INSPIRED BY EFFICIENCY

User Manual

Interroll Pallet Drive
DP 0080
DP 0089

Manufacturer
Interroll Trommelmotoren GmbH
Opelstr. 341836 Hueckelhoven/Baal
Germany
Phone: +49 2433 44 610
www.interroll.com

Contents
We strive for the information presented to be correct, up to date and complete. We have carefully worked out thecontents of this document. However, we assume no liability for the information. We expressly deny any liability fordamages or consequential damages that are connected in any form with the use of this document. We reserve theright to change the documented products and product information at any time.
Copyright / intellectual property rightTexts, images, graphics and the like as well as their arrangement are protected by copyright and other protection
laws. Reproduction, modification, transfer or publication of any part or the entire content of the document in any
form is prohibited. This document is intended exclusively for information purposes and for intended use and does not
authorize replicating the respective products. All signs contained in this document (registered trademarks, such as
logos and business designations) are the property of Interroll Trommelmotoren GmbH or third parties and may not be
used, copied or distributed without prior written consent.

Table of Contents
1

Introduction

1.1

Information about the operating instructions���������������������������������������������������������������������������������������������������������������������5

5

1.1.1

Contents������������������������������������������������������������������������������������������������������������������������������������������������������������������5

1.1.2

The instruction manual is part of the product����������������������������������������������������������������������������������������������5

1.2

Warning notices in this manual����������������������������������������������������������������������������������������������������������������������������������������������5

2

Safety2.1

State of the art���������������������������������������������������������������������������������������������������������������������������������������������������������������������������6

2.2

Intended use��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������6

2.3

Unintended use��������������������������������������������������������������������������������������������������������������������������������������������������������������������������66

2.4

Personnel qualification��������������������������������������������������������������������������������������������������������������������������������������������������������������6

2.5

Dangers����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������7

2.6

Interfaces to other devices������������������������������������������������������������������������������������������������������������������������������������������������������8

2.7

Legal provisions��������������������������������������������������������������������������������������������������������������������������������������������������������������������������8

3

Product information

3.1

Product description��������������������������������������������������������������������������������������������������������������������������������������������������������������������9

3.2

Options�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������9

3.3

Thermal protection��������������������������������������������������������������������������������������������������������������������������������������������������������������������9

3.4

Type plate of Pallet Drive����������������������������������������������������������������������������������������������������������������������������������������������������� 10

9

3.5

Product identification������������������������������������������������������������������������������������������������������������������������������������������������������������� 12

3.6

Technical data�������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 13

3.7

Electrical data�������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 13

3.8

Dimensions�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 13

4

Options and accessories

4.1

Electromagnetic brake for the Pallet Drive���������������������������������������������������������������������������������������������������������������������� 15

4.2

Asynchronous Pallet Drive with frequency inverters����������������������������������������������������������������������������������������������������� 16

15

4.2.1

Torque dependent on input frequency�������������������������������������������������������������������������������������������������������� 16

4.2.2

Frequency inverter parameters��������������������������������������������������������������������������������������������������������������������� 16

5

Transport and storage

5.1

Transport����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 18

18

5.2

Storage�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 18

6

Assembly and installation

6.1

Warning notices concerning the installation������������������������������������������������������������������������������������������������������������������� 19

6.2

Installing the Pallet Drive������������������������������������������������������������������������������������������������������������������������������������������������������� 19

19

6.2.1

Positioning the Pallet Drive������������������������������������������������������������������������������������������������������������������������������ 19

6.2.2

Installation of Pallet Drive in mounting brackets��������������������������������������������������������������������������������������� 20

6.3

Warning notices concerning the electrical installation������������������������������������������������������������������������������������������������� 21

6.4

Electrical connection of the Pallet Drive���������������������������������������������������������������������������������������������������������������������������� 21
6.4.1

Connection of the Pallet Drive - with cable����������������������������������������������������������������������������������������������� 21

6.4.2

Connection diagrams��������������������������������������������������������������������������������������������������������������������������������������� 21

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Table of Contents
6.4.3

External motor protection������������������������������������������������������������������������������������������������������������������������������� 24

6.4.4

Integrated thermal protection����������������������������������������������������������������������������������������������������������������������� 24

6.4.5

Frequency inverter�������������������������������������������������������������������������������������������������������������������������������������������� 24

6.4.6

Electromagnetic brake ����������������������������������������������������������������������������������������������������������������������������������� 25

7

Initial startup and operation

7.1

Checks before the initial startup����������������������������������������������������������������������������������������������������������������������������������������� 26

26

7.2

Initial startup���������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 26

7.3

Checks before every startup����������������������������������������������������������������������������������������������������������������������������������������������� 26

7.4

Operation��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 26

7.5

Procedure in case of accident or fault������������������������������������������������������������������������������������������������������������������������������ 27

8

Maintenance and cleaning

8.1

Warning notices concerning maintenance and cleaning��������������������������������������������������������������������������������������������� 28

8.2

Preparation for maintenance and cleaning by hand��������������������������������������������������������������������������������������������������� 28

8.3

Maintenance���������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 28

8.4

Checking the Pallet Drive������������������������������������������������������������������������������������������������������������������������������������������������������ 28

8.5

Cleaning������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 28

9

Troubleshooting

29

10

Decommissioning and disposal

33

10.1

Shutdown���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 33

28

10.2

Disposal������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 33

11

Appendix

11.1

List of abbreviations��������������������������������������������������������������������������������������������������������������������������������������������������������������� 34

11.2

Translation of the original Declaration of Conformity�������������������������������������������������������������������������������������������������� 36

11.3

UKCA Declaration of Conformity�������������������������������������������������������������������������������������������������������������������������������������� 37

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Introduction
1

Introduction

1.1

Information about the operating instructions

The following Pallet Drive types are described in these operating instructions:• DP 0080• DP 0089

1.1.1

Contents

This instruction manual contains important notes and information about the various operating phases of the Pallet
Drive.
The instruction manual describes the Pallet Drive as it is delivered by Interroll.
In addition to this instruction manual, special contractual agreements and technical documents apply to special
versions.

