rulmeca RDR BL3 User manual
RULLI RULMECA S.p.A., Via Toscanini 1, 24011 Almè, BG , Italy
Contents
1INTRODUCTION ..............................................................................................................................................4
1.1 This Technical Manual is protected by copyright......................................................................................4
1.2 Information on using the technical manual...............................................................................................4
1.3 Notices in this document...........................................................................................................................4
1.4 Basic safety instructions ...........................................................................................................................4
1.5 Prescribed use..........................................................................................................................................5
1.6 Non prescribed use...................................................................................................................................5
1.7 Qualified personnel...................................................................................................................................5
2HAZARDS ........................................................................................................................................................6
2.1 Personal injury..........................................................................................................................................6
2.2 Faults........................................................................................................................................................6
2.3 Prohibitions...............................................................................................................................................6
2.4 Installing the product in complex systems................................................................................................6
3PACKAGING AND DELIVERIES ....................................................................................................................7
3.1 Delivered Drive Rollers.............................................................................................................................7
4PRINCIPALS....................................................................................................................................................8
4.1 Roller distance..........................................................................................................................................8
4.2 Parallelism, orthogonality and alignment of the rollers.............................................................................8
4.3 Choosing the Drive Roller and its correct gear reduction ratio.............................................................. 10
4.4 Example of choosing the Drive Roller ................................................................................................... 11
4.5 Parameter conversions of the rotation speed of the Drive Roller.......................................................... 11
5Motion transmission systems.................................................................................................................... 12
6THE RDR BL3 DRIVE ROLLER................................................................................................................... 14
6.1 Configuration of the RDR BL3 Drive Roller ........................................................................................... 14
6.2 General Characteristics ......................................................................................................................... 15
6.3 Labelling Drive Roller............................................................................................................................. 16
7TECHNICAL DRAWINGS FOR DRIVE ROLLER ........................................................................................ 17
8WIRING.......................................................................................................................................................... 23
8.1 Prerequisites:......................................................................................................................................... 23
8.2 Power supply ......................................................................................................................................... 23
8.3 Prevention of electromagnetic interference........................................................................................... 23
8.4 Protection from spikes on the direct current line ................................................................................... 25
8.5 Electrical protection of the Drive Roller ................................................................................................. 25
9CONNECTING THE DRIVE ROLLER .......................................................................................................... 26
9.1 General.................................................................................................................................................. 26
9.2 Starting and stopping Drive Roller......................................................................................................... 27
9.3 Adjusting Drive Roller speed ................................................................................................................. 28
9.4 Reversal of direction of Drive Roller...................................................................................................... 29
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 3
10 FAULT SIGNALS.......................................................................................................................................... 30
10.1 Thermal overload fault........................................................................................................................... 31
10.2 Overcurrent fault.................................................................................................................................... 31
11 DRIVE ROLLER CURRENT ABSORPTION TABLES................................................................................. 32
11.1 Reduction ratio 12:1............................................................................................................................... 32
11.2 Reduction ratio 16:1............................................................................................................................... 32
11.3 Reduction ratio 24:1............................................................................................................................... 32
11.4 Reduction ratio 36:1............................................................................................................................... 33
11.5 Reduction ratio 49:1............................................................................................................................... 33
11.6 Reduction ratio 64:1............................................................................................................................... 33
11.7 Reduction ratio 96:1............................................................................................................................... 33
12 CONVEYOR COMMISSIONING PROCEDURE........................................................................................... 34
13 RECAPITULATION OF INSTRUCTIONS FOR ENSURING EFFICIENT OPERATION OF THE RDR DRIVE
ROLLER................................................................................................................................................................ 35
14 ADDITIONAL CABLE ................................................................................................................................... 36
15 DECOMMISSIONING - DISMANTLING THE DRIVE ROLLER ................................................................... 37
16 DISPOSAL OF THE DRIVE ROLLER .......................................................................................................... 37
17 WARRANTY.................................................................................................................................................. 38
18 CERTIFICATE OF INSTALLATION ............................................................................................................. 39
19 DATA REQUEST FORM FOR DRIVE ROLLERS APPLICATION .............................................................. 40
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 4
1 INTRODUCTION
1.1 This Technical Manual is protected by copyright
The owner of the copyright for this Technical Manual is Rulli Rulmeca S.p.A.
