Interroll ZoneControl User manual

INSPIRED BY EFFICIENCY
Operating Manual
Interroll ZoneControl

Manufacturer details
Interroll Engineering GmbH
Höferhof 16
42929 Wermelskirchen, Germany
Tel.: [phone]
Fax: [phone]
www.interroll.com
Content
We have carefully compiled the content of this document and made every eort to ensure that the information
is correct, complete and up to date. However, we cannot assume any kind of guarantee for this information. We
expressly exclude any liability for any damage or consequential damage connected with the use of this document. We
reserve the right to modify the documented products and product information at any time.
Copyright/industrial property rights
Text, images, graphics and similar elements as well as their arrangement are subject to copyright protection and other
protective laws. The reproduction, alteration, transfer or publication of this document in full or in part is prohibited
in every form. This document is solely for informational purposes and the intended use and does not entitle to the
reproduction of the products in question. All the marks contained in this document (protected trademarks, such as
logos and commercial designations) are the property of Interroll Engineering GmbH or third parties and may not be
used, copied or distributed without prior written consent.
Online version - only suitable for color printing!

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Inhalt
1 About this document 7
1.1 Information about this operating manual 7
1.2 Warning notices in this document 8
1.3 Symbols 9
2 Safety-related information 10
2.1 State of the art 10
2.2 Proper use 10
2.3 Improper use 10
2.4 Qualicationofpersonnel 11
2.5 Dangers 12
Injury to persons 12
Electricity 12
Work environment 12
Faults in operation 12
Maintenance 12
Unintentional start-up 12
2.6 Interface to other devices 13
2.7 Operating modes/operating phases 13
Standard operation 13
Special operation 13
2.8 Applicable documentation 14
3 Product information 15
3.1 Product description 15
Functions 16
Speed settings 16
Feedback of energy / Overvoltage protection 16
Temperature protection 17
Lockperiodforsignalmodications/Debouncing 17
After-run time 17
3.2 Setup 18
3.3 Scope of delivery 18
3.4 Label 19
3.5 Technical data ZoneControl 19

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Inhalt
3.6 Meaning of the LEDs 20
3.7 DIP switches 21
3.8 Meaning of signals 22
ZONE_STATUS 22
3.9 Dimensions 22
4 Transport and storage 23
4.1 Transport 23
4.2 Storage 23
5 Assembly and installation 24
5.1 Warning notices for installation 24
5.2 Assembling the ZoneControl 24
5.3 Warning notices for electrical installation 25
5.4 Electrical installation 26
Required cables: 26
Signal status of inputs 28
Signal status of outputs 28
Schematics of all outputs 28
5.5 Sensors 29
5.6 Inputs and outputs 30
RollerDrive connection: 8 mm snap-in, 5-pin, pin location in accordance with DIN EN 61076-2 30
Start sensor connector: WAGO 733-103 mating plug 30
Zone sensor connector: WAGO 733-103 mating plug 31
Upstream peer-to-peer connection: RJ45 socket, 8-pin Molex 43860 31
Power supply connector: WAGO 734-102 mating plug 32
Inputs/outputs connector: WAGO 733-108 mating plug 32
Downstream peer-to-peer connector: RJ45 socket, 8-pin Molex 43860 33
5.7 Wiring diagrams 34
ZoneControl within the conveyor section 34
ZoneControl at the start of the conveyor section 35
ZoneControl at the end of the conveyor section 36
Connection of the external speed control 37
Connection of a second RollerDrive 38
6 Initial startup and operation 39

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6.1 Commissioning 39
Pre-commissioning checks 39
Inspection before each commissioning 39
6.2 Operation 39
6.3 Speed setting 40
Internal speed setting on the ZoneControl 40
Speed setting via external analog signal 41
6.4 Externalinuenceonzeropressureaccumulationconveying 41
ZONE_STOPP 41
ZONE_START 42
Complete clearing of a conveyor 43
7 Maintenance and cleaning 44
7.1 Maintenance 44
Checking the ZoneControl 44
Replacing the ZoneControl 44
7.2 Cleaning 45
8 Troubleshooting 46
8.1 Troubleshooting 46
8.2 Deviations in the conveying process 48
Removingapackagefromthedetectionareaofthezonesensor 48
Time-outwhenleavingthezonesensor 48
Time-outwhenreachingthezonesensor 48
9 Decommissioning and disposal 49
9.1 Decommissioning 49
9.2 Disposal 49
10 Appendix 50
10.1 Electrical data of connectors 50
Inputs/outputs connectors 50
RollerDrive connector 51
10.2 Translation of the original Declaration of Conformity 53

