ITOH DENKI F-RAT-NX75 User manual

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Office Ph: 570-820-8811
Fax: [phone]
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Make sure to read this manual carefully before using, and start using only after you have
understood all the product’ s functions, safety information and precautions.
After reading the instructions, store the booklet in a designated location for readily accessing at
any time.
F-rat-nx75
Specifications subject to change without notice
Operating Instructions

table of contents
Introduction
3-4
Procedures
5
Safety Precautions
6-11
Advance Preparation
12-14
Product Check
15
Structures
16-17
Installation/Wiring
-Before Installation
-Installation
-Wiring
18-32
Control/Operation
-Basic Operation
-Switching the Transfer Direction
-Changing the Speed
-What to do Before Operation
-Timing Chart Example
33-39
Maintenance/Inspection
-Driver card LED Display and Errors
-Before Replacement Work
-Replacement of the MDR for Roller Transfer/Idlers/Drive Belts
-Replacement of the Carrier Wheel Cassette
40-50
Troubleshooting
51-53
Appendix
-Appendix 1: Product Specifications
-Appendix 2: Replacement Parts/Options
-Appendix 3: Residual Risk List
54-58
Subject page
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This product is a module to divert at a right angle without changing its level, and there is no impact
on the trays.
All-electric control. No pneumatics, which do not require compressor.
introduction
operation description (when diverting):
Features:
Load
Discharge
Switch to the diverting direction
Switch to the straight direction

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Driver Cards purchased separately
NPN/PNP must be specified
CB Series
IB Series
(1) CBK-109F_
(2) CB-016B_
(1) IB-E04F-_
(1) IB-E03B-_
This product is designed as a general industrial device. Do not use for other applications. We do not take any
responsibility for any damage that may result from the disregarding of these warnings.
Also, in the event that an accident results from the use of this product, we do not compensate for any damage,
including abnormalities of equipment, connection devices, and/or software, any damage resulting from
malfunctions, and/or any other secondary damage.
introduction
notes on industrial property rights:
disclaimer:
There are some examples of parts that need to be prepared by customers, as explained within this manual.
However, this does not provide any guarantee against the existence of any rights, such as our industrial
property rights, or those of other companies, in advance.
＊ 1: European machinery safety standards
＊ 2: This indicates that even though events that would result in serious injury occur infrequently under
assumed risk environment, there is a high probability to avoid danger if you observe the safety contents
described in this manual.
This product is intended to comply with the risk category 2 ＊ 2 or lower as defined in EN954-1 ＊ 1 . It does
not comply with purposes beyond risk category 3 or higher.
notes on technical support:
We respond to technical inquiries based on the contents described within this manual, and on this product
within the range of general items for this product unit with standard specifications, and for the options prepared
by us.
There are some descriptions in this manual, about parts, equipment, and wiring arranged by customers, as well
as the controls and operation under such circumstances. However, these are not included in the guaranteed
operating range and/or support.
When in use, please check and perform the aforementioned based on your responsibility according to operation.
About the Risk category for this system:
This product is not equipped with special dust proof/waterproof countermeasures, and is intended to be
used in environments of “Pollution Degree 2”, as defined in IEC60664- 1.
For these reasons, if users install this product in an environment that requires dust proof/waterproof
treatments, they need to add necessary countermeasures, and check the performance based on their
responsibility.
installation environment:
In this manual, F-RAT-NX75 is described as F-RAT, and F-RAT-NX75 and F-RAT are described separately, when
needed.
Depending on the signal type (NPN/PNP) specified by customers, different models of control driver cards are
supplied as being the standard for this product.
In this manual, CBK-109FN and CBK-109FP are described as CBK-109, CB-016BN6 and CB-016BP6 as CB-016.
Also, CBK-109FN and CBK-109FP, CB-016BN6 and CB-016BP6 are described separately, when needed.
description of the product:

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Start using only after you have understood all the product´s functions,
safety information, and precautions.
procedures
Prepare the 24V DC power supply, such as DC power supply units. Prepare
control devices, such as PLCs.
Open the package, and check the model, specifications, and voltage, etc.
Check accessories.
Install the F-RAT main unit.
Mount driver cards. Connect the F-RAT and driver cards. Connect power
and signal cables to driver cards. Perform settings of driver cards. Connect
to power supply units/PLCs.
Perform control (programming).
Perform start-up inspection before operation.
Read this Manual
Advance Preparation
Wiring
Installation
Product Check
Control
Start-Up Inspection
Run operation
Some errors have been found Yes
Perform maintenance and inspection
based on corresponding parts.
No
Maintenance/Inspection
Troubleshooting
Have the problems been solved?
Take appropriate measures based on
the corresponding symptoms.
Yes
No