This document contains design instructions and applicational and technical drawings.
No part of this technical manual may be reproduced or divulged.
Any transfer of this manual to third parties must be authorized beforehand by Rulli Rulmeca S.p.A.
Rulli Rulmeca S.p.A. is authorized to transmit this document to the end customer and it is recommended to include
this document in the machine's technical documentation.
1.2 Information on using the technical manual
This technical manual contains instructions on choosing and installing RDR BL3 series Drive Rollers.
Read this technical manual carefully before starting to install the RDR BL3 product, and preferably even before
designing the electrical system that will electrically supply and control the Drive Rollers.
Rulli Rulmeca S.p.A, and its subsidiaries accept no liability for damage to objects, personal injury, harm to
processes or operating faults arising from noncompliance with the instructions contained in this manual.
This manual is supplied to the customer if it is specifically requested. In addition to the RDR product, the relative
simplified installation manual is supplied that summarizes the main installation and electrical wiring guidelines and
contains the relative notices and warnings.
The validity of this technical manual is limited by the edition shown at the bottom. The product and the technical
manual are linked together by the edition of the document, by the date of delivery of the product and by the serial
number on the Drive Roller. Later editions will show (but will not highlight) the differences from the previous version.
Customer Care at Rulmeca will highlight the differences if requested to do so.
Rulli Rulmeca S.p.A. does not announce new editions of the document.
This document is valid only for standard non-customized RDR BL3 products. Customized products are all those
versions or uses not listed in the catalog at the moment of delivery of the product.
If you have further doubts or problems that are not specified in this manual, please contact Customer Care at
Rulmeca before commencing maintenance work.
The latest edition of this technical manual can be consulted and downloaded from
http://rdr.rulmeca.com
1.3 Notices in this document
The notices in this document alert to hazards that may occur during use of the RDR BL3 product.
There are three levels of precautionary statement that are indicated by the following key words:
• Hazard: indicates imminent hazards that if they are not avoided will cause death or grave personal injury.
• Warning: indicates imminent hazards that if they are not avoided will cause death or grave personal injury.
• Caution: indicates imminent hazards that if they are not avoided may cause minor personal injury.
1.4 Basic safety instructions
The RDR BL3 product is manufactured in compliance with manufacturing regulations and is delivered in perfect
working order. Each component is tested before assembly, just as each Drive Roller BL3 is tested thoroughly
before being handed over to the customer.
Failure to comply with the notices in this manual can cause safety problems at the 3 levels described in the previous
paragraph.
We therefore recommend:
➢Always read this manual in its entirety before starting to install the RDR product.
➢Abide strictly with the technical and safety instructions contained in this manual.
➢Only qualified and trained persons are authorized to install the RDR product.
➢Always comply with current safety standards.
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 5
1.5 Prescribed use
The BL3 series Drive Roller must be installed and used only in industrial environments for non
continuous service within environmental conditions and min. and max. temperatures indicated in the catalog (use
in internal environment, at temperature comprised between -10/+35 °C, without condensate).
The RDR BL3 product is designed to convey only material contained in boxes and/or cases, or which can in some
way be conveyed on rollers.
It is located on roller conveyors or conveyors for very light belts (in this case the approval of Rulmeca is required).
Any other use falls outside its prescribed scope unless duly discussed and approved in writing by Rulmeca and
such use is deemed to be non-conformant and voids the product warranty.
Using the RDR BL3 product still requires the equipment housing it to comply with current health and safety
regulations.
It is forbidden to make modifications to the delivered product unless they have been previously agreed with
Rulmeca.
1.6 Non prescribed use
The RDR BL3 Drive Roller must not be used:
➢to convey people
➢with stress from direct blows / in impact areas
➢in environments at risk of explosion (Atex)
➢in very wet conveyors and/or where washing takes place
➢in general in applications requiring (IP) protection marking outside the levels specified in the catalog.
➢if the customer applies a cladding (rubber, polyurethane or cover in other materials) that has not been
approved by Rulmeca after analysing actual operating conditions.