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About this document
1 About this document
1.1 Information about this operating manual
This operating manual covers the following Interroll ZoneControl.
Throughout this manual, the term “control system” is used as an alternative for referring to these models.
The operating manual is a component of the product and contains important advice and information regarding the
dierentoperatingphasesoftheZoneControl.ItdescribestheZoneControlatthetimeofshippingfromInterroll.
The currently applicable version of this operating manual can be found online at: www.interroll.com/support/
All the information and advice in this operating manual has been compiled with respect to applicable standards and
regulations as well as the current state of the art.
¾Toensuresafeandfaultlessoperationandtofullanywarrantyclaimsthatmayapply,readthisoperating
manualrstandobserveitsinstructions.
¾Keep this operating manual within close reach of the ZoneControl.
¾Pass this operating manual onto every subsequent owner or user.
The manufacturer assumes no liability for damage and malfunctions that occur as a result of non-
compliance with this operating manual.
Should you still have any unanswered questions after reading this operating manual, please contact Interroll
customer service. Contact details for your region can be found online at www.interroll.com/contact/
Please direct any comments and suggestions regarding our operating manuals to [email protected]

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About this document
1.2 Warning notices in this document
Warning notices are provided in the context in which danger can occur and describe the nature of the danger in
question. They are structured according to the following examples:
SIGNAL WORD
Type and source of hazard
Consequence(s) in the event of non-compliance
¾Measure(s)foravoidinghazard
Signalwordsindicatethetypeandseverityoftheconsequencesifmeasurestoavoidthehazardarenotobserved.
DANGER
Denotes an imminent hazard.
If measures to avoid the hazard are not observed, death or severe injury will occur.
¾Preventive measures
WARNING
Denotes a potentially hazardous situation.
If measures to avoid the hazard are not observed, death or severe injury may occur.
¾Preventive measures
CAUTION
Denotes the possibility of a hazardous situation.
If measures to avoid the hazard are not observed, minor or moderate injury may occur.
¾Preventive measures

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About this document
NOTE
Denotes a situation that can lead to material damage.
¾Preventive measures
1.3 Symbols
This symbol indicates useful and important information.
üThissymbolindicatesarequirementthatmustbefullledbeforecarryingoutassemblyorrepairwork.
This symbol indicates general information relating to safety.
¾This symbol indicates an action that needs to be performed.
•This symbol indicates a listed item.

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Safety-related information
2 Safety-related information
2.1 State of the art
The Interroll ZoneControl has been constructed with respect to applicable standards and the current state of the art
andhasbeendeliveredinaconditionthatissafetooperate.Nevertheless,hazardscanoccurasaresultofuse.
Non-compliance with the instructions in this operating manual can result in life-threatening injuries.
In addition, the applicable local accident prevention regulations for the area of application and general safety
regulations must be adhered to.
2.2 Proper use
The ZoneControl may only be used in an industrial environment for industrial purposes within the stipulated
performancelimitsthataregiveninthetechnicalspecications.
It controls an Interroll RollerDrive and must be integrated into a conveyor unit or conveyor system before
commissioning.
2.3 Improper use
Any use that goes beyond the proper use is considered improper, unless this has been authorised by Interroll
Engineering GmbH where applicable.
The equipment must not be installed in areas in which substances could form explosive atmospheres/dust atmospheres
or for application in the medical/pharmaceutical sector.
It is considered improper use to install the equipment in exposed spaces that are open to potentially adverse weather
conditions,orareasinwhichthetechnologywouldsuerfromtheprevailingclimacticconditionsandcouldpotentially
malfunction as a result.
The ZoneControl is not intended for use by private end users. The equipment must not be used in a residential
environment without further examination and without the use of EMC protective measures that have been adapted
accordingly.
It must not be used as a safety-relevant component or for performing safety-relevant functions.