INSPIRED BY EFFICIENCY

Operating manual
MultiControl AI / BI
Analogue Interface / Bus Interface – 24 V / 48 V DC
Manufacturer details
Interroll Engineering GmbH
Höferhof 16
42929 Wermelskirchen
Germany
Tel.: +49 (0) 2193 23 0
Fax: +49 (0) 2193 2022
www.interroll.com

Content
We strive for the accuracy, timeliness and completeness of the information and have carefully prepared the contents
in this document. Regardless of this, errors and changes are expressly reserved.

Copyright/industrial property rights

Any texts, images, graphics and the like, as well as their arrangement, are subject to protection under copyright and
other laws of protection. The reproduction, modification, transmission or publication of any part of this document or of
the entire document in any form is prohibited.
The document serves the exclusive purposes of information and of operation in accordance with the regulations and
does not justify any counterfeiting of the products concerned.
All signs contained in this document (protected marks, such as logos and trade names) are the property of Interroll
Holding AG, CH or of third parties and must not be used, copied or distributed without prior written consent.

Online version - only suitable for color printing!

 Contents

1 About this document 7

1.1 Information about this operating manual 7
1.2 Warning notices in this document 8
1.3 Symbols 9
2 Safety-related information 10
2.1 State of the art 10
2.2 Proper use 10
Application field 10
2.3 Improper use 11
2.4 Qualification of personnel 11
2.5 Dangers 12
Injury to persons 12
Electricity12
Work environment 12
Faults in operation 12
Maintenance12
Unintentional start-up 12
2.6 Interface to other devices 13
2.7 Functional safety 13
Information on the performance level according to DIN EN ISO 13849-1: 2015 13
2.8 Operating modes/operating phases 14
Standard operation 14
Special operation 14
2.9 Applicable documentation 14
3 Product information 15
3.1 Product description 15
Energy recovery/overvoltage protection 15
Overload protection 15
3.2 Setup 16
MultiControl AI and BI 16
Base plate 17
3.3 Scope of delivery 17
3.4 Rating plate 18
3.5 Technical specifications 19
3.6 Dimensions 20

Version 2.9 (11/2021) Online

Translation of the original operating manual 3 of 68
Contents

4 Transport and storage 21

4.1 Transport 21
4.2 Storage 21
5 Assembly and installation 22
5.1 Warning notices for installation 22
5.2 Assembling the MultiControl 22
Initial assembly 22
Subsequent assembly 24
5.3 Warning notices for electrical installation 25
5.4 Electrical installation 26
Connecting the power supply 26
Connecting the RollerDrive 27
RollerDrive AI 27
RollerDrive BI 27
Connecting the bus 28
Connecting the sensors 29
Overview of connections 30
6 Start-up and operation 31
6.1 Start-up 31
Check before the initial start-up 31
6.2 Configuration options 31
6.3 MultiControl user interface 32
Prerequisites32
Starting the user interface 32
“MultiControl Overview” home page 34
Network Settings 35
Motor Settings 36
Motor Information – MultiControl BI only 38
Motor Monitor – MultiControl BI only 39
Motor Test for EC5000  40

Version 2.9 (11/2021) Online

4 of 68 Translation of the original operating manual
 Contents

Digital I/O States 41

Digital I/O Settings 42
Control Program Settings 44
Error State 45
Error Handling Settings 45
MultiControl Error Log 47
Teach-in48
Plug&Play48
CAN Gateway 48
Service Change Password 49
Service Restore Factory Settings 49
Service MultiControl Restart 50
Service Version Information 50
Service – Up-/Download 51
6.4 Magnetic sensor 52
6.5 Service data objects (SDO) 52
6.6 Operation 53
Check before every start-up 53
Start53
Stop53
6.7 Procedure in the event of accidents or faults 54
7 Maintenance and cleaning 55
7.1 Maintenance 55
Checking the MultiControl 55
Replacing the MultiControl 55
7.2 Cleaning 56
8 Assistance in the event of faults 57
8.1 Understanding the LEDs 57
General LEDs 57
Connection LEDs 59
8.2 Troubleshooting 59
Error codes 62

Version 2.9 (11/2021) Online

Translation of the original operating manual 5 of 68
Contents

9 Decommissioning and disposal 65

9.1 Decommissioning 65
9.2 Disposal 65
10 Appendix 66
10.1 Accessories 66
10.2 Translation of the original Declaration of Conformity 67

Version 2.9 (11/2021) Online

6 of 68 Translation of the original operating manual
 About this document

1 About this document

1.1 Information about this operating manual
This operating manual describes the following versions of the Interroll MultiControl:
• Interroll MultiControl AI with analogue interface
• Interroll MultiControl BI with CANopen bus interface
Throughout this manual, the term “control system” is used as an alternative for referring to these models.
The operating manual is a component of the product and contains important advice and information regarding the
different operating phases of the MultiControl. It describes the MultiControl at the time of shipping from Interroll.
The currently applicable version of this operating manual can be found online at:
www.interroll.com/products-solutions/downloads/
All the information and advice in this operating manual has been compiled with respect to applicable standards and
regulations as well as the current state of the art.
¾ To ensure safe and faultless operation and to fulfil any warranty claims that may apply, read this operating
manual first and observe its instructions.
¾ Keep this operating manual within close reach of the MultiControl.
¾ Pass this operating manual onto every subsequent owner or user.

The manufacturer assumes no liability for damage and malfunctions that occur as a result of non-
compliance with this operating manual.

Should you still have any unanswered questions after reading this operating manual, please contact Interroll
customer service. Contact details for your region can be found online at www.interroll.com/contact/

Please direct any comments and suggestions regarding our operating manuals to [email protected]

Version 2.9 (11/2021) Online

Translation of the original operating manual 7 of 68
About this document

1.2 Warning notices in this document

Warning notices are provided in the context in which danger can occur and describe the nature of the danger in
question. They are structured according to the following examples:

SIGNAL WORD
Type and source of hazard
Consequence(s) in the event of non-compliance
¾ Measure(s) for avoiding hazard

Signal words indicate the type and severity of the consequences if measures to avoid the hazard are not observed.

DANGER
Denotes an imminent hazard.
If measures to avoid the hazard are not observed, death or severe injury will occur.
¾ Preventive measures

WARNING
Denotes a potentially hazardous situation.
If measures to avoid the hazard are not observed, death or severe injury may occur.
¾ Preventive measures

CAUTION
Denotes the possibility of a hazardous situation.
If measures to avoid the hazard are not observed, minor or moderate injury may occur.
¾ Preventive measures

Version 2.9 (11/2021) Online

8 of 68 Translation of the original operating manual
 About this document

NOTE
Denotes a situation that can lead to material damage.
¾ Preventive measures

1.3 Symbols

This symbol indicates useful and important information.

ü This symbol indicates a requirement that must be fulfilled before carrying out assembly or repair work.

This symbol indicates general information relating to safety.

 This symbol indicates an action that needs to be performed.

• This symbol indicates a listed item.

Version 2.9 (11/2021) Online

Translation of the original operating manual 9 of 68
Safety-related information

2 Safety-related information
2.1 State of the art
The Interroll MultiControl has been constructed with respect to applicable standards and the current state of the art
and has been delivered in a condition that is safe to operate. Nevertheless, hazards can occur as a result of use.

Non-compliance with the instructions in this operating manual can result in life-threatening injuries.

In addition, the applicable local accident prevention regulations for the area of application and general safety
regulations must be adhered to.

2.2 Proper use

The MultiControl may only be used in an industrial environment for industrial purposes within the stipulated
performance limits that are given in the technical specifications.
It controls up to four Interroll RollerDrives or VDC motors and must be integrated into a conveyor unit or conveyor
system before commissioning.

A suitable adapter must be used for connecting a VDC motor.

The MultiControl AI, 24 V DC can also be used to control the Interroll PalletControl.

Application field
The following applications are possible:

Use of a PLC Function of a PLC Function of the MultiControl

No None
Yes • Influence on ZPA logic Implementation of PLC specifications
• Tracking of material to be
conveyed
• Error diagnosis
Yes • The PLC program controls all Function as network card
connected RollerDrives Sends the status of all sensors and the
• Tracking of material to be RollerDrive and, if necessary, error
conveyed information to the PLC
• Error diagnosis

Version 2.9 (11/2021) Online

10 of 68 Translation of the original operating manual
 Safety-related information

2.3 Improper use

Any use that goes beyond the proper use is considered improper, unless this has been authorised by Interroll
Engineering GmbH where applicable.
The equipment must not be installed in areas in which substances could form explosive atmospheres/dust atmospheres
or for application in the medical/pharmaceutical sector.
It is considered improper use to install the equipment in exposed spaces that are open to potentially adverse weather
conditions, or areas in which the technology would suffer from the prevailing climactic conditions and could potentially
malfunction as a result.
The MultiControl is not intended for use by private end users. The equipment must not be used in a residential
environment without further examination and without the use of EMC protective measures that have been adapted
accordingly.
It must not be used as a safety-relevant component or for performing safety-relevant functions.