Rulli Rulmeca S.p.a. and its subsidiaries are not liable for noncompliant and improper use of the product and are
not liable for direct or indirect harm arising from such noncompliant use, which also voids the product warranty.
1.7 Qualified personnel
Qualified personnel are persons who are able to read and understand this user manual and perform tasks
competently, in compliance with national and local regulations.
Only qualified and trained persons are authorized to work with the RDR BL3 product who are able to use and
understand perfectly:
• manuals and technical drawings
• instructions on conformant use
• mechanical assembly and electrical wiring
• particular standards and provisions that apply to the system
• national and local health and safety regulations
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 6
2 NEAR THE CONVEYOR HAZARDS
2.1 Personal injury
All the maintenance and repair work on the machine housing the RDR product must be performed only by qualified
and authorized persons in strict compliance with current regulations.
Before starting up the system, make sure that no unauthorized persons are near the conveyor. Any presences
must be known and there must be no misunderstandings or difficulties in immediate communication.
Electrical installation and maintenance work must be performed only after electrical current has been disconnected
and locked out and electrical discharges have been eliminated.
Make sure, during maintenance and/or installation, that it is not possible to unintentionally start parts that are able
to cause the conveyor to move (including the Drive Rollers).
When working on the conveyors (whether assembling or maintaining them), all the required personal protective
equipment (PPE) must be worn to avoid possible accidents.
The customer is solely responsible for making the workplace safe. Rulli Rulmeca S.p.A. and its subsidiaries are
not liable for any accidents or damage caused by carelessness or failure to comply with the instructions in this
manual.
2.2 Faults
Check the RDR BL3 product regularly for visible damage that is visible to the naked eye.
If smoke or strange noises come from the Drive Roller or components splined on or connected to it, stop the
conveyor immediately and make the system safe. Inform the qualified personnel and assigned workers
immediately in order to identify the cause of the problem and fix it.
2.3 Prohibitions
It is explicitly forbidden to tamper with any part of the RDR BL3 product (unless agreed beforehand with Rulmeca).
It is forbidden to dismantle the product. Dismantling the product (or part of it) and removing the product by breaking
its parts voids the warranty.
Do not dump the product when it comes to the end of its life, comply strictly with the waste disposal regulations in
force in the country in which it is disposed of.
2.4 Installing the product in complex systems
The RDR BL3 product can be installed in conveyors that are part of complex logistic systems and logics.
This technical manual refers only to the RDR BL3 product.
Consult the system documentation drawn up by the conveyor manufacturer to understand the general hazard
points.
It is the customer's responsibility to draw up the specific machine documentation and certification that
are required by the regulations of the country in which the conveyor is going to be used.
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 7
3 PACKAGING AND DELIVERIES
The Drive Rollers are packed and delivered in suitable and completely undamaged packaging. The Drive Rollers
are padded and spaced apart to ensure that no part of the Drive Roller gets damaged during transport.
If the customer finds damage to the package, he must immediately inform the courier by writing "accepted with
reservations" on the delivery note and then send a copy to Rulli Rulmeca.
The material is always accompanied by the relative installation instructions in an updated version and by the
components if they cannot be fitted directly to the Drive Roller.
When opening the package, NEVER handle the Drive Roller by holding it, pulling it or moving it by its power cable
in order not to damage the internal electric joints.
Any breakages caused by such negligence are not covered by the warranty.
3.1 Delivered Drive Rollers
Each RDR BL3 Drive Roller, before being delivered to the customer, has all its functions tested.
A sticker is affixed to the Drive Roller BL3 that has passed all the function and quality tests to certify that it has
passed the inspections.
In the case of Drive Rollers with a shell covered with rubber or special finishes, the quality control label will be
placed on the installation manual in order not to spoil the outer finish of the Drive Roller.
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 8
4 PRINCIPALS
4.1 Roller distance
The elements that determine the design of a roller conveyor are:
- the dimensions of the package to be conveyed (X and Y)
- the weight of the packages to be conveyed (M).
- the conditions of the surface in contact with the rollers (U).
