
an application, it is important to take the condition of theconveying good into consideration. Conveying goods with anuneven bottom generally do not rest on all rollers that arelocated under them. With pallets, it must be ensured that only therollers under the bulk of the pallet are actually bearing the load.
The following diagram shows which runner load distribution
occurs for an evenly loaded euro-pallet.

Maximum throughput per time unit
Geometry of conveying good
Weight and weight distribution of the conveying goodControl requirements
Environmental conditions

Switching power supplies

Ribs, keyways, strips or grooves in the bottom of conveying goods
that run parallel to the direction of conveyance, do not pose a
problem concerning transportability. The required drive output
increases depending on their shape. Cross ribs can negatively
impact the transporting. It may be necessary to determine theroller pitch empirically.

·
·
·
·
·

Noise level
13%

Fig.: Support of 2 runners

8%

12%

8%

12%

20%

12%

8%

12%

8%

Fig.: Support of 3 runners© 06 | 2020 Interroll

Noise is created by different components of a conveyor and theconveying good itself.
Every drive creates noise. The RollerDrive is designed withdecoupling elements which reduce the noise of the gear box. In
most cases, the noise level of the RollerDrive is below 50 dBA.
More and more zero-pressure accumulation conveyor systems
are converted from pneumatic solutions with a centrally arranged
drive to a RollerDrive solution. The significantly lower noise levelis a deciding factor here.
The following applies to the noises of drive elements: A chain
drive causes more noise than a belt drive. At high accelerations
and decelerations, slipping round belts can cause squealing
noises. Interroll recommends reducing the acceleration anddeceleration of RollerDrive or using PolyVee belts. In this case, therisk of squealing noises is greatly minimized.
Very quiet rollers, RollerDrive and drive elements are of little use
if the conveying good on the conveyor creates noise. Various
measures can counteract it. The following should be observed inthis case:67

Accessories

24%

Planning basics

13%

PLANNING BASICS
DRIVE CONCEPTS· A small roller pitch generally causes less noise than a large
roller pitch.
· Keep height tolerances at transitions from conveyors and at thefastening of rollers/RollerDrive as small as possible.
· Fitting the rollers/RollerDrive with noise-reducing materials, e.g.
with a PVC or PU sleeve· Use of noise reduction inside of rollers for rollers with adiameter of 1.97".

Humidity
Humidity can occur in different forms as a result of the following:· moist conveying goods, e.g. bottle crates stored in the rain
· moist environment, e.g. sculleries· applications that become moist, e.g. because of cleaning or
tripped sprinkler systems
If humidity can be expected in a system, then all components
should be checked for corresponding resistance.
Interroll offers a series of products that are suitable forapplications with humidity, water exposure, or water jets:
Tube material: Rollers and RollerDrive can be manufactured
from rust-free material, such as stainless steel. In addition,materials can be protected with different finishing processes, suchas zinc-plating.
Shaft material: Shafts for conveyor rollers can be manufactured
from rust-free material, such as stainless steel.
Drives: The RollerDrive already has a high degree of protection
with protection rating of IP54. If water jets can be expected in theapplication, Interroll recommends the design with protection
rating IP66.
Bearing: All rollers with precision ball bearings are well
protected against moisture and dust. For systems with constanthumidity or moisture, Interroll offers designs with stainless steel
ball bearings.

Applications in deep freeze area
Applications with an ambient temperature of approx. –18 °F areparticularly prevalent in the food processing sector. Many items
must be taken into account in the so-called deep freeze area:· Changed starting torque of conveyor rollers and drives.
· Increased viscosity of greases, e.g. in ball bearings or gearboxes.
· Possibly frozen and, therefore, less flexible components, such as
drive elements.
· Functional safety of all components through different
contraction of various materials.

68

The solutions from Interroll
Materials: For various products, Interroll offers variants that are
particularly suited for deep freeze applications. The tapered
elements for conveyor rollers and RollerDrive are manufactured
impact-resistant. Conventional materials used are often brittle
and break easily. The bearing housings of series 1700 are
designed as high impact-resistant for deep freeze applications.
Drives: The RollerDrive EC5000 is available in a deep freeze
design (starting with Series EC5000). The special design with oiledball bearing offers a restart for many gear stages, even after
extended downtime.
Drive elements: Before using a drive element, its suitability fordeep freeze applications should be checked. It should also beensured that the friction at temperatures below zero is sufficientand the drive elements cannot freeze since frozen drive elements
could pose unplanned torque requirements for the drive. The
PolyVee belts offered by Interroll are suitable for deep freeze
application (see page 60).
Bearing: The precision ball bearings used also work in deep
freeze conditions. However, the startup of the roller is higher inthis case than at an ambient temperature of 68 °F. RollerDriveare either designed for this higher startup, or oiled ball bearings
are being used. The oiled bearings run significantly smoother attemperatures below zero.
Under deep freeze conditions, materials such as steel andpolymer contract in different ways. For functional reliability, a
PolyVee drive head for a RollerDrive is not only pressed into thesteel tube, but it is also flanged. Additional security is provided bya metal star. This star, which is being produced with laser cutting,is engaged in the drive head and channels itself into the insidewall of the tube. This innovative solution inside the tube allows
avoiding interfering edges on the outside contour of the tube.
This solution is available as an option for various designs series
3500 and 3500KXO.

Drive concepts
With respect to drives, Interroll distinguishes between drives (suchas round belts, PolyVee belts, chains, etc.) and the actual drive.
Different drives are used in conveyor systems, such as drum
motors, gear motors, motor rollers, etc. Furthermore, the potential
energy of conveying good, e.g. on gravity conveyors, is also
being utilized.

