ITOH DENKI POWER MOLLER 24 F-RAT-S300 User manual

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
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Before using the product, carefully read this manual and retain it for future reference.
Make sure that the product you received matches your purchased order, with its designation, specification,
and operating voltage.
Photos and drawings for explanations in this manual are Size B.
f-rat-S300
Specifications subject to change without notice
Operating Instructions
Thank you for purchasing the Flat Right Angle Transfer.

table of contents
Specifications subject to change without notice
General Cautions
3-4
Product Designation
5
Structure
5
Power Supply
5
Dimensions
6-8
Installation/Operation
-Cautions during Transportation
-Cautions during Uncrating
-Cautions during Installation - Electrical
-Cautions during Installation - Main Unit
-Installation
-Precautions for Trial Run
8-14
Maintenance
-Transfer MDR replacement
-Transfer belt replacement
-Belt transfer MDR replacement
15-18
Specifications
19-21
Appendix 1: CBR-306F □
22-24
Appendix 2: Remaining Risks/MAP
25
Subject page
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Office Ph: 570-820-8811
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2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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General cautions
warning and caution:
Be sure to comply with all of the caution items and instructions contained in this safety manual.
To avoid functional deterioration, unexpected accident or product failure, check the operation according to
this manual.
Shown below are the caution items for using the product safely and avoiding danger and damage to the user.
Caution items can be classified into danger, warning and caution as described below.
Danger
The most serious danger with possibility of death or serious injury
Warning
Incorrect handling may lead to death or serious injury, indicating potential danger.
Caution
Possible danger of light or medium injury, or only a material damage
Basic warnings:
Warning
Incorrect handling may lead to death or serious injury, indicating potential danger.
Comply with the following warning and perform the work correctly.
Do not use the product in an explosive, flammable or corrosive atmosphere, or near flammable material. It
may cause explosion, fire, electrical shock or injury
Basic Cautions:
Caution
Incorrect work or use may lead to light or medium-level injuries and/or property
damages. Comply with the following warning and perform the work correctly.
Do not step on the product or apply a load. It may lead to a failure or unexpected accident.
Do not touch the mechanism by hand during operation. The hand may be caught by the mechanism and
injured.
Do not absolutely modify the Pop-up Diverter or the driver. Serious injury may be caused.
Do not forcibly bend or pull the wire. Do not put a heavy item on the wire or pinch the wire. The cord may
break and cause fire or electrical shock.
To avoid a failure or electrical shock, ground the DC power supply or driver to the conveyor frame.
Do not touch the equipment immediately after stopping. It may cause skin burn.
Do not splash water on the equipment. Electrical shock or failure may be caused.
Do not apply a strong impact or excessive force such as hitting the equipment or dropping an object.
Do not use the equipment after it is impacted or deformed. It may cause a failure.
When abnormal sound is heard during motion, stop the operation. Continued operation may cause an
accident or failure.
Do not use the equipment by exceeding the specification. It may cause a failure, fire or injury.
Do not carry out operation of transfer, connection, maintenance inspection (except maintenance
inspection to be performed during operation). Switch off the power before operation.
Comply with the safety rules required for the location and equipment to be used.

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Basic Cautions (Continued):
Caution
Incorrect work or use may lead to light or medium-level injuries and/or property
damages. Comply with the following warning and perform the work correctly.
Some type of driver failure may make the input/output ON condition or OFF condition. Apply an external
monitoring circuit for the input/output signal that may lead to an injury or property damage.
Connect or disconnect a connector when the power is shut off. Do not perform wiring with the connector
inserted in the driver.
Securely attach the connector of each connecting cable to the connection point.
Incorrect wiring may cause a failure. Carefully check the wiring.
Do not apply excessive force for operating the DIP switch.
Do not perform on/off operation of a relay or connector near the power line, signal line, or driver. That may
cause malfunction by noise.
When LED circuit or Pull-up/Pull-down circuit is connected to the output circuit, unexpected operation may
occur.
Apply power ON in the order of external controller→Driver. Perform power OFF in the order of
Driver→External controller. Incorrect order may cause malfunction.
Cutting the power disables electrical braking control, and the roller becomes easy to be rotated.
Do not pull out a cable during operation. It may cause a failure.
Do not forcibly rotate MDR except during maintenance inspection. That may cause driver breakage or make
the operation life extremely short.
Do not shut off the power during MDR rotation. It may cause a failure.
Do not apply power while riding on the conveyor or while a tray is unstable condition. MDR rotation
immediately after power ON may cause injury, accident or breakage.
When error occurs frequently, remove the cause.
When disposing the equipment, make a consignment contract with an authorized industrial waste
processing company for disposal.
About Risk Category of this System:
Warning
About Risk Category of this System
This equipment intends to comply with risk category 2 or below in EN 954-1. It does not comply with risk
category 3 or higher.