The correct definition of the distance between the rollers or roller pitch (I) depends on the conformation of the
package to be transported. In order to obtain correct movement of the packages on the roller conveyor, make sure
that the contact surface of the package on the rollers is sufficiently stiff not to deform under the weight of the rollers.
In order to obtain an optimum transfer of the package without jumps or jams, at least 3 rollers must rest on the
material to be conveyed. In general, the more rollers are below the package, the better the linear travel of the
package will be.
WARNING. The maximum radial load of the rollers is indicated in the catalog.
Comply strictly with the conveyable weight limits stated in the definition of the correct roller pitch (I) of the conveyor.
The system designer is responsible (solely responsible) for checking that the maximum load (M) exerted by the
packages on all the components of the conveyor is within the required safety limits. In the case of a Drive Roller
applied to move a conveyor belt, the sum of the upper and lower belt tensions and the tangential force supplied
by the motor (T1+T2) must not exceed the declared load capacity of the Drive Roller.
If the surface of the package subjected to its own weight or through its nature is soft or deformable, provide a
greater number of rollers and a narrower roller pitch (I) in order to distribute the weight as much as possible.
X: Front of package forward conveying Y: Package length I: Roller pitch
4.2 Parallelism, orthogonality and alignment of the rollers
In order to obtain a package transfer that is as linear and rectilinear as possible on the roller conveyor, make sure
that the structure of the conveyor is horizontal (level) and with the support holes of the rollers aligned on one
another both in height and perpendicularly to the direction of travel.
Always make sure that the transferred package is as centred as possible and that its load is distributed as evenly
as possible over its entire surface resting on the rollers.
where
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 10
4.3 Choosing the Drive Roller and its correct gear reduction ratio
The Drive Roller is a roller with a built-in 24 VDC brushless electric motor.
Once it is started up, the Drive Roller can start movement of the package on the conveyor.
In order to obtain suitable movement, the following information is required for a correct gear reduction ratio of the
built-in motor:
- the maximum weight on the zone driven by each single Drive Roller (M in kg)
- the transit speed of the package on the conveyor (V in m/s)
- friction coefficient between package and rollers to calculate the required torque settings (U).
- the Speed / Tangential force / (and torque settings) table on the Drive Rollers catalog.
In order to calculate the tangential force required to transfer the package, the driven area (rollers + Drive Roller
connected by transmission system), defining the number of rollers connected to the Drive Roller.
With the above available (indispensable) data, apply the following formula:
Ft= P x G x U
Where:
Ft) Required tangential force (in Newton [N]).
P) Weight of the package (in kg).
G) Force of gravity (9.81 m/s2).
U) Revolving friction coefficient between package and rollers.
The revolving friction coefficient between package and rollers varies according to the material, hardness and
configuration of the contact surface of the packages.
Refer to the following friction coefficient values to make the calculation:
Steel, flat surface 0.03
Smooth PVC 0.04
Polymer section 0.05
Wood 0.05
Stiff cardboard 0.06
Soft cardboard 0.08
Stiff materials (of the same weight) require less tangential force to be moved whereas soft packages (again of the
same weight) tend to sag between one roller and the next one, requiring more tangential force to be moved.
In order to prevent the packages sagging between the rollers, with resulting jams or excessive torque required to
transport them, if the type of conveyed package cannot be changed, make the pitch between the rollers as small
as possible. In the case of packages or materials with feet or protrusions or very soft parts at the bottom, use a
support base, container or tray.
Once the tangential force (Ft) has been set that is necessary to move the package, after the package conveying
speed is known, refer to the tables for the single Drive Rollers to find the most suitable gear reduction ratio.
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 11
4.4 Example of choosing the Drive Roller
Weight of the conveyed material: 30 kg.
PVC package.
Conveying speed: 0.5 m/s.
Ft = 30 kg x 9.81 m/s2 x 0.04 = 11.7 N.
If you also need to know the torque required, consider the radius of the Drive Roller (equal to 25 mm = 0.025 m).
The torque (force x radius) is equal to 11.7 N x 0.025 m = 0.3 Nm.
The necessary mechanical power (W) (Tangential Force x Speed) will be 11.7 N x 0.5 m/s = 5.9 W.
Remember that the calculation does not take account of possible power absorption due to belts or transmission
systems for conveying the driven rollers (conveying differs according to the number, type and tension of connected
belts).
