ITOH DENKI POWER MOLLER 24 HB-510N User manual

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HB-510N/P
Designed to be functional with the FS and
FE series motors, as well as the higher
torque series FP
Run Hold timer added to the Forcible RUN
input
Now there is no need for an external
controller/timer with, or awkward
positioning of, a second sensor used for
infeeding the conveyor
Specifications subject to change without notice
Integral indexed rotary switch provides easy
speed adjustment without the need for
“tweaking”
More LED functionality to communicate
operating and error statuses
Selectable automatic or manual recovery for
thermal overload protection
Motor lock protection shuts motor down if it is
locked for at least 4 seconds
Lead free design for RoHS conformity
What's New:
Driver Card Manual
Features:
Logic for general zero pressure
accumulation (ZPA) control is built-in
Direct connection for a photo-sensor to
both power it and receive its output signal
Easy connection between adjacent HB-
510s with communication cables
simplifies wiring
Selectable singulated or slug (train)
release modes for ZPA function
Flexible Zone Recognition (patented) to
handle long articles which simultaneously
block multiple sensors
Only available in slug release mode
Synchronized speed variation to
simultaneously adjust the speed of the rollers
with a single external speed control signal
Stable speed function to ensure that different
weight articles travel at the same rate
As long as the load does not exceed the
rated torque for a given speed
Enclosure is made from fire resistant ABS

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Office Ph: 570-820-8811
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Features
-What's New
-General Features
1
Table of Contents
2
Specifications
-Dimensions
-User Interface
-Standard Conveyor Figuration
3
Connections
4-6
Installation Precautions
7-8
Switch Settings
-Signal Blocking
-Input/Output Settings
-Timer Settings
-Other Settings
-Speed Adjustment
-Jumper Settings
9-17
LED and Error Indications
18
Conveyor Zone Configuration
19-22
Connecting to HB-508S
23-25
Using HB-510 as a Driver/Slave Card
26
Revision History
27
table of contents
Subject page

Specifications
Specifications subject to change without notice
dimensions:
User interface (default settings):
standard conveyor configuration - npn output signal types:
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CN1
2 PIN Connector for Power
Male Connector on Card
WAGO #734-162
Female Connector for Wiring
WAGO #734-102
PIN
Description
1
+24V DC ±10% (full-wave rectified, smoothed current <10% ripple)
Wire Size
28~14AWG
2
0V
CN2
(Ordered Separately)
5 PIN connector for External
Control
Male Connector on Card
WAGO #733-335
Female Connector for Wiring
WAGO #733-105
PIN
Description
1
+24V DC or 0V output (ERR – open collector: 25mA max)
Wire Size
28~20AWG
2
+24V DC or 0V output (OUT A – open collector: 25mA max)
3
0~+10V DC input (V-IN)
4
+24V DC or 0V input (DIR/E-stop)
5
+24V DC or 0V input (INPUT)
CN3
3 PIN connector for Sensor
Male Connector on Card
WAGO #733-363
Female Connector for Wiring
WAGO #733-103
PIN
Description
1
+24V DC
Wire Size
28~20AWG
2
+24V DC or 0V (sensor signal input)
3
0V
Specifications subject to change without notice
Connection Instructions for CN1, CN2, & CN3:
connections:
Press down spring clamp in connector with a small screwdriver.
Insert leads in proper order. (Lead should be stripped approx:
0.31~0.35”)
WAGO connector must be inserted and/or pulled out carefully,
so as not to damage other parts.
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CN4 & CN5
8 PIN Connector for
Communication Cable
Male Connector on Card
Molex #52018-8845
Female Connector for Wiring
RJ-45
CN4
PIN
CN5
PIN
Description
1
2
Sensor signal output
Wire Size:
26AWG
or
Equivalent 8 wire cable
2
1
Sensor signal input
3
3
Speed variation signal
4
4
Error signal
5
6
Drive input
6
5
Drive output
7
7
Direction signal
8
8
Emergency stop signal
Specifications subject to change without notice
Connections (Continued):
communication cable - straight-through wiring:
This straight through cable is intended for use between HB-510 cards. Please refer to the
section Connect to HB-508S for further instruction when using HB-510 with HB-508S cards.
