Interroll MultiControl User manual

Instruction Manual
Interroll MultiControl
1103563

Manufacturer address
Interroll Engineering GmbH
Hoeferhof 16
D-42929 Wermelskirchen
Tel. [phone]
Fax [phone]
www.interroll.com
Content
We make every effort to ensure that the information is correct, up-to-date and complete and
have carefully compiled the contents of this document. However, we cannot assume any liability
for the information. We expressly exclude any liability for damages and consequential damages
in any form in connection with the use of this document. We reserve the right to change the
documented products and product information at any time..
Copyright / Intellectual Property Law
Texts, pictures, graphics and similar as well as their arrangement are protected by copyright and
other protective laws. The reproduction, modification, transmission or publication of part or all of
the document in any form is prohibited. This document is intended solely for information and
intended use and does not entitle the user to reproduce the products concerned. All trademarks
contained in this document (protected trademarks, such as logos and business names) are the
property of Interroll Engineering GmbH or third parties and may not be used, copied or
distributed without prior written consent..

Version 3.0 (08/2018)
Translation of original instruction manual I
Table of contents
1About this document..........................................................................................................................................1
1.1 Information about this user manual ..............................................................................................................1
1.2 Warning notices in this manual......................................................................................................................2
1.3 Symbols.................................................................................................................................................................3
2Safety related information...............................................................................................................................4
2.1 State of the art....................................................................................................................................................4
2.2 Intended use ........................................................................................................................................................4
Areas of application..........................................................................................................................................4
2.3 Unintended use...................................................................................................................................................5
2.4 Personnel qualification......................................................................................................................................5
Operator ..............................................................................................................................................................5
Service personnel...............................................................................................................................................5
Electrician..............................................................................................................................................................5
2.5 Dangers.................................................................................................................................................................6
Personal injury.....................................................................................................................................................6
Electricity...............................................................................................................................................................6
Working environment.......................................................................................................................................6
Faults during operation ....................................................................................................................................6
Maintenance........................................................................................................................................................6
Unintentional start up........................................................................................................................................6
2.6 Interfaces to other devices...............................................................................................................................7
2.7 Operating modes / Operating phases........................................................................................................7
Normal mode......................................................................................................................................................7
Special mode.......................................................................................................................................................7
2.8 Additional documentation................................................................................................................................8
3Product information...........................................................................................................................................9
3.1 Product description ............................................................................................................................................9
Energy recovery / Overvoltage protection................................................................................................9
Overload protection .........................................................................................................................................9
3.2 Structure ............................................................................................................................................................10

Version 3.0 (08/2018)
II Translation of original instruction manual
MultiControl......................................................................................................................................................10
Baseplate...........................................................................................................................................................11
3.3 Scope of delivery ............................................................................................................................................11
3.4 Nameplate ........................................................................................................................................................12
3.5 Technical Data..................................................................................................................................................13
3.6 Dimensions.........................................................................................................................................................14
4Transport and storage...................................................................................................................................15
4.1 Transport ...........................................................................................................................................................15
4.2 Storage ..............................................................................................................................................................15
5Assembly and installation..............................................................................................................................16
5.1 Warning instructions for assembly.............................................................................................................16
5.2 Assembling the MultiControl........................................................................................................................16
Initial assembly.................................................................................................................................................16
Repeated assembly.........................................................................................................................................18
5.3 Warning instructions for electrical installation........................................................................................19
5.4 Electrical installation .......................................................................................................................................20
Connecting the power supply......................................................................................................................20
Connecting the RollerDrive...........................................................................................................................21
Connecting the bus.........................................................................................................................................22
Connecting the sensors..................................................................................................................................23
Overview connections ...................................................................................................................................24
6Initial start up and operation .......................................................................................................................25
6.1 Initial start up....................................................................................................................................................25
Check before initial start up.........................................................................................................................25
6.2 Configuration options ....................................................................................................................................25
6.3 User interface...................................................................................................................................................26
Requirements ....................................................................................................................................................26
Start the user interface..................................................................................................................................26
Homepage "MultiControl Overview"........................................................................................................27
Network Settings.............................................................................................................................................28
Motor Settings..................................................................................................................................................30

