Interroll RollerDrive BT100, RollerDrive EC100, RollerDrive EC110 User Manual
User manual
Version 3.0 (04/2013) en
Translation of the original
instructions
Interroll RollerDrive
BT100
Chapter-ID: User manual
Chapter-ID: Version
Chapter-ID: Translation of the or iginal instructions
Version 3.0 (04/2013) en
Translation of the original instructions
Manufacturer's address
Interroll Engineering GmbH
Hoeferhof 16
D-42929 Wermelskirchen
Tel. +49 2193 23 0
Fax. +49 2190 2022
www.interroll.com
Copyright
The copyright of this manual remains with Interroll Engineering GmbH. The
operating instructions contain technical regulations and drawings which may not
be reproduced partially or in full, transmitted by any means, utilized without
permission for competitive purposes or disclosed to third parties.
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Version 3.0 (04/2013) en
Translation of the original instructions
RollerDrive BT100
Table of contents
Introduction
Information about the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Further symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety
General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unintended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Qualified persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product information
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
RollerDrive label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Performance data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Motor cable and plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DriveControl for the RollerDrive BT100 . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dimensions of the motor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dimensions of bearing seats on the non-driven side . . . . . . . . . . . . . . . . 12
Round belt groove locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Conical RollerDrives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transport and storage
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly
Warning information for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Warning notices for the electrical installation . . . . . . . . . . . . . . . . . . . . . . 16
RollerDrive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mounting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Initial startup and operation
Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Procedure in case of accident or malfunction . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance and cleaning
Warnings concerning maintenance and cleaning . . . . . . . . . . . . . . . . . . . 22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Abandonment and disposal
Abandonment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Appendix
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation Declaration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Version 3.0 (04/2013) en
Translation of the original instructions
RollerDrive BT100
Introduction
Information about the operating instructions
Contents This manual contains important advice, notes and information about the
RollerDrive BT100 in all phases of its lifecycle:
• Transport, assembly and start-up
• Safe operation, maintenance and troubleshooting, disposal
• Accessories
Validity of the manual The manual describes the RollerDrive BT100 as it is delivered by Interroll.
In addition to this manual, special contractual agreements and technical
documents apply to special versions.
The manual is part of the
product
For trouble-free, safe operation and warranty claims, read the manual and
follow the instructions before handling the RollerDrive BT100.
Keep the manual near to the RollerDrive BT100.
Pass the manual on to any subsequent operator or occupant of the
RollerDrive BT100.
Interroll does not accept any liability for malfunctions or defects due to non-
observance of this manual.
If you have any questions after reading the operation manual, feel free to
contact our customer service. See the last page for your local contact.
Warnings in this manual
The warnings in this document refer to risks which may arise while using the
RollerDrive BT100. For relevant warnings, see "Safety", page 4 and the warnings
at the beginning of each chapter.
There are three categories of danger. The following signal words are used in the
document as required:
• Danger
• Warning
• Caution
Signal word Meaning
Danger Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Warning Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Caution Indicates a hazardous situation which, if not
avoided, may result in minor or moderate injury.
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Version 3.0 (04/2013) en
Translation of the original instructions
RollerDrive BT100
Introduction
Structure of warnings
Further symbols
This symbol marks the steps that have to be carried out.
Nature and source of the hazard
Possible consequence of non-observance
Information about how to avoid the hazard.
DANGER
This symbol identifies possible material damage.
Information about how to avoid damage.
Important
This symbol displays safety instructions.
Hint
This symbol marks useful and important information.
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Version 3.0 (04/2013) en
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RollerDrive BT100
Safety
General safety instructions
The RollerDrive BT100 is designed according to the technical state of the art and
is reliable in operation, once distributed. However, risks may still arise.
• Risks of physical injury to the user or bystanders.
• Adverse effects of the RollerDrive and other material.
Always read the entire operating and safety instructions before starting to
work with the RollerDrive and follow the information contained herein in full.
Only instructed and qualified persons may work with the RollerDrive.
Always keep this user manual at hand when working on the RollerDrive so
that you can consult it quickly if required.
Always comply with relevant national safety regulations.
If you have any questions after reading this user manual, feel free to contact
our customer service. See the last page for contact information.
Intended use
The RollerDrive BT100 may only be used for industrial applications and in an
industrial environment to convey goods such as parts, cartons, totes or boxes. It
must be integrated in a conveyor module or a conveying system. Any other use is
not permitted.
Any changes that affect the safety of the product are not allowed.
The RollerDrive BT100 may only be used within the given operation limits.
Unintended use
The RollerDrive BT100 may not be used to transport persons, bulk cargo or small
parts.
The RollerDrive is not intended for use under impact or shock loads.