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CN6
9 or 10 PIN
connector for Motor
Male Connector on Card
JST #S?B-XH-A (? = 9 or 10)
Female Connector for Wiring
JST #XHP-? (? = 9 or 10)
PIN
Description
1
GND – Grey
Wire size:
28~22AWG
&
24~22AWG motor phases
Terminal Pins:
JST #SXH-001T-P0.6
2
+12V DC – Blue
3
Motor phase U – Red
4
Motor phase V – White
5
Motor phase W – Black
6
Hall sensor U - Violet
7
Hall sensor V – Orange
8
Hall sensor W – Green
9
Thermistor – Light Blue
10
Brake - Yellow
Specifications subject to change without notice
Connections (continued):
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Precaution
Action
Reason
Sensor
Use a sensor that would have an active
output when the zone is occupied
Example: A retro-reflective
photosensor would need to be dark-
operate
-The HB-510 responds to the active signal received from
the sensor to denote zone occupation. If the incorrect
type is used, the HB-510 would “think” that a zone is
occupied when it is really clear. Not only would there be
problems in ZPA logic operation, but there will also be
JAM errors appearing.
More than 30
cards connected
together with the
communication
cable
The first card after each set of 30*
must be set as follows:
DIP Switch 1-1: OFF
DIP Switch 1-2: OFF
DIP Switch 1-3: OFF
*Standard conveyor configuration;
starting with first upstream card. If
using any of these signals, they need to
be connected to this point as well.
-When a card has its ERR, DIR, or ESTOP signal activated,
that signal is communicated through the communication
cable by sinking the signal. Because of this, that card’s
circuitry must be able to handle the current sourced by
the other cards. When there are more than 30 cards, the
signal’s current level is too high and will damage the
card’s circuitry
Restarting the
system after
applying ESTOP
signal
Wait until sufficient time has passed
before removing the ESTOP signal from
the system.
-RUN Hold Timer continues to operate even after the
ESTOP signal is applied. If the signal is removed before
the timer times out, an article will begin to move
downstream. This may cause a collision of articles
Make sure transported articles are not
between photo-sensors.
-Any article between photo-sensors will not be
recognized as occupying a zone. Therefore, any upstream
articles being transported may collide into them.
Powering ON
Keep away from the system when it is
first powered ON.
-When the system is first powered ON and there is no
signal from the photo-sensor for presence of an article,
the zone will RUN for a short time at a slow speed to
receive or advance any articles which may be between
photo-sensors. There may be a risk for bodily injury
because of moving rollers and transported articles.
As a standard driver card, connect the
sensor input (CN3-2) to 0V (NPN) or to
24V (PNP) to provide a constant
“sensor ON” signal.
-Used in conjunction with DIP switch 2-6 (OFF/ZE). This
eliminates the power ON running sequence. Please see
page 24.
Correct Cables
RJ-45 connectors
8-wire cables
Straight-through wiring pattern
-Straight-through wiring means that the connectors on
both ends of the cable are wired in the exact same
pattern.
-Cross-over wiring or any other wiring pattern will cause
communication problems.
Specifications subject to change without notice
Installation Precautions IMPORTANT: PLEASE READ
BEFORE ISNTALLATION
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Precaution
Action
Reason
Compatibility
with HB-508S
Please refer to the section: Connecting
to HB-508S
SPEED, DIR, and E-STOP/GND signals will conflict
Low impedance
connection to
PNP output(s)
DO NOT connect an output terminal
(CN2-2, CN2-1) set for PNP directly to
0V, GND, or a low impedance input on a
controller
When the PNP signal is active, the low impedance input will
draw a high current and subsequently damage the output
circuit. Damage may also occur to the input circuit on the
controller.