Version 3.0 (08/2018)
Translation of original instruction manual III
Digital I/O - States..........................................................................................................................................31
Digital I/O - Settings ......................................................................................................................................32
Control Program..............................................................................................................................................34
Error - State......................................................................................................................................................35
Error - Settings.................................................................................................................................................36
Error - Log.........................................................................................................................................................38
Service - Teach-in............................................................................................................................................39
Service - Plug&Play.........................................................................................................................................39
Service - Change Password.........................................................................................................................40
Service - Factory Reset..................................................................................................................................40
Service - Restart...............................................................................................................................................41
Service - Version .............................................................................................................................................41
Service - Up-/Download...............................................................................................................................42
6.4 Magnetic sensor...............................................................................................................................................43
6.5 Service Data Objects (SDO)........................................................................................................................43
6.6 Operation..........................................................................................................................................................44
Check before every start up........................................................................................................................44
Start ....................................................................................................................................................................44
Stop.....................................................................................................................................................................44
6.7 Procedure in case of accident or malfunction.........................................................................................45
7Maintenance and cleaning...........................................................................................................................46
7.1 Maintenance.....................................................................................................................................................46
Check the MultiControl..................................................................................................................................46
Replace the MultiControl...............................................................................................................................46
7.2 Cleaning.............................................................................................................................................................47
8Troubleshooting...............................................................................................................................................48
8.1 Meaning of the LED........................................................................................................................................48
General LED......................................................................................................................................................48
LED of the connections...................................................................................................................................50
8.2 Troubleshooting...............................................................................................................................................50
Error codes........................................................................................................................................................53

Version 3.0 (08/2018)
IV Translation of original instruction manual
9Decommissioning and disposal....................................................................................................................56
9.1 Decommissioning.............................................................................................................................................56
9.2 Disposal..............................................................................................................................................................56
10 Appendix ...........................................................................................................................................................57
10.1 Accessories........................................................................................................................................................57
10.2 Declaration of conformity.............................................................................................................................58

About this document
Version 3.0 (08/2018)
Translation of original instruction manual 1
1About this document
1.1 Information about this user manual
The instruction manual describes the Interroll MultiControl.
In the further course, the term "control" is used alternatively.
The instruction manual is part of the product and contains important notes and information on the
various operating phases of the MultiControl. It describes the MultiControl at the time of its
delivery by Interroll.
The latest version of this manual is available on the Internet at:
www.interroll.com/support/
All information and instructions in this manual have been compiled taking into account the
applicable standards and regulations as well as the state of the art.
➢For trouble-free and safe operation and the fulfilment of any warranty claims, first read
the user manual and follow the instructions.
➢Keep the user manual near the MultiControl.
➢Pass on the user manual to each subsequent owner or user.
The manufacturer assumes no liability for damage and malfunctions resulting from
non-compliance with this instruction manual.
If you still have questions after reading the operating instructions, contact Interroll
Customer Service. Contact persons in your area can be found on the internet at
www.interroll.com/contact/

About this document
Version 3.0 (08/2018)
2 Translation of original instruction manual
1.2 Warning notices in this manual
Warning notices are given in the context in which a hazard can occur to which the warning
notices refer. They are structured according to the following pattern:
SIGNAL WORD
Type an source of danger
➢Consequence(s) if disregarded
Measures to avoid the danger
Signal words indicate the type and severity of the consequences if the measures to avoid the
hazard are not followed.
DANGER
Indicates an imminent danger.
Failure to follow the preventive measures will result in death or serious injury.
➢Preventive measures
WARNING
Indicates a possible dangerous situation.
Failure to follow the preventive measures may result in death or serious injury.
➢Preventive measures
CAUTION
Indicates a potentially dangerous situation.
Failure to follow the preventive measures may result in minor or moderate injury.
➢Preventive measures
NOTICE
Indicates a situation that can lead to property damage.
➢Preventive measures

About this document
Version 3.0 (08/2018)
Translation of original instruction manual 3
1.3 Symbols
This symbol indicates useful and important information.
✓This symbol indicates a prerequisite that must be met before installation or maintenance
work.
This symbol represents general safety-related information.
➢This symbol marks the steps to be carried out.
•This symbol stands for enumerations.

Safety related information
Version 3.0 (08/2018)
4 Translation of original instruction manual
2Safety related information
2.1 State of the art
The Interroll MultiControl is built in compliance with applicable standards and state of the art
technology and is delivered safely. Nevertheless, hazards can arise during use.
Failure to follow the instructions in this manual may result in life-threatening injuries.
In addition, the local accident prevention regulations and general safety regulations applicable to
the area of application must be complied with.
2.2 Intended use
The MultiControl may only be used in industrial environments for industrial purposes within the
specified performance limits specified in the technical data.
It controls up to four Interroll RollerDrive or VDC Motors and must be integrated into a conveyor
unit or conveyor system before commissioning.
A corresponding adapter must be used to connect a VDC motor.
Areas of application
The following areas of application are possible:
Using a
PLC
Function of a PLC
Function of the MultiControl
No
None
Realization of the ZPA Logic
Yes
-Influencing the ZPA logic
-Tracking of conveyed items
-Fault diagnosis
Implementation of PLC specifications
Yes
-The PLC program controls all
connected RollerDrive
-Tracking of conveyed items
-Fault diagnosis
Function as network card
Sends the state of all Sensors,
RollerDrive and, if necessary, error
information to the PLC