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Model Example: F - RAT - S300 - 17N - B - S1
Speed 17 m/min, NPN signal type, W 497 x L 758 mm, Type S1
power supply
24VDC Battery
Switching power supply (24VDC ・ 5A 120W ）
Rectified power (With a rectifying capacitor, ripple rate 10% or below ）
Supplied power must be a stabilized power supply of 24VDC, 5A or higher without fluctuation
by load. In addition, the power supply should not activate protection with peak current 20A,
1ms or below
Accessories:
The other driver cards are also available as option
F-RAT mounting hardware
4 sets of M8-20 bolt / M8 nut
Standard driver card
MDR for roller transfer / belt transfer; CB-016N × 2 or CB-016P × 2
MDR for lifting; CBR-306FN or CBR-306FP
Proximity NPN sensor or Proximity PNP sensor
1. Speed
17 … 17 m/min (Belt / Roller transfer : 17 m/min)
60 … 60 m/min (Belt / Roller transfer : 60 m/min)
90 … 90 m/min (Belt / Roller transfer : 90 m/min)
2. Signal type selection
N … NPN signal type (NPN proximity sensor / driver card included)
P … PNP signal type (PNP proximity sensor / driver card included)
3. Size
A…W379mm×L758mm
B…W497mm×L758mm
C…W597mm×L758mm
D…W697mm×L758mm
4. Type
S1
Product Designation
main unit:
f-rat-s300- (1) (2) - (3) - (4)
structure

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Dimensions
Size A:
W379mm×L758mm
W497mm×L758mm
Size B:

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Size C:
W597mm×L758mm
W697mm×L758mm
Dimensions
Size D:

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Caution
Avoiding injuries
-The majority of this product is made from metal and careless handling may cause injury of hands. Be
sure to wear protective means such as gloves to avoid injury
Handle the heavy item by two persons as a rule
-Some product type weighs over 50kg. To protect the operators, transport the unit by two or more
persons as a rule of handling a heavy item
Caution
Avoiding injuries
-Majority of this product is made from metal and careless handling may cause injury of hands. Be sure
to wear protective means such as gloves to avoid injury
installation and operation
caution when transporting:
accessory dimensions:
CB-016 □ 6
This product contains precision components such as bearings and microchips. Use caution for avoiding
impacts by dropping or collision during transportation as impacts may cause damage of such components.
Caution for Unpacking:
Check the following when opening the crate.
1. Abnormalities on the unit such as dents, concave marks, smears, corrosion (rust), etc.
2. Loose or missing screws. Please report to the supplier if you find abnormalities.
Caution during Installation - Electrical:
For the facility equipment using this product, check that a power breaker with appropriate capacity has
been installed. In case the product generates abnormal motions, protection by the breaker is sometimes
effective. If the earth leakage breaker is planned for use as a breaker, select a type compatible with
inverter. Certain types of incompatible ground fault interrupter may cause malfunction by sensing
high frequency components of switching power supply as leak current.
Prohibiting Impacts
Appearance Check
Checking the Circuit breaker
□ =N （ NPN input/output)
or P (PNP input/output)
CBR-306F □
□ =N （ NPN input/output)
or P (PNP input/output)

