SOCO S491800510 User manual
9724740011_2008.12.17_SPR_GB
www.socosystem.com
MANUAL
SOCO Power Roller - SPR
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9724740011_2008.12.17_SPR_GB
Table of contents
1. Introduction ................................................................................................................. 3
1.1. Functional description .............................................................................................................. 3
1.2. Safety information .................................................................................................................... 3
1.3. Keeping of the manual ............................................................................................................. 3
1.4. Who should read this manual? ................................................................................................ 3
1.5. Technical specifications for SPR ............................................................................................. 3
2. Safety ........................................................................................................................... 4
2.1. Safety in general...................................................................................................................... 4
2.2. Disposal ................................................................................................................................... 4
3. Survey .......................................................................................................................... 5
3.1. Survey of SPR ......................................................................................................................... 5
4. Operation, application, and compatibility................................................................. 6
4.1. Operation ................................................................................................................................. 6
4.2. Application ............................................................................................................................... 6
4.3. Compatibility ............................................................................................................................ 7
5. Accumulation systems ............................................................................................... 8
5.1. Accumulation principles ........................................................................................................... 8
5.2. Electric connection................................................................................................................... 8
5.3. Pressure or zero pressure accumulation ................................................................................. 9
5.4. Design of an accumulation section .......................................................................................... 9
5.5. Configuration of pressure accumulation .................................................................................. 10
5.6. Configuration of zero pressure accumulation .......................................................................... 11
6. Fault finding................................................................................................................. 13
6.1. Fault finding round belt conveyors ........................................................................................... 13
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9724740011_2008.12.17_SPR_GB
1. Introduction
1.1 Functional description
A SOCO Power Roller (SPR) is a stainless steel roller with incorporated motor, gear, and control
electronics. A speed regulator ensures that the roller operates a fixed speed by regulating the motor
current.
■SPR can be used partly for simple roller conveyor transport and partly for accumulation purposes.
■SPR can be controlled by means of a SOCO Power Supply Box (PSB) and/or by means of a PLC
control system.
■SPR fits SOCO SYSTEM’s series of 48 mm roller conveyors mechanically.
The following chapters describe the motor roller first and then the construction of the various
accumulation systems.
1.2 Safety information
This manual contains all information relating to safety required in connection with installation, operation,
and maintenance of the product.
This is a standard manual, and changes may have been made in connection with the individual product.
In that case, such changes are not described in this manual.
1.3 Keeping of the manual
The manual should be kept near the product or at least at a place to which the daily personnel has
access.
1.4 Who should read this manual?
The manual should primarily be read by the technical staff installing and maintaining the product as well
as the staff operating the product.
1.5 Technical specifications for SPR
Supply 24 VDC, +/- 2 VDC, max. ripple.
Maximum current 3 A.
Nominal current 1 A.
Ambient temperature during
operation
5-40°C. May not be placed in direct sun.
Speed 6, 10, 12, 20, 27, or 40 m/min.
Maximum number of non-driven
rollers
6 units (when more than 6 rollers are used, the maximum transport
weight is reduced).
Maximum transport weight 30 kg.
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9724740011_2008.12.17_SPR_GB
2. Safety
2.1 Safety in general
2.2 Disposal
The product is subject to directive 2002/96/EC on Waste Electrical and Electronic
Equipment (WEEE) and, in jurisdictions adopting that directive, is marked as being put
on the market after August 13, 2005, and should not be disposed of as unsorted
municipal waste.
Please utilize your local WEEE collection facilities in the disposal of this product and
otherwise observe all applicable requirements.
Our products conform to all relevant EC directives on safety and health. The
products are manufactured with reference to EC harmonised standards.
Some of our products require further safety guarding before use. This will appear
from the EC declaration of components.
Local authorities can make demands on the arrangement of a working place. This
does not encompass this delivery.
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9724740011_2008.12.17_SPR_GB
3. Survey
3.1 Survey of SPR
Five wires are led out of the roller and joined in a 6-poled
female socket. The illustrated socket is seen from the wire
side.
Colour Pin Name Application Direction Description
Brown 1Supply Supply To SP R 24 VDC
Green 3Neutral Supply To SP R 0 VDC
Should be connected with protective
conductor through power supply.
White 2 Direction Required direction
of rotation
To SP R 0 VDC = anti-clockwise (seen from the
supply end of the roller)
24 VDC = clockwise (seen from the
supply end of the roller)
Grey 6Accu Required operating
mode
To SP R 0 VDC = normal operation
24 VDC = pressure accumulation
operation
Yellow 5Status Start/stop
command
To SP R This wire is an inlet signal to SPR during
normal operation:
■0 VDC = motor in operation
■24 VDC = motor stopped
Status report From SPR This wire is an outlet signal from the roller
during pressure accumulation operation:
■0 VDC = motor in operation
■24 VDC = motor stopped in accumula-
tion operation
654
321
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9724740011_2008.12.17_SPR_GB
4. Operation, application, and compatibility
4.1 Operation
When connecting voltage, the motor control system initialises. This takes 1-2 seconds. During the
initialisation, the roller does not rotate.