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WARNING
This indicates a high possibility that severe injury may result.
CAUTION
This indicates a high possibility that injury or property damage may result.
This symbol indicates forced operations that users should always perform.
This symbol indicates operations that are prohibited.
This symbol indicates a reminder which users should pay attention to.
Safety Precautions
Danger Level:
To prevent hazards to users and/or others, and/or damage to property in advance, the important precautions
to be followed securely are described below.
The degree of hazard and/or damage that may result if a user disregards the description and operates the
product improperly is categorized as the following symbols and explained below.
Symbol Explanation:
The type of precautions is categorized as the following symbols and explained below.
General Precautions:
WARNING
Do not use the product near places subject to explosive, flammable gas, and/or corrosive atmosphere,
and/or combustible materials.
Failure to follow this could result in explosion, fire, electric shock and/or injury.
When using the product in places where serious accidents and/or damage may possibly occur, install
backup and/or fail-safe functions systematically.
Failure to follow this could result in the inability to control this product, which could lead to serious
accidents.
Do not come into contact with the moving parts, such as carrier wheels, rollers, or lifting sections,
and/or allow clothes to get close to them.
Failure to follow this could result in them getting caught and/or stuck.
CAUTION
Do not apply heavy loads to this product, such as stepping on it.
Failure to follow this could result in people falling and/or malfunction.

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Safety Precautions
General Precautions (Continued):
Never remodel the product and/or driver cards.
Failure to follow this could result in serious accidents.
Make sure to attach ground wires to this product and the DC power supply unit.
Failure to follow this could result in electric shock if any malfunction or leakage occurs.
Do not forcibly bend and/or pull cables. Also, do not put heavy materials on cables, or do not get them
stuck between cables.
Failure to follow this could result in fire and/or electric shock due to cable damage.
Do not touch the product when it has just stopped operation.
Failure to follow this could result in burns.
Do not put water and/or oil on the product, and do not transfer wet and/or oily trays.
Failure to follow this could result in electric shock, and/or malfunction.
Do not apply strong impact and/or excessive force to the product, such as hitting it with objects, or
dropping it. Also, do not use the equipment if strong impact has been applied, and/or if the
appearance has become deformed.
Failure to follow this could result in malfunction due to applied impact.
Turn off the power supply to the product before moving and/or installing the product, and performing
maintenance and inspection (excluding those during operation). Working while the power is on could
result in accidents due to unexpected operation.
Do not turn on/off relays and/or contactors near power cables, signal cables, and/or driver cards.
Failure to follow this could result in malfunction due to noise generation.
Observe the safety regulations required for installation locations, and/or products in use.
LED or Pull-up/Pull-down circuits implemented in the output circuit of control devices could result in
unexpected operation.
Carefully check the output circuit.
Turn on the power in order of external control devices, and then the product.
Turn off the power in order of the product, and then external control devices.
Turning on/off the power in the wrong order could result in malfunction.
Stop operation when abnormal sound is heard during operation. Failure to follow this could result in
unexpected accidents.
CAUTION
Do not use in a way exceeding the range of the product specifications. Failure to follow this could
result in malfunction, fire, and/or injury.
Securely wire each cable to connection parts. Improper wiring could result in electric shock and/or
malfunction.

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CAUTION
Safety Precautions
Do not unplug power and/or signal cables during operation. Also, do not run/stop this product by the
power supply. (Use the signal.)
Failure to follow this could result in malfunction.
Make sure to perform the start-up inspection, and check that devices are free from any abnormalities,
and that safety equipment functions correctly before using the product.
When disposing of the product, make consigning contracts with licensed industrial waste disposers,
and consign the disposal to them.
CAUTION
When handling, wear protective equipment, such as gloves. Since this product consists in large part of
metal, careless handling could result in hands getting injured.
Make sure to use the recommended tightening torque to tighten bolts for installing the F-RAT main
unit and/or fastening screws of driver cards.
Failure to follow this could result in bolts and/or screws loosening, and/or malfunction.
General Precautions (Continued):
Do not forcibly rotate the MDR at times other than maintenance and inspection. Failure to follow this
could result in damage to driver cards, and/or their lifetime to be significantly shortened.
Do not turn on the power when trays are unstable. Failure to follow this could result in injury,
accidents, and/or damage due to load collapse.
WARNING
INSTALLATION Precautions:
In principle, have two or more persons work when carrying and/or installing the product as it is a heavy
load.
When hoisting this product, never enter the area under the suspended load.
When hoisting, use appropriate hoisting equipment, and pay special attention to prevent the balance
of the suspended load from being lost and/or falling. Also, have only qualified workers conduct the
operation. Improper hoisting could result in serious accidents.
Do not hoist this product with goods loaded.
Failure to follow this could result in objects falling.
Check the corresponding installing direction to the loading/discharging sides before installing.
Failure to follow this could result in objects/body parts getting caught and/or stuck