Gravity conveyors
A gravity conveyor differs significantly from the other concepts. It
is not horizontally aligned, but always mounted at an incline.
There are driven and non-driven gravity conveyors. Driven
gravity conveyors can be driven with RollerDrive. If theRollerDrive and, as such, the conveyor is stopped, the conveying© 06 | 2020 Interroll

On the one hand, the conveying good must reach the end of theconveyor. It must not stop because its weight is too low to startmoving rollers at rest. If many conveying goods are already on a
gravity conveyor and, as a result, a piece of conveying goodstops in the last section of the conveyor, then it must be ensured
that the last item will start again and reach the end of the gravity
conveyor after the first conveying goods have been conveyed.
On the other hand, the speed of the conveying goods must not
be or get too high. There is the risk that a conveying good hits
another jammed conveying good or the end stop at the end of
the conveyor. This creates an injury risk for employees who may
want to remove the conveying good by hand, as well as the riskof damaging the conveying good.
Establishing the matching properties of a gravity conveyor
becomes a challenge if different conveying goods have to be
moved. Generally, the conveying goods on a gravity conveyor
differ by at least one of the following properties: Weight, size,
material and base condition. A mixture of different conveying
goods can also be transported by a gravity conveyor withrespect to personnel and conveying good safety as well asprocess reliability. Interroll offers different products for thispurpose. The rollers of series 1100 are designed for use ingravity conveyors.
The magnetic speed controller MSC 50 enables the restart ofconveying goods starting at 1.1 lbs and reliably decelerates
conveying goods up to 77 lbs depending on the properties of theconveyor. If conveying goods are lighter than 1.1 lbs or heavier
than 77 lbs, it is also possible to use the RollerDrive series
EC5000.

© 06 | 2020 Interroll

Controls

In principle, it is recommended to test every gravity conveyor
design under original conditions.

Fixed drive conveyor
If a conveying good moves in harmony with the drive, then it isgenerally a fixed or constantly driven conveyor. The drive headof the rollers used is permanently connected with the tube. If the
fixed drive heads are replaced with friction drive heads, theycreate a friction conveyor. Many different types of fixed drive
conveyors are possible. They generally differ with respect to theselected drive element, such as chains, PolyVee belts, round belts,
etc., and the drives used.
For all current fixed drive conveyors, Interroll offers matching
conveyor rollers, with the RollerDrive EC5000, the Pallet Drive
and PolyVee belt even drives and drive elements. When using aRollerDrive as drive, it is recommended to place it in the middle ofthe driven conveyor rollers (for information about the Pallet
Drive, see the separate product documents). If many rollers haveto be driven, then PolyVee belts offer advantages over roundbelts. The use of PolyVee belts reduces the number of roller
revolutions with increasing distance to the RollerDrive.

Zero pressure accumulation conveyor
The zero pressure accumulation conveying is often abbreviatedas ZPA. A ZPA conveyor is generally divided into zones. The zone
length is based on the length of the conveying good or the
longest conveying good. Each zone features an option ofidentifying conveying goods, e.g. via a photo cell. In addition,
every zone can be switched on and off. The zones are driven indifferent ways, see the examples below.
One option consists of a central drive, often a gear motor, thatdrives a flat belt. The flat belt is pressed onto the rollers using aswitchable unit or guided past them. In the case of bypassing, therollers are also often decelerated. It is feasible that the flat belt ispressed onto only a few rollers of a zone and the remaining
rollers are connected with them by means of other drive69

Switching power supplies· The incline of the conveyor· The already existing speed of a conveying good when placed
upon the gravity conveyor· The ease of movement of the rollers· The conveyor length· The condition of the underside of a conveying good
· The weight of the conveying good
· Other properties

Accessories

The conveying good rolls without additional drive as a result of
the potential energy up to the end of the conveyor or up to thepreceding conveying good. The speed and the restart capabilityof conveying goods is heavily influenced by:

The driven RollerDrive ensures that every lightweight conveying
good, regardless of its weight, can be moved or moved again.
When decelerating heavy conveying goods, the energy
recovered by the RollerDrive must not be too high. If one orseveral RollerDrive are used within a gravity conveyor, it also
provides the advantage of accumulation pressure reduction. If a
RollerDrive, which may be connected with additional rollers via
drive elements, is stopped, then the conveying goods stop. This
allows reducing the pressure on conveying goods that are
already on the conveyor or on the stop at the end of theconveyor. On long gravity conveyors, it may be advisable to use
several RollerDrive in order to reduce the accumulation pressure
even further. If the incline is so high that conveying goods slide
over the steel tube of stopped RollerDrive or rollers, then thefriction may be increased with a PVC sleeve on the tube.

Planning basics

goods remain in place and do not slide downward. The EC5000
holds its position with a certain torque which prevents any
downward sliding. The different gear boxes and powers offerdifferent continuous blocking torques. It must be ensured thatconveying goods do not slide over standing rollers; if necessary,
friction must be increased, e.g. with PVC sleeve on rollers and RD.
Gravity conveyors use the potential energy of conveying goods.
This means that other technology must first move the conveying
good to a corresponding spatial height.

