rulmeca RDR BL3 User manual

RULLI RULMECA S.p.A., Via Toscanini 1, 24011 Almè, BG , Italy
Tel [phone] - Email: [email protected] -Web: www.rulmeca.com
TECHNICAL MANUAL
FOR THE RDR BL3 DRIVE ROLLER
Rev 0.2

RULLI RULMECA S.p.A., Via Toscanini 1, 24011 Almè, BG , Italy
Tel [phone] - Email: [email protected] -Web: www.rulmeca.com
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 9
RIGHT
WRONG

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.