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Safety Precautions
INSTALLATION Precautions (continued):
Take appropriate measures to prevent trays from popping out of the equipment. For example, mount
guide rails on the conveyor frames.
Failure to follow this could result in workers getting injured by trays popping out of the equipment.
If necessary, warning/caution labels become hidden after installing fences, affix again on places where
they can be seen.
Perform wiring when the power is shut off.
Failure to follow this could result in electric shock and/or accidents due to unexpected operation.
When attaching or removing connectors, turn off the power first, securely hold connectors, and
perform operation. Also, do not apply excessive force to the driver card connection parts, such as
obliquely attaching or removing connectors. Failure to follow this could result in electric shock,
malfunction, and/or accidents due to unexpected operation.
CAUTION
Securely attach connectors to the driver card connection parts. Improper wiring could result in
electric shock and/or malfunction.
CAUTION
WIRING Precautions:
Do not change the VR1 and VR2 values on CBK-109 and CB-016. (Minimum (leftmost): Factory setting)
Do not turn the driver card switches with excessive force.
Failure to follow this could result in malfunction.
Perform wiring to connectors so that cables make secure contact with connectors. Barb lines from the
cable core could result in heat generation and/or fire due to changes of contact resistance, and/or
short circuit with the adjacent contact.
Control precautions:
CAUTION

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Safety Precautions
Do not forcibly move trays when they are placed on the carrier wheels.
Failure to follow this could result in damage and/or malfunction.
At the start-up inspection, shut off the power, and perform inspection. (excluding inspection to be
performed when operating this product.) Failure to follow this could result in injury due to unexpected
operation, such as getting caught and/or stuck
When operating this product at the start-up inspection, take appropriate measures to prevent fingers
from getting stuck and/or caught in carrier wheels and/or rollers. Also, get ready to shut off the power
in the event that something should happen. Failure to follow this could result in accidents/injury by
getting caught and/or stuck.
If any abnormalities are found, do not use this product until the causes have been eliminated
completely.
Using this product with unattended abnormalities could result in not only damage to the devices,
but also unexpected accidents.
Have specialists (or people who have sufficiently acquired skills) perform maintenance and
inspection under instructions by management supervisors.
CAUTION
OPERATING Precautions:
Make sure to perform the start-up inspection before starting operation.
Wear protective equipment, such as gloves.
maintenance and inspection Precautions:
At the time of repair and replacement work, turn off the power to all connecting devices. To
prevent wraparound for the power circuits and/or signals, shut off the power, wait a sufficient
amount of time, and discharge electricity inside the DC power supply equipment.
At the time of maintenance and inspection, post warning labels so as to prevent unauthorized
persons from turning on the power.
Failure to follow this could result in malfunction and/or unexpected accidents
CAUTION
If any abnormalities are found at the start-up inspection, make sure to take countermeasures before
the trial run. Failure to follow this could result in damage and/or malfunction.
When repairing/replacing, wear protective equipment, such as gloves. Failure to follow this could
result in hands getting injured by metal parts.

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Safety Precautions
maintenance and inspection Precautions (CONTINUED):
CAUTION
Do not disassemble sections and/or parts other than those specified.
Failure to follow this could result in malfunction and/or unexpected accidents.
Depending on sections and/or parts to be repaired and/or replaced, they need to be rotated
and/or lifted by hand. Pay attention not to get caught and/or stuck.
Failure to follow this could result in injury
Check that the roller drive belts have been mounted properly.
Check that there is no friction between the moving parts, or between the moving and fixed parts.
Check that screws/covers previously removed have been securely mounted again.
Check that all parts are installed.
Before the trial operation after repair/replacement,
Failure to follow this could result in malfunction and/or unexpected accidents.
Make sure to prepare repair/replacement parts designated by ITOH DENKI. Using parts other
than those designated by ITOH DENKI could result in malfunction.