Multiple power
supplies
0V line of all power supplies on the
same conveyor line (powering the
card/rollers, & controls) need to be
physically linked together
This completes the signal path from one section of the
conveyor (powered by a power supply) to the adjacent
section of conveyor (powered by another power supply)
and allows for proper communication through the cable
and external interfaces.
Voltage drop
across the
power bus
Use suitable gauge wire in relation to
distance and current draw to prevent
voltage drop.
Operating DC voltage is 24V ±10%
When running long distances from a DC power supply, the
voltage drop during motor operation across the power bus
may be significant (may drop below 15V). If there is a large
enough drop in voltage, the roller(s) may behave in a
strange manner. In order to prevent this, a larger gauge wire
must be used.
Grounding
Ensure the control card is securely
grounded to the conveyor frame. The
conveyor frame should also be at the
same potential reference as earth
ground. Standard grounding practices
should be followed.
Static discharge may interfere and damage internal
components.
Environment
Ambient temperature is 32~104°F
Ambient humidity is < 90% RH
Atmosphere has no corrosive gas
Vibration is < 0.5G - Indoor use only
Extreme environmental variables may cause poor or no
performance and damage the card.
Electrical
24V DC ±10%
4A maximum current limiter (motor lock
is 4A)
Diode protection for miswiring
Sensor power short circuit protection
5A fuse for power supply protection
Auto-sensing inputs for PNP or NPN
Improper power will damage the card. The motor/ card
should not be subject to locked conditions repeatedly.
Internal fuse is not replaceable. If the fuse has blown, more
serious damage has occurred within the card/motor.
If inputs are subjected to a low potential the card may see
this as a signal, use of a diode inline is recommended to
prevent this.
Over-Speeding
Over-speeding of the roller’s no-load
speed by more than 50% may cause
damage.
Back EMF will be generated.
Specifications subject to change without notice
Installation Precautions IMPORTANT: PLEASE READ
BEFORE ISNTALLATION
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Signal blocking is independent from the ZPA logic direction (which can be reversed with the DIR
signal)
Signal blocking occurs on the right-hand side communication port (CN4) when looking at the
card in normal orientation
Signals will always be transmitted or received from the left-hand side communication port
(CN5).
The exception to this design is the SPEED signal which can be blocked on both CN4 & CN5
DIP
Switch
Function
ON
OFF
Default
Setting
CN5 (Left)
CN4 (Right)
CN5 (Left)
CN4 (Right)
1-1
ERR signal transmission
Transmit &
Receive
Transmit &
Receive
Transmit &
Receive
Blocked
ON
1-2
DIR signal transmission
Blocked
ON
1-3
ESTOP signal transmission
Blocked
ON
1-4
SPEED signal transmission
Left (Downstream)
n/a
Blocked
n/a
ON
1-5
SPEED signal transmission
Right (Upstream)
n/a
Transmit &
Receive
n/a
Blocked
ON
Specifications subject to change without notice
Operation
signal block settings:
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Specifications subject to change without notice
Illustration: signal blocking:
Dashed box represents HB-510. The circle is a light (green=ON; Black=OFF). The “signal”
for the lights is being provided by the power supply
The uppermost case is a signal being provided from the right-hand side (CN4). In this
case the DIP switch is ON for transmit/receive
The middle case is the same set-up as the upper case, but with the center card’s DIP
switch OFF. Note that the signal is blocked at CN4
The bottom case is the same set-up as the middle case, but with the signal from the left-
hand side. Note the difference in the light response when the signal is coming from the
other side
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To control the speed on an individual card
DIP switch 1-6 must be OFF
Rotary switch must be used to adjust speed
▪ Rotary switch setting is independent of transmitted SPEED signal
▪ Rotary switch setting will not have any effect on other cards
To control the speed simultaneously on more than one card
DIP switch 1-6 must be ON for all cards being controlled by SPEED signal
SPEED signal (0~10V DC) applied to CN2-3 on 1 (one) card
DIP Switch
Function
ON
OFF
Default Setting
1-6
SPEED adjustment
External: 0~10V DC
Internal: Rotary
switch
OFF
1-7
DIR or ESTOP input (CN2-4)
ESTOP signal input
DIR signal input
OFF
1-8
Reset for thermal recovery
Manual input recovery
Automatic recovery
ON
2-1
Output signal type
(CN2-2 & CN2-1)
PNP signal output
NPN signal output
OFF
2-2
Sensor or Synchronous output
(CN2-2)
Output is active while
internal motor RUN
signal is ON
Output is active
while photo-sensor
(CN3-2) signal is ON.