1.1.2

The instruction manual is part of the product• For trouble-free, safe operation and warranty claims, read the instruction manual first and follow the instructions.
• Keep the instruction manual close to the Pallet Drive.
• Pass the instruction manual on to any subsequent operator or occupant.
• NOTICE! The manufacturer does not accept any liability for faults or defects due to non-observance of this
instruction manual.
• If you still have questions after reading the instruction manual, please contact Interroll customer service. Contact
persons close to you can be found on the Internet under www.interroll.com/contact.

1.2

Warning notices in this manual

The warning notices refer to risks that may arise while using the Pallet Drive. They are available at four danger levels
with the following signal words:

DANGER
Identifies a danger with high risk that will result in death or serious injury if it is not avoided.

WARNING
Identifies a danger with medium risk that could result in death or serious injury if it is not avoided.

CAUTION
Identifies a danger with low risk that could result in minor or medium injury if it is not avoided.

NOTICE
Identifies a danger that results in property damage.

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Safety2

Safety2.1State of the art

The conveyor is designed according to the state of the art and is reliable in operation, once distributed. However, risks
may still arise.
Disregarding the notices in this manual may lead to serious injury.
• Carefully read the manual and follow its content.
• Observe local accident prevention regulations and general safety regulations that apply in the area of use.

2.2

Intended use

The Pallet Drive is intended for use in industrial environments, super markets and airports and is used for the transportof unit handling, such as pallets, cartons or crates. The Pallet Drive must be integrated into a conveyor module orconveyor system. Any other use is considered inappropriate.
Any modifications that affect the safety of the product are not permitted.
The Pallet Drive may only be operated within the defined operating limits.

2.3

Unintended use

The Pallet Drive must not be used for transporting people.
The Pallet Drive is not intended for use under impact or shock loads.
The Pallet Drive is not designed to be used under water. Such a use leads to personal or fatal injuries fromelectrocution as well as the penetration of water, resulting in a short circuit or motor damage.
The Pallet Drive may not be used as a drive for cranes or lifting devices or for the corresponding hoist ropes, cables orchains.
Use of the Pallet Drive for anything other than the intended purpose is subject to approval by Interroll.
Unless otherwise stated in writing and/or specified in a quote, Interroll and its dealers shall assume no liability for
product damage or failure which result from failure to observe these specification and restrictions (see the chapter„Technical data” and „Electrical data” of the respective series).

2.4

Personnel qualification

Unqualified personnel cannot recognize risks and, as a result, is subject to greater dangers.
• Authorize only qualified personnel to perform the activities described in these instructions.
• The operating company must ensure that personnel follow locally applicable regulations and rules about safety andhazards while working.
The following target groups are addressed in these instructions:

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Safety
Operators
Operators have been instructed in operating and cleaning the Pallet Drive and follow the safety guidelines.
Service personnel
The service personnel features a technical training or has undergone training by the manufacturer and performs thetransport, assembly, maintenance and repair tasks.
Electricians
Persons working on electrical installations must have pertinent technical training.

2.5

Dangers

The following list informs you about the various types of danger or damage that may occur while working with thePallet Drive.
Bodily injury• Maintenance or repair work on Pallet Drives must only be performed by authorized service persons in accordancewith applicable regulations.
• Before turning on the Pallet Drive, ensure that no unauthorized persons are near the conveyor
Electricity
Perform any installation and maintenance tasks only after following the five safety rules:• Disconnect• Secure against reactivation• Determine de-energized state at all poles• Ground and short circuit• Cover or block neighboring live parts
Rotating parts• Do not reach into areas between Pallet Drive and conveyor belts or roller chains.
• Tie long hair together.
• Never wear loose clothing.
• Never wear jewelery, such as necklaces or bracelets.
Hot motor parts• Attach appropriate warning notices to the conveyor.
• Do not touch the surface of the Pallet Drive. It can result in burns, even under regular operating temperature.
Working environment• Do not use the Pallet Drive in explosive atmospheres.
• Remove equipment or material which is not required from the workspace.
• Wear safety shoes.
• Clearly specify and monitor the way materials are placed on the conveyor.
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Safety
Faults during operation• Regularly check the Pallet Drive for visible damage.
• In case of fumes, unusual noise or blocked or damaged materials, stop the Pallet Drive at once and ensure that the
RollerDrive cannot be started accidentally.
• Contact qualified personnel immediately to find the source of the fault.
• During operation, do not step on the Pallet Drive or the conveyor/the system in which it is installed.
Maintenance• Check the product regularly for visible damages, unusual noise and firm seating of fittings, screws and nuts. An
additional maintenance is not required.
• Do not open the Pallet Drive.
Accidental motor start• Caution during installation, maintenance and cleaning or in the event of a malfunction: Secure the Pallet Drive
against unintentional start-up.

2.6

Interfaces to other devices

Hazards may occur while integrating the Pallet Drive into a complete system. These are not part of this manual andhave to be analyzed during the design, installation and startup of the complete system.
• After assembling the Pallet Drive in a conveyor module, check the whole system for a new potential dangerous spot
before switching on the conveyor.
• Additional constructive measures may be required.

2.7

Legal provisions

Ecodesign Regulation (EU) 2019/1781
Interroll Pallet Drives are not subject to the requirements of the Ecodesign Regulation.
Interroll Pallet Drives are excluded from the scope of Regulation (EU) 2019/1781 on the basis of Article 2(2)(a), as the integrated electric motor cannot be tested and operated independently of the gearbox.