RollerDrive EC5000

PLANNING BASICS
DRIVE CONCEPTS

PLANNING BASICS
DRIVE ELEMENTS

elements. In many cases, this switching unit consists of pneumatic
valves. They frequently cause an undesired noise level. A highlevel of energy can be expected for this ZPA solution since thepowerful gear motor must also be powered if, for example, only
one conveying good has to be moved on a 40-zone section.
Another option always presses the flat belt against a section of aroller in every zone. The remaining portion of the roller isswitched in or out via a coupling. The remaining rollers of every
zone are connected with the driven roller via other drive
elements.
Another concept is the use of decentral drives. Motor rollers areoften used for this purpose. In this case, drives which are directly
driving the respective rollers, are installed in one or several
rollers of a zone. A drive element connecting the entire conveyor
is redundant. The remaining rollers of a zone are generally
connected with the motor roller(s) using PolyVee or round belts.
The zones can be activated or deactivated by purposefully
switching the motor rollers on or off.
Depending on the length of the conveyor, the design with central
drive usually falls below the investment costs of a solution withmotor rollers. However, the operating costs tend to be higher due
to the constant turning of the drive, even when nothing may be
conveyed at the time. For most solutions with motor rollers, higher
investment costs are possibly amortized after a short time.
Not only the lower energy consumption speaks in favor of asolution with motor rollers, but also the compact design. The
motor is installed in a roller and does not have to be placed next
to or below the conveyor.
Compared to gear motors, motor rollers are maintenance-free,they do not have to be greased and generally offer a higher
safety level with a protected extra-low voltage.
But solutions with motor rollers can also have disadvantages. For
solutions with many motor rollers per zone, the availability
decreases – the more motors are being used, the higher the
probability that a motor roller fails.
For this reason, Interroll recommends the use of the RollerDrive
EC5000. In this case, one RollerDrive per zone is generally
sufficient, and flexible control concepts are available.
Furthermore, the controls offer many other options, such aschange of direction of rotation or start and stop ramps which are
not being offered by conventional ZPA conveyors.

Drive elements
With respect to drives, Interroll distinguishes between the actual
drive, such as RollerDrive, drum motor, Pallet Drive, gear motor,
etc. and the drive elements. Drive elements refers to different
types of the torque transmission. Only the following drive
elements are considered in this chapter:· Toothed belt
· PolyVee belt
· Round belt

Toothed belt
The share of toothed belts as drive element in roller conveyor
systems is declining. Toothed belts are generally used from roller
to roller and are unable to negotiate curves. Compared to roundor PolyVee belts, the power requirement of a toothed belt issignificantly higher because of its design. This must be taken into
account in the selection of the drive. Toothed belts pose a highdemand on the tolerance of the roller pitch since the toothengagement is form-fit with the profile of the drive head. Interroll
recommends obtaining the tolerances to be followed from the
manufacturer of the selected toothed belt.
One advantage of the toothed belt compared to round and
PolyVee belts, is the fact that it passes movements withoutslipping when used properly. On top of that, toothed belts are
low-noise and maintenance-free, lubricating or retensioning is not
required.
The drive length of a conveyor with toothed belt drive should be
dimensioned so that the overall load of 2697 lbs conveying goodbeing conveyed at the same time is not being exceeded.
For the roller series 3500 and the RollerDrive EC5000, a
maximum toothed belt width of 0.47" and a Poly-Chain GT
gearing is recommended.

PolyVee belt
PolyVee belts are ribbed V-belts that are generally used for thetorque transmission from roller to roller in roller conveyor
systems. The belts must feature a flexible tension member which
renders them significantly less flexible than most round belts.
Nevertheless, they can accept tolerances within the roller pitch
because of their flexibility and used as drive elements in curves.
For the installation of PolyVee belts, Interroll recommends the useof a PolyVee tensioning device.
Compared to round belts, PolyVee belts can transfer a higher
torque of up to 300 %, the service life is longer and, when usedproperly, a PolyVee belt does not slip over the drive head. In
start-stop operation, the rollers can be stopped more precisely
and, compared to round belts, a higher number of conveyor
rollers can be driven because of the high torque transmission.

70© 06 | 2020 Interroll

The round belt guides with the RollerDrive EC5000 can be
carried out via grooves in the tube or a round belt drive head.
The drive head made from polyamide offers the advantage thatthe round belts can be guided closer at the end of the RollerDriveor at the side profile of the conveyor. In this case, it is more likely
to separate torque transmission and running surface of conveying
goods. Furthermore, the concentric precision is increased since nomechanical change of the tube occurs compared to grooves inthe tube.
The round belt drive head offers a higher conveyance for mostbelts because of its material. This significant advantage must be
taken into account if acceleration and deceleration for start-stop
operation are so high that the belt briefly slips and wears out
because of it. The better the conveyance from the guide, thehigher the wear in this case. Groove solutions in tubes and also
the round belt drive head offer 0.39" wide grooves. This allows
using round belts with a maximum diameter of 0.23". In case ofhigher round belt diameters, there is the risk of two contact pointsof the round belt – at the bottom and at the side of the groove.
In this case, the belt is subjected to two different speeds andexperiences above average wear.

Controls

The diameter of the tapered rollers increases towards the
direction of the outside curve diameter. With the increasing
diameter, the circumferential speed increases. This allows
conveying goods to be transported through the curve without
losing their orientation. With the usual speeds (max. 157 fpm)
and ideal curve design, a side guide is not required.
Interroll offers different curve-capable rollers that feature thedesignation KXO. These are rollers with cylindrical steel tube onto
which tapered elements are pressed. Compared to conventional
curve rollers/curve motor rollers, the Interroll products are
additionally secured against shifting on the steel tube by meansof a form fit. This safety mechanism is not visible from the outside
so that no interfering edges are being created.

Installing the rollers/RollerDrive

For the curve construction, it must be taken into account that the
top side of the curve RollerDrive is level. Hence, the fastening
shaft is not horizontal. As a result, vertically arranged side
profiles do not have a 90° angle. For this reason, Interroll
recommends an angle compensation so that the fastening shaft
does not experience any warping. The EC3500 with protection
rating IP54 is exclusively available for installation in the curve.
The installation length of curved sections must be longer than thatof straight sections to ensure that the conveying good does nottouch the side guide in the curve. Please select the next larger
installation length grid.

Drive
The RollerDrive has established itself as the drive for poweredroller curves. It allows implementing a cost-efficient, compact andquiet curve. RollerDrive in conjunction with PolyVee belts as drive
element are the simplest solution for torque transmission in© 06 | 2020 Interroll

Switching power supplies

Round belts, also referred to as O-rings, are available in different
materials, colors and diameters. They are often used for thetorque transmission from roller to roller. Round belts are costeffective with respect to their purchase, are very flexible and canbe installed with ease. The disadvantage is a relatively poor
power transmission and relatively short service life. For thisreason, the use of PolyVee belts predominates in conveyor
systems.

