ITOH DENKI POWER MOLLER 24 HBK-608FN User manual

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hbk-608fn/p
Operates FH and KT series motors
12 pin motor connector only
Runs one or two Power Mollers in one or
two zone configurations
LED indications for operation and error
statuses
Automatic or manual recovery for error
statuses
Motor protection against overheating,
stall condition and overspeeding
Lead free design for RoHS conformity
Logic for general zero pressure
accumulation (ZPA) is built-in
Singulated release
Slug (train) release with Flexible Zone
Recognition (patented)
Specifications subject to change without notice
Direct connection for two photo-sensors for
power and signal
Easy connection between adjacent HBK-608F’s
with communication cables simplifies wiring
Independent speed control for each motor
Adjustable timers by rotary switch
Automatically detects the end of a conveyor
line for accumulation when the communication
cable is disconnected
Stable speed function to ensure that different
weight articles travel at the same rate
Enclosure is made from fire resistant ABS
Features:
Driver Card Manual

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table of contents
Specifications subject to change without notice
Features
1
Table of Contents
2
Specifications
-Dimensions
-User Interface
-Standard Conveyor Figuration
3
Connections
4-7
Installation Precautions
8-9
Operation
-Input/Output Settings
-Speed Adjustment
-Timer Settings
-Other Settings
-PNP/NPN Settings
10-16
LED and Error Indications
17-20
Conveyor Zone Configuration
-Standard Zone
-Infeed Zone
-Discharge Zone
-Single Zone One MDR
-Single Zone Two MDRs
-Handshake Signals HBK-608 to IB-E
21-26
Revision History
27
Subject page

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Specifications
Specifications subject to change without notice
Dimensions:
user interface - default settings:

CN4
Ordered Separately
6 PIN connector for External Control
Female Connector for Wiring: WAGO #733-106
PIN
Description
1
Direction or error reset (selectable on SW1-1)
Wire size:
28~20AWG
2
Motor A forcible run or stop (selectable on SW2-3)
3
Motor B forcible run or stop (selectable on SW2-4)
4
Error output (selectable output on SW1-6 for steady voltage or pulsed signal)
5
Motor A synchronization or sensor output (selectable on SW2-1)
6
Motor B synchronization or sensor output (selectable on SW2-2)
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CN301,
CN401
3 PIN connector for Photo Sensor
Female Connector for Wiring: WAGO #733-103
PIN
Description
1
+24V DC
Wire size:
28~20AWG
2
+24V or 0V DC input (sensor signal input)
3
0V
CN1
2 PIN connector for Power
Female Connector for Wiring: WAGO #231-302 / 026-000
PIN
Description
1
+24V DC ±10% (full-wave rectified, smoothed current < 10% ripple)
Wire size:
28~14AWG
2
0V
connections
Specifications subject to change without notice
Connection Instructions for CN1, CN4, CN301 & CN401:
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.

Specifications subject to change without notice
Input / Output settings CN4:
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Direction input (SW1-1; OFF) [Default]
Reverses the logic flow and motor direction while the input is active. Logic flow is independent
of motor direction.
This signal is shared through the communication cable.
Error reset input (SW1-1; ON)
Resets error conditions at the time the signal is input only when the card is in operational
condition and causes of errors have been removed. This signal is shared through the
communication cable.
CN4-1 – Direction / Error reset (selectable by SW1-1; see page 11)
Forcible run motor A input (SW2-3; ON) [Default]
Forcibly runs motor A while signal is active
Forcible stop motor A input (SW2-3; OFF)
Forcibly stops motor A when sensor A becomes blocked while signal is active
CN4-2 – Input A (selectable by SW2-3; see page 12)
Forcible run motor B input (SW2-3; ON) [Default]
Forcibly runs motor A while signal is active
Forcible stop motor B input (SW2-3; OFF)
Forcibly stops motor B when sensor B becomes blocked while signal is active
CN4-3 – Input B (selectable by SW2-4; see page 12)
Pulsed output (PLS; ON)
Used when connecting the error output to an IB-E03 / 04 remote input 1 (CN301-1 on IB-E series)
▪ PNP pulse with SW2-3 ON
▪ NPN pulse with SW2-3 OFF
Output signal (ERR ON; OFF) [Default]
Outputs a signal when an error occurs
▪ PNP signal with SW2-3 ON
▪ NPN signal with SW2-3 OFF
CN4-4 – Error output (selectable by SW1-8; see page 11)
Synchronous output (SYN A; SW2-1 ON) [Default]
Outputs a signal on CN4-5 when motor A runs
Sensor output (SEN A; SW2-1 OFF)
Outputs a signal on CN4-5 when sensor A is blocked
CN4-5 – Output A (selectable by SW2-1; see page 12)
Synchronous output (SYN B; SW2-1 ON) [Default]
Outputs a signal on CN4-6 when motor B runs
Sensor output (SEN B; SW2-1 OFF)
Outputs a signal on CN4-6 when sensor B is blocked
CN4-6 – Output B (selectable by SW2-2; see page 12)