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Product information
3

Product information

3.1

Product description

The Pallet Drive is a completely enclosed electrical drive roller. It replaces external components such as motors andgears, which require frequent maintenance.
The Pallet Drive can be operated in environments with heavy coarse and fine dust exposure.
The Pallet Drive is driven by an asynchronous three-phase induction motor. It is available in a single power stage only
and for most of the international supply voltages.
The Pallet Drive does not contain any oil and is not intended for continuous operation.

3.2

Options

Integrated thermal overload protection
A thermal circuit breaker integrated in the winding head protects against overheating. The switch trips if the motor
overheats. However, it has to be connected to a suitable external control device that interrupts the current supply tothe motor in case of overheating:Integrated electromagnetic brake
The integrated electromagnetic brake can hold loads. It acts directly on the rotor shaft of the Pallet Drive and isdriven by a rectifier. The holding force of each Pallet Drive with brake corresponds to the belt pull of the motor. The
electromagnetic brake is available for all Pallet Drive:

3.3

Thermal protection

Under normal operating conditions, the thermal circuit breaker integrated in the stator winding is closed. When the
motor limit temperature is reached (overheating), the switch opens at a preset temperature to prevent damage to themotor.

WARNING
The thermal circuit breaker is automatically reset after the motor has cooled off.
Inadvertent start-up of the motor¾

Connect the thermal circuit breaker in series with a suitable relay or contactor so that the current supply tothe motor is safely interrupted when the switch trips.

¾

Ensure that the motor can be switched on again after overheating only with a confirmation button.

¾

After the switch has tripped, wait until the motor has cooled off, and ensure prior to switch-on that there isno danger to persons.

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Product information

Standard design: temperature limiter, automatically switching backService life: 10.000 cyclesACcos φ = 1

2,5 A

250 V ACcos φ = 0,61,6 A

250 V AC

1,6 A

24 V DC

1,25 A

48 V DC

6,3 A

250 V ACDC

Service life: 2.000 cyclescos φ = 1

AC
Reset temperature

40 K ± 15 K

Resistance< 50 mΩContact bounce time

< 1 ms3.4

Type plate of Pallet Drive

The information on the nameplate of the Pallet Drive is intended for its identification. This is the only way for the Pallet
Drive to be used properly.
A laser-cut nameplate is located on the cover of the Pallet Drive. In addition, the Pallet Drive includes a label that canbe used for documentation.

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Product information

Nameplate (1) for Pallet Drive DP 0080/DP 0089

Nameplate (2) for Pallet Drive DP 0080/DP 0089
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Product information
1 Connection diagram number

16 CE mark2 Rated power

17 UKCAmark

3 Number of poles + operating mode

18 UL mark4 Rated frequency

19 International Electrotechnical Commission: Standard
for drum motors

5 Rated voltage at rated frequency

20 Type + design

6 Rated current at rated frequency

21 Installation length

9 QR code

22 Weight

10 Power factor

24 Circumferential speed of drum tube

12 Serial number

25 Manufactured week/year/country

15 Manufacturer’s address

27 Technical data of option

3.5

Product identification

The information given below is required in order to identify a Pallet Drive. The values for a specific Pallet Drive can beentered in the last column.
Information

Possible value

Type plate of Pallet Drive

Motor type

Own value

Speed in m/s
Serial number
Between frames (BF) in mm
Number of poles
Power in kW
Drum diameter (tube diameter)

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e.g. 80 mm

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Product information
Interroll Product App
Product-specific data can be read out using the QR code printed on the type plate. The Interroll Product App isavailable in all major app stores:

3.6

Technical data

Protection rate

IP54

Ambient temperature range for standard applications-5 °C to +40 °C

Cycle times (duty cycle DC50)

120 pallets per hour

Ramp times

Pallet Drive: ≥ 0,5 s

Installation altitude above sea levelmax. 1000 m

3.7
PNElectrical data
nP

W

nN

fN

UN

IN

-1

min

Hz

V

A

cos φ

η

JR

IS/IN

MS/MN

MB/MN

MP/MN

kgcm2

MN

RM

Nm

Ω

70

2

2889

50

400

0,33

0,56

0,54

1,25

4,2

4

4,5

4

0,23

72,7

70

2

2889

50

230

0,57

0,56

0,54

1,25

4,2

4

4,5

4

0,23

72,7

Abbreviations see page 34.

3.8

Dimensions

All length-related dimensions in the catalog and in these operating instructions comply with the requirements of DIN/
ISO 2768 (medium quality).

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Product information
The recommended distance between the mounting brackets (EL) while taking into account the maximum
thermal expansion and internal tolerances is EL + 2 mm.

Dimensions of Pallet Drive
Type

A

EL

AGL

mm

mm

mm

DP 0080

80

RL+V+13

RL+V+28

DP 0089

89

RL+V+13

RL+V+28

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Options and accessories
4

Options and accessories

4.1

Electromagnetic brake for the Pallet Drive

The electromagnetic brake, which is available as an option, acts directly on the rotor shaft. If the power supply isinterrupted, the brake is applied and holds the Pallet Drive in position until the power supply is re-established. The load
held by the brake corresponds to the maximum transport weight specified for the Pallet Drive.
Features:• Applied directly to the rotor shaft of the Pallet Drive.
• Holds a load equal to the specified transport weight.
• Operation via an external rectifier.
• Operating temperature from -10 °C to +120 °C.
The rated braking torque is heavily influenced by the operating conditions inside of the Pallet Drive as wellas the ambient temperature. For safety reasons, the specified braking torque should be reduced by 50% forload calculations.
Brake type24

Rated braking
torqueRated output

Rated supply voltage

Rated current

Nm

W

V DC

mA

2

11

24

500

The installed brake disk is a wear part and has a limited service life in relation to the operating conditions. In caseof premature wear, the operating conditions must be checked and evaluated. The wear parts of the brake are notincluded in the product warranty.
The braking torque at the Pallet Drive tube corresponds to the gear ratio of the motor times the braking
torque listed in the table above. For safety purposes, 25% reserve have to be figured into the dimensioningof the brake. The brake is not a safety holding brake.
All brakes are dimensioned for start/stop operation.
The rise and fall delays of the brakes can vary significantly depending on the following factors:• Ambient temperature• Internal operating temperature of Pallet Drive

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Options and accessories
4.2

Asynchronous Pallet Drive with frequency inverters

4.2.1

Torque dependent on input frequency

Operating frequency [Hz]

5

10

15

20

25

30-50

Available motor torque in % of
rated motor frequency 50 Hz

80

85

90

95

100

100

The torque dependency depicted in the figure above is expressed as P = T x ω. With a reduced operating frequency
of below 20/24 Hz, the motor torque is reduced by changing heat dissipation conditions.

