Interroll DP 0080 User manual

INSPIRED BY EFFICIENCY
User Manual
Interroll Pallet Drive
DP 0080
DP 0089

Manufacturer
Interroll Trommelmotoren GmbH Interroll (Suzhou) Co. Ltd.
Opelstr. 3 No.16 Huipu Road
41836 Hueckelhoven/Baal Suzhou Industrial Park, Jiangsu
Germany Province 215126, Suzhou
Phone: [phone] China
www.interroll.com www.interroll-group.cn
Contents
We strive for the information presented to be correct, up to date and complete. We have carefully worked out the
contents of this document. However, we assume no liability for the information. We expressly deny any liability for
damages or consequential damages that are connected in any form with the use of this document. We reserve the
right to change the documented products and product information at any time.
Copyright / intellectual property right
Texts, images, graphics and the like as well as their arrangement are protected by copyright and other protection
laws. Reproduction, modication, 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.

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Table of Contents
1 Introduction 5
1.1 Information about the operating instructions.....................................................................................................................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 6
2.1 State of the art...........................................................................................................................................................................6
2.2 Intended use................................................................................................................................................................................6
2.3 Unintended use...........................................................................................................................................................................6
2.4 Personnelqualication..............................................................................................................................................................6
2.5 Dangers........................................................................................................................................................................................7
2.6 Interfaces to other devices......................................................................................................................................................8
3 Product information 9
3.1 Product description....................................................................................................................................................................9
3.1.1 Options...................................................................................................................................................................9
3.2 Thermal protection....................................................................................................................................................................9
3.3 Type plate of Pallet Drive..................................................................................................................................................... 10
3.4 Productidentication............................................................................................................................................................. 12
3.5 Technical data.......................................................................................................................................................................... 12
3.6 Electrical data.......................................................................................................................................................................... 13
3.6.1 DP 0080 3-phase and DP 0089 3-phase.................................................................................................. 13
3.7 Dimensions................................................................................................................................................................................ 13
4 Options and accessories 15
4.1 Electromagnetic brake for the Pallet Drive...................................................................................................................... 15
4.2 Asynchronous Pallet Drive with frequency inverters ..................................................................................................... 16
4.2.1 Torque dependent on input frequency........................................................................................................ 16
4.2.2 Frequency inverter parameters..................................................................................................................... 16
5 Transport and storage 18
5.1 Transport ................................................................................................................................................................................... 18
5.2 Storage...................................................................................................................................................................................... 18
6 Assembly and installation 19
6.1 Warning notices concerning the installation ................................................................................................................... 19
6.2 Installing the Pallet Drive....................................................................................................................................................... 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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6.4.3 External motor protection............................................................................................................................... 23
6.4.4 Integrated thermal protection ....................................................................................................................... 23
6.4.5 Frequency inverter............................................................................................................................................ 23
6.4.6 Electromagnetic brake .................................................................................................................................... 24
7 Initial startup and operation 25
7.1 Initial startup ............................................................................................................................................................................ 25
7.1.1 Checks before the initial startup................................................................................................................... 25
7.2 Operation................................................................................................................................................................................. 25
7.2.1 Checks before every startup.......................................................................................................................... 26
7.3 Procedure in case of accident or fault.............................................................................................................................. 26
8 Maintenance and cleaning 27
8.1 Warning notices concerning maintenance and cleaning............................................................................................. 27
8.2 Preparation for maintenance and cleaning by hand....................................................................................................27
8.3 Maintenance ............................................................................................................................................................................ 27
8.3.1 Checking the Pallet Drive................................................................................................................................ 27
8.4 Cleaning.................................................................................................................................................................................... 27
9 Troubleshooting 28
10 Decommissioning and disposal 32
10.1 Shutdown.................................................................................................................................................................................. 32
10.2 Disposal..................................................................................................................................................................................... 32
11 Appendix 33
11.1 List of abbreviations............................................................................................................................................................... 33
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rst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
Identiesadangerwithhighriskthatwillresultindeathorseriousinjuryifitisnotavoided.
WARNING
Identiesadangerwithmediumriskthatcouldresultindeathorseriousinjuryifitisnotavoided.
CAUTION
Identiesadangerwithlowriskthatcouldresultinminorormediuminjuryifitisnotavoided.
NOTICE
Identiesadangerthatresultsinpropertydamage.