It is possible to build roller curves with cylindrical rollers. With
such a design, conveying goods are not conveyed in the center ofthe curve, but alongside a required side guide. This requires moreenergy and it poses the risk of damage to the side guide orconveying good. For this reason, the design with tapered
conveyor rollers is recommended.

Accessories

Round belt

How to build a curve?

71

Planning basics

In container conveyor systems, 2-rib and 3-rib PolyVee belts are
generally used. Interroll offers PolyVee belts for these designs forthe most common roller pitches, see PolyVee belt. The 9-rib drive
head also allows using 4-rib belts. The ability of high torquetransmission also carries with it a high demand on safety. Injuries,
such as jammed fingers between PolyVee belt and drive head,must be avoided. Interroll offers a finger guard for the mostcommon roller pitches. It does not have to be fastened to the side
profile and, for this reason, can be used for almost all side
profiles.

Roller curves

1,8˚

Due to the design of the PolyVee drive head and the small widthof the belts, they can be placed very close to the side profile. This
leads to an optimal tube utilization for conveying goods. With thesmall diameter of the PolyVee drive head, any contact of PolyVeebelt and conveying good is generally ruled out.

RollerDrive EC5000

PLANNING BASICSROLLER CURVESPLANNING BASICSROLLER CURVES

curves. Such curves can be constructed and set up in an easy way– for constantly rotating as well as for curves for start-stop
operation.

PolyVee belt: For example, if a PolyVee belt is used in the curve
for a roller pitch of 2.95", then a hole pitch of 2.9" must beplanned at the inside radius. The roller pitch at the outside radius
can be calculated using the following formula:

Drive element
R
Po = Pi ∙ oPiRound belts and PolyVee belts are suitable as drive element.
Round belts can be guided via grooves which are located in thearea of a tube projection. As an alternative, round belts can also
be guided via a drive head at the inside radius.
PolyVee belts are exclusively guided via a drive head, also at theinside radius.
The most frequent solution is the PolyVee belt. For use in curves,
2-rib and 3-rib flexible belts are suitable. The belts must occupy
the first grooves from the direction of the inner curve radius. A
distance of one groove is required between the two belts.

Length of tapered elements
1.8° elements: The first tapered element has a length of 1.77"
or 3.74". All additional elements have a length of 3.94". The total
length of the tapered elements can be selected in increments of
1.97". The different lengths of the first tapered elements result in
2 different inside curve radii.
2.2° elements: The length of the first tapered is always 5.51".
Hence, the inner curve radius does not vary.

Radii
Different inside curve radii can be created with the different
tapered elements. A conveying good will be conveyed perfectly
through a curve only if the radii are being maintained.
Inside curve radii for RollerDrive with PolyVee or round belt
drive head
Inner curve radius

Conicity

Reference lengths

25.98"

2.2°

7.48", 9.44", 11.41",
13.38", 17.32", 21.25",
25.19", 29.13"

32.28"

1.8°

5.9", 9.84", 13.77",
17.71", 21.65", 25.59",
29.52", 33.46", 37.4"

30.31"

1.8°

7.87", 11.81", 15.75",
19.68", 23.62", 27.55",
31.5", 35.43", 39.36"

Roller pitch

Po
Pi
Ro

= Roller pitch on the outside diameter= Roller pitch on the inside diameter= Outside radius of the curveInterroll recommends an angle of 5° between two rollers. The
angle must not be greater than 5.5°.
Round belts: Any length can be used here. To ensure a sufficientdistance of the rollers,Interroll recommends not to plan more than
22 rollers in a 90° curve. This also applies to non-driven curves.

Number of rollers
The calculation or determination of the roller pitch and the angleof the roller curve result in the number of rollers to be used,which is not always an even number. In this case, the value must
be rounded up or down.
If a PolyVee belt is used in the curve for a roller pitch of 2.87"(based on a straight conveyor line), it results in an even roller
count for the following curve angles:

Angle

Number of rollers

30°

6

45°

9

90°

18

180°

36

Speed
For a conveying good to be conveyed perfectly through thecurve, the speed of the curve and the adjacent straight conveyor
lines must be identical. The curve speed refers to the average
speed, see the following sample calculation. If the speeds ofstraight and curve are different, the conveying good can loose its
orientation and, as a result, reach the side guide.
Sample calculation of average diameter
First, the average diameter of the tapered rollers is to be
calculated. When tapered elements with an angle of 1.8° and alength of 17.71" are used, the starting diameter is 2.19" and theending diameter 3.3", see page 19.

The roller pitch depends on the selected drive element.

72© 06 | 2020 Interroll

Let us assume that the straight section before and after the curveis equipped with 1.97" diameter rollers and runs at a speed of
157 fpm. The speed in the curve is to be of the same value andmust be converted to the average diameter of 2.74".

SRD =

SRD
SStrai.
ØØØStrai.

SStrai.
157 FPM· 1.97“ = 112 FPM∙ ØStrai. =
ØØ
2.74“

= Speed to be set of the RollerDrive= Required speed on the straight line
= Average diameter of tapered elements= Diameter of rollers on the straight line

Mechanical output power
The RollerDrive EC5000 is available in three power designs: 20,
35 and 50 W. It can be identified via the label imprint.
20W
Interroll recommends the cost-effective 20-W power stage forconveying empty containers or conveying good weights of no
more than 33 lbs.

Controls

Sample calculation of same speed

RollerDrive variant selection

35W
The allrounder of the power stages is the EC5000 with 35 W. It is
recommended to use this power stage for conveying goodweights of up to 110 lbs. This classic for zero pressure
accumulation conveyor systems is the perfect solution between
acceleration and cost effectiveness.