2.4 Qualification of personnel

Non-qualified personnel are unable to identify risks and are therefore exposed to higher levels of danger.
¾ Only qualified personnel may be assigned with the tasks outlined in this operating manual.
¾ The operating company is responsible for ensuring that personnel adhere to the locally valid rules and
regulations for working in a safe and risk-aware manner.
This operating manual is intended for the following target audiences:
Operators
Operators are trained in how to operate and clean the Interroll MultiControl and follow the safety regulations.
Service engineers
The service engineers have a specialist technical education or have successfully completed a training course from the
manufacturer. They carry out repair and maintenance work.
Qualified electricians
Qualified electricians have a specialist technical education. Moreover, due to their knowledge and experience as well
as knowledge of applicable regulations, they are able to carry out work on electrical equipment in an appropriate
manner. They are able to identify hazards independently and prevent electrical damage to persons and property.
All work on electrical equipment must generally only be performed by a qualified electrician.

Version 2.9 (11/2021) Online

Translation of the original operating manual 11 of 68
Safety-related information

2.5 Dangers
Here, you will find information about the different types of dangers or damage that can occur in
connection with the operation of the MultiControl.

Injury to persons
 Maintenance, installation and repair work on the unit must only be carried out by authorised technical personnel
in compliance with the applicable provisions.
 Before switching on the MultiControl, ensure that no unauthorised personnel are situated in the vicinity of the
conveyor/conveying system.
Electricity
 Installation and repair work must only be carried out when the system has been disconnected from the power
supply. Switch off the power to the MultiControl and ensure that it cannot be unintentionally switched on again.
Work environment
 Remove any materials and objects that are not required from the working area.
Faults in operation
 Regularly check the MultiControl for visible damage.
 If smoke develops, immediately switch off the power to the MultiControl and ensure that it cannot be
unintentionally switched on again.
 Immediately contact specialist personnel to determine the cause of the malfunction.
Maintenance
 Since the product in question requires no maintenance, it is sufficient to simply examine the MultiControl for
visible damage on a regular basis.
 Never open up the MultiControl.
Unintentional start-up
 Ensure that the connected RollerDrives/motors cannot start up unintentionally, particularly during assembly and
maintenance work or in the event of a fault.

Version 2.9 (11/2021) Online

12 of 68 Translation of the original operating manual
 Safety-related information

2.6 Interface to other devices

The integration of the MultiControl into a conveyor system can create additional potential hazards. Such potential
hazards are not covered by this operating manual and must be analysed during the development, installation and
commissioning of the conveyor system as a whole.
¾ Following the integration of the MultiControl into a conveyor system, the entire system must be checked for any
new potential hazards that may be present before the conveyor is switched on.

2.7 Functional safety

Information on the performance level according to DIN EN ISO 13849-1: 2015
The statistical analysis of the MultiControl AI / BI according to the „Part Counts Method” has led to the following result
if the maximum permissible ambient temperature of 40 °C is observed:

MTTF (h):
812691 Hours
MTTF (a):
93 Years

Provided that the behavior of the MultiControl is changed in the event of system-relevant errors in the “Error
Handling Settings” of the MultiControl user interface, this results in an achievable performance level of “C” (see
„Error Handling Settings“ on page 45).

Error Handling Settings

System Errors Control Errors
 
Network Error : Immediate Stop  Control Error 1 : Ignore 
Over Voltage Error : Immediate Stop  Control Error 2 : Ignore 
Under Voltage Error : Immediate Stop  Control Error 3 : Ignore 
Motor Error : Immediate Stop  Control Error 4 : Ignore 
General Control Error : Immediate Stop  Control Error 5 : Ignore 
Sensor Error : Ignore Control Error 6 : Ignore 
Control Error 7 : Ignore 
Control Error 8 : Ignore

Submit Reset

In order to fulfill a safety function, the safety-related disconnection of the load voltage (motor voltage) is also
required.

Version 2.9 (11/2021) Online

Translation of the original operating manual 13 of 68
Safety-related information

2.8 Operating modes/operating phases

Standard operation
Operation in the installed condition at the end customer as a component in a conveyor in an overall system.
Special operation
Special operation encompasses all operating modes/operating phases that are necessary to guarantee and maintain
safe standard operation.

Special operating mode Comments

Transport/storage -
Assembly/commissioning In de-energised state
Cleaning In de-energised state
Maintenance/repair In de-energised state
Fault location -
Troubleshooting In de-energised state
Decommissioning In de-energised state
Disposal -

2.9 Applicable documentation

The MultiControl AI/BI is part of the Interroll DC Platform, consisting of:
• Interroll High Performance power supply unit HP5424 or HP 5448 (24 V DC/48 V DC)
• Interroll MultiControl AI/BI
• RollerDrive EC5000 AI/BI (24 V DC/48 V DC)
• Interroll DriveControl 20/54/2048

Also ensure that you adhere to the information given in the operating manuals of the connected devices.

Further notes on operating and programming the MultiControl can be found in the “MultiControl / RollerDrive - Start-
up and Programming” supplement.
The latest version of this supplement can be found online at: www.interroll.com

Version 2.9 (11/2021) Online

14 of 68 Translation of the original operating manual
 Product information

3 Product information
3.1 Product description
The MultiControl is a control system for conveyor systems, which can control up to four Interroll RollerDrives. It is also
a certified I/O device for PROFINET, EtherNet/IP and EtherCAT and can therefore be linked with other MultiControls
and a PLC.
Sensors and RollerDrives can be directly integrated into the fieldbus level via the MultiControl. This completely
eliminates the need for an additional sensor/actuator level.
Some applications are already pre-programmed in the MultiControl for applications with special conveying logic. It
can therefore be used as a standalone control system – with or without connected PLC.
The MultiControl is compatible with all 24 V/48 V conveyor modules from Interroll Automation GmbH. So-called ZPA
(zero pressure accumulation) programs are used for operating the conveyor modules with zero pressure accumulation.
The MultiControl BI communicates with the connected RollerDrive EC5000 BI via the CANopen protocol.

Further information on the integrated programs and functions can be found in accompanying document
"MultiControl / RollerDrive - Start-up and Programming".

Energy recovery/overvoltage protection

If the RollerDrive is stopped or the speed is abruptly reduced, the kinetic energy of the conveyed material in the
RollerDrive is converted into electrical energy, akin to a generator. This energy is fed back into the system, where it
can be used by other RollerDrive units.
If more energy is fed back than can be used, the excess energy is converted into heat via a brake chopper in the
MultiControl. The brake chopper is activated when the voltage rises above 28 V/52 V. This prevents excessively high
voltages within the system.

Note the energy recovery capacity of the power supply units used.
We recommend the use of Interroll High Performance power supplies HP 5424 / HP5448 with a
regenerative strength up to 35 V / 60 V.
With the MultiControl 24 V it is possible to reduce the brake chopper operating voltage to 26 V
(see „Motor Settings“ on page 36).

Overload protection
If the brake chopper remains switched on for longer than two seconds, it is switched off again as it is assumed that the
power supply unit is delivering an incorrect voltage. The activated overload protection is indicated by the LED display.
Whenever the overload protection is active, the motors cannot be switched on.
The MultiControl does not provide a protective mechanism against excess temperature in the connected RollerDrive.

Version 2.9 (11/2021) Online

Translation of the original operating manual 15 of 68
Product information

3.2 Setup
MultiControl AI and BI

1 Magnetic sensor 9 Motor RD 4 connection

2 LED for connections on the left 10 Sensor 4 / I/O 4 connection
3 Control status LED 11 Fastening screw
4 LED for connections on the right 12 Rating plate
5 Identification plate 13 Sensor 2 / I/O 2 connection
6 Sensor 3 / I/O 3 connection 14 Motor RD 2 connection
7 Motor RD 3 connection 15 Motor RD 1 connection
8 Bus connection 16 Sensor 1 / I/O 1 connection
17 Functional earth connection

Version 2.9 (11/2021) Online

16 of 68 Translation of the original operating manual
 Product information

Base plate

1 Cable guide for power supply to logic and sensors (L1)

2 Cable guide for power supply to RollerDrive (L2)
3 MultiControl fixing
4 Holes/slot for attaching the base plate

3.3 Scope of delivery

The scope of delivery of the MultiControl includes the following parts:
• MultiControl
• Base plate
• Two screws for attaching the MultiControl to the base plate

Version 2.9 (11/2021) Online

Translation of the original operating manual 17 of 68
Product information

3.4 Rating plate

The information on the rating plate allows the MultiControl to be identified. This is essential to be able to use the
MultiControl as intended.