Use an appropriate safety coefficient to calculate oversizing.
When selecting the Drive Roller, in addition to the above data, you must also consider the type of use (intermittent
or continuous), average life required and the electronic functions required to run the system.
If you have doubts, fill in the form at the end of this manual and contact Rulli Rulmeca S.p.A. in order to check the
calculations made and that the correct Drive Roller has been chosen before you place your order.
WARNING! Allthe calculations described above (and the information in the catalog) assume that the tube diameter
is 50 mm. If claddings, rubberized features or liners increase tube diameter, speed increases proportionally and
torque decreases, in inverse proportion to the diameter.
Selecting the correct Drive Roller is the exclusive responsibility of the customer, unless agreed otherwise with Rulli
Rulmeca S.p.A. or its subsidiaries, which shall not be liable for any system malfunction, production loss or damage
to the conveyed items that are due to choosing the wrong type of Drive Roller.
4.5 Parameter conversions of the rotation speed of the Drive Roller
Linear speed is normally expressed in m/s. Use these formulas to convert speed from metres per minute [m/’] or
[m/min] to metres per second [m/s] and vice versa:
speed [m/sec] = [m/min] speed [m/min] = [m/s] x 60
60
Speed in terms of number of revolutions per minute or Rpm is the unit of measurement of the speed of rotation of
a body over one minute.
To convert the number of roller revolutions per minute [Rpm] into tangential linear speed in [m/s] and vice versa,
the Ø of the roller must be known (the thickness of the roller cladding could vary) and these formulas are used for
the conversion:
Known speed in m/s and roller diameter:
Speed [Rpm] = [m/s] x 1000 x 60
Ø[mm] x 3.14
Known speed in Rpm and roller diameter
Speed [m/s] = [Rpm] x Ø[mm] x 3.14
1000 x 60
Known speed in m/s and speed in Rpm:
Ø Roller [mm] = [m/s] x 1000 x 60
[Rpm] x 3.14
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 12
5 Motion transmission systems
It is possible to construct a driven roller conveyor using a Drive Roller connected to several rollers using specially
designed transmission systems. These systems are:
- Transmission of motion by round straps
- Transmission of motion by Poly-V belts
The rollers used in this type of conveyor are defined as DRIVEN. The portion of conveyor consisting of the Drive
Roller connected to "n” driven rollers by belts or straps, is defined as the ZONE.
Depending on requirements, Drive Rollers can also be made with double pinions 1/2" Z=14 for transmission to
chain link driven rollers.
Strap transmission
The straps are polyurethane rings (with different surface finishes, depending on the type of use) Ø 4 or 5 mm.
The extent / endless length of these rings depends on the roller pitch defined during the conveyor design phase.
The rings are obtained by cutting a cord, whose ends are then heat-welded together. For large quantities and
heavy-duty applications, the straps can be manufactured by molding, already closed and without welding.
Contact the strap manufacturer for the definition of the correct extent of the straps. In general, the diameter, the
extent and the pretensioning of the straps depends on the load conveyed; usually the manufacturers
recommend pretensioning that is not less than 8% of the extent.
Contact Rulmeca for check of chosen extent or in the event of doubts.
Each strap (like any transmission system) dissipates through its operation, part of the tangential force (Ft) supplied
by the Drive Roller. Allow for a tangential force loss of about 1N per strap. The total loss due to straps must be
subtracted from the tangential force supplied by the Drive Roller to transfer the packages.
Poly-V belt transmission
Using the transmission system with Poly-V belts is the best method to transmit motion to the driven rollers next to
the Drive Roller.
The driven rollers can be moved by Drive Rollers for conveyors even on slight inclines. Using belts with up to 4
ribs (max) for loads of medium weight.
The pulley for Poly-V belts of the Drive Roller enables belts with up to 4 ribs to be used, maintaining a free spacing
groove between the two belts, although most applications (max 50 daN) use 2-rib belts.
Owing to the compactness of the pulleys, there can be a greater free surface on the shell of the rollers and Drive
Rollers, using, where necessary, guards to protect the transmission from possible damage and/or for safety
reasons and to give the roller conveyor a neater appearance (with no visible belts).