Interroll recommends using different gear stages for the straightline sections and curves. A gear stage of 30:1 would be ideal forthe calculated curve example. Based on a diameter of 1.97", amaximum speed of 118 fpm can be calculated. Based on anaverage diameter of 2.74", a RollerDrive with this gear box could
also be set to 157 fpm. For sections with cylindrical rollers andRollerDrive before and after the curve, a gear stage of 21:1
would present itself. In general, the gear stage 21:1 could also be
used in both parts of the system. The recommendation of the gearstage 30:1 for the curve is based on the fact that it has a higher
torque and a higher torque is often required in curves. In
principle, we recommend using the powerful 50-W version foruse in curves.

50W
The 50-W version should be used for conveying good weights of
up to 550 lbs. This highest-torque design is suitable for thecontainer conveyor system (ø 1.97") as well as for light pallet
conveyor system (ø 2.36"). With the enormous acceleration,
conveying goods reach their target speeds the fastest, which has
a very positive effect on the demands of the throughput.

Different forces occur in a curve. If the centrifugal force is greaterthan the static friction force, conveying goods will almost always
loose their orientation. This occurs at speeds over approx. 157
fpm. At that point, conveying goods will no longer be conveyed
through the center of the curve and come into contact with theside guide at the outside radius. Besides the conveying speed, thisalso depends on, e.g. material and condition of the underside of
the conveying good. Corresponding factors must also be taken
into consideration when planning the curves.

Analog interface

Deep freezing
Roller curves can also be operated in the deep freeze area. An
ideal drive is the RollerDrive EC5000 in deep freeze design.
Driven rollers should feature oiled ball bearings so that therequired drive power is not increased unnecessarily. Interroll© 06 | 2020 Interroll

Switching power supplies= Average diameter of tapered elements= Starting diameter= Ending diameterrecommends PolyVee belts as drive element. They have to bewatched for suitability for deep freezing and that the belt tension
is not too high.

Interface
The RollerDrive EC5000 is available with two different interfaces– analog and bus. Its identification is possible via label imprint
and a color ring at the connector.

The analog interface (AI) is a very cost-effective solution. With ananalog voltage, it allows the speed setting within the range
specified by the gear box. It also allows influencing start and/or
braking ramps. The direction of rotation can be predefined andthe error status can be read. The motor commutation technology
integrated in the tube allows for a flexible control of theRollerDrive. If not start signal (at the same time speed
specification) is active, the RollerDrive holds its position. Hence, it
is also suitable for incline and decline conveyors. The AI isavailable with voltages of 24 and 48 V, with power stages of 20,
35 and 50 W, as well as tube diameters of 1.97" and 2.36".
Bus interface
The bus interface (BI) enables the data exchange between
RollerDrive and a control system via CANopen. It allows for thefollowing specifications:73

Accessories

ØØ
Ømin.
Ømax.

(Ømin + Ømax) 2.18“ + 3.3“= 2.74“=22

Planning basics

ØØ =RollerDrive EC5000

PLANNING BASICSROLLERDRIVE VARIANT SELECTION

PLANNING BASICSROLLERDRIVE VARIANT SELECTION

·
·
·
·
·
·
·

Speed specification within the range specified by the gear box
Exact specification of start and/or braking ramps
Specification of direction of rotation
Toggling between “Hold position” and “Free-running”
Exact positioning (when switching to the speed mode)
Specification of the motor temperature warning threshold
Activating a derating mode

Many data can be read out – including:· Error cause (e.g. temperature, blocking or overvoltage)· System status indicators (high temperature of RollerDrive, hightorque demand and an above-average high number of error
messages)· Service life indicator (information about statistical end ofservice life)· Operating data – for example:– Operating hours– Stand-by hours– Number of start cycles– Current motor temperature– Maximum motor temperature reached– Current torque– Current speed– Serial number– Date of manufacture
Compared to the AI, the BI enables an exact error analysis and,as a result, an easier cause analysis or avoidance of error causes.
When the three system status indicators are evaluated, thecauses analyzed and remedied, it allows for reaching the optimal
service life. The service life indicator enables a preventive
maintenance of conveyor lines with a very high availability
requirement. Last, but not least, the operating data with the useof the BI enable the implementation of an Industry 4.0 conveyor
system. Not only do they reading out the operating state of every
RollerDrive, but also exact conclusions on the conveyor system.
Regardless of whether the RollerDrive was manufactured in
Chine, Germany or the United States, it features a unique serial
number. It can be read on the label or read out electronically. If a
RollerDrive was damaged, the transmission of the serial number issufficient to manufacture an identical spare part.
The EC5000 with BI can be controlled with MultiControl. In thiscase, an automatic addressing of up to four connectible EC5000
takes place. MultiControl is capable of reading out RollerDrive
data, such as the diameter.
The BI is available with voltages of 24 and 48 V, with powerstages of 20, 35 and 50 W, as well as tube diameters of 1.97"
and 2.36".

Voltage
The RollerDrive EC5000 is available in two operating voltage
designs: 24 V DC and 48 V DC. It can be identified via the label
imprint, a color ring at the connector or electronically when using
an EC5000 BI.

74

24 V DC voltage supply
RollerDrive with a voltage supply of 24 V DC have establishedthemselves worldwide for many decades now. The extra-low
voltage allows a high flexibility for installation and cabling as well
as a high level of safety during operation. The RollerDrive isfrequently found adjacent to sensors, PLCs and other electronic
products that are operated with a voltage of 24 V DC. The
uniform voltage enables the exclusive use of 24-V DC switching
power supplies. The 24 V DC EC5000 is available for bothinterfaces with power stages of 20, 35 and 50 W as well as
diameters of 1.97" and 2.36".
48 V DC voltage supply
Interroll introduced the 48-V DC voltage supply for RollerDrive in2019 – motivated by customer requests, the automotive industry
and many 48-V DC motors that were already in use in otherareas of conveyor technology. The extra-low voltage allows ahigh flexibility for installation and cabling as well as a high levelof safety during operation. Sensors and other electronic products
adjacent to the RollerDrive continue to be supplied with 24 V DC
and the comparatively more power-intensive RollerDrive with 48
V DC. The 48-V DC voltage is a very cost-effective supply option.
In most cases, fewer switching power supplies are needed. Thistranslates in cost savings as a result of fewer units, more costeffective power supplies and less planning, installation andcabling. Not least, the flexibility in cabling due to longer line
lengths, cost savings by using smaller line cross sections or lower
error risk from voltage drop on lines speak in favor of a supply
with 48 V DC. The 48-V DC design is available for bothinterfaces with power stages of 20, 35 and 50 W as well as
diameters of 1.97" and 2.36".