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Caution
During installation, use caution for installing direction (orientation). Be sure to use the specified
mounting holes. (Refer to Section 5-Dimension p.6-10)
Incorrect direction (orientation) or using non-specified securing holes may cause unexpected accident
This product is not equipped with special dust or water proof measures, and is intended for use in
"pollution level 2" defined by IEC60664-1. For this reason, when the product is installed in the
environment requiring dust or water proof measures, the user needs to provide additional protection and
check the performance.
Vibration level of the environment in which this product is used must be 0.5G or below.
Install this product with the tilt of 5/1000 or below
Secure a work space around this product for maintenance purposes.
Comply with the safety rules required for the place of installation or equipment to be used.
Caution during Installation - Electrical:
DC power supply must be an insulation type switching power supply certified by the safety standard
(IEC60950-1 or UL90950-1) for ensuring safety. Do not use non-insulation type series power supply for
safety as well as conforming to radiation noise restriction.
Current capacity of the DC power supply should have sufficient capacity to accommodate this product.
Current capacity of the wiring material should also provide sufficient margin to the specified current value.
When the DC power supply is integrated, check if the equipment breaker and emergency stop switch
correctly operate. Test operation and any further procedure should be performed after finishing this check.
1. ON/OFF operation of the breaker reliably turns ON/OFF of the input (single phase 100V, 200V) to the
DC power supply unit.
2. ON/OFF operation of the emergency switch reliably turns ON/OFF of the input (DC24V) to this product.
Carefully check that the wiring does not contact any moving parts of this product.
Caution during Installation - Main Unit:
Main unit installation
Checking the DC Power Supply
Checking the Wiring
Installation environment
Perform mounting operations always by 2 persons or
more.
Use caution for motor cable or sensor cable not to be
pinched by other object.
Do not attach the driver card on the F-RAT unit. It may
cause loose screws or other failure by vibration.
Securely attach the unit on the frame by considering
the product weight, tray weight, and vibration.

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Warning
Operator should not come close to any moving
part that may hook or roll-in objects. Provide a
means for not permitting the operator to touch
the moving part with a safety fence
Caution
To prevent any object from popping out of the
area by collision, and to avoid injury by such
object, install a safety fence around the
equipment.
Caution
Use mounting holes for F-RAT-S installation, otherwise it may cause a failure or accident
Safety Assurance
If the warning label becomes hidden by installing the
product, reattach the warning label in a visible place.
When performing maintenance operation, make sure
the main power is completely shut off.
Caution during Installation - Main Unit:
Installation:
Use assistance and recheck the installation precaution before starting the installation.
Firmly mount the product in consideration of product weight, load weight and vibration.
Mounting
Reference example for the mounting: In case of using a mounting stay (option). (Frame height is 160mm)

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Connector attachment and detachment must be made after shutting off the power and by holding the
connector.
Securely attach each connector to the contact part.
Install MDR connector on each driver card.
Installation
F-RAT zone sensor is not included. User needs to provide it
Connection
Wiring

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Caution
Make sure to turn OFF SW1-5. It
cannot operate by external input
signal, or may cause a failure if SW1-5
is set to ON. SW1 needs to be set to
“1” when F-RAT-S is controlled. It
may cause a failure in case of other
setting.
For the detailed specification of CB-016, please download the driver operating instruction manual at
itohdenki.com/tech-documents
For details of CBR-306, refer to Appendix 1, CBR-306F Detail
Connector Wiring Common to CB-016/CBR-306
Do not connect any branching wire. It may cause electrical
shock, short-circuit or failure due to over capacity of the
connector. (Connector capacity: 10A ）
Do not wire in reverse polarity.
Wiring should be made before inserting the connector into
the driver card.
Input voltage supplied to CN2#1 (MDR run/stop), CN2#2
(MDR rotation direction change) must be common to the
power supply voltage. (Connector capacity: 4A ）
Connector attachment/detachment must be made after
shutting off the power and by holding the connector.
Securely insert the connector to the contact part.
1. Connect 24V DC / 0V wires to the power connector
< CN1(2 contacts)>.
2. Connect wires to control connector < CN2(5 contacts)>.
3. Plug the power connector < CN1(2 contacts)>, control
connector < CN2 (5 contacts)>, MDR connector <CN3> to the
driver card.
installation:
M3 : CBR-306F □ Switch setting
For detail, refer to Appendix 1. CBR-306F □ Detail (p.28)
1. SW1: #1-ON, #2-OFF, #3-OFF, #4-OFF, #5-OFF
2. SW5: 1

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Response time of a control device should be within 20ms. If not, it may cause a malfunction
installation:
Control
Time Chart Example
Rotation Direction Setting