1 Article number 5 Serial number

2 MAC address 6 UL marking
3 Week/year of production 7 CE marking
4 Manufacturer 8 Connection data

Version 2.9 (11/2021) Online

18 of 68 Translation of the original operating manual
 Product information

3.5 Technical specifications

Rated voltage for logic and sensors (L1) 24 V DC, protected extra-low
voltage (PELV)
Voltage range L1 22 to 27,5 V DC
Rated voltage for RollerDrive (L2) 24 V DC, protected extra-low 48 V DC, protected extra-low
voltage (PELV) voltage (PELV)
Voltage range L2 22 to 27,5 V DC 44 to 51,5 V DC
Current consumption Logic supply voltage L1:
MultiControl: Max. 0.2 A + connected sensors/actuators = max.
1.6 A
RollerDrive supply voltage L2:
RollerDrive rated current: RollerDrive rated current:
Max. 4 x 3.5 A = 14.0 A Max. 4 x 1.75 A = 7.0 A
RollerDrive starting current: RollerDrive starting current:
Max. 4 x 7.5 A = 30.0 A Max. 4 x 3.8 A = 15.2 A
Protection rate IP54 (not UL-tested)
Degree of contamination 2
Weight 500 g (incl. base plate)
Ambient temperature in operation -30 °C to +40 °C
Ambient temperature during transport and -40 °C to +80 °C
storage
Max. temperature change 1 K/min, 3 h, 2 cycles
Max. relative humidity 93% at +40 °C, 14 days, non-condensating
Altitude of installation site Max. 1000 m
In principle, it is possible to install the equipment at altitudes
higher than 1000 m. However, this may reduce the performance
values.

Version 2.9 (11/2021) Online

Translation of the original operating manual 19 of 68
Product information

3.6 Dimensions

The distance between the MultiControl and neighbouring components must be at least 10 mm in order to
be able to operate the magnetic sensor.

Version 2.9 (11/2021) Online

20 of 68 Translation of the original operating manual
 Transport and storage

4 Transport and storage

4.1 Transport

CAUTION
Risk of injury from improper transport.
¾ Transport operations must only be carried out by authorised, qualified personnel.

Please note the following:

¾ Do not stack pallets on top of one another.
¾ Prior to transport, check whether the MultiControl is correctly attached.
¾ Avoid heavy impacts during transport.
¾ Check each MultiControl after transport for any visible damage.
¾ If any damage has been identified, photograph the damaged parts.
¾ In the event that damage has been incurred during transport, inform the shipping agent or Interroll
immediately to ensure that you do not lose any potential damage claims.
¾ Do not expose the MultiControl to any strong fluctuations in temperature, since this can lead to condensation
forming.

4.2 Storage

CAUTION
Risk of injury due to improper storage.
¾ Ensure that the MultiControl is stored safely.

Please note the following:

¾ Do not stack pallets on top of one another.
¾ Check each MultiControl after storage for any visible damage.

Version 2.9 (11/2021) Online

Translation of the original operating manual 21 of 68
Assembly and installation

5 Assembly and installation

5.1 Warning notices for installation

NOTE
An improper approach to installing the MultiControl can lead to material damage or reduce the service life of
the MultiControl.
¾ To preserve the interior of the MultiControl, do not allow the MultiControl to fall or for it to be used in an
improper fashion.
¾ Check each MultiControl before assembly for any visible damage.
¾ Ensure that the MultiControl is not tensioned during the assembly process (no bending or torsional load).
¾ Do not drill any additional mount holes into the housing or the base plate and do not enlarge any existing
holes.

5.2 Assembling the MultiControl

Initial assembly
To attach the MultiControl to the conveyor frame, the base plate provided must first be mounted on the conveyor
frame. There are two sets of two holes in the base plate for attaching the MultiControl. The holes on the left should be
used for initial assembly.

To simplify electrical installation, all MultiControls should only be attached to one side of the conveyor
system if possible. In the case of curves, the MultiControls should be attached as close to the outer radius of
the curve as possible, as the RollerDrive connection is on this side.

¾ Find a level surface on the conveyor frame where the MultiControl can be attached. Leave approximately
25 mm to the left of this to enable the MultiControl to subsequently be moved if necessary (see „Subsequent
assembly“ on page 24).
¾ Use the base plate as a template and mark the middle of the installation holes. Ensure the correct orientation
of the base plate (the cable guide label must be legible).

Version 2.9 (11/2021) Online

22 of 68 Translation of the original operating manual
 Assembly and installation

¾ Drill two holes with a diameter of 6.5 mm through the markings in the conveyor frame.
¾ Attach the base plate to the conveyor frame with M6 screws.
¾ Make sure the base plate has not been distorted.
¾ Insert the ribbon cables for the power supplies (see „Connecting the power supply“ on page 26).
¾ Place the MultiControl on the left-hand holes and press it down until the lock engages.

¾ Screw the MultiControl onto the base plate (max. tightening torque 2,5 - 2,75 Nm). This drives the piercing
contacts through the ribbon cable and makes contact with the power supplies.

Use the screws provided to attach the MultiControl to the base plate.

Version 2.9 (11/2021) Online

Translation of the original operating manual 23 of 68
Assembly and installation

Subsequent assembly
If a MultiControl that has already been connected needs to be detached from the base plate, the ribbon cables must
not make contact again at the same point, as otherwise proper contact cannot be guaranteed. So as not to have
to disconnect the ribbon cables from all MultiControls and then reconnect them, in this case the MultiControl can be
attached via the installation holes on the right.

Version 2.9 (11/2021) Online

24 of 68 Translation of the original operating manual
 Assembly and installation

5.3 Warning notices for electrical installation

CAUTION
Risk of injury when working on electrical equipment.
¾ Electrical installation work must only be carried out by a qualified electrician.
¾ Before installing, removing or connecting the MultiControl, switch off the power to the conveyor system and
ensure that it cannot be unintentionally switched on again.
¾ Set all the power supplies used to the same earth potential in order to avoid compensating currents via the
MultiControl or bus cable.
¾ Ensure all components are earthed correctly. Improper earthing can lead to a build-up of static charge,
which can result in a fault or premature failure of the MultiControl.
¾ Ensure that suitable switching devices and protective systems are in place that will allow the equipment to be
operated safely.
¾ Only switch on the operating voltages when all cables are connected.

NOTE
Improper electrical installation can result in damage to the MultiControl.
¾ Observe national regulations for electrical installation.
¾ Only operate the MultiControl with a protective extra-low voltage (PELV) of 24 V or 48 V.
¾ Never operate the MultiControl with an alternating voltage.
¾ Ensure that the polarity of the power supply is correct.
¾ Ensure that the existing electrical installation has no disruptive influence on the MultiControl.
¾ Only use cables that are adequately dimensioned for the specific operating conditions.
¾ Ensure that the calculations for the drop in voltage in the cables are taken into account.
¾ Observe regulations for laying cables.
¾ Do not expose the connectors to excessively high tensile or pressure loads. If the connector cable is bent, this
can damage the cable insulation and cause the MultiControl to fail.

Version 2.9 (11/2021) Online

Translation of the original operating manual 25 of 68
Assembly and installation

5.4 Electrical installation

Connecting the power supply
Two type 3G3G-FL ribbon cables with a wire cross-section of 2 x 2.5 mm2 are used for the power supplies.
By using two ribbon cables, the RollerDrives and the sensors/logic have a separate voltage supply. This enables the
RollerDrives to be safely shut down without interrupting bus communication.

A ribbon cable distributor can be used to enable the MultiControl to be used as a replacement part in
existing systems (see „Accessories“ on page 66).

Both earth potentials (L-) of the power supplies are connected to one another in the MultiControl.
¾ Insert the ribbon cables with the correct orientation, without mechanical tension or torsion, into the cable
guides on the base plate. The cable guides have a form-fit design (see figure). This means that the ribbon
cables can only be inserted with the correct orientation and the polarity of the cables cannot be reversed.
¾ If necessary, implement appropriate strain relief and vibration reduction measures.

1 Cable guide for power supply to logic and 2 Cable guide for power supply to RollerDrive (L2)
sensors (L1)
Upper pin: L+, brown cable wire Upper pin: L+, brown cable wire
Lower pin: L-, blue cable wire Lower pin: L-, blue cable wire

¾ Seal the ends of the ribbon cables with end caps to achieve protection rate IP54.
¾ Mount the MultiControl on the base frame to establish contact (see „Initial assembly“ on page 22).
¾ Connect the cables to the power source. Connect the brown wire to L+ and the blue wire to L-.

Version 2.9 (11/2021) Online

26 of 68 Translation of the original operating manual
 Assembly and installation

Connecting the RollerDrive

RollerDrive AI

1 +24 V/48 V 4 Input: Error

2 Output: Rotational direction 5 Output: Speed
3 Earth

¾ Seal unused RollerDrive connections with an M8 blind cap to achieve protection rate IP54.

RollerDrive BI

1 +24 V/48 V 4 CAN bus signal CAN Low

2 CAN bus signal CAN High 5 Service manufacturer
3 Earth

¾ Seal unused RollerDrive connections with an M8 blind cap to achieve protection rate IP54.

NOTE
Incorrect connected loads can destroy the RollerDrive.
¾ Do not attempt to operate a RollerDrive EC5000 24 V DC at 48 V DC. This will destroy the motor
electronics.

NOTE
Connecting/disconnecting under voltage can destroy the MultiControl / RollerDrive EC5000 with bus interface
¾ The MultiControl and the RollerDrive EC5000 BI are not hot-plug-compatible. Disconnect the power supply
to connect/disconnect the RollerDrive EC5000 BI.