Safety related information
Version 3.0 (08/2018)
Translation of original instruction manual 5
2.3 Unintended use
Any use that goes beyond the intended use shall be deemed not to be intended or shall be
authorised by Interroll Engineering GmbH if necessary.
The installation in areas where substances can form explosive atmospheres / dust atmospheres
and the use in the medical pharmaceutical sector are prohibited.
The installation in unprotected, weather-accessible spaces or areas in which the technology can
suffer and fail under the prevailing climatic conditions is considered to be not used as intended.
The use of the MultiControl is not intended for private end users! Use in a residential environment
is prohibited without further testing and without the use of appropriately adapted EMC
protective measures!
2.4 Personnel qualification
Not qualified personnel cannot identify risks and are therefore exposed to higher dangers.
➢Only qualified personnel are responsible for the activities described in these operating
instructions.
➢The operating company is responsible for ensuring that the personnel comply with local
regulations and rules for safe and risk-conscious work.
The following target groups are addressed in this manual:
Operator
Operators are instructed in the operation and cleaning of the Interroll MultiControl and follow
the safety instructions.
Service personnel
The service personnel has a technical training or has completed training of the manufacturer and
performs the maintenance and repair work.
Electrician
A qualified electrician has a technical training and is also able to perform work on electrical
equipment properly due to their knowledge and experience and the knowledge of the relevant
regulations. It can detect possible dangers on its own and avoid damage to persons and
property caused by electrical voltage.
All work on the electrical equipment may only be carried out by a qualified electrician.

Safety related information
Version 3.0 (08/2018)
6 Translation of original instruction manual
2.5 Dangers
Here you will find information about various types of hazards or damage that may
occur in connection with the operation of the MultiControl.
Personal injury
➢Only carry out maintenance and repair work on the device by authorized specialist
personnel in compliance with the applicable regulations.
➢Before switching on the MultiControl, make sure that there are no unauthorized personnel
in the vicinity of the conveyor / conveyor system.
Electricity
➢Carry out installation and maintenance work only when de-energized. De-energize the
MultiControl and secure against unintentional restart.
Working environment
➢Remove unnecessary material and objects from the work area.
➢Wear safety shoes.
➢Prescribe and monitor careful laying of the conveyed items.
Faults during operation
➢Check the MultiControl regularly for visible damage.
➢If smoke develops, switch the MultiControl off immediately and secure against unintentional
restart.
➢Immediately contact qualified personnel to determine the cause of the fault.
Maintenance
➢Since it is a maintenance-free product, it is sufficient to check the MultiControl regularly for
visible damage.
➢Never open the MultiControl!
Unintentional start up
➢Ensure that the connected RollerDrive / motors cannot start unintentionally, especially
during assembly, during maintenance work and in the event of a fault.

Safety related information
Version 3.0 (08/2018)
Translation of original instruction manual 7
2.6 Interfaces to other devices
When integrating the MultiControl into a conveyor system, danger spots may arise. These danger
spots are not part of these operating instructions and must be analysed during the development,
installation and commissioning of the conveyor system.
➢After integrating the MultiControl into a conveyor system, check the entire system for
potentially new danger spots before switching on the conveyor.
2.7 Operating modes / Operating phases
Normal mode
Operation in the installed state at the end customer as a component in a conveyor in a complete
system.
Special mode
Special mode are all operating modes / operating phases that are necessary to ensure and
maintain safe normal operation.
Special mode
Comment
Transport/Storage
-
Assembly/Initial start-up
In de-energized state
Cleaning
In de-energized state
Maintenance/Repairs
In de-energized state
Troubleshooting
-
Fault elimination
In de-energized state
Decommissioning
In de-energized state
Disposal
-

Safety related information
Version 3.0 (08/2018)
8 Translation of original instruction manual
2.8 Additional documentation
The MultiControl is part of the Interroll DC platform, consisting of:
•Power control
•RollerDrive
•RollerDrive-Control
Follow the instructions in the manuals of the connected devices.
The supplementary document "Interroll MultiControl - Operating and Programming" contains
further notes on the operating and programming of the MultiControl.
The latest version of the supplementary document is available on the Internet at:
www.interroll.com/support/