ON
2-8
STOP or RUN input
(CN2-5)
RUN signal input
STOP signal input
ON
Specifications subject to change without notice
input/output settings:
DIP Switch 1-6: Speed adjustment can be controlled by two methods
If both signals need to be used
Set DIP switch 1-7 OFF for one card and input the DIR signal to CN2-4 on the same card
Set DIP switch 1-7 ON for another card and input the ESTOP signal to CN2-4 on the same card
DIP Switch 1-7: Direction (DIR) and emergency stop (ESTOP) signals cannot be applied to the
same card
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Specifications subject to change without notice
Manual recovery (MANU; ON)
Some form of user intervention is needed to reset the thermal protection
The temperature of the motor or card must be in operating range in order for the recovery to work
Remove power (CN1) to the card, then reapply – most likely case o Input a signal to CN2-5 and
have DIP switch 2-8 set ON for forcible RUN
▪ The roller may operate while this signal is active, especially if the downstream zone is clear
Input a signal to CN2-4 and have DIP switch 1-7 set ON for ESTOP
▪ This will send an ESTOP signal through the communication cable to all the connected cards
• ESTOP Signal blocking may be necessary in order to not affect the adjacent zones
Automatic recovery (AUTO; OFF)
The card will automatically reset the thermal protection once it or the motor has cooled to
operating temperature
DIP switch 1-8: Reset for thermal recovery
When the signal is not active, there is no voltage present
NPN (OFF) – when active the output will be 0V
PNP (ON) – when active the output will be +24V DC
▪ Do not connect to a low impedance input, 0V, or GND
DIP switch 2-1: Output signal type for both CN2-2 (OUT A) & CN2-1 (ERR)
Sensor (SEN; OFF) – OUT A is active while the output from the photo-sensor is active
Synchronous (SYN; ON) – OUT A is active while the internal RUN signal (for motor operation) is active
This signal is usually used to slave drive another card/powered roller
DIP switch 2-2: Sensor or Synchronous output (CN2-2)
Forcible STOP (OFF) – Prevents an article from advancing downstream once the present zone (while
receiving the signal) becomes occupied
Forcible RUN (ON) – Forces the present zone to RUN (while receiving the signal) under these
conditions:
When DIP switch 2-6 is set ON (ZB) – Allows the present unoccupied zone to RUN until it becomes
occupied
▪ This setting does not override accumulation logic
▪ If the zone is already occupied and stopped, it will not RUN
▪ RUN Hold timer has been added to this input and setting to alleviate the need of an external
controller/timer with an infeed photo-sensor. Therefore, once an article clears the photo-sensor
connected to this input (CN2-5), the present zone will continue to operate and allow the article to
reach the present zone’s photo-sensor (CN3).