Version 2.9 (11/2021) Online

Translation of the original operating manual 27 of 68
Assembly and installation

Connecting the bus

Connections “Link A” and “Link B” are suitable for M12 connectors, four-pin, D-coded, contact assignment as per IEC
61076-2-101.

1 Transmission Data TD+ 3 Transmission Data TD-

2 Receive Data RD+ 4 Receive Data RD-

The MultiControl features an integrated two-port switch. This enables the MultiControl to be integrated into line
structures of the bus wiring, for example.
¾ Observe the installation guidelines for the corresponding bus systems:
• PROFINET: PROFIBUS & PROFINET International (PI), www.profibus.com
• EtherCAT: EtherCAT Technology Group, www.ethercat.org
• EtherNET/IP: ODVA, www.odva.org
¾ Seal any unused connections with an M12 blind cap to achieve protection rate IP54.

It is possible to connect the shielding of the bus cables on both sides of the MultiControl. This minimises EMC
problems.

Version 2.9 (11/2021) Online

28 of 68 Translation of the original operating manual
 Assembly and installation

Connecting the sensors

Four sensors and four additional inputs or outputs (AUX I/O) can be connected at connections “Sensor 1, I/O 1” to
“Sensor 4, I/O 4”. PNP or NPN sensors as well as sensors with N/C or N/O contact can be used. The sensor type and
the function of the additional I/Os can be parametrised (see „Digital I/O - Settings“ on page 42). A Y-cable can be
used to connect a sensor and an input/output at the same connection (see „Accessories“ on page 66).

4 2
3 1

1 +24 V 3 Earth
2 AUX I/O 4 Sensor input

¾ Seal any unused connections with an M8 blind cap to achieve protection rate IP54.

NOTE
Connections are not short circuit-proof
In the event of a short circuit, particularly between Pin 1 and Pin 3, the internal fuse (PTC) in the MultiControl trips.
Standard operation can be resumed once the internal fuse has cooled down.
¾ Ensure the correct polarity.

The inputs and outputs are not galvanically separated.

Characteristic values for the inputs

Input voltage 0 V to 24 V DC
Input resistance ≥ 15 kΩ
Switching thresholds ≥ 15 V "High"
≤ 5 V "Low"

Version 2.9 (11/2021) Online

Translation of the original operating manual 29 of 68
Assembly and installation

Characteristic values for the outputs

Output voltage 24 V DC
Maximum output current ≤ 200 mA
Output voltage "1" for PNP > 15 V at 200 mA
Output voltage "1" for NPN ≤ 5 V at 200 mA

¾ Seal any unused sensor connections with an M8 blind cap to achieve protection rate IP54.

Overview of connections

1 Zone sensor 3 AUX I/O

2 Start sensor 4 Y-cable

Version 2.9 (11/2021) Online

30 of 68 Translation of the original operating manual
 Start-up and operation

6 Start-up and operation

6.1 Start-up
Check before the initial start-up
¾ Ensure that the base plate of the MultiControl has been correctly attached to the profile, that the MultiControl
has been correctly attached to the base plate and that all screws have been properly tightened.
¾ Ensure that no additional hazards are formed through the interfaces to other components.
¾ Ensure that the wiring conforms to the specifications and legal provisions.
¾ Check all protective equipment.
¾ Ensure that no persons are in the hazardous areas by the conveyor system.

6.2 Configuration options

CAUTION
Risk of malfunction!
¾ Change the motor configuration via SDO or web browser only when motors are stopped!

The MultiControl must be configured before it can be started up. There are various ways of doing this:
• All settings can be configured via a web-based user interface on a computer connected to the MultiControl.
• Directly on the MultiControl via the built-in magnetic sensor (see the “MultiControl / RollerDrive - Start-up and
Programming” supplement).
• All settings except the bus type can be configured via service data objects (SDOs) written by a higher-level control
system (see the “MultiControl / RollerDrive - Start-up and Programming” supplement).
• The station name, the IP configuration and the connection settings can be modified via a PLC development
environment.
• The data is automatically transferred by the Plug&Play function when the MultiControl is replaced.

NOTE
Possible loss of data during the start process
If the supply voltage is interrupted during the start process, this can result in a loss of data.
¾ Do not switch off the supply voltage during the start process (approx. 10 seconds).

Version 2.9 (11/2021) Online

Translation of the original operating manual 31 of 68
Start-up and operation

6.3 MultiControl user interface

The MultiControl has an integrated web server that generates a user interface for configuring the MultiControl. This
user interface can be opened on a computer connected to the MultiControl.
Except for a web browser, no further software needs to be installed on the computer.
Prerequisites
The following prerequisites must be fulfilled in order to start the web-based user interface:
• The MultiControl has a valid IP address that is known (default setting: IP address 192.168.0.1, subnet mask
255.255.255.0).
• The connected computer must be in the same IP range (see system description/network settings for the PC).
• There is an Ethernet connection between the MultiControl and the computer.
• Port 80 can be accessed (user interface is HTTP-based).
• The MultiControl is not configured for EtherCAT, as EtherCAT does not permit HTTP communication. The bus
type can be read using the magnetic sensor (see the “MultiControl / RollerDrive - Start-up and Programming”
supplement).
Starting the user interface
¾ Start the web browser on the computer connected to the MultiControl.
¾ In the address line, enter the IP address of the MultiControl (default setting: http://192.168.0.1/).
¾ On the login page, enter the login data (default setting: User name “Interroll”, password “Interroll”).

Unless otherwise specified, the figures apply to the MultiControl AI and the MultiControl BI.

Version 2.9 (11/2021) Online

32 of 68 Translation of the original operating manual
 Start-up and operation

MultiControl AI

MultiControl Overview
Bus Info
Overview Bus Protocol : PROFINET
Network and Settings Host Name : multicontrol2
Motor IP Adress : 192.168.0.2
State : Disconnected
Settings
TestPanel
Error Info
Digital I/O
State : Operational
States
Active Error : BusComFail (21)
Settings Last Error : 00:00:42.536.21 BusComFail
Control Program
Settings
Error Control Program Info
State Program ID : I/O Device
Settings Version : 2017-04-10-09
Log
Find Device
Service
Teach-In Start Identify
Plug&Play
System
Change Password
Factory Reset
Restart
Version
Up-/Download
Log Out

MultiControl BI

MultiControl Overview
Bus Info
Overview Bus Protocol : PROFINET
Network and Settings Host Name : multicontrol2
Motor IP Adress : 192.168.0.2
Settings State : Disconnected
Information
Monitor Error Info
TestPanel State : Operational
Digital I/O Active Error : BusComFail (21)
States Last Error : 00:00:42.536.21 BusComFail
Settings
Control Program Control Program Info
Settings Program ID : I/O Device
Error Version : 2017-04-10-09
State
Settings Find Device
Log Start Identify
Service
Teach-In
Plug&Play
CAN Gateway
System
Change Password
Factory Reset
Restart
Version
Up-/Download
Log Out

Use the menu on the left-hand side of the screen to navigate through further information and settings.

Version 2.9 (11/2021) Online

Translation of the original operating manual 33 of 68
Start-up and operation

“MultiControl Overview” home page

MultiControl Overview
Bus Info
Bus Protocol : PROFINET
Host Name : multicontrol2
IP Adress : 192.168.0.2
State : Disconnected

Error Info
State : Operational
Active Error : BusComFail (21)
Last Error : 00:00:42.536.21 BusComFail

Control Program Info

Program ID : I/O Device
Version : 2017-04-10-09

Find Device
Start Identify

The following information is displayed on the home page:

• Information regarding the set bus system
• Information regarding the most recent error
• Information regarding the set application program

“Start Identify” button

Starts a “running light” of all LEDs in order to identify the MultiControl in the conveyor.

The EDS file for the respective software version is stored on the MultiControl and can be downloaded via
the link at the bottom of the home page.

¾ To exit the user interface, click on “Log Out” (not necessary if the MultiControl is restarted).

Version 2.9 (11/2021) Online

34 of 68 Translation of the original operating manual
 Start-up and operation

Network Settings

Network Settings
Bus Protocol Neighbours
EtherCAT IP address upstream : 192.168.0.16
EtherCAT BI IP address downstream : 192.168.0.17
EtherCAT/CAN
EtherCAT/CAN Pro
PROFINET Option
EtherNet/IP Big Endian Format

Process Image In/Out: Universal Full / Universal Full

Addresses
IP address : 192.168.0.1
Network Mask : 255.255.255.0
Gateway : 0.0.0.0

Domains
Host Name : multicontrol
Domain Name :
DNS server 1 : 0.0.0.0
DNS server 2 : 0.0.0.0

Configuration Mode
Static
I/O Controller
Submit Reset

In order to integrate the MultiControl into an automation system, bus parameters may also need to be modified. This
includes the setting for the bus type used as well as addressing.
The MultiControl supports the following bus types:
• PROFINET I/O device – Conformance Class B, Netload Class 1
• EtherNet/IP slave
• EtherCAT slave
The following parameters can be modified in order to address the MultiControl:
• IP address and subnet mask
• Gateway
• Host name: When using the MultiControl with PROFINET, the unique PROFINET name of the MultiControl must be
entered here
• Domain name plus DNS server 1 and 2
• Configuration mode of the address:
Static: The IP address is assigned by the user
I/O controller: The IP address is assigned by the PLC (input field is greyed out)

To avoid communication problems in the bus system, we recommend changing the standard IP address
192.168.0.1.
Depending on the system configuration, in PROFINET projects we recommend manually increasing the
update time of the MultiControl (automatic 2 ms) to half the CPU cycle time or at least 8 ms.