To determine the max. transmittable load, the max. number of driven rollers upstream and downstream of the
Drive Roller, and the type of bottom of the conveyable package, if the designer is unskilled, the following data
should be supplied to Rulmeca to enable the chosen solution to be evaluated: type, speed, length and execution
of the chosen Drive Rollers, the number of driven rollers connected to each Drive Roller (in front and behind), min.
and max. dimension of the packages, min. and max. weight of the individual package, total maximum load per
area driven by a single Drive Roller, speed, shape and hardness of the bottom of the packages, environmental
conditions (min. and max. temperature, humidity, indoor, outdoor, rain, possible washing, foodstuffs). Rulmeca
can use this data to check the system designer's choices and advise on possible modifications or limitations.
The Poly-V pulley fitted to RDR Drive Rollers provides superior motion transmission. Internally, the pulley is splined
on the motor's transmission shaft to avoid slippage between the motor and the pulley; externally there is a
transmission tooth between the pulley and shell of the Drive Roller.
This arrangement totally eliminates any slippage between the motor and the pulley and between the pulley and
the tube due to temperature fluctuations or loose coupling between the tube and the pulley.
The direct transmission of motion between the motor and the pulley (Rulmeca patent) together with the mechanical
coupling between the pulley and the tube ensures safe and efficient traction in any working situation.
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 13
POSSIBLE POLY-V BELTS AND ROLLER PITCHES
Order code
Number of
ribs (*)
Reference printed
on belt
Description
Roller pitch (pulley
Ø43) [mm]
Actual extent of belt at
rest [mm]
BELT-*PJ-60
2 or 3
PJ 256
Poly-V belt, 2 or 3 ribs, PJ 256
60
252.5
BELT-*PJ-68
2 or 3
PJ 270
Poly-V belt, 2 or 3 ribs, PJ 270
65
259.8
BELT-*PJ-73
2 or 3
PJ 282
Poly-V belt, 2 or 3 ribs, PJ 282
70
271
BELT-*PJ-75
2 or 3
PJ 286
Poly-V belt, 2 or 3 ribs, PJ 286
75
275.3
BELT-*PJ-78
2 or 3
PJ 288
Poly-V belt, 2 or 3 ribs, PJ 288
78
280.1
BELT-*PJ-80
2 or 3
PJ 290
Poly-V belt, 2 or 3 ribs, PJ 290
80
284.5
BELT-*PJ-90
2 or 3
PJ 314
Poly-V belt, 2 or 3 ribs, PJ 314
90
306
BELT-*PJ-94
2 or 3
PJ 316
Poly-V belt, 2 or 3 ribs, PJ 316
95
313.5
BELT-*PJ-100
2 or 3
PJ 336
Poly-V belt, 2 or 3 ribs, PJ 336
100
325.5
BELT-*PJ-105
2 or 3
PJ 346
Poly-V belt, 2 or 3 ribs, PJ 346
105
336.6
BELT-*PJ-110
2 or 3
PJ 356
Poly-V belt, 2 or 3 ribs, PJ 356
110
347
BELT-*PJJ-120
2 or 3
PJ 376
Poly-V belt, 2 or 3 ribs, PJ 376
120
363.1
BELT-*PJ-125
2 o 3
PJ 388
Poly-V belt, 2 or 3 ribs, PJ 388
125
375
BELT-*PJ-133
2 or 3
PJ 416
Poly-V belt, 2 or 3 ribs, PJ 416
133
388
BELT-*PJ-153
2 or 3
PJ 442
Poly-V belt, 2 or 3 ribs, PJ 442
153
429
BELT-*PJ-160
2 or 3
PJ 456
Poly-V belt, 2 or 3 ribs, PJ 456
160
438.5
BELT-*PJ-175
2 or 3
PJ 486
Poly-V belt, 2 or 3 ribs, PJ 486
175
466
BELT-*PJ-200
2 or 3
PJ 536
Poly-V belt, 2 or 3 ribs, PJ 536
200
515
Warning the order code does not give the roller pitch. For permitted roller pitches, see the relevant column.