CN302 &
CN402
8 PIN connector for Communication Cable
Connector for Wiring
#
PIN
Description
1
Error status
Wire size:
26AWG
or Equivalent 8 wire cable
2
Error status
3
Motor status
4
Motor status
5
Error reset and direction
6
0V DC
7
Sensor status
8
Sensor status
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Specifications subject to change without notice
communication cable:
Straight-through wiring (not crossover)
Connections (continued):

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12 PIN connector for Motor
Male Connector on Card
JST #S12B-XH-A
Female Connector for Wiring
JST #XHP-12
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 U – Pink
5
Motor phase V – White
6
Motor phase V – Yellow
7
Motor phase W – Black
8
Motor phase W – Brown
9
Hall sensor U - Violet
10
Hall sensor V – Orange
11
Hall sensor W – Green
12
Thermistor – Light Blue
Specifications subject to change without notice
Connections (continued):

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 HBK responds to the active signal received from
the sensor to denote zone occupation. If the incorrect
type is used, the HBK 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.
Restarting the
system after
applying
ESTOP signal
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.
Using as a slave card be sure the timer
switch SW5 to zero (0) for slave mode
This eliminates all timer functions and communication.
Roller(s) will not run on initial start up in slave mode
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.
Low impedance
connection to
PNP output(s)
DO NOT connect an output terminal
(CN2-4, CN2-5) 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.
Specifications subject to change without notice
Installation Precautions IMPORTANT: PLEASE READ
BEFORE ISNTALLATION
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Precaution
Action
Reason
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
The conveyor frame should be at the
same potential reference as earth
ground. Standard grounding practices
should be followed.
Static discharge may interfere with general logic
processing, and in possibly damage IC components on
the circuit board. The grounding screw ensures proper
contact against the grounded metal frame. If a
grounded frame is not available to mount against, a
ground wire can be attached.
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.
Over-speeding
Over-speeding of the roller’s no-load
speed by more than 50% may cause
damage
Back EMF will be generated
Electrical
24V DC ±10% 7A maximum current
limiter (motor lock is 7A) Diode
protection for miss-wiring Sensor
power short circuit protection 10A
fuse per motor driver for power
supply protection
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.
Specifications subject to change without notice
Installation Precautions IMPORTANT: PLEASE READ
BEFORE ISNTALLATION
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Specifications subject to change without notice
Operation
Input / Output Settings SW1:
DIP
Switch
Function
ON
OFF
Default Setting
1-1
Error Reset or Direction input
Error reset
Direction
OFF
1-2
Error recovery
Manual
Automatic
ON
1-3
PNP or NPN output
PNP
NPN
ON HBK-608FP
OFF HBK-608FN
1-4
ZPA release mode
Train / Slug
Singulated
OFF
1-5
Motor A direction
Based on MDR type
Based on MDR type
ON
1-6
Motor B direction
Based on MDR type
Based on MDR type
ON
1-7
Zone count
One zone
Two zones
OFF
1-8
Error output function
Pulsed
Signal when error occurs
OFF
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Error Reset (RST; ON)
When the signal is applied then removed it resets an error(s) on all cards connected by
communication cables
Direction (DIR; OFF) [Default]
Reverses the logic and motor direction while signal is applied to all cards connected by
communication cables
▪ SW 1-5 and 1-6 only change motor direction and do not change logic direction
If both signals need to be used
Set DIP switch 1-1 ON for one card and input the RST signal to CN4-1 on the same card
Set DIP switch 1-1 OFF for another card and input the DIR signal to CN4-1 on the same card
DIP switch 1-1 – Error Reset or Direction
Manual recovery (MANU; ON) [Default]
Some form of user intervention is needed to reset if the card is in thermal protection
The temperature of the motor and card must be in operating range in order for the recovery to work
Remove power (CN1) to the card, then reapply – most likely case
Input then remove a signal to CN4-1 and have DIP switch 1-1 set ON for Error Reset (RST)
▪ This will send an error reset signal through all cards connected by communication cables
Input a signal to CN4-2 and have DIP switch 2-3 set ON for forcible run for errors on motor A
▪ This will reset errors for motor A
Input a signal to CN4-3 and have DIP switch 2-4 set ON for forcible run for errors on motor B
▪ This will reset errors for motor B
Automatic recovery (AUTO; OFF)
The card will automatically reset the thermal protection once it or the motor has cooled to
operating temperature.
This will also reset a low voltage error once the voltage becomes stable
DIP switch 1-2 – Error recovery