Version 2.9 (11/2021) Online

Translation of the original operating manual 35 of 68
Start-up and operation

• IP addresses of neighbouring MultiControls (with ZPA and ZPA+ programs)

IP address upstream: Address of the MultiControl from which articles, trays, materials to be conveyed, products, etc.
are transferred
IP address downstream: Address of the MultiControl to which articles, trays, materials to be conveyed, products,
etc. are delivered
• Definition as to whether the PLC data is in big-endian format (High/Low byte switched)

Press the "Submit" button to transfer the modified parameters to the MultiControl.

NOTE
Irreparable damage to the MultiControl due to premature shutdown of the supply voltage
¾ Ensure that the power supply is not interrupted during the entire process of changing the bus type until the
restart is complete. This process takes approx. two minutes.

Motor Settings

Motor Settings
Motor 1  Motor 2  Motor 3  Motor 4 
Motor Type EC5000 EC5000 Disabled Disabled
Roller Diameter [mm] 50.0  50.0  50.0  50.0 
Gearing Ratio 49:1 49:1 none none
Direction CW CCW CW CCW CW CCW CW CCW
Normal Speed [m/s]: 1.00 1.00 1.00 1.00
Alternate Speed [m/s]: 0.50 0.50 0.50 0.50
Acceleration [m/s2]: 0.00 0.00 0.00 0.00
Decceleration [m/s2]: 0.00 0.00 0.00 0.00

Apply Motor 1 Settings to all

Avoid parallel Motor Start/Stop - ZPA
Start Delay [ms]: 100
Stop Delay [ms]: 100

28 V
Brake Chopper Level: 26 V Submit Reset

CAUTION
Risk of malfunction!
¾ Change the motor configuration via web browser only when motors are stopped!

Version 2.9 (11/2021) Online

36 of 68 Translation of the original operating manual
 Start-up and operation

¾ Deactivate unused motors to avoid error messages.

¾ Select the connected motor – EC5000 / EC310 / VDC Speed / VDC Position

If a motor is activated but not connected, the RD1 – RD4 LED flashes.

¾ Enter the “Roller diameter”, “Gearing ratio” and “Normal speed” according to the RollerDrive used.

In the case of conical rollers (curves), enter the average roller diameter as the diameter.

In the “I/O device” control program, the speed in % relates to the value set here under “Normal speed”.
Due to tolerances and / or voltage drop on cables, it is possible that the RollerDrive does not rotate when it is set to
its minimum values. In this case a higher setting and thus speed must be selected.
The “Direction” parameter is used to adapt the rotational direction of the RollerDrive to the installation location
(rotational direction as viewed from the cable end of the RollerDrive).
“Acceleration” and “Deceleration” adapt the start/stop behaviour of the RollerDrive. The “Alternate speed” parameter
is not currently in use.

Acceleration values for the RollerDrive EC5000 BI

The optimum acceleration ramp for the EC5000 BI is achieved by entering the following acceleration values.

Gear 9:1 13:1 18:1 21:1 30:1 42:1 49:1 78:1 108:1
Acceleration value m/s2 13,2 9.2 6.6 5.7 4.0 2.8 2.4 1.5 1.1

Avoid parallel Motor Start/Stop - ZPA

Start Delay: The connected RollerDrives are started one after the other at the set time interval to prevent overloading
the power supply when it is switched on.
Stop Delay: The connected RollerDrive are stopped one after the other at the set time interval to prevent overloading
the power supply when it is switched off.

Brake Chopper Level

For the MultiControl 24 V AI/BI, the brake chopper operating voltage can be reduced to 26 V.
The factory setting is 28 V.

Press the "Submit" button to transfer the modified parameters to the MultiControl.

Version 2.9 (11/2021) Online

Translation of the original operating manual 37 of 68
Start-up and operation

Motor Information – MultiControl BI only

Motor Information

Motor 1 Motor 2 Motor 3 Motor 4

Gear Ratio 49:1 49:1 --- ---
Max. Speed [m/s] 0.37 0.37 --- ---
Status Stop Stop N.C. N.C.
Motor Name EC5000 EC5000 --- ---
Hardware Vers. 1.0000 1.0000 --- ---
Software Vers. 0.11.07 0.11.07 --- ---
Product Code --- --- --- ---
Serial Number 381 --- --- ---

Display of motor data:

• Gear ratio
• Maximum speed
• Rated power
• Status
• Motor name
• Hardware version
• Software version
• Product code
• Serial number

Version 2.9 (11/2021) Online

38 of 68 Translation of the original operating manual
 Start-up and operation

Motor Monitor – MultiControl BI only

Motor Monitor
Motor 1 Motor 2 Motor 3 Motor 4
Lifetime
Temperature
Power
Error

Start/Stops 177 31536065 --- ---

Run Time (hh:mm:ss) 0:19:42 3140:26:15 --- ---
Up Time (hh:mm:ss) 288:45:16 8984:58:28 --- ---
Temp. Max (°) 46 99 ---- ---
Temp. Min (°) 16 16 --- ---
Current Temp. (°) 21 20 --- ---
Num. Quick Stops 0 0 --- ---
Actual Torque (mNm) 0 0 --- ---
Power/Time (Wh) 0 0 --- ---
Num. Rotations 2174 172911880 --- ---

Visual displays
Service life indicator lights
Health indicator lights for:
• Temperature
• Power
• Frequency of errors

Monitoring data
Start/stops – Number of start/stops per minute
Run time (s)
Up time (s)
Temp. max (°C) – Maximum temperature of the motor electronics
Temp. min (°C) – Minimum temperature of the motor electronics
Current temp. (°C) – Actual temperature of the motor electronics
Num. quick stops – Number of quick stops
Actual Torque (mNm) - Actual Torque
Power/time (Wh) – Average mechanical power output
Num. rotations – Number of motor revolutions

Version 2.9 (11/2021) Online

Translation of the original operating manual 39 of 68
Start-up and operation

Motor Test for EC5000

WARNING
Risk of crushing due to unintentional start-up of the RollerDrive!
¾ Changes in this menu have direct influence on the connected RollerDrive!
¾ Before starting motors make sure, ensure that no persons are present in the hazardous areas surrounding
the conveyor system!

Motor Test for EC5000

Simple Test Select effected Motors Motor Commands
Start all Motor 1 Velocity Mode:
Start all motors in positive direction Motor 2 CCW stop CW
Stop all Motor 3
Motor 4

¾ Select the desired motor

¾ Select the test:
• Simple test – Starts all connected motors in a positive rotational direction
• Velocity mode – Start and stop selected motors clockwise or anti-clockwise

Version 2.9 (11/2021) Online

40 of 68 Translation of the original operating manual
 Start-up and operation

Digital I/O States

Digital I/O States

Sensor 1 Sensor 3
State: Off Throughput: 0 Parts/Hour State: Off Throughput: 0 Parts/Hour

I/O 1 I/O 3
State: Off State: Off

Sensor 2 Sensor 4
State: Off Throughput: 0 Parts/Hour State: Off Throughput: 0 Parts/Hour

I/O 2 I/O 4
State: Off State: Off

Display of the switching states of the connected sensors and I/Os.

Throughput
Based on the sensor signals, the throughput of the individual zones is determined.
For this, the signals of the last five minutes are extrapolated to one hour.
This means that the system must have been running for at least five minutes.
The counters are active in all operating modes.

Not a real-time status. Status changes are only visible once the web browser has been refreshed ("F5" key).

Version 2.9 (11/2021) Online

Translation of the original operating manual 41 of 68
Start-up and operation

Digital I/O Settings

Digital I/O Settings

Sensor 1 Sensor 3
Type : PNP NPN Type : PNP NPN
Polarity : positive negative Polarity : positive negative
ON Delay [ms] : 0 ON Delay [ms] : 0
OFF Delay [ms] : 0 OFF Delay [ms] : 0

I/O 1 I/O 3
Type : PNP NPN Type : PNP NPN
Polarity : positive negative Polarity : positive negative
 
Function : PLC Input Function : PLC Input

Sensor 2 Sensor 4
Type : PNP NPN Type : PNP NPN
Polarity : positive negative Polarity : positive negative
ON Delay [ms] : 0 ON Delay [ms] : 0
OFF Delay [ms] : 0 OFF Delay [ms] : 0

I/O 2 I/O 4
Type : PNP NPN Type : PNP NPN
Polarity : positive negative Polarity : positive negative
 
Function : PLC Input Function : PLC Input

 I/O State LEDs enabled

Shutdown Aux Output Submit Reset

Sensors 1–4 are assigned to the zone sensors.