Warning the printed reference number on the belt (PJ-XXX) is not the extent and must not be used to calculate roller pitch.
The original winding diameter of the belt is calculated as 1 mm above the pulley: Dp = Ø pulley + 2 mm.
Recommended average tension 5%. Min/max permitted tension range 4-6%.
Torque transmitted by Poly-V belts with 4% min. pretensioning
Type
Torque
Torque loss per transmission ring
2PJ
1.0 Nm
0.028 Nm
3PJ
1.5 Nm
0.042 Nm
4PJ
2.0 Nm
0.056 Nm
Recommendations on fitting Drive Rollers
In roller conveyors provided with transmission systems with round straps or Poly-V belts, it is fundamental to install
the Drive Roller in a position that is central to the conveying area, with a similar number of driven rollers upstream
and downstream of the Drive Roller. If there is a precision stop or a significant package load, the Drive Roller can
be positioned as the first or second roller of the area, provided that the driven rollers on the other side are limited.
Technologically, the two different transmission systems ensure different performance with use restrictions.
If round straps are used, do not exceed the maximum number of 10 driven rollers connected to each Drive
Roller, and position the Drive Roller in the middle of the area.
If Poly-V belts are used, do not exceed the maximum number of 20 driven rollers connected to each Drive
Roller, and position the Drive Roller in the middle of the area.
The above quantities are maximum quantities for ensuring efficient transmission. If the above quantities are
exceeded, the decline in general performance may be considerable and may not ensure sufficient conveying
torque. These maximum numbers of driven rollers could be decreased, depending on the torque that can be
supplied by the different Drive Roller ratio reductions, depending on the loads to be conveyed and calculating the
torque required on the basis of the data specified above and the type of belt chosen.
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 14
6 THE RDR BL3 DRIVE ROLLER
The RDR Drive Roller is a motorized roller equipped with a 24Vdc low-voltage electrical Brushless motor.
The drive electronics, the motor and the reduction gear are contained inside the tube of the Drive Roller, with IP54
protection rating against penetration by solid and liquid bodies. The Drive Roller is available with different reduction
ratios for a vast range of torque settings and speeds. See the product specifications below.
6.1 Configuration of the RDR BL3 Drive Roller
•Standard tube: 50x1.5 galvanized Sendzimir (Z),
•Tube option 50x1.5 galvanized electrolytic (J)
•Tube option 50x1.5 AISI 304 stainless steel (I)
•Tube option with 1 or 2 grooves (standard position a=35 b=20)
•Tube lagging option - soft PVC sleeve (P)
•Tube lagging option - vulcanized rubber (R)
•Tube option with greater thickness, turned, cylindrical or convex, with surface processing or special heat
treatment.
•Size 11 hex (A/F) standard hexagonal pinion, male threaded M12, in galvanized steel (with standard bearings)
•Size 11 hex (A/F) , threaded male M12, stainless steel (with stainless steel bearings)
•Rulmeca cut-proof 5-wire cable, without halogens, 600 mm in length, with stripped wires, ready for cabling or
with 5-core connector (STD).
•Control head opposite the cable: standard with 6002-RS bearing, galvanized floating pin (or stainless steel
floating pin in combination with stainless steel pins) bored and threaded M8, size 19 wrench, with hexagonal
head screw and washer.
•Motor driven or friction driven control head opposite the cable: alternative, with 9 groove pulley, for flexible
Poly-V belts, PJ ISO 9981 DIN 7867 shape, with 6002-RS bearing, galvanized floating pin (or stainless steel
floating pin in combination with stainless steel pins), bored and threaded M8, size 19 wrench, supplied with
hexagonal head screw and washer. The floating pin is provided with an anti-extraction system.
•Motor driven or friction driven control head opposite the cable: alternative, with pulley, for 2 round straps
measuring 4 or 5 Ø with 6002-RS bearing, galvanized floating pin (or stainless steel floating pin in combination
with stainless steel pins), bored and threaded M8, size 19 wrench, supplied with hexagonal head screw and
washer. The floating pin is provided with an anti-extraction system.