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Important:
As for the sensor input, and input/output signals of driver cards, adopt
the number of inputs/outputs based on operation.
wiring reference:
Advance Preparation
IB-E Series
CB Series

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items to be prepared by customers:
A switching power supply is recommended as the DC power supply (24V DC±10%) for drivers.
Use a stabilized power supply that has an adequate capacity of 24V DC and 10A or higher and does
not fluctuate due to load variation.
The power supply shall have a capacity larger than the rated value of this product. ■ A transformer
type power supply cannot be used.
Secure a voltage of 24V DC±10% at the power supply terminal of a driver card.
If the capacity of the power supply is less than the rated power of this product, it may cause the
supply voltage leading malfunction or damage. Be sure to use the power supply with a capacity larger
than the rated power of this product.
The power supply should not activate protection with peak current 30A for 1ms or below.
For the power supply unit, use an isolation type switching power supply compliant with the
safety standard (IEC60950-1 or UL60950-1). Do not use a non-isolation type power
supply for safety reasons, since it may not conform to the radiation noise regulations.
Advance Preparation
Before introducing this product, prepare the following devices separately.
Switching power supply (24V DC/10A, 240W or more)
Rectified power (With a rectifying capacitor, ripple
rate 10% or below)
24V DC Battery
2. 24V DC Power Supply: power supply equipment to supply 24 VDC to this product
1. Emergency Stop Equipment
This product does not include the emergency stop equipment. Customers must make sure to install it.
Install the emergency stop equipment on the side of the DC power supply unit to which the power is
supplied.
Regarding facilities where this product is incorporated, check that a breaker with appropriate capacity for
the 24V DC power supply unit has been installed. If abnormal operation should occur, protection through
the breaker could be effective. Note that when using an earth leakage breaker, select one that is “inverter
corresponding”. Some inverter non-corresponding earth leakage breakers could result in malfunction, since
they may recognize high-frequency components of the switching power supply as leakage.
Checking the Breaker
Input to the DC power supply (single phase 100V/200V) is securely turned ON/OFF when turning ON/OFF
the breaker.
Input to this product (24V DC) is securely turned ON/OFF when turning ON/OFF the emergency stop switch.
When the 24V DC power supply unit has been incorporated, check that the breaker and emergency stop switch
can work properly. Perform operation following the trial operation after checking them.
1.
2.
Operation Check
Since F-RAT uses MDR for each of carrier wheel transfer, roller transfer, and drive switching
(3 MDRs in total), it is not recommended to use multiple MDRs at the same time.

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Connector/Driver Card
CBK-109
CB-016
Power Connector
（ AWG ： 18 〜 14 ）
（ AWG ： 20 〜 14 ）
Control Connector
（ AWG ： 28 〜 20 ）
Zone Sensor: A sensor to detect the
existence of trays within the zone
Area sensor: A sensor to detect load and
discharge of trays
items to be prepared by customers (Continued):
To select the current capacity of wiring materials, secure a high safety margin based on the current
value in the equipment to be used.
Longer wiring between the power supply unit and driver cards/controllers could cause the voltage
to decrease, resulting in malfunction and/or damage.
2. Control Devices: devices to control this product, such as PLCs
Advance Preparation
4. Wiring materials: necessary for wiring of power and signal cables to the controller.
5. MDR Extension Cable (optional)
Necessary when the installing location of the F-RAT
main unit is far from that of the driver cards.
3. Sensors: Zone sensors to check the tray, and area sensors
to check loading and discharging, etc.
CBK-109: 12P
extension cable
CB-016: 10P
extension cable
Use extension cables of 1200 mm or less.
Do not extend cables by connecting multiple extension cables.

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Product Check
checking appearance:
checking the model:
Unpack the product, and check that the
product model is what you ordered.
Check that the main unit is free from any abnormalities, such as traces of scratches, dents, dirt, and/or
corrosion (rust).
Check that there is no omission and/or looseness of screws.
If any abnormalities are found, contact the supplier immediately.
*Cable length depends on the model. Refer to P.17.

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checking accessories:
Check that all the following items are included.
Driver Cards
Product Check
Depending on the F-RAT input and
output signal type, driver cards
with the NPN (N) or PNP(P) signal
input are available.
For installing the F-RAT main unit

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Nominal Speed: The speed on the MDR roller surface (m/min), and the nominal speed with a
nice round value for convenience. Values differ slightly from the actual speed.
structures
Structures:
Product Designation:
*The image is for size 7550

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installation/wiring
7-1. Before installation
Prepare stands, and perform frame processing in advance by reference to the mounting holes in dimensions.
Determine the mounting location for zone sensors to check the existence of trays, and area sensors to check
loading and discharging. Then, prepare for them to be mounted.
Dimensions of F-rat main unit:
Size 6040
L595mm x W395mm
Size 6050
L595mm x W495mm

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installation/wiring
Size 6060
L595mm x W595mm
Size 6070
L595mm x W695mm

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Size 6080
L595mm x W795mm
installation/wiring
Size 7540
L745mm x W395mm