Additional I/Os can be connected by using an optional Y-cable.
I/O 1 to I/O 4 can be configured as inputs or outputs with the following functions:

Function Description
None -
PLC input Input signal from the PLC
PLC output Output signal to the PLC
Sensor 5 Start sensor zone 1 (polarity must be negative)
Sensor 6 Spare
Sensor 7 Spare
Sensor 8 Spare
Control input 1 Stops zone 1
Control input 2 Stops zone 2
Control input 3 Stops zone 3
Control input 4 Stops zone 4
Control input 5–8 No function
Control output 1 Zone 1 occupied
Control output 2 Zone 2 occupied

Version 2.9 (11/2021) Online

42 of 68 Translation of the original operating manual
 Start-up and operation

Function Description
Control output 3 Zone 3 occupied
Control output 4 Zone 4 occupied
Control output 5–8 No function
Handshake in up Handshake signals to neighbouring ZPA modules
Handshake in down
Handshake in left
Handshake in right
Handshake out up
Handshake out down
Handshake out left
Handshake out right
VDC motor #1 error in VDC motor error input
VDC motor #2 error in
VDC motor #1 direction out VDC motor directional rotation
VDC motor #2 direction out
VDC motor #1 step pulse out VDC motor pulse output
VDC motor #2 step pulse out

The functions have no influence on the “I/O device” control program.

Shutdown Aux Output

Not activated The aux outputs are reset when the RollerDrive voltage is switched off and cannot be
controlled.
Activated The Aux outputs keep their current status when the RollerDrive voltage is switched off and can
still be controlled.

The functions vary depending on the selected control program (see the description of control programs in
the "MultiControl / RollerDrive - Start-up and Programming" supplement).
Press the "Submit" button to transfer the modified parameters to the MultiControl.

Version 2.9 (11/2021) Online

Translation of the original operating manual 43 of 68
Start-up and operation

Control Program Settings

Control Program Settings

Control Program Settings

Program ID : I/O Device
Version : 2017-12-12-11

Control Timer
Timer 1 [ms] : 0
Timer 2 [ms] : 0
Timer 3 [ms] : 0
Timer 4 [ms] : 0

Submit Reset

Selection of control programs

ZPA single release program ZPA train release program ZPA module program No ZPA program ID
ID ID ID
Single release 1 zone Train release 1 zone ZPA transfer in I/O device
Single release 2 zone Train release 2 zone ZPA transfer out
Single release 3 zone Train release 3 zone ZPA merge
Single release 4 zone Train release 4 zone ZPA HPD
HPD semi automatic
Transfer semi automatic

Control Timer
Timer 1: Single release: Transfer communication time
Train release: Time-delayed start of the RollerDrive
Timer 2: Internal monitoring of the material to be conveyed
Timer 3: RollerDrive overrun
Timer 4: Error reset

The functions and default settings for the timers vary depending on the selected control program (see
the description of control programs in the "MultiControl / RollerDrive - Start-up and Programming"
supplement).
Press the "Submit" button to transfer the modified parameters to the MultiControl.

Version 2.9 (11/2021) Online

44 of 68 Translation of the original operating manual
 Start-up and operation

Error State

Error State
Error Info
State : Operational
Active Error : BusComFail (21)
Last Error : 00:02:29:756 51 DriveError #2

• Display of the current status of the MultiControl

• Display of the current error
• Display of the most recent error

Error Handling Settings

Error Handling Settings

System Errors Control Errors
 
Network Error : Warning  Control Error 1 : Ignore 
Over Voltage Error : Warning  Control Error 2 : Ignore 
Under Voltage Error : Warning  Control Error 3 : Ignore 
Motor Error : Warning  Control Error 4 : Ignore 
Generl Control Error : Ignore  Control Error 5 : Ignore 
Sensor Error : Ignore Control Error 6 : Ignore 
Control Error 7 : Ignore 
Control Error 8 : Ignore

Submit Reset

Network error
Monitoring of communication between MultiControl and PLC:
Ignore: Error is not displayed.
Warning: Error is indicated by fault LED flashing twice.
The conveying process is not interrupted.
Immediate stop: Error is indicated by fault LED flashing twice.
The conveying process is interrupted.

If the MultiControl is operated without PLC, we recommend the "Ignore" setting.

If the MultiControl is operated with PLC, we recommend the "Immediate stop" setting.

Over voltage error

Supply voltage too high:
Ignore: Error is not displayed.
Warning: Error is indicated by fault LED flashing six times.
The conveying process is not interrupted.
Immediate stop: Error is indicated by fault LED flashing six times.
The conveying process is interrupted.

Version 2.9 (11/2021) Online

Translation of the original operating manual 45 of 68
Start-up and operation

Under voltage error

Supply voltage too low:
Ignore: Error is not displayed.
Warning: Error is indicated by fault LED flashing five times.
The conveying process is not interrupted.
Immediate stop: Error is indicated by fault LED flashing five times.
The conveying process is interrupted.

Motor error
Monitoring of the motors:
Ignore: Error is not displayed.
Warning: Error is indicated by fault LED flashing three times.
The LED goes out when the error is no longer present. Further motors connected to the
MultiControl rotate.
Immediate stop: Error is indicated by fault LED flashing three times.
Further motors connected to the MultiControl stop.

General control error

Monitoring of the control system:
Ignore: Error is not displayed.

"Immediate stop" and "Normal stop" have the same function.

The control error 1–8 settings have no function.
Press the "Submit" button to transfer the modified parameters to the MultiControl.
Changes only come into effect when the control is switched off/on.

Version 2.9 (11/2021) Online

46 of 68 Translation of the original operating manual
 Start-up and operation

MultiControl Error Log

MultiControl Error Log

Error Info 
Time Error Description
00:00:06:823 70 SystemRestart
00:00:06:460 70 SystemRestart
00:00:06:459 70 SystemRestart
00:00:06:790 70 SystemRestart
00:00:06:799 70 SystemRestart
00:00:07:823 22 BusStartUp
00:00:11:131 102 NewStateTable
00:00:11:153 102 NewStateTable
00:00:11:154 50 DriveError #1
00:00:11:154 51 DriveError #2
00:00:11:154 52 DriveError #3
00:00:11:154 53 DriveError #4
00:00:11:161 50 DriveError #1
00:00:11:161 51 DriveError #2

Error log for the most recent errors/messages with time stamp.
For an explanation of error codes, see „Error codes“ on page 62.

Version 2.9 (11/2021) Online

Translation of the original operating manual 47 of 68
Start-up and operation

Teach-in

WARNING
Risk of crushing due to unintentional start-up of the RollerDrive!
¾ Changes in this menu have direct influence on the connected RollerDrive!
¾ Before starting motors make sure, ensure that no persons are present in the hazardous areas surrounding
the conveyor system!

Teach-in
Teach-in Feature
Please read the manual before trigger any of the options below!

Init
Start
Finish
Abort

Submit Reset

Plug&Play

Plug&Play
Plug and Play Feature
Enabled  Submit

The "Teach-in" and "Plug&Play" functions are described in the "MultiControl / RollerDrive - Start-up and
Programming" supplement.

CAN Gateway

CAN Gateway
CAN Bus Terminal

Mode Node ID SDO Idx Sub Idx Length Data

Read dec num hex num hex num dec num hexabytes, e.g. 0FF640
Write

Send

Node 0>> Response: Unknown, Error: 0  

Only used for service purposes.

Version 2.9 (11/2021) Online

48 of 68 Translation of the original operating manual
 Start-up and operation

Service Change Password

Service Change Password

Change password
Enter old password :
Enter new password :
Repeat new password :

Submit Reset

¾ To change the password, enter the old password followed by the new password twice and transfer this to the
MultiControl by pressing the “Submit” button.

The user name cannot be changed.

Loading the default settings resets the changed password to the default.

Service Restore Factory Settings

Service Restore Factory Settings

Restore Factory Settings

Reset all settings to factory default values?

Yes
No

Submit Reset

Loading the default settings:

¾ Select “Yes”
¾ “Submit” button

NOTE
Irreparable damage to the MultiControl due to premature shutdown of the supply voltage
¾ Ensure that the power supply is not interrupted until the restart is complete. This process takes approx. two
minutes.

Version 2.9 (11/2021) Online

Translation of the original operating manual 49 of 68
Start-up and operation

Service MultiControl Restart

Service MultiControl Restart

MultiControl restart

CAUTION: A restart of MultiControl will stop the control process and interrupt the network connection.
Do you want to restart MultiContol now?

Yes
No

Submit Reset

Restarting the MultiControl:

¾ Select “Yes”
¾ “Submit” button

While the MultiControl is being restarted, the existing bus connection to the computer or PLC is interrupted
and this must subsequently be restored.