The motor can be started in one of the following ways:
■Normal start: 0 VDC on the Status wire.
■Start after pressure accumulation stop: When voltage on the Accu wire changes from 24 VDC to
0 VDC, the roller will start after 1.5 seconds.
The motor can stop in one of the following ways:
■If 24 V DC is switched to the Status wire.
■If the motor load rate causes exceeding of the current limit.
Three current limits are defined for the motor: Maximum current, nominal current, and accumula-
tion current limits.
- During start (1.5 seconds), roller consumption up to maximum current is allowed.
- During normal operation, maximum roller current consumption is allowed for 2 seconds.
Otherwise, only up to nominal current.
- During accumulation operation, the roller consumption can only be up to its accumulation current
limit.
If the motor stops due to exceeding of the current limit, 24 VDC is switched to its Status wire. The signal
is reset to 0 VDC when the motor has started again.
4.2 Application
An SPR can be used during the following 2 operating modes: Normal operation and pressure
accumulation operation.
■During normal operation, the roller is controlled by means of the Status wire (Start/Stop).
■During pressure accumulation operation, the roller stops when passage for the item being
transported is blocked. When it receives information that the passage is clear again, it restarts.
IMPORTANT: If the roller is started while laying loose or held in the hand, please note that the end
part and not the metal roller will rotate. In this way, the cable from the roller will be damaged.
If the motor does not start, it waits 5 seconds until it makes another start attempt. When it has
made 10 start attempts, the waiting time between the start attempts increases to 15 seconds.
Important: An SPR should only be used in such a way that it does not rotate under an item for a
long period of time if the forward movement of the item is blocked. If this happens, the roller gets
very hot which will reduce the life of the motor. Furthermore, the blocked item can be damaged.
9724740011_2008.12.17_SPR_GB
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4.3 Compatibility
Old rollers with 5 wires
Full compatibility.
Old rollers with 2 wires
If a start-up time of 1-2 seconds is acceptable, the old roller with 2 wires can be connected with the brown
and green wires only. To avoid this start-up time, provide constant supply to the roller on the brown and
green wires. Start/Stop are then to be controlled by means of the yellow Status wire. Note: 0 VDC=Start,
24 V DC=Stop.
The direction of rotation of the motor is changed by switching 24 V DC to the white Direction wire (e.g.
by connecting it to the brown wire).
In some cases, a roller has been supplied through a resistance of 5 ohm. This can be removed with
advantage.
Rollers with 5 wires will often be regarded as weaker than rollers with 2 wires. This is correct and due to
the fact that the motor may not get as hot as previously due to the incorporated electronics. The tractive
power is, however, sufficient to handle the tasks for which it is designed.
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9724740011_2008.12.17_SPR_GB
5. Accumulation systems
5.1 Accumulation principles
An SPR is typically used for accumulation conveyors where each roller can accumulate one item. This
can be controlled either by a PLC system or by a SOCO power supply box.
This section describes accumulation by means of a Power Supply Box, subsequently named PSB.
An SPR can accumulate items according to two principles by means of a PSB:
■Pressure accumulation
■Zero pressure accumulation
Both principles can be compared with cars arriving at a traffic light with red light. The cars stop one by
one and await green light. When the light turns green, they start one at a time and continue forwards
spaced.
The difference between the two accumulation methods is that the cars will bump into each other in
connection with pressure accumulation whereas the cars will stop spaced in connection with zero
pressure accumulation.
Both principles imply a division of the roller conveyor into equally large zones. A zone consists of an SPR
and a number of non-driven rollers. The non-driven rollers are driven by an SPR by means of a belt drive.
If the zone is to have zero pressure accumulation, it must be equipped with a transmitter (photocell).
5.2 Electric connection
An SPR is connected to a PSB in connection with both accumulation principles. The PSB functions partly
as power supply for up to 7 rollers and partly generates the electric communication from SPR to SPR
and, if required, from PSB to PSB.
5 conductors are led out of an SPR. The 5 conductors are connected in a plug allowing easy installation
and, if required, relocation of an SPR without the use of tools.
The socket is available with wire lenghts in various standard dimensions. The free wire end is mounted
in PSB.
A PSB can be supplied with 110, 230, 400, or 440 V AC, 50 or 60 Hz, and its 24 V DC outlets to the roller
and transmitters are protected against overload and short-circuit.