Product information
Version 3.0 (08/2018)
Translation of original instruction manual 9
3Product information
3.1 Product description
The MultiControl is a conveyor control system that can control up to four Interroll RollerDrive. It is
also a certified I/O device for PROFINET, EtherNet/IP and EtherCAT and can thus be networked
with other MultiControls and a PLC.
Sensors and RollerDrive can be integrated directly into the fieldbus level via the MultiControl. An
additional sensor/actuator level can thus be completely eliminated.
For applications with special conveyor logic, several applications are already pre-programmed in
the MultiControl. It can therefore be used as an individual control - with or without a PLC
connected.
The MultiControl is compatible with all 24V conveyor modules from Interroll Automation GmbH.
ZPA programs (Zero Pressure Accumulation) are used for the operation of the conveyor modules.
Further information on the integrated programs and functions can be found in the
supplementary document "Interroll MultiControl - Operating and Programming".
Energy recovery / Overvoltage protection
When the RollerDrive is stopped or the speed is abruptly reduced, the kinetic energy of the
conveyed material in the RollerDrive is converted into electrical energy as a generator. This
energy is fed back into the system, where it can be used by other RollerDrive.
If more energy is fed back than can be used, the excess energy is converted into heat by a brake
chopper in the MultiControl. The brake chopper becomes active when the voltage rises above
28 V. This avoids excessive voltages within the system.
Overload protection
If the brake chopper remains switched on for more than two seconds, it will be switched off
again, since in this case it is assumed that the power supply unit delivers an incorrect voltage. The
activated overload protection is indicated by the LED display. As long as the overload protection
is active, the motors cannot be switched on.
The MultiControl provides no protection against overheating of the connected RollerDrive.

Product information
Version 3.0 (08/2018)
10 Translation of original instruction manual
3.2 Structure
MultiControl
1 Magnetic sensor
9 Connection motor RD 4
2 LEDs for left-hand connections
10 Connection sensor 4 / I/O 4
3 General LEDs
11 Fastening screw
4 LEDs for right-hand connections
12 Nameplate
5 Labelling field
13 Connection sensor 2 / I/O 2
6 Connection sensor 3 / I/O 3
14 Connection motor RD 2
7 Connection motor RD 3
15 Connection motor RD 1
8 Connection bus
16 Connection sensor 1 / I/O 1
17 Connection Functional ground

Product information
Version 3.0 (08/2018)
Translation of original instruction manual 11
Baseplate
1 Logic and sensor power supply flat cable guide (L1)
2 RollerDrive power supply flat cable guide (L2)
3 Screw guides for fastening the MultiControl
4 Holes for fastening the MultiControl to the baseplate
3.3 Scope of delivery
The scope of delivery of the MultiControl includes the following parts:
•MultiControl
•Baseplate
•Two screws for fastening the MultiControl to the baseplate

Product information
Version 3.0 (08/2018)
12 Translation of original instruction manual
3.4 Nameplate
The information on the nameplate enables the identification of the MultiControl. This is necessary
in order to use the MultiControl as intended.
1 Article number
5 Serial number
2 MAC address
6 UL mark
3 Week and year of production
7 CE mark
4 Manufacturer
8 Connection data

Product information
Version 3.0 (08/2018)
Translation of original instruction manual 13
3.5 Technical Data
Rated voltage logic and sensors (L1)
24 V DC, Protective Extra Low Voltage PELV
Voltage range L1
22 to 26 V DC
Rated voltage RollerDrive (L2)
24 V DC, Protective Extra Low Voltage PELV
Voltage range L2
22 to 28 V DC
Current consumption
Logic supply voltage:
MultiControl: max. 0,2 A + connected
sensors/actors = max. 1,6 A
Motor supply voltage:
RollerDrive rated current: 4 x 1,75 A = 7 A
RollerDrive start up current: 4 x 3,5 A = 14 A
Protection rate
IP54 (not UL approved)
Pollution degree
2
Weight
500 g (incl. baseplate)
Ambient temperature in operation
-30 C bis +40 C
Ambient temperature during
transport and storage
-40 C bis +80 C
Max. temperature change
1 K/min, 3 h, 2 cycles
Max. relative humidity
93 % at +40 C, 14 days, not condensing
Max. installation height above sea
level
Max. 2000 m
The installation in systems at an altitude above
2000 m is possible in principle. However, it may
result in a reduction of the performance values.

Product information
Version 3.0 (08/2018)
14 Translation of original instruction manual
3.6 Dimensions
The distance from the MultiControl to neighbouring components must be at least 10
mm in order to operate the magnetic sensor.