Service Version Information

Service Version Information

Version Info
Hardware Version : V.x
Hardware Variant : Bus
Application Software Version : V.x.x.x.x
System Software Version : V.x.x.x.x
Network Software Version : V.x.x.x.x
Serial Number : 00000093
MAC Address : 24:0b:b1:20:01:70

Display of the version, serial number and software version of the MultiControl.

Version 2.9 (11/2021) Online

50 of 68 Translation of the original operating manual
 Start-up and operation

Service – Up-/Download

Up- Download
Download Upload
For download under a different name, please use „Right Click --> Save To make settings effective, please restart module afterwards!
As...“-option Bus Config : upload
Bus Config : download Application Config : upload
Application Config : download

The MultiControl settings can be downloaded via the user interface and saved to a computer. By storing this data, the
settings can be restored when the MultiControl is replaced.
¾ Right-click on the desired file and select “Save as” to save to the connected PC.

Follow the correct sequence for the upload.

• Bus config
• Application config

NOTE
Irreparable damage to the MultiControl due to premature shutdown of the supply voltage
¾ Ensure that the power supply is not interrupted during the entire process of changing the bus type until the
restart is complete. This process takes approx. two minutes.

Version 2.9 (11/2021) Online

Translation of the original operating manual 51 of 68
Start-up and operation

6.4 Magnetic sensor

The magnetic sensor can be used to perform the following functions:
• Setting the sensors
• Setting the bus type
• Executing the teach-in process
• Switching the LED displays for the sensors / I/Os on or off
• Deactivating Plug&Play
• Resetting the MultiControl to the default settings
A magnet is required in order to operate the magnetic sensor (see „Accessories“ on page 66). The magnetic sensor
is located on the top of the MultiControl, between the two Rs of “INTERROLL” directly in front of the base plate (see
„Setup“ on page 16).

Further information can be found in the "MultiControl / RollerDrive - Start-up and Programming"
supplement.

6.5 Service data objects (SDO)

Virtually all MultiControl settings (except the bus type) can be modified by means of acyclical communication. This
communication corresponds to the service data objects (SDO) of the CANopen protocol. They can be accessed via
the RDREC and WRREC functions according to IEC 61131-3.

Further information can be found in the "MultiControl / RollerDrive - Start-up and Programming"
supplement.

Ethernet/IP, Object Class Adapter = 0x64, Get Attribute Single, Set Attribute Single
Profinet, HW Identification acyclic access point, RDREC, WRREC

Version 2.9 (11/2021) Online

52 of 68 Translation of the original operating manual
 Start-up and operation

6.6 Operation

WARNING
Risk of crushing due to unintentional start-up of the RollerDrive!
¾ Before switching on the power supply, ensure that no persons are present in the hazardous areas
surrounding the conveyor system!
¾ In ZPA mode, all connected RollerDrives carry out an initialization run for a maximum of four seconds after
switching on the supply voltage!

When the MultiControl is functioning as an I/O device, it cannot start or stop motors or carry out other
actions independently. To do this, it requires commands from a higher-level control system, e.g. a PLC.

Check before every start-up

¾ Check all MultiControls for any visible damage.
¾ Check all protective equipment.
¾ Ensure that none of the RollerDrives connected to the MultiControl are jammed.
¾ Specify in detail how the material to be conveyed should be set down on the conveyor and monitor this to
ensure it is carried out correctly.

Take the ambient conditions into account during operation (see „Technical Specifications“ on page 19).

Start
¾ Ensure that the ambient conditions are maintained during operation (see „Technical Specifications“ on page 19).
¾ Switch on the power supply.
¾ MultiControl BI: After switching on the motor voltage, wait 30 seconds until all connected RollerDrive are
initialized.
¾ Send the corresponding signal to the MultiControl.

Stop
The conveyor system will stop under the following circumstances:
• When the power supply is switched off
• When no start signal is present
• When an error from a corresponding error class is present (see „Error Handling Settings“ on page 45)

Version 2.9 (11/2021) Online

Translation of the original operating manual 53 of 68
Start-up and operation

6.7 Procedure in the event of accidents or faults

¾ Stop the conveyor system immediately, switch off the power supply and ensure that it cannot be unintentionally
switched on again.
¾ In the event of an accident: Perform first aid and call for the emergency services.
¾ Inform the relevant supervisor.
¾ Have specialist personnel rectify the fault.
¾ Only resume operating the conveyor system once this has been approved by the specialist personnel.

Version 2.9 (11/2021) Online

54 of 68 Translation of the original operating manual
 Maintenance and cleaning

7 Maintenance and cleaning

CAUTION
Risk of injury from following incorrect procedure.
¾ Maintenance and repair work must only be carried out by authorised and trained (specialist) personnel.
¾ Maintenance and repair work must only be carried out when the system has been disconnected from the
power supply. Switch off the power to the MultiControl and ensure that it cannot be unintentionally switched
on again.
¾ Put up signs to indicate that maintenance or cleaning work is being carried out.

7.1 Maintenance
Checking the MultiControl
The MultiControl itself requires no maintenance. However, in order to prevent faults from occurring, the connections
and fixings must be examined on a regular basis.
¾ In the course of regular inspection and maintenance work on the conveyor, ensure that the screws of the
MultiControl are still tight, that the cables are still arranged correctly and that the corresponding connections
are correctly attached.
Replacing the MultiControl
If a MultiControl is damaged or defective, it must be replaced.

Do not attempt to open the MultiControl.

¾ Install a new MultiControl (see „Decommissioning“ on page 65 and „Assembling the MultiControl“ on page 22).
¾ Configure the new MultiControl (see „Start-up and operation“ on page 31).

Version 2.9 (11/2021) Online

Translation of the original operating manual 55 of 68
Maintenance and cleaning

7.2 Cleaning
Under humid conditions, dust and dirt can cause a short circuit. Therefore, ensure dirty environments are cleaned
regularly to prevent short circuits that could damage the MultiControl.

NOTE
The MultiControl can be damaged if it is not properly cleaned.
¾ Never immerse the MultiControl in fluids.

¾ If necessary, vacuum any dust or dust that is present.

¾ To clean the MultiControl more thoroughly, disconnect it from the power supply, detach it and wipe it with a
damp cloth.

Version 2.9 (11/2021) Online

56 of 68 Translation of the original operating manual
 Assistance in the event of faults

8 Assistance in the event of faults

8.1 Understanding the LEDs
LEDs on the MultiControl indicate the operating state of the conveyor.
Status description of the LEDs:
• Off: LED is permanently off
• On: LED is permanently on
• Flashes at 1 Hz: LED flashes at a frequency of 1 Hz; duty ratio 1:1
• Flashes at 2 Hz: LED flashes at a frequency of 2 Hz; duty ratio 1:1
• - : LED status is variable

General LEDs

Power Ready Net run Fault Meaning Priority

On On On Off Ready for operation, no error
- On Flashing Off Bus start-up mode: After starting, the
1 Hz system waits 30 s for a connection to be
established by the PLC.
- - - Flashes x1 Error in the application program, e.g. time 1
out
- - - Flashes x2 Communication error: Connection not 3
established within 30 s of start-up or
connection to PLC lost. Error acknowledges
itself automatically.
- - - Flashes x3 RollerDrive error: Defective RollerDrive 2
indicated by flashing of the corresponding
"RD" LED
On On - Flashes x4 No power supply to motors. 5
- - - Flashes x5 Voltage error, undervoltage 4

Version 2.9 (11/2021) Online

Translation of the original operating manual 57 of 68
Assistance in the event of faults

Power Ready Net run Fault Meaning Priority

- - - Flashes x6 Voltage error, overvoltage 4
- - - Flashes x7 Temperature in the MultiControl too high. 6
- - - Flashes x8 Overload protection for the brake resistor 7
active.
- - - Flashes x9 Handshake communication interrupted.
See instructions on ZPA and ZPA+
applications.
- - - Flashes x10 No connection to the neighbouring
devices. See instructions on ZPA and ZPA+
applications.
- - - Flashes x11 A configured neighbouring device has an
error (see ZPA+, "RemoteEmergency" in
the error log)

If several errors occur at the same time, only the error with the highest priority is displayed.

¾ To eliminate the errors, refer to „Troubleshooting“ on page 59.