4.2.2

Frequency inverter parameters

Clock frequency:
A high clock frequency leads to a better utilization factor of the motor. Optimum frequencies are 8 or 16 kHz.
Parameters such as smooth running test quality (motor is running smoothly) and noise development are also affected
positively by high frequencies.
Voltage increase:
Pallet drives are generally suitable for operation with frequency inverters and therefore also for high voltage rise
speeds.
Nevertheless, high voltage rise speeds in conjunction with long motor cables cause high pulse voltages, which stressand age the insulation system. To prevent premature ageing of the winding insulation and thus damage to the pallet
drive, motor chokes, dU/dt filters or even sine filters can be installed between the inverter and the pallet drive.
Please refer to the operating instructions of the frequency inverter for the cable length above which this measure isrecommended.

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Options and accessories
Voltage:
If a frequency inverter with single-phase supply is installed in the Pallet Drive, the specified motor must be designed forthe frequency inverter output voltage and must be connected accordingly. Single-phase motors cannot be operated
with a frequency inverter.
Frequency inverter parameters:
Frequency inverters are usually delivered with factory settings. Given these settings, the inverter is generally not
immediately ready for operation. The parameters have to be adjusted to the respective motor. For frequency inverters
sold by Interroll, startup instructions specifically created for Pallet Drive for the respective frequency inverters can besupplied upon request.
Maximum frequency:
The Pallet Drive may be operated only in a frequency range from 10 - 60 Hz.

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Transport and storage
5

Transport and storage

5.1

Transport
CAUTION

Improper transport poses a risk of injury!
¾

Transport-related tasks should only be carried out by qualified and service personnel.

¾

For Pallet Drives with a weight of 20 kg or more, use a crane or hoisting equipment during the transport.
The rated load of the crane or hoisting equipment must be greater than the weight of the Pallet Drive. Crane
rope/cable and hoisting equipment must be securely fastened to the shafts of the Pallet Drive during lifting.

¾

Do not stack pallets.

¾

Before the transport, ensure that the Pallet Drive is sufficiently secured.

NOTICE
Risk of damage to the Pallet Drive due to improper transport!
¾

Avoid strong impacts during transport.

¾

Do not lift the Pallet Drive at the cable or at the terminal box.

¾

Do not transfer the Pallet Drives between warm and cold environments. This may cause condensation to
form.

¾

For transport in shipping containers, ensure that the temperature in the container is not permanently above
70 °C (158 °F).

1.

Check each Pallet Drive for damage after transport.

2.

In the event of damage, take photos of the damaged parts.

3.

In case of a transport damage, immediately notify the carrier and Interroll to avoid losing any claims forcompensation.

5.2

Storage
CAUTION

Risk of injury due to improper storage!
¾

Do not stack pallets.

¾

Do not stack more than four cardboard boxes on top of each other.

¾

Ensure that proper fastening is in place.

1.

Store the Pallet Drive in a clean, dry and enclosed location at +15 to +30 °C; protect it from moisture andhumidity.

2.

Check each Pallet Drive for damage after storage.

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Assembly and installation
6

Assembly and installation

6.1

Warning notices concerning the installation

CAUTION
Risk of injury due to incorrect assembly!
The Pallet Drive strikes against the mounting bracket during reversing operation if it is installed incorrectly. This canlead to material breakage in the long term, causing components to fall or the cable to be damaged.
¾

Observe the installation position.

¾

Observe axial play of min. 1.0 mm and max. 2.0 mm.

¾

Observe torsional play of max. 0.4 mm.

NOTICE
Risk of damage leading to failure or shortened service life of the Pallet Drive!
¾

Do not drop or mishandle the Pallet Drive to avoid internal damages.

¾

Prior to the installation, inspect each Pallet Drive for damage after storage.

¾

Do not hold, carry, or support the Pallet Drive by the wires or terminal boxes extending out of the mounting
shaft to avoid damage to the internal parts and seals.

¾

Do not twist the motor cable.

6.2

Installing the Pallet Drive

6.2.1

Positioning the Pallet Drive

Ensure that the data on the type plate are correct, and match the ordered and confirmed product.
The installation of a Pallet Drive is permissible only in horizontal applications. In case of doubt, contact
Interroll.
The Pallet Drive must be mounted horizontally with a clearance of +/- 2°.
The Pallet Drive can be installed in any orientation.

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Assembly and installation
6.2.2

Installation of Pallet Drive in mounting brackets

The mounting brackets must be sufficiently robust to withstand the motor torque.
1.

Install the brackets at the conveyor or machine frame. Ensure that the Pallet Drive is installed parallel to thetransport rollers and at a right angle to the conveyor belt frame.

2.

Ensure that at least 80% of the key surfaces of the Pallet Drive are held by the mounting brackets (cable side).

3.

Ensure that the distance between the key surfaces and the bracket is free from play.

4.

On the side without cable, use a screw M12; 8.8 and tighten with a tightening torque of 80 Nm.
The Pallet Drive can also be installed without mounting brackets. In this case, the shaft end of the cable side
must be installed in a corresponding recess in the conveyor belt frame; this recess must be designed in sucha way that the aforementioned requirements are met.

