ITOH DENKI POWER MOLLER HBM-604BN User manual

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HBM-604Bn/BP
Operates FS, FE and FP series motors
Runs one or two Power Mollers in one or
two zone configurations
10 pin motor connector only
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 HBM-
604B’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
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
10-15
LED and Error Indications
-Solution
16-19
Conveyor Zone Configuration
-Standard Zone
-Infeed Zone
-Discharge Zone
-Single Zone One MDR
-Single Zone Two MDRs
-Handshake Signals HBM-604 to IB-E
20-26
Revision History
27
Subject page

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Specifications
User Interface:
Dimensions:

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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
5
Motor A synchronization or sensor output (selectable on SW2-1)
6
Motor B synchronization or sensor output (selectable on SW2-2)
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
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
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.

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)
Connections

CN302 &
CN402
8 PIN connector for Communication Cable
Female Connector for Wiring
RJ-45
PIN
Description
1
Error status
Wire size:
26 AWG
or
Equivalent 8 wire cable
2
Error status
3
Motor status
4
Motor status
5
Error reset
6
0V DC
7
Sensor status
8
Sensor status
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Communication Cable – Straight-through wiring (Not crossover)
connections (continued):
Connections

CN6
10 PIN Connector for Motor
Male Connector on Card
JST #S10B-XH-A
Female Connector for Wiring
JST #XHP-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
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connections (continued):
Connections

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 HBM responds to the active signal received from
the sensor to denote zone occupation. If the incorrect
type is used, the HBM 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)
Ambient temperature is 32~104°F
Ambient humidity is < 90% RH
Atmosphere has no corrosive gas
Vibration is < 0.5G
Indoor use only
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.
Installation Precautions
IMPORTANT: PLEASE READ BEFORE INSTALLATION
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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
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
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
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.
Installation Precautions
IMPORTANT: PLEASE READ BEFORE ISNTALLATION
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Operation
Input / Output Settings SW1:
DIP-SW
Function
ON Setting
OFF Setting
Initial 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 HBM-604BP
OFF HBM-604BN
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 o 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

Input / Output Settings SW1 (Continued):
DIP-SW
Function
ON Setting
OFF Setting
Default Setting
1-5
Motor A direction
FE
FS/FP
FE
FS/FP
ON
CCW
CW
CW
CCW
1-6
Motor B direction
FE
FS/FP
FE
FS/FP
ON
CCW
CW
CW
CCW
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PNP (ON) [Default on HBM-604BP]
When active the output will be +24V DC
▪ Do not connect to a low impedance input, 0V, or GND
NPN (OFF) [Default on HBM-604BN]
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)
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
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]
DIP switches 1-5 and 1-6 - Motor Direction
* Motor direction (as viewed from the cable side; PM486 series) 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
Operation

Input / Output Settings SW2:
DIP-SW
Function
ON Setting
OFF Setting
Initial 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 setting to alleviate the need of an
external controller/timer with an infeed photo-sensor. Therefore, once an article clears the
photosensor 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 setting to alleviate the need of an
external controller/timer with an infeed photo-sensor. Therefore, once an article clears the
photosensor 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
Operation

Speed adjustment:
Rotary Switch
(SW3 & SW4)
Speed*
m/min +/-3%
ft/min +/-3%
9
60
196.8
8
55
180.4
7
50
164.0
6
45
147.6
5
40
131.2
4
35
114.8
3
30
98.4
2
25
82.0
1
20
65.6
0
15
49.2
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Used to vary the speed on motor A
Rotary switch SW3 – 10 step speed setting for Motor A
Used to vary the speed on motor B
Rotary switch SW4 – 10 step speed setting for Motor B
PM486FE-60
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
* Card controls speed through motor RPM feedback
Operation

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
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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 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
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
Sensor Timer: controls the RUN time of the motor during the zone’s infeed operation in the ZPA system
Operation

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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.
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
timer settings (continued):
Jam Timer: controls the RUN time of the motor during the zone’s running operation in the ZPA system
Slave Mode: this setting is used when the HBM-604 is used as a driver / slave card
Other Settings:
PNP / NPN inputs
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.
• HBM-604BP – PNP input type
• HBM-604BN – 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
Operation

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led and error indications:

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led and error indications:

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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.
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
led and error indications:

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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 HBM-604B 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
led and error indications:

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COnveyor zone configuration
standard zone:
This configuration (factory set) is the standard set-up for any zone that is not specifically an
infeed or discharge zone. Review page 3 for default dip switch settings.