Tube material
Various aspects must be taken into account when selecting thecorrect tube material.
If the conveying good or the environment is moist, if water is used
for cleaning, or if there is a risk that a sprinkler system could be
activated, then a tube with a high corrosion protection should beselected. A tube made of stainless steel is recommended.
Furthermore, it must be checked whether protection rating IP54 issufficient or whether the design should be used in IP66.
The RollerDrive and also adjacent rollers must be capable ofreliably moving the conveying good. In many cases, this also
includes stopping and starting the conveying good without letting
it slide on the tubes. This is particularly important for conveyors
with an incline. For many conveying goods, the friction to themetal tube of the RollerDrive is sufficient, e.g. tires. For otherconveying goods, a suitable sleeve or a lagging of the tube isrequired. It is recommended to fit the tube with a PU sleeve. It is
more robust than a PVC sleeve and more cost-effective than alagging. However, it is indispensable to adjust the friction of theRollerDrive to the application properties.

© 06 | 2020 Interroll

On the opposite side, the RollerDrive can be fastened in different
ways. An M8 screw can be screwed into a shaft pin with female
thread. For the IP66 variant, the shaft bolt sits in a slide bearing.
For the conventional variant with protection rating IP54, it sits ina ball bearing. The fastening is also possible for a spring-loaded
shaft solution. In combination with a drive head, e.g. a PolyVee
drive head, the spring-loaded shaft is designed as hexagon.
Without drive head, e.g. if round belts are guided via grooves,
the spring-loaded shaft is designed as tapered hexagon. With thissolution, the hexagon slides so far into the fastening hole until it isbacklash-free. This solution reduces the noise level and possible
wear.
RollerDrive with tapered elements require an angle compensation
during fastening.

Protection rate
The RollerDrive has a protection rating of IP54. If this should not
be sufficient due to moisture or dirt, a design with protection
rating of IP66 is available.

RollerDrive planning
For safe and reliable conveyance, at least one RollerDrive andtwo conveyor rollers have to be located under the conveying
good. It is recommended to place the RollerDrive in the center ofthe conveyor zone that it is driving.
If the conveying good is to be moved on a conveyor
perpendicular to the direction of the roller shaft, that is free oftransverse force, then the static friction and rolling friction haveto be overcome.
The following equation applies to conveying goods, which are
moved at a constant speed along a conveyor track:

F=m·g·μFmgµ= Required tangential force in N
= Mass in kg= Max. gravitational acceleration 9.81 m/s= Coefficient of friction

Sample calculation

Temperature range

If the weight of the conveying good is 30 kg and the coefficientof friction is 0.04, the resulting required tangential force is
11.8 N.

The RollerDrive is designed for a temperature range from 32 to
104 °F. For deep freeze applications up to –22 °F, Interroll
recommends the use of a corresponding deep freeze variant, seestarting from page 22.

With a roller radius of 25 mm, the required torque(force × distance) is 0.3 Nm. The required mechanical power at a
speed of 0.5 m/s (force × speed) measures 5.9 W.

Several drive heads are available, and grooves can also be fitted
in the tube. Interroll recommends the use of PolyVee belts since
they are suitable for almost all applications (straight, curve,
gravity, etc.).

Coefficients of friction for different container materials whenusing rollers with steel tubes:
Planning basics

Drive element

Speed/torque
The RollerDrive EC5000 covers all common speeds for ZPA
conveyors. 9 gear stages are available to meet the requirementsof different applications. The gear stage should be selected with© 06 | 2020 Interroll

Controls

Compared with some drive solutions without gear box, theRollerDrive allows implementing a broad spectrum of applications
with different torque requirements. It is sufficient to use the same
drive with the same interface and control at all times, but employ
different gear stages.

Switching power supplies

On the conducting side, the RollerDrive is fastened via a hexagon
shaft in the side profile. The hexagon features an M12 malethread, an M12 fastening nut is supplied as standard. This nut
features ribs on the contact surface to the side profile which
prevents a loosening of the nut in almost all side profiles due tovibration. The ribs are also intended to enable electrical contact
between RollerDrive shaft and powder-coated side profiles. The
electrical connection and, as a result, the possibility of static
discharge must be checked in principle. This very simple fastening
solution prevents the shaft from turning inside the fastening holeand damaging the connecting cable. The nut must be tightenedwith a torque of 51.6 ft-lbs. A fastening socket for a torquewrench with opening for the RollerDrive connecting cable issuitable for this purpose, see page 61.

respect to the required speed and the required torque. For thispurpose, the RollerDrive can be varied with respect to speed. For
example, the gear ratio 18 : 1 can turn with a maximum speed of
196 fpm, but also with every lower speed up to 8 fpm.