A light-emitting diode can be seen through the lid of the PSB. If it lights green, everything is OK. If it lights
red, there is a short-circuit on the 24 V DC side. If it changes between green and red light, there is
overload on the 24 V DC side.
9724740011_2008.12.17_SPR_GB
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5.3 Pressure or zero pressure accumulation
Pressure accumulation can be used when the following requirements can be met:
■The lengths of the items are always identical.
■The weights of the items exceed 5 kg.
■The items can withstand collision with other items.
■The items are led to a fixed end stop.
Zero pressure accumulation must be used if:
■The lenghts of the items vary.
■The weights of the items are below 5 kg.
■The items cannot withstand collision with other items.
■There is no fixed end stop to lead items to.
The weight limit of 5 kg is an approximate limit. The essential factor is that the friction between item and
roller has the effect that the roller power consumption exceeds nominal current when the item is blocked.
This means that factors such as base dimensions, number of non-driven rollers, and the rolling friction
(paper quality) of the transported item are also important.
5.4 Design of an accumulation section
The design of an accumulation section starts at the outlet end of the section.
Components
The first SPR (SPR1) is placed here. A transmitter (S1) is also placed here when using the zero pressure
principle. A PSB (PSB1) for the first 7 rollers is also placed here. It partly functions as power supply and
partly transfers signals from one SPR to the next.
Wiring
SPR1 and S1 are connected to PSB1, terminal strip KL1.
SPR2 and S2 are connected to PSB1, terminal strip KL2.
This continues to SPR7 and S7 which are connected to PSB1, terminal strip KL7.
The subsequent numbering is as follows:
SPR8 and S8 are connected to PSB2, terminal strip KL1.
SPR9 and S9 are connected to PSB2, terminal strip KL2.
This also applies further backwards in the system.
9724740011_2008.12.17_SPR_GB
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The illustration above shows an accumulation section with 9 rollers, 9 photocells, and 2 power supply
boxes. Items are conveyed from left to right and accumulated by means of zero pressure accumulation.
Signal transfer between PSBs takes place by means of a cable with 2 conductors. Please see more
details on this in the PSB diagram.
5.5 Configuration of pressure accumulation
It is important that all zones are equally large and equal to the length of an item. If this is not completely
possible, remove the belt drive on a non-driven roller between 2 zones so that an accumulated item can
never be placed on a driven roller in the neighbouring zone.
Place the 6 DIP-switches on the PSB terminal strip printed circuit board in position “On”.
Design of “red stop light”
A transmitter to function as “the red stop light signal” must be installed. It could be a microswitch, a
photocell, a capacitive/inductive sensor, or the like with a 24 V DC PNP outlet.
The transmitter is connected to PSB1, terminal strip KL1, according to diagram.
Examples:
■If items are removed automatically or manually from the accumulation conveyor outlet, the
transmitter could be a photocell activated by the item just before it hits the mechanical end stop.
■If items are to be conveyed further on after the accumulation conveyor, the transmitter could be a
signal informing that a movable product stop is in position “stop further transport”.
Accumulation
The transmitter informs SPR1 to stop when SPR1 power consumption exceeds nominal current.
When item no. 1 hits the conveyor end stop, the friction between the item and SPR1 must have the effect
that SPR1 power consumption exceeds nominal current. This causes SPR1 to stop and switch 24 V DC
to its Status wire.
The Status signal from SPR1 is sent to the Accu wire of SPR2 through PSB and, thus, informing SPR2
to stop immediately upon the exceeding of nominal current.
When item no. 2 hits item no. 1, nominal current for SPR2 is exceeded. SPR2 stops and 24 V DC is
switched to its Status wire.
SPR5 S5
M
S
SPR6 S6
M
S
SPR7 S7
M
S
SPR8 S8
M
S
SPR1 S1
M
S
SPR2 S2
M
S
SPR3 S3
M
S
SPR4 S4
M
S
SPR9
M
S
S9
PSB1
PSB2
9724740011_2008.12.17_SPR_GB
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The Status signal from SPR2 is sent to the Accu wire of SPR3. This continues further backwards in the
system.
Onward transport
Outlet starts when the transmitter is switched off/opened (this means when the front carton is removed
or product stop is lowered). SPR1 starts after 1.5 seconds.
When SPR1 has accelerated (after yet another 1.5 seconds) it switches off its Status signal. This is
registered in SPR2, which starts after 1.5 seconds. This continues further backwards in the system.
5.6 Configuration of zero pressure accumulation
The length of the zone is determined by the length of the longest item to be conveyed plus approximately
100 mm depending on deceleration time and required distance between items.