Specifications subject to change without notice
Input / Output Settings SW1:
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PNP (ON) [Default on HBK-608FP]
When active the output will be +24V DC
▪ Do not connect to a low impedance input, 0V, or GND
NPN (OFF) [Default on HBK-608FN]
When active the output will be 0V DC
DIP switch 1-3 – Output signal type for both CN4-5 (OUT A) & CN4-6 (OUT B)
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 1-4 – Release modes [Default OFF]
1 Zone on a card (ZONE 1; ON)
Connect motor to CN101 Motor A and sensor to CN301 sensor A
▪ When using one motor per zone set SW2-4 to OFF
▪ When using two motors per zone set SW2-4 to ON
2 Zones on one card (ZONE 2; OFF) [Default]
Utilizes both motor ports and sensor ports for two individual zones
DIP switch 1-7 – Zone Count
DIP switches 1-5 and 1-6 - Motor Direction
DIP-SW
Function
ON Setting
OFF Setting
Default Setting
1-5
Motor A direction
KT
FH
KT
FH
ON
CCW
CW
CW
CCW
1-6
Motor B direction
KT
FH
KT
FH
ON
CCW
CW
CW
CCW
* Motor direction (as viewed from the cable side) is independent of ZPA logic flow direction.
Direction also changes with DIP switch 1-1 OFF and signal input to CN4-1.
Pulsed output (PLS; ON)
Used when connecting the error output to an IB-E03 / 04 remote input 1 (CN301-1 on IB-E series)
Output signal (ERR ON; OFF) [Default]
Outputs a signal when an error occurs
▪ PNP signal with SW2-3 ON
▪ NPN signal with SW2-3 OFF
DIP switch 1-8 – Error output function

Specifications subject to change without notice
Input / Output Settings SW2:
DIP
Switch
Function
ON
OFF
Default Setting
2-1
Sensor A or Motor A synchronous
Synchronization signal
Sensor signal
ON
2-2
Sensor B or Motor B synchronous
Synchronization signal
Sensor signal
ON
2-3
Motor A input function
Forcible run
Forcible stop
ON
2-4
Motor b input function
Forcible run
Forcible stop
ON
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Synchronous output (SYN A; ON) [Default]
Outputs a signal on CN4-5 when motor A runs
Sensor output (SEN A; OFF)
Outputs a signal on CN4-5 when sensor A is blocked
DIP switch 2-1 – Sensor A or Motor A synchronous output
Synchronous output (SYN B; ON) [Default]
Outputs a signal on CN4-6 when motor B runs
Sensor output (SEN B; OFF)
Outputs a signal on CN4-6 when sensor B is blocked
DIP switch 2-2 – Sensor B or Motor B synchronous output
Forcible STOP (OFF)
Prevents an article from advancing downstream once motor A’s zone (while receiving the signal)
becomes occupied
Forcible RUN (ON) [Default]
Forces motor A’s zone to RUN
▪ This setting overrides accumulation logic
▪ RUN Hold timer (SW5) has been added to this input and alleviates the need of an external
controller/timer with an infeed photo-sensor. Therefore, once an article clears the photo-sensor
connected to this input (CN4-5), zone A will continue to operate and allow the article to reach the
next zone’s photo-sensor.
DIP switch 2-3 – Motor A input function
Forcible STOP (OFF)
Prevents an article from advancing downstream once motor B’s zone (while receiving the signal)
becomes occupied
Forcible RUN (ON) [Default]
Forces motor B’s zone to RUN
▪ This setting overrides accumulation logic
▪ RUN Hold timer (SW5) has been added to this input and alleviates the need of an external
controller/timer with an infeed photo-sensor. Therefore, once an article clears the photo-
sensor connected to this input (CN4-5), zone B will continue to operate and allow the
article to reach the next zone’s photo-sensor.
DIP switch 2-4 – Motor B input function

Specifications subject to change without notice
Speed Adjustment:
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Used to vary the speed on motor A
Rotary switch SW3 – 10 step speed setting for Motor A
Roller surface speed is dependent on a combination of motor RPM, gear-staging, and roller
diameter
This table is based on a PM635KT-16 roller which has 3 stage gearing, a 2.5” 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: PM486FH-20 will reach its maximum speed at setting 2. Any higher settings (3~9)
will have no effect on its speed
Rotary Switch
(SW3 & SW4)
Speed*
m/min +/-3%
ft/min +/-3%
9
18.0
59.1
8
16.6
54.5
7
15.0
49.2
6
13.6
44.6
5
12.0
39.4
4
10.6
34.8
3
9.0
29.5
2
7.6
24.9
1
6.0
19.7
0
4.6
15.1
PM635KT-16
* Card controls speed through motor RPM feedback
Used to vary the speed on motor B
Rotary switch SW4 – 10 step speed setting for Motor B