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Safety
2 Safety
2.1 State 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 transport
of unit handling, such as pallets, cartons or crates. The Pallet Drive must be integrated into a conveyor module or
conveyor system. Any other use is considered inappropriate.
UseofthePalletDriveisonlyallowedintheareasdescribedintheproductinformationchapter.Anymodications
thataectthesafetyoftheproductarenotpermitted.
ThePalletDrivemayonlybeoperatedwithinthedened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from
electrocution 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 or
chains.
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speciedinaquote,Interrollanditsdealersshallassumenoliabilityfor
productdamageorfailurewhichresultfromfailuretoobservethesespecicationandrestrictions(seethechapter
„Electrical data” of the respective series).
2.4 Personnel qualication
Unqualiedpersonnelcannotrecognizerisksand,asaresult,issubjecttogreaterdangers.
• Authorizeonlyqualiedpersonneltoperformtheactivitiesdescribedintheseinstructions.
• The operating company must ensure that personnel follow locally applicable regulations and rules about safety and
hazards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 the
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 the
Pallet Drive.
Bodily injury
• MaintenanceorrepairworkonPalletDrivesmustonlybeperformedbyauthorizedservicepersonsinaccordance
with 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ve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
• 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qualiedpersonnelimmediatelytond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rmseatingofttings,screwsandnuts.An
additional maintenance is not required.
• Do not open the Pallet Drive.
Accidental motor start
• Take care during installation, maintenance work and cleaning or in the event of a Pallet Drive fault: The Pallet Drive
could start up unintentionally.
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and
have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.

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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 and
gears, which require frequent maintenance.
ThePalletDrivecanbeoperatedinenvironmentswithheavycoarseandne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.
3.1.1 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 to
the 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 is
drivenbyarectier.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:
3.2 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 the
motor.
WARNING
The thermal circuit breaker is automatically reset after the motor has cooled o.
Inadvertent start-up of the motor
¾Connect the thermal circuit breaker in series with a suitable relay or contactor so that the current supply to
the motor is safely interrupted when the switch trips.
¾Ensurethatthemotorcanbeswitchedonagainafteroverheatingonlywithaconrmationbutton.
¾Aftertheswitchhastripped,waituntilthemotorhascooledo,andensurepriortoswitch-onthatthereis
no danger to persons.

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Product information
Standard design: temperature limiter, automatically switching back
Service life: 10.000 cycles
AC cos φ = 1 2,5 A 250 V AC
cos φ = 0,6 1,6 A 250 V AC
DC 1,6 A 24 V DC
1,25 A 48 V DC
Service life: 2.000 cycles
AC cos φ = 1 6,3 A 250 V AC
Reset temperature 40 K ± 15 K
Resistance <50mΩ
Contact bounce time < 1 ms
3.3 Type plate of Pallet Drive
TheinformationonthenameplateofthePalletDriveisintendedforitsidentication.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 can
be 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 mark
2 Rated power 17 UKCAmark
3 Number of poles + operating mode 18 UL mark
4 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
3.4 Product identication
TheinformationgivenbelowisrequiredinordertoidentifyaPalletDrive.ThevaluesforaspecicPalletDrivecanbe
entered in the last column.
Information Possible value Own value
Type plate of Pallet Drive Motor type
Speed in m/s
Serial number
Between frames (BF) in mm
Number of poles
Power in kW
Drum diameter (tube diameter) e.g. 80 mm
3.5 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 level max. 1000 m

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Product information
3.6 Electrical data
Abbreviations see page 33.
3.6.1 DP 0080 3-phase and DP 0089 3-phase
PN nPnNfNUNINcos φηJRIS/INMS/MNMB/MNMP/MNMNRM
W min-1 Hz V A kgcm2Nm Ω
0,07 2 2889 50 400 0,33 0,56 0,54 1,25 4,2 4 4,5 4 0,23 72,7
0,07 2 2889 50 230 0,57 0,56 0,54 1,25 4,2 4 4,5 4 0,23 72,7
3.7 Dimensions
All length-related dimensions in the catalog and in these operating instructions comply with the requirements of DIN/
ISO 2768 (medium quality).
The recommended distance between the mounting brackets (EL) while taking into account the maximum
thermal expansion and internal tolerances is EL + 2 mm.