Axial play
1 Torque tension displacement
The entire axial clearance of the Pallet Drive should measure 1 mm minimum and 2 mm maximum.

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Assembly and installation
6.3

Warning notices concerning the electrical installation
WARNING

Electrocution due to improper installation!
¾

All electrical work must only be performed by qualified electricians.

¾

Disconnect the power supply before installing, removing or rewiring the Pallet Drive.

¾

Always observe the connection instructions and ensure that the power and control circuits of the motor are
correctly connected.

¾

Ensure that metal conveyor belt frames are sufficiently grounded.

NOTICE
Damage of the Pallet Drive due to incorrect power supply
Do not connect an AC Pallet Drive to an excessive DC voltage supply – it will lead to permanent damages.

¾

6.4

Electrical connection of the Pallet Drive

6.4.1

Connection of the Pallet Drive - with cable1.

Ensure that the motor is connected to the correct supply voltage according to the motor type plate.

2.

Ensure that the Pallet Drive is correctly grounded with the yellow-green cable.

NOTICE
Damage of the Pallet Drive due to incorrect polarity
In case of incorrect polarity, the brake cannot lift properly which leads to overloads.
¾

Ensure that the correct polarity of the brake is observed.

Connect the Pallet Drive according to the connection diagrams (see „Connection diagrams”). Observe the correct
polarity of the brake.

6.4.2

Connection diagrams

These operating instructions list only standard connection diagrams. For other connection types, the connection
diagram is supplied separately with the Pallet Drive.
Abbreviations see page 34.

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Assembly and installation
Cable connections

3-phase, 7+2-core cable, winding for 1 voltage, delta or star connection (switched internally), with brake
Delta connection: Low voltage

Star connection: High voltage

3-phase, 4+2-core cable, winding for 1 voltage, delta or star connection (internally connected)
Delta connection: Low voltage

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Star connection: High voltage
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Assembly and installation

3-phase, 7+2-core cable, winding for 2 voltages, delta or star connection
Delta connection: Low voltage

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Star connection: High voltage

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Assembly and installation
6.4.3

External motor protection

The motor must always be installed together with suitable external motor protection, e.g., a motor circuit breakeror frequency inverter with protection against excessive current. The protective device must be adjusted to the rated
current of the corresponding motor (see type plate).

6.4.4

Integrated thermal protection

CAUTION
Accidental motor start
Crushing hazard for fingers¾

Connect the integrated thermal circuit breaker to an external control device that interrupts the current
supply to the motor at all poles in case of overheating.

¾

After the thermal circuit breaker has tripped, examine and remove the cause for overheating before thecurrent supply is reactivated.

The standard maximum switching current of the thermal circuit breaker is 2.5 A. For other options, please contact
Interroll.
For operational safety, the motor must be safeguarded against overload with an external motor protection, as well as
an integrated thermal protection; otherwise, there is no warranty if the motor fails.

6.4.5

Frequency inverter

Asynchronous Pallet Drives can be operated with frequency inverters. Frequency inverters from Interroll are generaladjusted to factory setting and have to be parameterized for the respective Pallet Drive. For this purpose, Interroll can
supply parameterization instructions. In this case, please contact your local Interroll partner.
• If no frequency inverter from Interroll is used, the frequency inverter must be correctly parameterized according to
the specified motor data. Interroll can provide only very limited support for frequency inverters that are not being
sold by Interroll.
• Resonance frequencies in the power supply line must be prevented since the create voltage spikes in the motor.
• If the cable is too long, frequency inverters generate resonance frequencies in the line between frequency inverter
and motor.
• Use a completely shielded cable to connect the frequency inverter to the motor.
• Install a sine-wave filter or a motor choke if the cable is longer than 10 meter or if a frequency inverter controls
several motors.
• Ensure that the cable shield is connected to a grounded part according to the electrotechnical guidelines and local
EMC recommendations.
• Always observe the installation guidelines of the frequency inverter manufacturer.

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Assembly and installation
6.4.6

Electromagnetic brake

The Pallet Drive is delivered with an installed electromagnetic brake (if it does not feature a 24V DC brake). The
rectifier is an accessory part and must be ordered separately from the motor.
Connect the rectifier and the brake according to the connection diagrams.
    The rectifier has an AC input and a DC output to the brake winding.

DANGER
Risk of injuries when used as safety brake!
When large loads are being held, the motor can unexpectedly rotate in the opposite direction. As a result, loads
may fall down and hit or fatally injure persons.
¾

Do not use the electromagnetic brake as safety brake.

¾

If a safety brake is required, install a suitable additional safety brake system.

NOTICE
Damage of the Pallet Drive and the brake if both are operated simultaneously!
¾

Route the control circuits in such a way that motor and brake do not work against each other.

¾

Consider the response time for applying and releasing the brake (depending on temperature and oil
viscosity, it can amount to 0.4 to 0.6 seconds).

¾

Apply the brake only after the current supply to the motor has been switched off.

¾

Start the motor only after the brake has been released.

The cable should be as short as possible, and the cable cross section should correspond to the national/international
regulations so that the voltage supply at the rectifier does not deviate from the rated voltage by more than ±2%.
The electromagnetic brake is a pure holding brake and should not be used for positioning or braking the motor.
Braking applications should be implemented with a frequency inverter.

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Initial startup and operation
7

Initial startup and operation

7.1

Checks before the initial startup

Prior to the initial startup of the motor, the following steps have to be performed:
1.

Ensure that the motor type plate matches the version ordered.

2.

Ensure that no contact points exist between objects, conveyor belts and rotating or moving parts.

3.

Ensure that the Pallet Drive and the conveyor belt can move freely.

4.

Ensure that the belt features the correct tension according to the recommendations from Interroll.

5.

Ensure that all bolts are tightened according to the specifications.