Version 2.9 (11/2021) Online

58 of 68 Translation of the original operating manual
 Assistance in the event of faults

Connection LEDs

LED Status Meaning

Sensor 1 On Logical switching status of the displayed sensor: Positive logic configured and
Sensor 2 logical "1" (PNP 24 V, NPN 0 V) at the input, or negative logic configured and
Sensor 3 logical "0" at the input
Sensor 4
I/O 1 I/O 2 On Logical switching status of the displayed input/output: Positive logic configured
I/O 3 I/O 4 and logical "1" (PNP 24 V, NPN 0 V) at the input, or negative logic configured
and logical "0" at the input
RD 1 RD 2 On Target value applied to the displayed RollerDrive
RD 3 RD 4
Link/act A On or flashing Displayed network connection is OK
Link/act B (with EtherCAT
bus type)

8.2 Troubleshooting
The MultiControl is a complex system. There are many correlations between all participants in the system. In such a
system, errors are of course likely to occur, either as a result of the conveying processes or the interaction between
the individual components. Not all errors can be displayed in detail and it is not always possible to make a correlation
between the error location and the place at which it is displayed. More detailed error diagnosis is possible via the
PLC.
If you are not able to successfully troubleshoot the problem or eliminate the error, contact Interroll Support and have
the following information to hand:
• Serial number of the affected MultiControl
• Information about the configuration
• Information about the LED displays
• Information about the error codes

Version 2.9 (11/2021) Online

Translation of the original operating manual 59 of 68
Assistance in the event of faults

Fault Possible cause Remedy

Communication error Connection to PLC interrupted ¾ Check the bus wiring
¾ Check the bus type
¾ Check the network address
and bus name
RollerDrive error Error signal from the RollerDrive ¾ Check the motor
or RollerDrive not connected to the configuration
activated motor output ¾ Ensure that all RollerDrives
are connected correctly
¾ Check for faults in
accordance with the
RollerDrive operating manual
No power supply to motors ¾ Check the power supply
(emergency stop?)
The MultiControl is not working No or insufficient power supply ¾ Ensure that the power supply
or not working properly is within the specified voltage
range
¾ Check the connections and
correct them if necessary

The MultiControl is defective or Internal fuse has been triggered or is ¾ Replace the MultiControl
damaged defective

Version 2.9 (11/2021) Online

60 of 68 Translation of the original operating manual
 Assistance in the event of faults

Fault Possible cause Remedy

RollerDrive does not rotate RollerDrive not or not correctly ¾ Ensure that the power supply
connected or RollerDrive defective is within the specified voltage
range
¾ Check the connections and
correct them if necessary
¾ Replace the RollerDrive if
necessary
Brake resistor overheating: The ¾ Allow the system to cool
application is recovering too much down
energy or the power supply is too high ¾ If necessary, reduce the
ambient temperature
¾ Ensure that the power supply
is within the specified voltage
range

Version 2.9 (11/2021) Online

Translation of the original operating manual 61 of 68
Assistance in the event of faults

Error codes

No. Short text Comments

0 ApplErrorNone No error in the application program
1 ApplErrUnk Unknown error in the application program
2 ApplErrSystemSevere Severe system error
3 ApplErrSystemMinor Minor system error
4 ApplErrSystemWarning Warning
5 PllErrItemNotFound Searched for object not found
6 ApplErrRange Number outside the valid value range
10 ApplErrNoTerminlInput Terminal has no input data
11 ApplErrStopByOperator Terminal session aborted
12 ApplErrParamlll Invalid parameter or input value
13 ApplErrModuleInit Initialisation error in the module
14 ApplErrBufferOverflow Buffer overflow
20 ApplErrInvalidBusConf Invalid network or bus configuration
21 ApplErrBusCom Network communication error
22 ApplErrBusStartUp Network restart after system (re)start
23 ApplErrNbrMsgRegister Message received from neighbouring device
24 ApplErrNbrMsgReceive Error in communication with neighbouring device: Reception interrupted
25 ApplErrNbrMsgTransmit Error in communication with neighbouring device: Transmission interrupted
26 ApplErrNbrMsgInvalid Error in communication with neighbouring device: Invalid message received
27 ApplErrNbrHandShake Error in communication with neighbouring device: No response to
handshake message received
28 ApplErrNbrLifeCheck Error in communication with neighbouring device: No life signal received
from neighbouring device
29 ApplErrNbrEmergency Error in communication with neighbouring device: No response to
emergency stop message
30 ApplErrErrorDataUpdate Access error to error data

Version 2.9 (11/2021) Online

62 of 68 Translation of the original operating manual
 Assistance in the event of faults

No. Short text Comments

31 ApplErrErrorLogUpdate Access error to error log file
40 ApplErrPanellllMode Change of mode not permitted
41 ApplErrPanelLedBlocked Access to LED control not permitted
42 ApplErrInvalidApplConf Invalid configuration of the application program
50 ApplErrDriveError1 RollerDrive 1 error
51 ApplErrDriveError2 RollerDrive 2 error
52 ApplErrDriveError3 RollerDrive 3 error
53 ApplErrDriveError4 RollerDrive 4 error
60 ApplErrStateTable Error in the application program
61 ApplErrCtrlError1 Specific errors in the application program. Errors in the ZPA/ZPA+
programs are explained in the "MultiControl / RollerDrive - Start-up and
62 ApplErrCtrlError2
Programming" supplement.
63 ApplErrCtrlError3
64 ApplErrCtrlError4
65 ApplErrCtrlError5
66 ApplErrCtrlError6
67 ApplErrCtrlError7
68 ApplErrCtrlError8
69 ApplErrStartProgram Application program cannot be started
70 ApplErrSysRestart (Re)start of the application program/system
71 ApplErrPowerFail Voltage error: Supply voltage failure
90 ApplErrTemperature Temperature error: Temperature at the brake resistor too high
91 ApplErrLowVoltage Voltage error: Supply voltage (L2) too low
92 ApplErrHighVoltage Voltage error: Supply voltage (L2) too high

Version 2.9 (11/2021) Online

Translation of the original operating manual 63 of 68
Assistance in the event of faults

No. Short text Comments

93 ApplErrMotorVoltage Voltage error: No motor voltage
94 ApplErrOvcOverloaded Brake resistor overload
95 ApplErrRemoteEmergency Emergency stop from neighbouring transfer device
96 ApplErrLogVoltLow Voltage error: Supply voltage (L1) too low
97 ApplErrLogVoltHigh Voltage error: Supply voltage (L1) too high
101 ApplErrInvalidStateTblConf Error when loading the application program
102 ApplErrNewStateTable New application program loaded
103 ApplErrInvalidErrConf Invalid configuration for the selected application program
104 ApplErrInvalidTeachParams Invalid parameters for teach-in procedure
105 ApplErrPapSaveConfig Not possible to save connection settings for communication with
neighbouring devices
106 ApplErrPapReadConfig Not possible to read connection settings for communication with
neighbouring devices

Version 2.9 (11/2021) Online

64 of 68 Translation of the original operating manual
 Decommissioning and disposal

9 Decommissioning and disposal

CAUTION
Risk of injury from following incorrect procedure.
¾ Decommissioning must only be carried out by authorised, qualified personnel.
¾ Only decommission the MultiControl when the system has been disconnected from the power supply.
¾ Switch off the power to the MultiControl and ensure that it cannot be unintentionally switched on again.

9.1 Decommissioning
¾ Remove all cables from the MultiControl.
¾ Loosen the screws that have been used to attach the MultiControl to the base plate and remove the
MultiControl.
¾ If the MultiControl is to be completely dismantled, also loosen the screws that have been used to attach the
base plate to the conveyor frame and remove the base plate from the conveyor frame.
9.2 Disposal
The operating company is responsible for disposing of the MultiControl according to correct procedure. In
doing so, the industry-specific and local provisions for disposing of the MultiControl and its packaging must
be observed.

Version 2.9 (11/2021) Online

Translation of the original operating manual 65 of 68
Appendix

10 Appendix
10.1 Accessories
Article Article number
Ribbon cable distributor S-1115717
Ribbon cable for power supply (25 m) S-1004030
High Performance power supply unit HP 5424 S-1113899
High Performance power supply unit HP 5448 S-1113900
Magnetic key S-64100210
MultiControl Y-cable S-1104460
MultiControl communication cable (3 m) S-1104438
MultiControl dummy plugs S-1104466
Pack:
3 x RollerDrive M8, plug-in
3 x sensor M8, screw-in
1 x communication M12, screw-in
RollerDrive EC310 extension cable (2 m) S-1004033
RollerDrive EC5000 extension cable (2 m) S-1113897
Cable bridge for ribbon cable S-1004028
Cable bridge for shielding S-1113876

Version 2.9 (11/2021) Online

66 of 68 Translation of the original operating manual
 Appendix

10.2 Translation of the original Declaration of Conformity

EU Declaration of Conformity
EMC Directive 2014/30/EU
RoHS Directive 2011/65/EU

The manufacturer

Interroll Engineering GmbH

Höferhof 16
42929 Wermelskirchen
Germany

hereby declares that the

• Interroll MultiControl AI – model number 1103563

• Interroll MultiControl BI – model number 1103564

conform to the applicable provisions and the associated CE marking in accordance with
the aforementioned Directives.

List of the coordinated standards that have been applied:

EN 61326-1:2013
EN 61000-3-2:2014
EN 61000-3-3:2013
EN IEC 63000:2018

Authorised for compiling technical documentation:

Interroll Engineering GmbH, Höferhof 16, 42929 Wermelskirchen, Germany

Jörg Schiffler
Product Compliance Officer
Interroll Engineering GmbH
Wermelskirchen 08.01.2019

Version 2.9 (11/2021) Online

Translation of the original operating manual 67 of 68
INSPIRED BY
EFFICIENCY EN | 11/2021 | Version 2.9

© 2021 INTERROLL