When DIP switch 2-6 is set OFF (ZE) – present zone will RUN (occupied or unoccupied) as
long as the signal is present
▪ Use this setting if the card is being used as a regular driver/slave card
(no photo-sensor)
DIP switch 2-8 – Forcible Stop or Run (CN2-5)
input/output settings (Continued):
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Present zone must receive signals through the communication cable from the upstream zone to
function
Present zone will RUN when
Present zone’s photo-sensor is clear o Upstream zone’s photo-sensor becomes blocked
▪ Also, it sends a RUN signal to the present zone
Sensor Timer starts when
Present zone is running due to the condition above
AND the upstream zone’s photo-sensor becomes clear
▪ If a jam occurs in the upstream zone
• Sensor Timer never starts
• Present zone will stop when upstream zone’s Jam Timer reaches set time
Sensor Timer will STOP the present zone when
Present zone is running and its photo-sensor remains clear
AND Sensor Timer reaches the set time
Sensor Timer is RESET when o It reaches the set time
Present zone’s photo-sensor becomes blocked
Upstream zone’s photo-sensor becomes blocked again
DIP Switch
Gear Stages
Time* (s)
2-3
2-4
Sensor Timer
Run Hold Timer
Jam Timer
OFF
OFF
1
0.3~1.2
0.3~1.2
0.6~2.2
OFF
ON
2
1.0~4.0
1.0~4.0
2.0~8.0
ON
OFF
2
4.0~14.0
4.0~14.0
7.5~27.0
ON
ON
N/A
Motor runs continuously; troubleshooting purposes only
Specifications subject to change without notice
timer settings:
Sensor Timer: controls the RUN time of the motor during the zone’s infeed operation in the ZPA system
* Time range is also dependent on the rotary switch position (i.e. higher position = shorter timing)
A range of time should be selected for use. In most applications, the default setting should suffice.
However, if longer or shorter times are necessary, select the appropriate DIP switch settings
Because the roller speed may be affected by the rotary switch position, it is suggested that the
speed required be set first, then the timing adjusted by use of these DIP switches
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Specifications subject to change without notice
timer settings (C0ntinued):
Present zone will RUN when
Present zone’s photo-sensor is blocked
Downstream zone’s photo-sensor is clear
▪ This also applies if there is no downstream zone connected
Run Hold Timer starts when
Present zone is running and its photo-sensor becomes clear
Run Hold Timer will STOP the present zone when
Present zone is running and its photo-sensor remains clear
AND Run Hold Timer reaches the set time
Run hold Timer is RESET when
It reaches the set time
Present zone’s photo-sensor becomes blocked
Upstream zone’s photo-sensor becomes blocked
Run Hold Timer: controls the RUN time of the motor during the zone’s discharge operation in the
ZPA system
Jam Timer starts when
Present zone is running and its photo-sensor becomes blocked
Jam Timer will STOP the present zone when
Present zone is running and its photo-sensor remains blocked
AND Jam Timer reaches the set time
Jam Timer is RESET when
Present zone’s photo-sensor becomes clear
Downstream zone’s photo-sensor becomes blocked
Jam Timer: controls the RUN time of the motor during the zone’s running operation in the ZPA system
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ZP2 (OFF) – In singulated release mode (assuming accumulated conveyor) each zone will
advance when its downstream zone is unoccupied
ZP1 (ON) – In train/slug release mode (assuming accumulated conveyor) all zones will advance
in unison
DIP
Switch
Function
ON
OFF
Default
Setting
2-5
Release modes
ZP1
Train/Slug release
ZP2
Singulated release
ON
2-6
Last zone mode
ZB
Standard zone
ZE
Last zone
ON
2-7
Motor direction*
FE
FS/FP
FE
FS/FP
ON
CCW
CW
CW
CCW
Specifications subject to change without notice
other settings:
DIP switch 2-5 – Release modes
ZB (ON) – Standard zone (zone beginning) mode
ZPA logic in this mode must receive a signal to prevent an article from advancing past the
present zone
▪ Through the communication cable from a downstream card
▪ From an external control to the INPUT on CN2-5 and DIP switch 2-8 set OFF
ZE (OFF) – Last zone (zone end) mode
ZPA logic in this mode stops an article in the present zone
Downstream ZPA communication is overridden
DIP switch 2-6 – Last zone mode
* Motor direction (as viewed from the cable side; PM486 series) is independent of ZPA logic
flow direction.