6.

Ensure that no additional dangerous areas arise due to interfaces to other components.

7.

Ensure that the Pallet Drive is correctly wired and connected to the voltage supply with the correct voltage.

8.

Check all safety devices.

9.

Ensure that no bystanders are in dangerous areas around the conveyor.

10.

Ensure that the external motor protection is correctly adjusted to the rated motor current and a corresponding
switching device can switch off the motor voltage at all poles if the integrated thermal circuit breaker trips.

7.2

Initial startup

The Pallet Drive may be put into operation only if it is correctly installed and connected to the power supply and all
rotating parts have been fitted with the corresponding protective devices and guards.

7.3

Checks before every startup

1.

Check the Pallet Drive for visible damage.

2.

When using Interroll Pallet Control, ensure that the latest software version is installed.

3.

Ensure that no contact points exist between objects, conveyor belts and rotating or moving parts.

4.

Ensure that the Pallet Drive and the conveyor belt can move freely.

5.

Check all safety devices.

6.

Ensure that no bystanders are in dangerous areas around the conveyor.

7.

Clearly specify and monitor the way materials are placed on the conveyor.

7.4

Operation
CAUTION

Rotating parts and accidental starting!
Risk of crushing for fingers.
¾

Do not reach between Pallet Drive and belt.

¾

Do not remove the protection device.

¾

Keep fingers, hair and loose-fitting clothes away from Pallet Drive and chains/toothed belts.

¾

Keep watches, rings, chains, piercings and comparable jewelry away from the Pallet Drive and chains/
toothed belts.

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Initial startup and operation
NOTICE
Damage of Pallet Drive in reversing operation!
¾

Ensure that a time delay is in place between forward and reversing movement. Before reversing, the motor
must come to a complete standstill.
If exact speeds are required, a frequency inverter and/or encoder may have to be used.
The specified rated speeds of the motor can deviate by ± 10 %. The belt speed indicated on the type plateis the calculated speed at the drum diameter under full load, rated voltage and rated frequency.

7.5

Procedure in case of accident or fault

1.

Stop the Pallet Drive at once and ensure that it cannot be started accidentally.

2.

In case of an accident: Provide first aid and make an emergency call.

3.

Inform the responsible person.

4.

Have the malfunction repaired by service personnel.

5.

Start the Pallet Drive only after this has been approved by service personnel.

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Maintenance and cleaning
8

Maintenance and cleaning

8.1

Warning notices concerning maintenance and cleaning
CAUTION

Risk of injury due to improper handling or accidental motor starts!
¾

Maintenance and cleaning work must only be performed by authorized service persons.

¾

Perform maintenance work only after switching off power. Ensure that the Pallet Drive cannot be turned on
accidentally.

¾

Set up signs indicating that maintenance work is in progress.

CAUTION
Risk of injury from hot surfaces!
The Pallet Drive can heat up during operation and therefore has hot surfaces even after it has been switched off.
This leads to burns on contact.
¾

Allow the Pallet Drive to cool down to ambient temperature before maintenance and cleaning.

¾

Wear personal protective equipment.

8.2

Preparation for maintenance and cleaning by hand1.

Switch off the power supply to the Pallet Drive.

2.

Switch off the main power switch to switch off the Pallet Drive.

3.

Open terminal box or distribution box and disconnect the cables.

4.

Attach a sign to the control station that maintenance work is in progress.

8.3

Maintenance

Generally, Interroll Pallet Drives do not have to be maintained and require no special care during their regular service
life. Nevertheless, certain checks have to be performed at regular intervals.

8.4

Checking the Pallet Drive• Ensure daily that the Pallet Drive can rotate freely.
• Check the Pallet Drive for visible damage every day.
• Ensure weekly that motor shaft and brackets are firmly fastened to the conveyor frame.
• Ensure weekly that cables, lines and connections are in good condition and securely fastened.

8.5

Cleaning

1.

Remove foreign material from the drum shell.

2.

Do not use sharp-edged tools to clean the drum shell.

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Troubleshooting
9

Troubleshooting

Troubleshooting
Fault

Possible cause

RemedyMotor does notstart or stops
during operation

No voltage supply

Check the voltage supply.

Incorrect connection orloose/ defective cableconnection

Check connection according to connection diagram.

Motor overheating

See the fault „Motor heats up during regular operation”.

Motor overload

Disconnect main power supply, determine and repair cause ofoverload.

Internal thermal circuit
breaker tripped/failure

Check whether there is overload or overheating. After coolingoff, check continuity of internal thermal protection. See the fault„Motor heats up during regular operation”.

External overload
protection tripped/ failure

Check whether there is overload or overheating. Check continuity
and function of external overload protection. Check whether thecorrect motor current is set in the external overload protection.

Motor winding phaseerror

Replace Pallet Drive or contact the local Interroll dealer.

Motor winding shortcircuit (insulation fault)

Replace Pallet Drive or contact the local Interroll dealer.

Brake is not triggered

Check whether the brake works during start-up.

Check whether cables are defective or connections are loose.

During the brake release, the clicking noise of the brake in the
motor can generally be heard. It must then be possible to turn the
drum tube manually. Depending on the gear ratio, the motors canbe turned more easily or with more difficulty.
Check connections and continuity of the brake winding.
If connections and brake winding are OK, check the rectifiers.
Motor does notstart or stops
during operation

Motor is running,
but drum shell
does not turn

Drum or chain blocked

Ensure that the Pallet Drive is not being blocked and all rollers
and drums can turn freely.
If the Pallet Drive cannot turn freely, the gear box or the bearing
may be blocked. In this case, contact the local Interroll dealer.

Gear box or bearing
blockedCheck by hand if the drum shell can be turned freely. If not,replace Pallet Drive or contact local Interroll dealer.

Incorrect assembly

Ensure that the motor is not rubbing against the conveyor belt
frame.