M12 THREADED
HEXAGONAL PIN
BRUSHLESS
MOTOR
CASING
DRIVE-AXIS
CENTERING
COUPLER
TRANSMISSION
AXIS
CONNECTION
CABLE
REDUCTION GEAR
CONTROL
HEAD
ROLLER TUBE
5 CORE
CONNECTOR
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 15
6.2 General Characteristics
Dimensional data
Environmental conditions
Tube standard diameter
50 mm
Ambient operating temperature
-10 - +35 °C
Tube standard thickness
1.5 mm
Storage ambient temperature
-30 - +75 °C
Maximum length C
1500 mm
Maximum humidity
90% without
condensate
Electrical data
GENERAL TECHNICAL DATA
Nominal voltage
24 Vdc
Noise levels (Correctly assembled)
55 dB(A)
Power supply range
18 - 26Vdc
Theoretical average life in nominal
conditions
15'000 h
Max. operating current
3.8 A
Maximum static load on the Drive Roller
35 daN
No-load current
0.8 A
Max. inrush current
4.5 A
DRIVE ROLLER BL3 PERFORMANCE
Reduction ratio
Nominal max. tangential speed
Nominal
torque
Inrush
torque
Nominal
tangential
force
m/s
m/min
revs/min
Nm
Nm
N
min
MAX
min
MAX
min
MAX
12:1
0.03
1.25
1.8
75
11.6
484
0.9
1
36
16:1
0.02
1.00
1.2
60
7.7
387
1.15
1.3
46
24:1
0.02
0.70
1.2
40
7.7
258
1.75
1.95
70
36:1
0.01
0.45
0.6
27
3.8
172
2.6
2.9
104
49:1
0.01
0.33
0.6
20
3.8
126
3.2
3.6
128
64:1
0.01
0.25
0.6
15
3.8
97
4.2
4.7
166
96:1
0.005
0.16
0.3
10
1.9
65
6.3
7
252
The declared performance data refer to the Drive Roller with tube measuring 50 mm in diameter.
When adjusting speed, do not reduce below 10% of max. nominal speed
Extra-short* version
Standard version
Shell
Without
pulleys
or
pinions
With Poly-
V fixed
pulley
With Double
Groove pulley,
extractable
clutch or motor
With double
pinion
1/2" Z=14
extractable
clutch or
motor
Without
pulleys
or
pinions
With
grooves
on the
tube
Con Poly-
V fixed
pulley
With Double
Groove pulley,
extractable
clutch or motor
With double
pinion
1/2" Z=14
extractable
clutch or
motor
Red.
mm
mm
Mm
mm
mm
mm
mm
mm
mm
12-1
240
260
277
300
292
314
310
334
350
16-1
240
260
277
300
292
314
310
334
350
24-1
240
260
277
300
292
314
310
334
350
36-1
240
260
277
300
292
314
310
334
350
49-1
252
272
289
312
304
326
322
346
362
64-1
252
272
289
312
304
326
322
346
362
96-1
252
272
289
312
304
326
322
346
362
The weight of a Drive Roller measuring C=500 is about 2.8 kg, with cm increase of 0.026 kg/cm
* The length C of the Drive Roller in in the extra short version is a fixed value and is without grooves.
TECHNICAL MANUAL FOR THE RDR BL3 - V1.1 DRIVE ROLLER Rev. 21/09/2018 page 16
Warning the extra short version of the Drive Rollers could be a little noisier, as noise dampeners removed to
achieve smaller roller lengths.
6.3 Labelling Drive Roller
Each RDR Drive Roller has an adhesive identifying label placed on the plastic head on the cable output side.
The information on the label enables all the manufacturing data on the Drive Roller to be traced.
If you require information, contact Rulmeca Customer Care, quoting the serial number of the Drive Roller (S/N) so
that you can obtain the information more easily.
IDENTIFYING DATA
TYPE –REDUCTION
SERIAL NUMBER –
MONTH/YEAR
DRIVE MOTOR PERFORMANCE
R: REDUCTION RATIO
S: MAXIMUM SPEED
C: ROLLER LENGTH
V: CONTROL HEAD
MOTOR ELECTICAL DATA
IO: NO LOAD CURRENT
IF: NOMINAL CURRENT
IK: MAXIMUM CURRENT
PM: MOTOR POWER
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