Accessories

Fastener

RollerDrive EC5000

PLANNING BASICSROLLERDRIVE PLANNING

75

PLANNING BASICS
POWER SUPPLY DIMENSIONING

Material

Coefficient of friction µ

Steel

0.03

Polymer, smooth

0.04

Polymer, profiled

0.05

Wood

0.05

Cardboard carton

0.06

During zero-pressure accumulation conveying, the RollerDrive isstarted and stopped many times. The RollerDrive is designed for ahigh number of cycles. The previously described calculations areused for checking to what extent a RollerDrive is capable ofconveying certain conveying goods. On top of that, the cycle
count, i.e. how often the RollerDrive switches off and on per time
unit, also plays a decisive role. The higher the cycle count, thehigher the motor temperature. The motor temperature is also
affected by the turning time per time unit. The less the standstilltime of the motor, the less cooling time for the motor. With cycle
times that are too high and standstill times that are too low, theRollerDrive switches to a temperature protection function and canno longer be operated until is has cooled off. This must be taken
into account for the planning.
The required drive force to convey an item at a constant speed
along a roller conveyor depends on the condition of theunderside of the conveying good. A minimal force has to beexerted for a rigid, difficult to deform underside, such as a steel
container.
However, a steel container tends to slide on the tube material
during acceleration and deceleration. Approx. 3 % of theconveying good weight must be applied as propelling force
during constant travel. μ is approx. 8 % with a cardboard
container. This can be explained by the soft and malleable
underside. With a cardboard container, the differential figure isapplied to the steel container for the deformation of theunderside of the container and is therefore no longer available
for the forward motion.

As a conveyor cycle consists of acceleration, constant travel andbraking, acceleration is critical for assessing the output.

76

In the acceleration phase, the static friction is overcome and atransition to significantly lower roller friction takes place. For thisreason, a power surge can be measured at the start of every
conveyor cycle.
For zero-pressure accumulation conveying, the conveyor should
be divided into zones. As a rule, every zone is driven by aRollerDrive. The zone length must orient itself at the conveying
good length or the longest conveying good. The zone length must
be longer than the longest conveying good so that a gap
prevents the conveying goods from contacting each other. In
most cases, light barriers are used to detect conveying good inevery zone. The run-on depends on various factors, such as
speed or conveying good weight, but also the selected drive
element. The run-on describes the distance from the sensor to thefront edge of the stopped conveying good. In an ideal case, therun-on is very small, although the conveying good comes to a
standstill later in most cases. The programming of the logic of thezero-pressure accumulation conveying does not have to becomplex, it is already contained in most Interroll controls. A
power surge can be measured at the switch-on time of theRollerDrive. This application-dependent current peak must be
taken into account for the power supply dimensioning.

Power supply dimensioning
Introduction
The Interroll RollerDrive is supplied with a voltage of 24 or
48 V DC. Interroll offers the matching switching power supply forevery voltage. The power supplies are exactly dimensioned forthe requirements of the RollerDrive and its controls. The following
must be observed if conventional power supplies are used:· The rated and startup current of the RollerDrive must be taken
into account when dimensioning the power supply.
· The RollerDrive, and also its controls, feed back voltage, i.e. thepower supply must be feedback-capable.
· The Interroll RollerDrive controls each contain one brake
chopper. This safety function is activated when the voltage
exceeds a certain value (see the chapter of the respective
control). This voltage may be elevated due to feedback of theRollerDrive or a supply voltage that has been set too high. If
the voltage is elevated over a period of a few seconds, thecontrol system will switch off for cooling purposes because of ahigh brake chopper temperature. For this reason, it isrecommended not to set the voltage of the power supply to theswitch-on threshold of the brake chopper.
· Long line lengths (particularly for 24 V) should be avoided
since they could be accompanied by a high voltage drop.

© 06 | 2020 Interroll

Basic information
The RollerDrive EC5000 can be connected to the following
controls:

start simultaneously, it is recommended to dimension the power
supply with the assumption that all RollerDrive will startsimultaneously.

Sample calculation/dimensioning
EC5000 48 V

The calculation refers to the HP5448 switching power supply with
20 A rated and 30 A peak current.

DriveControl 20
DriveControl 54
DriveControl 2048

ZoneControl
ConveyorControl
MultiControl AI

MultiControl AI

MultiControl BI

MultiControl BI

Controls

DriveControl 2048

It must be checked with a calculation whether one power supply
is sufficient for 24 units of EC5000 48 V 20 W. Since noapplication currents were determined, the catalog current values
are used for the calculation:
Rated current 0.7 A
Startup current 1.5 A
Total rated current:

Each control (without connected RollerDrive or connected sensor)
allows a current flow of approx. 0.5 A (generally significantly
lower). This current is not taken into account for the power supply
dimensioning in the following example. The same applies to thesensors. As a rule, they can be assumed to have a current flow of
50 mA. If additional current-relevant inputs or outputs are
switched, they should be included in the dimensioning, but they
have been omitted in the example.

It is assumed that up to 80 % of the RollerDrive can startsimultaneously.
Switching power supplies

EC5000 24 V

INges = n · IN

Example: INges = 24 · 0.7 A = 16.8 A
Total startup current:

Depending on the power and voltage version, the RollerDrive
EC5000 has a different rated and startup current:

48 V DC

35 W

50 W

20 W

35 W

50 W

Rated
current

1.4 A

2.4 A

3.4 A

0.7 A

1.2 A

1.7 A

Starting
current

3.0 A

5.5 A

7.5 A

1.5 A

2.8 A

3.8 A

The currents depend on different factors, e.g. The acceleration of
the RollerDrive, the number of rollers connected with theRollerDrive, the weight of the conveying good, the speed of theRollerDrive, etc. In many applications, the currents are below thevalues listed here.
In general, several RollerDrive are supplied by one power supply.
The RollerDrive are mostly used for zero-pressure accumulation
conveying. In this case, not all RollerDrive are started
simultaneously in the so-called single release. For this reason, asimultaneity factor must be taken into account for the power
supply dimensioning. If it is not clear how many RollerDrive could

Example: IAges = 24 · 1.5 A = 36 A
Total startup current80 %:Accessories

20 W© 06 | 2020 InterrollIAges = n · IA

IA80% = n · 80% · IA
Example: IA 80% = 24 · 80 % · 1.5 A = 28.8 A
IN
INges
IA
IAges
IA80%
n

= rated current in A
= total rated current in A
= startup current in A
= total startup current in A
= total startup current 80% in A
= number of RollerDrive