Specifications subject to change without notice
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timer settings:
Rotary Switch
(SW5)
Time (seconds)
Run Hold & Sensor
Jam
9
18
36
8
16
32
7
14
28
6
12
24
5
10
20
4
8
16
3
6
12
2
4
8
1
2
4
0
Slave mode
Used to vary timer settings for the run hold timer, sensor timer and jam timer
Rotary switch SW5 – 10 step timer setting for both motors
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
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
It reaches the set time
Present zone’s photo-sensor becomes blocked
Upstream zone’s photo-sensor becomes blocked again
Sensor Timer: controls the RUN time of the motor during the zone’s infeed operation in the ZPA system

Specifications subject to change without notice
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timer settings (continued):
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
Initial startup seek to sensor time is the same as the jam timer value. ZPA will not begin until this
time expires.
Jam Timer: controls the RUN time of the motor during the zone’s running operation in the ZPA system

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This setting is used when the HBK-608 is used as a driver / slave card
Motor runs when a signal is present on CN4 and stops when the signal is removed
• SW5 must be set to zero (0)
• SW2-3 set to ON and signal input to CN4-2 to run motor A
• SW2-4 set to ON and signal input to CN4-3 to run motor B
The card(s) are ordered with the inputs preset from the factory – ALL PNP or ALL NPN. The model
designation will show the factory preset.
HBK-608FP – PNP input type
HBK-608FN – NPN input type
Note –signal type for all outputs can be manually switched in the field by DIP switch 1-3. When
the signal is not active, there is no voltage present
NPN (OFF) – when active the output will be 0V DC
PNP (ON) – when active the output will be +24V DC
Specifications subject to change without notice
Other settings:
Slave Mode
PNP / NPN inputs

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Specifications subject to change without notice
leds and error indications

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Specifications subject to change without notice
LED AND ERROR INDICATIONS (continued):

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Specifications subject to change without notice
LED AND ERROR INDICATIONS (Continued):
solution:
1. Indicates either a low voltage error or the fuse has blown.
First check that there is a stable +24V DC power. If in manual recovery cycle the power to reset
a low voltage error, if in automatic recovery the error will reset once a stable +24V DC is
reached. See more information under Input/Output settings, DIP switch 1-2.
If the voltage is a stable +24V DC power then the fuse has blown and the card must be replaced.
2. Motor unplugged.
Check motor ports to ensure the motor connectors are properly inserted into their respective
motor ports. If using only one motor per zone select forcible stop on the motor you are not
using. See more information under Input/Output Settings, DIP switch 2-3 and 2-4.
3. Motor lock.
Remove the cause of the motor lock and clear the zone A signal applied to CN4-2 for motor A or
CN4-3 for motor B with DIP switch 2-3 ON for motor A and DIP switch 2- 4 ON for motor B will
reset this error. Review Connections CN4 and Input/output settings, DIP switch 2-3 and 2-4.

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Specifications subject to change without notice
LED AND ERROR INDICATIONS (Continued):
4. Thermal protection.
See more information under Input/Output Settings, DIP switch 1-2 A signal applied to CN4-2 for
motor A or CN4-3 for motor B with DIP switch 2-3 ON for motor A and DIP switch 2- 4 ON for
motor B will reset this error. Review Connections CN4 and Input/output settings, DIP switch 2-3
and 2-4.
Thermal protection can only be reset if the temperature has fallen back into operating range
5. Back EMF error.
See more information under Input/output Settings, DIP switch 1-2. Roller(s) were driven faster
than their designed speed and the HBK-608F activates the dynamic brake to slow the product
down. In automatic recovery the card returns to normal operation once the voltage decreased
to a safe level. In manual recovery a signal applied to CN4-2 for motor A or CN4-3 for motor B
with DIP switch 2-3 ON for motor A and DIP switch 2-4 ON for motor B will reset this error.
Review Connections CN4 and Input/output settings, DIP switch 2-3 and 2-4.
6. Sensor signal ON.
Should be on only when the photo sensor is blocked. If it is on when the zone is clear then it is
the incorrect type of sensor output and needs to be replaced with one that outputs a signal
when it is blocked.
7. Sensor signal OFF.
Should be OFF only when the photo sensor’s zone is clear. If it is OFF when the sensor is
blocked then it is the incorrect type of sensor output and needs to be replaced with one that
does output a signal when blocked.
8. Remove the cause of the jam and clear the zone.
A signal applied to CN4-2 for motor A or CN4-3 for motor B with DIP switch 2-3 ON for motor A
and DIP switch 2-4 ON for motor B will reset this error. Review Connections CN4 and
Input/output settings, DIP switch 2-3 and 2-4. As long as a run signal is applied a jam error
status will not turn ON