Applications not according to the intended use of the RollerDrive BT100 require
approval from Interroll.
Important
Disregarding the warnings in this manual may lead to serious injury.
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Version 3.0 (04/2013) en
Translation of the original instructions
RollerDrive BT100
Safety
Qualified persons
Qualified persons are persons who read and understand the manual and, taking
national regulations into account, can competently execute incidental work.
Only instructed and qualified persons may work with the RollerDrive, taking the
following into account:
• the relevant manuals and diagrams,
• the warning and safety instructions in this manual,
• the system specific regulations and requirements,
• national or local regulations and requirements for safety and accident
prevention.
Dangers
Persons Maintenance or repair work must only be executed by authorized and qualified
persons in accordance with the applicable regulations.
Before turning on the RollerDrive, ensure that no unauthorized persons are
near the conveyor.
Electricity
Only perform installation and maintenance work after you have switched off
the power. Ensure that the RollerDrive cannot be turned on accidentally.
Rotating parts
Keep your fingers and hair away from moving parts.
If you have long hair, always wear a hair net.
Never wear loose clothing.
Never wear jewellery, such as necklaces or bracelets.
Wear safety shoes.
Working environment
Do not use the RollerDrive in explosive atmospheres.
Always remove materials and objects which are not required from the work
area.
Wear safety shoes.
Regulate and monitor careful placement of the goods on the conveyor.
Malfunctioning during
operation
Regularly check the RollerDrive for visible damage.
In case of fumes, unusual noise or blocked or damaged goods, stop the
RollerDrive at once and ensure that the RollerDrive cannot be started
accidentally.
Contact qualified personnel immediately to find the source the malfunction.
Do not step on the RollerDrive during operation.
Maintenance
As the product is maintenance free, you only need to check regularly for
visible damages, unusual noise and that the screws and nuts are still
tightened.
Do not open the RollerDrive.
Accidental start-up
Make sure that the RollerDrive cannot start up accidentally, particularly during
assembly, maintenance work and in the event of a fault.
Important
The following list informs you about the various types of danger or damage that
may occur while working with the RollerDrive BT100.
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RollerDrive BT100
Safety
Interfaces
By assembling the RollerDrive in a conveyor module, potential hazards may
occur. These are not described in this manual and have to be analyzed during the
design, installation, and startup of the conveyor module.
After assembling the RollerDrive in a conveyor module, check the whole
system for any new potential dangerous condition prior to turning on the
conveyor.
Operating modes
Normal mode Operation of the installed device at the end customer's as a component in a
conveyor in a complete system.
Special mode All operating modes which are required to guarantee and maintain safe and
normal operation.
Special operating mode Explanation Comment
Transport/Storage Loading and unloading, transport and
storage
-
Assembly/Initial start-up Installation at the end customer's and
performing the test run
When de-energized
Cleaning External cleaning When de-energized
Maintenance/Repairs Maintenance and inspection tasks When de-energized
Troubleshooting Troubleshooting in the event of a fault When de-energized
Fault elimination Eliminating the fault When de-energized
Shut-down Dismantling from the conveyor When de-energized
Disposal Disposal of RollerDrive and packaging -
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Version 3.0 (04/2013) en
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RollerDrive BT100
Product information
Components
Product description
The RollerDrive BT100 is an electrically driven roller. It replaces external
components such as motors and gears, which require frequent maintenance.
The RollerDrive BT100 can be used in dusty and/or moist environments due to its
protection class IP54.
The RollerDrive BT100 is powered by a brushed, mechanically commutated
24 VDC motor.
Overload protection device Thermal protection against permanent overload with temperature switch: A
temperature switch (bimetal switch) is installed on the brush bridge. This
switches off the RollerDrive when the temperature of the motor winding exceeds
110 °C (230 °F). When the motor winding has cooled down again to
approx. 90 °C (194 °F), the RollerDrive is switched back on again. Since the
switch is not located directly in the winding, it takes a certain time until a
temperature increase reaches the switch. If the roller is blocked immediately after
the first switching on [at a temperature of 20 °C (68 °F)], there is a risk of the
motor winding being burned through. A slow-blow 2A fuse can therefore also be
used as an additional, faster fuse safeguard.
If the RollerDrive is over-stressed by increased friction, excessive load, too many
cycles etc., it is automatically switched off by the overload protection. After
cooling down, the RollerDrive starts up again automatically without a reset. If the
overload persists, the motor switches itself off again. If there in no overload, it
continues to run normally.
1 Motor cable
2 Motor cartridge shaft
3 Fixed bearing housing assembly
4 Motor
5 Idler cartridge shaft
6 Idler bearing housing assembly
7 Tube
8 Non-slip drive
9 Gearbox
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