Planning basics

24 V DC

RollerDrive EC5000

PLANNING BASICS
POWER SUPPLY DIMENSIONING

77

PLANNING BASICS
POWER SUPPLY DIMENSIONING

Explanations
If only the total rated current would be taken into account, all 24
RollerDrive could be supplied with one power supply and startsimultaneously, since the power supply offers a current of up to
20 A.
However, the startup must also be taken into account. With 36 A,
it is significantly higher than the maximum current of the power
supply (30 A). As such, a second power supply would have to be
used or it must be avoided to switch on all RollerDrive at thesame time.
If it can be ensured that no more than 80 % of the RollerDrive
will start at the same time, the total startup current 80 % can betaken into account. In the example, this current is 28.8 A. Hence,all 24 RollerDrive could be supplied with one power supply.
If calculations are made with current values below the catalog
values and/or with a simultaneity factor (like the 80 % in theexample), these values should be validated through field tests.
In principle, it is recommended to position the power supply in the
middle of the RollerDrive or control systems to be supplied so thata cable can be routed to the left and to the right. This reduces
the total cable length and, as a result, the risk of excessive line
voltage drop.
If train release is used instead of single release, it must be
assumed for conventional logic programs that all RollerDrive startsimultaneously. The Interroll controls avoid a cumulative highstartup current of all RollerDrive:· ZoneControl: The control has a permanently set delay time of
125 ms in the train release program. After an enabling signal,
the first RollerDrive starts. The next RollerDrive starts 125 ms
later, etc.
· ConveyorControl: The delay time is adjustable, function
identical to ZoneControl.
· MultiControl: The delay time is adjustable, function identical to
ZoneControl.

78© 06 | 2020 Interroll

Planning basics

Accessories

Switching power supplies

Controls

RollerDrive EC5000

PLANNING BASICS
POWER SUPPLY DIMENSIONING© 06 | 2020 Interroll

79

INDEXInterroll from A to Z

Numeric

H

24-V switching power supply

52, 76

HP5424 (24-V power supply)

52

48-V switching power supply

56, 76

HP5448 (48-V power supply)

56

C

I

Cable bridge

65

Interroll Group

Cable distribution

63

IP54

10, 16, 22, 26

Chain

70

IP66

30

Communication cable

63

Control

44, 48Controls

34, 36, 38, 40

Conveying good

66

Counter wrench

62

Curve

71

4

M
Magnetic key

65

Motor roller

10, 16, 22, 26, 30

MultiControl

44, 48MultiControl dummy plug

64

MultiControl Y-cable

63

D
Drive concepts

68

DriveControl 20

34

DriveControl 2048

38

DriveControl 54

36

Dummy plug

64

P
PolyVee belt

60, 70Power supply HP5424 (24 V)

52, 76

Power supply HP5448 (48 V)

56, 76

Product locator
Profinet

E

Protected against water jets

EC500010, 16, 22, 26, 30

EtherCat44, 48

EtherNet/IP

44, 48Extension cable

62

80

44, 4830

R
Roller pitch

67, 70, 71

RollerDrive

10, 16, 22, 26, 30

RollerDrive controlsF834, 36, 38, 40, 44, 48

RollerDrive counter wrench

62

Fastening socket

61

RollerDrive extension cable

62

Flat belt

70

RollerDrive fastening socket

61

Flat cable62© 06 | 2020 Interroll

INDEXInterroll from A to Z

S
Sealing inserts (power supply)

64

Shield connection cable

64

Sprocket70

Suitable for deep freeze application

22

Y
Y-cable63

Z
Zero-pressure accumulation conveying

68

ZoneControl

40© 06 | 2020 Interroll

81

COMPETENCE CENTER

The Interroll Center of Excellence in Wermelskirchen (nearCologne, Germany) concentrates on conveyor rollers, RollerDriveand controls, used as key products in roller conveyors forcontainer transport and other internal logistics systems.
In this product sector, the company certified in compliance with
ISO 9001 is responsible within the global Interroll Group for alltechnical concerns ranging from development and applicationengineering to production and support for local Interroll
companies. With an annual production volume of several million
units, Interroll is currently seen in the logistics sector as the world‘slargest specialist manufacturer of conveyor rollers.

LEGAL NOTICES
Contents
We strive for the information presented to be correct, up to date andcomplete. We have carefully developed the contents of this document.
Nevertheless, errors and changes are expressly subject to change.

Copyright/intellectual property rightText, images, graphics and the like, as well as their arrangement, areprotected by copyright and other protective legislation. Reproduction,
modification, transfer or publication of any part or the entire content of
this document in any form is prohibited. This document is intended
exclusively for informational purposes and for intended use and does not

Interroll Engineering GmbH
Höferhof 16 | 42929 Wermelskirchen |Germany Tel.: +49 2193 23-0

authorize replication of the corresponding products. All identification
symbols used in this document (protected trademarks, such as logos andcommercial designations) are the property of Interroll AG or theirrespective owners and may not be used, copied or disseminated without
prior written permission.

About Interroll
The Interroll Group is a globally leading provider of solutions formaterial handling. The company was founded in 1959 and has
been listed on the SIX Swiss Exchange since 1997. Interroll
supplies system integrators and machine builders with a broad
product range of platform-based products and services in the
categories "Rollers" (conveyor rollers), "Drives" (motors anddrives for conveyor systems), "Conveyors & Sorters“ as well as"Pallet & Carton Flow” (flow storage systems). Solutions fromInterroll are used by express and postal services, in e-commerce,in airports and in the areas of food & beverage, fashion,
automotive and other industries. The company counts leading
brands, such as Amazon, Bosch, Coca-Cola, DHL, Nestlé, Procter& Gamble, Siemens, Walmart, or Zalando, among its users.
Interroll, with its headquarters in Switzerland, features a global
network of 34 companies with annual revenues of roughly 530.6
million francs and 2300 employees (2020).
interroll.com

EN-US | © 06 | 2020

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