Transfer loss

Contact the local Interroll dealer.

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Troubleshooting
Fault

Possible cause

RemedyMotor heats up
during regular
operation

Overload of Pallet Drive

Check rated current for overload.
Ensure that the motor is not rubbing against the conveyor belt
frame.

Ambient temperature
above 40 °C

Check ambient temperature. If the ambient temperature is too
high, install a cooling unit. Contact the local Interroll dealer.

Excessive or frequent
stops/ starts

Check whether the number of stops/starts and the weight of thepallets corresponds to the specifications of the Pallet Drive andreduce this number if necessary. Install a frequency inverter to
optimize the motor output.
For Pallet Drive, the start-and-stop ramps may not be less than
0.5 seconds. Ramps can be set with a frequency inverter.
Contact local Interroll dealer.

Motor is not suitable forthe application

Check whether the application meets the specifications of thePallet Drive.

Wrong voltage supply

Check the voltage supply.
For 3-phase motors, ensure that no phase has failed.

Loud noise ofPallet Drive during
regular operation

Pallet Drive
vibrates heavily
Pallet Drive runs
with interruptions

Wrong settings at
frequency inverter

Check whether the frequency inverter settings meet the
specifications of the Pallet Drive and change them if necessary.

Incorrect settings at
frequency inverter

Check whether the frequency inverter settings meet the
specifications of the Pallet Drive and change them, if necessary.

Loose motor mount

Check motor mount, shaft tolerances and fastening screws.

An outer conductor failed

Check connection, check power supply.

Incorrect settings at
frequency inverter

Check whether the frequency inverter settings meet the
specifications of the Pallet Drive and change them, if necessary.

Loose motor mount

Check motor mount, shaft tolerances, and fastening screws.

Pallet Drive/chain/
toothed belt is partially orintermittently blocked

Ensure that chain and Pallet Drive are not being blocked and allrollers and drums can turn freely.

Incorrect or loose power
cable connection

Check connections.

Gear box is damaged

Check by hand if the drum shell can be turned freely.
If not, replace the Pallet Drive or contact the local Interroll dealer.

Incorrect or faulty voltage
supply30 of 40Check the voltage supply.
For single-phase motors: check capacitors.

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Troubleshooting
Fault

Possible cause

RemedyPallet Drive/chain
runs more slowly
than specified

Incorrect motor speedordered/ delivered

Check Pallet Drive specifications and tolerances.

Pallet Drive/chain ispartially or intermittently
blockedEnsure that chain and Pallet Drive are not being blocked and allrollers and drums can turn freely.

Incorrect settings at
frequency inverter

Check whether the frequency inverter settings meet the
specifications of the Pallet Drive and change them, if necessary.

Pallet Drive
runs faster thanspecified.

Incorrect motor speedordered/ delivered

Check Pallet Drive specifications and tolerances.

Incorrect settings at
frequency inverter

Check whether the frequency inverter settings meet the
specifications of the Pallet Drive and change them, if necessary.

Motor winding:
one phase failed

Failure/overload ofwinding insulation

Check continuity, current and resistance of each phase winding.

Motor winding:two phases failed

Power failure in one
phase which leads tooverload in the other twophases/ separating failure

Check power supply to all phases. Check continuity, current andresistance of each phase winding.

Motor winding:
three phases
failedMotor overload/incorrect
power connection

Check whether the correct supply voltage is applied.

Cable defective
or damaged

Wrong operation by the

Check type of damage and possible cause.

customer or damage
during installation

Replace Pallet Drive or contact local Interroll dealer.

Damage during transport

Check type of damage and possible cause.

Replace Pallet Drive or contact the local Interroll dealer.

Replace Pallet Drive or contact the local Interroll dealer.

Replace Pallet Drive or contact the local Interroll dealer.

Replace Pallet Drive or contact the local Interroll dealer.

Check continuity, current and resistance of each phase winding.
Replace Pallet Drive or contact the local Interroll dealer.

Replace Pallet Drive or contact local Interroll dealer.
Cap bearing
failedGear box failure

Overload

Check whether the load of the application meets the specificationsof the Pallet Drive.

Impact load

Check whether the load of the application meets the specificationsof the Pallet Drive.

Load or incorrect
adjustment of shaft

Check whether screws have been overtightened and whether
frame or motor mount are incorrectly adjusted.

Loose or tight seating of
bearing on shaft

Contact the local Interroll dealer.

Overload/impact load or
regular wear

Check whether the load of the application meets the specificationsof the Pallet Drive.
Check service life.

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Troubleshooting
Fault

Possible cause

RemedyRotor drive wornor teeth broken
off

Excessive or frequent
stops/starts, very highstarting torque

Check whether the load of the application meets the specificationsof the Pallet Drive.

Toothed sprocket
worn or teeth/bolts broken off

Start-up under overload
and/or impact load or
while blocked

Complete or
temporary failureof brake andrectifierWrong operating voltage
appliedEnsure that the correct rectifier was installed and that the correct
input voltage (V/ph/Hz) is present.

Wrong connection

Never connect the rectifier to the frequency inverter.

Check maximum number of stops/starts and permissible starting
torque.
Use frequency inverter with start-and-stop ramps (0.5 s or more).
Check whether the application and load meet the specifications of
the Pallet Drive.
Check whether start-up is blocked.
Use frequency inverter with start-and-stop ramps (0.5 s or more).

Complete or
temporary failureof brake andrectifierEnsure that the brake was connected according to connection
diagram.
Insufficient shielding
against external voltage
spikes from cables andexternal devices

Ensure that all cables between brake, rectifier and voltage supply
are shielded and grounded according to IEC recommendations.

Voltage drop due tocable with excessive
lengthCheck whether a voltage drop occurs in long cables and ensurethat the cable cross section meets the IEC specifications.

Excessive stops/starts

Ensure that the specifications for brake and rectifier meet therequirements of the application.