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Roller surface speed is dependent on a combination of motor RPM, gear-staging, and roller
diameter
This table is based on a PM486FE-60 roller which has 2 stage gearing, a 1.9in diameter tube, and
motor RPM which is adjustable through the entire selectable range
If a motor is a slower speed, and all other factors remain the same, any settings above the
motor’s top speed will have no effect
For example: PM486FE-20 will reach its maximum speed at setting 2. Any higher settings
(3~9) will have no effect on its speed
Integral Indexed Rotary
Switch
External Speed Variation
Signal
V ±0.2
Speed*
m/min ±3%
ft/min ±3%
9
9.5
60
196.8
8
8.5
55
180.4
7
7.5
50
164.0
6
6.5
45
147.6
5
5.5
40
131.2
4
4.5
35
114.8
3
3.5
30
98.4
2
2.5
25
82.0
1
1.5
20
65.6
0
0.5
15
49.2
Specifications subject to change without notice
speed adjustment:
* Card controls speed through motor RPM feedback
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Note – the output can be manually switched in the field by DIP switch 2-1 – Output signal type for
both CN2-2 (OUT A) & CN2-1 (ERR)
When the signal is not active, there is no voltage present
• NPN (OFF) – when active the output will be 0V
• PNP (ON) – when active the output will be +24V DC
Position for Signal Type
Initial Setting
NPN Setting
PNP Setting
Up
Down
Up
Specifications subject to change without notice
NPN/pnp inputs:
The card(s) are ordered with the inputs preset from the factory – ALL NPN or ALL PNP. The model
designation will show the factory preset.
• HB-510N – NPN input type (Default)
• HB-510P – PNP input type
• HB-510BN – NPN input type for brake card (Default)
• HB-510BP – PNP input type for brake card
If it is necessary to change the input type, the internal dip switch will need to be changed as shown
below:
1. Pry open the plastic cover at
screwdriver slots on front of the card
2. Adjust internal dip switch to
appropriate setting and replace cover
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Specifications subject to change without notice
operation
LED AND ERROR INDICATIONS:
*solution:
1. See more information under Input/Output Settings, DIP switch 1-8
A signal applied to CN2-5 (INPUT) will reset this error status
Thermal overload can only be reset if the temperature has fallen back into operating range
2. Remove the cause of the motor lock and clear the zone
A signal applied to CN2-5 (INPUT) AND DIP switch 2-8 set to ON (RUN) will reset this error status
3. Remove power from the card, plug in the motor connector, and then reapply power
4. Remove the cause of the jam and clear the zone
A signal applied to CN2-5 (INPUT) will reset this error status
As long as a signal is applied to CN2-5, jam error status will not turn ON
5. Replace the card
6. Not usually a cause for concern, unless it is occurring frequently over the entire running cycle
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Conveyor Zone Configuration
Specifications subject to change without notice
Standard Zone:
This configuration (factory set) is the standard set-up for any zone that is not specifically an
infeed or discharge zone.
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Conveyor Zone Configuration
Specifications subject to change without notice
infeed Zone:
The infeed zone can use 2 photo-sensors
1. Main photo-sensor
2. Infeed photo-sensor
Set up
Card is in standard configuration
Distance between the infeed photo-sensor and the main photo-sensor should be set the same
distance that is between all the adjacent zone photo-sensors
Photo-sensor is powered from the 24V DC bus
Output from infeed photo-sensor is connected to INPUT (CN2-5)
The infeed RUN hold timer is active when INPUT (CN2-5) is being used while the card is set for ZB
(DIPSW 2-6). There is no need for an external controller in these simple infeed applications.
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