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Product information
Dimensions of Pallet Drive
Type A
mm
EL
mm
AGL
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 is
interrupted, 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speciedforthePalletDrive.
Features:
• Applied directly to the rotor shaft of the Pallet Drive.
• Holdsaloadequaltothespeciedtransportweight.
• Operationviaanexternalrectier.
• Operating temperature from -10 °C to +120 °C.
TheratedbrakingtorqueisheavilyinuencedbytheoperatingconditionsinsideofthePalletDriveaswell
astheambienttemperature.Forsafetyreasons,thespeciedbrakingtorqueshouldbereducedby50%for
load calculations.
Brake type Rated braking
torque
Rated output Rated supply voltage Rated current
Nm W V DC mA
24 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 case
of premature wear, the operating conditions must be checked and evaluated. The wear parts of the brake are not
included 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guredintothedimensioning
of 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signicantly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gure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aected
positively by high frequencies.
Voltage increase:
Interrollmotorwindingsaredesignedforaratedvoltageincreaserateof1kV/μs.Ifafrequencyinvertergenerates
a steeper voltage increase, motor chokes must be installed between the frequency inverter and the motor. However,
since all Interroll Pallet Drives run in an oil bath, the risk of overheating or damage to the motor due to high voltage
increase rates is extremely low. Contact your local Interroll dealer about the need for motor chokes.
Voltage:
Ifafrequencyinverterwithsingle-phasesupplyisinstalledinthePalletDrive,thespeciedmotormustbedesignedfor
the frequency inverter output voltage and must be connected accordingly. Single-phase motors cannot be operated
with a frequency inverter.

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Options and accessories
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specicallycreatedforPalletDrivefortherespectivefrequencyinverterscanbe
supplied upon request.
Maximum frequency:
ThePalletDrivemaybeoperatedonlyinafrequencyrangefrom10-50Hz.

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Transport and storage
5 Transport and storage
5.1 Transport
CAUTION
Improper transport poses a risk of injury!
¾Transport-relatedtasksshouldonlybecarriedoutbyqualiedandauthorizedpersons.
¾For 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.
¾Do not stack pallets.
¾Beforethetransport,ensurethatthePalletDriveissucientlysecured.
NOTICE
Risk of damage to the Pallet Drive due to improper transport!
¾Avoid strong impacts during transport.
¾Do not lift the Pallet Drive at the cable or at the terminal box.
¾Do not transfer the Pallet Drives between warm and cold environments. This may cause condensation to
form.
¾For 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 for
compensation.
5.2 Storage
CAUTION
Risk of injury due to improper storage!
¾Do not stack pallets.
¾Do not stack more than four cardboard boxes on top of each other.
¾Ensure 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 and
humidity.
2. Check each Pallet Drive for damage after storage.

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Translation of original operating instructions 19 of 40
Assembly and installation
6 Assembly and installation
6.1 Warning notices concerning the installation
CAUTION
otating parts and inadvertent startup of the motor!
Riskofcrushingforngers.
¾Do not reach into areas between Pallet Drive and conveyor belts or roller chains.
¾Installaprotectiondevice(suchasaguardplate)topreventngersfromgettingtrappedinthechainbelts
or roller chains.
¾Install an appropriate warning on the conveyor.
NOTICE
Risk of damage leading to failure or shortened service life of the Pallet Drive!
¾Do not drop or mishandle the Pallet Drive to avoid internal damages.
¾Prior to the installation, inspect each Pallet Drive for damage after storage.
¾Do 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.
¾Do 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conrmed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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Version 1.2 (08/2022) en
Translation of original operating instructions
Assembly and installation
6.2.2 Installation of Pallet Drive in mounting brackets
Themountingbracketsmustbesuciently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 the
transport 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 such
a 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.