Wrong rectifier connected Contact Interroll. We will give you the name of the correct
rectifier for the corresponding brake and application.

Slow switchingof brake andrectifier

32 of 40

Short circuit of brakewinding

Check continuity of winding and rectifier.

Wrong brake/wrong
rectifier selected or
specified

Ensure that the specifications for brake and rectifier meet therequirements of the application.

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Decommissioning and disposal
10

Decommissioning and disposal• The packaging must be recycled to provide environmental relief.

10.1

Shutdown
CAUTION

Risk of injury due to incorrect handling!
¾

Shut-down may only be executed by service personnel.

¾

Allow the Pallet Drive to cool down to ambient temperature before decommissioning.

¾

Only shut down the Pallet Drive after switching off the power. Ensure that the Pallet Drive cannot be turnedon accidentally.

1.

Disconnect the motor cable from the power supply and motor control.

2.

Remove holding plate from the motor mount.

3.

Remove the Pallet Drive out of the conveyor frame.

10.2

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

When disposing of the Pallet Drive and its packaging, follow local and industry-specific regulations.

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Appendix
11

Appendix

11.1

List of abbreviations

Electrical data
PN in W

Rated output in wattnP

Number of poles

in 1/min.

Rated speed of rotor in revolutions per minute fN in Hz

fN in Hz

Rated frequency in Hz

UN in V

Rated voltage in volt

IN in A

Rated current in amperescos φPower factorη

Efficiency

JR in kgcm

Rotor moment of inertia

IS/IN

Ratio of startup current to rated current

MS/MN

Ratio of starting torque to rated torque

MP/MN

Ratio of pull-up torque to rated torque

MB/MN

Ratio of pull-out torque to rated torque

MN in Nm

Rated torque of rotor in Newton meters

RM in ΩPhase resistance in ohms

2

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Appendix
Connection diagrams
3~

Three-phase motor

BR

Brake (optional)

L1

Phase 1

L2

Phase 2

L3

Phase 3N

Neutral conductorNC

Not connected

T1

Input thermistor

T2

Output thermistorTC

Thermal protection

U1

Input winding phase 1

U2

Output winding phase 1

V1

Input winding phase 2

V2

Output winding phase 2

W1

Input winding phase 3

W2

Output winding phase 3

Z1

Input auxiliary winding single-phase motor

Z2

Output auxiliary winding single-phase motor

Color coding
Color coding of cables in the connection diagrams:
bk: blackgn: greenpk: pink

wh: whitebn: browngy: grayrd: redye: yellow

bu: blueor: orange

vi/vt: violet

ye/gn: yellow/green( ): alternate color

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Appendix
11.2

Translation of the original Declaration of Conformity

EU Declaration of conformity
EMC Directive 2014/30/EU
RoHS Directive 2011/65/EU
The manufacturer
Interroll Trommelmotoren GmbH
Opelstraße 341836 Hueckelhoven/Baal
Germany
hereby declares that the "incomplete machine"• Pallet Drive DP 0080; DP 0089
conforms to the applicable provisions and the associated CE marking in accordance with theaforementioned Directives.
List of the coordinated standards that have been applied:
EN ISO 12100:2010
EN 60204-1:2018
EN IEC 63000:2018

Declaration of incorporation
EC Machinery Directive 2006/42/EC
In addition to the information specified above, the manufacturer declares that:
The health and safety requirements have been applied in accordance with Annex I (1.1.2, 1.1.5, 1.2.6, 1.3.2,
1.3.4, 1.3.9, 1.5.1, 1.5.2, 1.5.4, 1.5.5, 1.5.6, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.6.1, 1.6.4, 1.7.2, 1.7.3, 1.7.4, 1.7.4.2). The
relevant technical documentation has been compiled in accordance with Annex VII B and has been passed on to the relevant
authorities where applicable.
The commissioning of the incomplete machine is prohibited until the conformity of the overallmachine/system in which it is installed with the EC Machinery Directive has been declared.
Authorised for compiling technical documentation:
Interroll Trommelmotoren GmbH, Opelstraße 3, D-41836 Hueckelhoven/Baal

Nico Schmidt
Product Compliance Counsel – Interroll Trommelmotoren GmbH
Hueckelhoven/Baal, 05.12.2023

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Appendix
11.3

UKCA Declaration of Conformity

Declaration of conformity
UK Electromagnetic Compatibility Regulations 2016
UK Restriction of the Use of Certain Hazardous Substances inElectrical and Electronic Equipment Regulations 2012
The manufacturer
Interroll Trommelmotoren GmbH
Opelstraße 341836 Hueckelhoven/Baal
Germany

represented in the UK by

Interroll Limited
Unit 1a, Orion Way, Kettering, Northants
NN15 6NL
Englandhereby declares that the "incomplete machine"• Pallet Drive DP 0080; DP 0089
conforms to the applicable provisions and the associated UKCA marking in accordance with theaforementioned Directives.

Declaration of incorporation
UK Supply of Machinery (Safety) Regulations 2008
In addition to the information specified above, the manufacturer declares that:
The health and safety requirements have been applied in accordance with the EC Machinery Directive 2006/42/EC as listed
in the EC Declaration of incorporation. The relevant technical documentation has been compiled in accordance with Annex
VII B and has been passed on to the relevant authorities where applicable.
The commissioning of the incomplete machine is prohibited until the conformity of the overallmachine/system in which it is installed with the UK Supply of Machinery (Safety) Regulations 2008
has been declared.
Authorised for compiling technical documentation:
Interroll Trommelmotoren GmbH, Opelstraße 3, D-41836 Hueckelhoven/Baal

Nico Schmidt
Product Compliance Counsel – Interroll Trommelmotoren GmbH
Hueckelhoven/Baal, 05.12.2023

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Appendix

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EN | 01/2024 | Version 1.3

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