If possible, remove the belt drive on one or two non-driven rollers between 2 zones so that an
accumulated item can never be placed on a driven roller in the neighbouring zone. This will give more
flexibility between short and long, heavy and light items.
A transmitter is placed in each zone approximately 100-150 mm before the outlet end of the zone.
The distance is chosen so that the heaviest item to be conveyed has time to brake within the zone.
Place the 6 DIP-switches on the PSB terminal strip printed circuit board in position “Off”.
Design of “red stop light”
Whether items are to be accumulated or be led straight through is determined by the connection between
terminals 13 and 14 on KL1 in PSB1. A jumper or an external contact signal can be inserted between
them depending on the application. This is described below.
Accumulation
Item no. 1 activates S1, and SPR1 stops. SPR1 sends a signal to SPR2 to stop when S2 is activated by
item no. 2. This continues further backwards in the system.
Onward transport
If item no. 1 is removed manually or automatically:
- When the item is removed S1 switches off and SPR1 and SPR2 start.
- Item no. 2 then leaves SPR2 and stops at S1.
- When S2 is no longer activated, SPR3 starts, and this continues further backwards in the system.
This function is made by inserting a jumper between terminals 13 and 14 on KL1 in PSB1.
If an item with a too low weight arrives at the accumulation section, the pressure accumulation
principle will not function, and zero pressure accumulation must be used.
9724740011_2008.12.17_SPR_GB
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In connection with further conveyance of items:
- Connect an external contact signal between terminals 13 and 14 on KL1 in PSB1.
- When the contact signal is opened SPR1 starts and item no. 1 is conveyed onward.
- When S1 is no longer activated, SPR2 starts. In this way, item no. 2 is conveyed to S1.
- When the external contact signal is closed again, SPR1 stops when S1 is activated again.
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9724740011_2008.12.17_SPR_GB
6. Fault finding
6.1 Fault finding round belt conveyors
If the roller does not function and is to be returned to SOCO SYSTEM, please include the following
pieces of information with the roller:
■What is the weight of the items?
■What is the capacity (number of items per minute)?
■How is the roller used: Pressureless accumulation, pressure accumulation, or continuous
accumulation?
Error Action
SPR does not rotate. ■Check wires from the roller visually. Is the cable damaged or has a wire
been pulled out?
■Connect supply voltage (only the brown and the green wires) - does the
roller rotate? If so, the problem is due to the control of the Status signal
to the roller.
IMPORTANT: If the roller is started while laying loose or held in the hand, please note that the end
part and not the metal roller will rotate. In this way, the cable from the roller will be damaged.
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SOCO SYSTEM companies
Main office Denmark:
SOCO SYSTEM A/S
Helgeshøj Allé 16D
2630 Taastrup
Denmark
Tel.: +45 43 52 55 66
Fax: +45 43 52 81 16
E-mail: [email protected]
www.socosystem.com
Sales office Denmark:
SOCO SYSTEM A/S
Jegstrupvej 8
8361 Hasselager
Denmark
Tel.: +45 86 28 77 22
Fax: +45 86 28 77 79
E-mail: [email protected]
U.K.:
SOCO SYSTEM Ltd.
Unit 18, Palmerston Street
Hanley, Stoke-On-Trent
Staffs. ST1 3EU
U.K.
Tel.: +44 1 782 274 100
Fax: +44 1 782 272 696
E-mail: [email protected]
Germany:
SOCO SYSTEM GmbH
Graf-Zeppelin Strasse 12
46149 Oberhausen
Germany
Tel.: +49 208 629 350
Fax: +49 208 629 3511
E-mail: [email protected]
Hungary:
SOCO SYSTEM EED KFT.
Eastern Europe Division
1031, Budapest, Záhony u. 7.
1300 Budapest, Pf. 32
Hungary
Tel.: +36 1 436 0460
Fax: +36 1 436 0461
Spain:
SOCO SYSTEM Spain S.A.
Juli Galvé Brusson, 8
Poligono Industrial Sur
08918 Badalona - Barcelona
Spain
Tel.: +34 9 3464 3016
Fax: +34 9 3464 4877
France:
SOCO SYSTEM S.A.
Avenue des deux Vallées
Z.A. Actipôle de L’A2
59554 Raillencourt Sainte Olle
France
Tel.: +33 3 27 729 729
Fax: +33 3 27 729 730
E-mail: [email protected]
USA:
SOCO SYSTEM Inc.
1931 MacArthur Road
Waukesha
Wisconsin, 53188
USA
Tel.: +1 262 547 0777
Fax: +1 262 547 4707
E-mail: info@socosysteminc.com
Forhandler-Dealer-Händler-Agent
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