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Caution
Wiring, securely connector connection and cable damaging condition.
Driver card switch setting.
SW1-5 and SW5 of CBR-306 for lifting MDR are set to “OFF” and “1”
Make sure other devices in the system do not run. In the case of a conveyor line integrated in a
system, starting signal would cause a tray to flow down the conveyor and cause danger. Before trial
run, make sure that other elements of the system does not operate.
Check the below before trial run.
Is the wiring correct? Did you check that no loose connector or wire breakage exists?
Before starting a trial run, check the following.
Checking the environment for permitting trial run
Precautions for a trial run
Confirm that proximity sensor for belt transfer (SN ・ S) ON makes the belt lift up, or proximity sensor for
roller transfer (SN ・ R) ON makes the roller lift up.
When both the proximity sensor for belt transfer (SN ・ S) and proximity sensor for roller transfer (SN ･ R)
are OFF, then perform the following operation and, confirm that proximity sensor for belt transfer (SN ･ S)
ON makes the belt lift up.
Check the proximity sensor for belt transfer (SN ・ S) and proximity sensor for roller transfer (SN ・ R)
M3 ： In the lifting driver card (CBR-306), is SW1#5 OFF and SW5 "1"?
Is the driver card setting correct?
No error LED blinks on the driver card.
No abnormal sound or high temperature is detected.
Trial run should be performed without trays and make sure no abnormal operation occurs.
At such time, check the following points.
Caution
Do not apply external force to tote during operation. It
may cause a problem of transfer belt deviation.

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Warning
After turning off the power switch, leave for more than 3 minutes for discharging the DC power supply.
Indicate warning to prevent other people from turning the power
In order to avoid interference by power circuit and signals, turn off the power of all connected devices.
1.
2.
Warning
Perform repair or replacement operations by wearing protective means such as gloves. Working without
protective means results in hand injury such as cut by metal part.
Maintenance
Transfer MDR replacement:
Safety Check Before Repairing/Replacing a Part
Part Repair/Replacement
When a damaged component is discovered, promptly replace it with a new component.
Do not perform disassembly other than in a designated place. Unexpected accident may occur.
Repair/replacement operation sometimes requires turning or lifting a component. Use caution to avoid
being caught or pinched by other parts and injured.
Component repair and confirmation after replacement
Cover is properly closed.
All parts are attached
After maintenance/inspection, check the following before starting trial run.
1. Turn off F-RAT-S and then remove the motor cable of MDR for roller transfer from the driver card (CB-016N6).
2. Loosen the screws for the pulley holding plate to remove it.
3. Remove the screws for the side cover, and then remove the side cover.
4. Remove idlers and belts.
5. Remove a mounting bracket and MDR paying attention to not damage on motor cable or connector.
6. Make sure v-ribbed belts are placed in correct position as showing on fig.2. Motor cable must be fixed with a
cable tie to avoid contact with moving parts.
7. Install new MDR in the step 5 〜 1 mentioned above.

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1. Remove idlers for roller transfer adjoining the replaced transfer belt. (Refer to Transfer MDR replacement, p.15)
2. Loosen the screws for the belt cover, and then remove the belt cover.
3. Loosen the screws for idler wheel that is for belt tension adjustment. (Do not remove the screws). Remove
transfer belt.
*Remember installed position of the transfer belt.
4. Install the new transfer belt, and then tighten a screw of tension adjusting idler wheel applying tension to adjust
belt tension. (Only one idler wheel per a transfer belt is used for belt tension adjustment.)
5. Attach the belt cover to roller plate, and then tighten a bolt to fix the belt cover.
Transfer belt replacement:
After transfer belt and MDR for belt transfer
replacement, make sure there is no interference and do
running test. After running test, check tension according
to the belt tension reference mentioned above.
Too strong tension of transfer belt may cause a
malfunction because overload is applied to MDR for belt
transfer. On the other hand too loose tension may cause
decrease transfer belt’s speed.
The check position of belt tension depends on the plate
attaching position.
After tension adjustment in the steps mentioned above, current value should be as shown in the right table.

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Checking Position of tension for transfer belt:
＊ Make a measurement in 108mm-pitch
between idlers wheel.
＊ Make a measurement in 117mm-pitch
between idlers wheel.

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Belt transfer MDR replacement:
1. Remove the MDR and all idlers. (Refer to Transfer MDR replacement, p.15)
Belt transfer unit multiplier depends on F-RAT-S type’s size.
2. Remove all belt transfer units from the belt transfer unit in the center.
3. Remove nut A, B and bolt and then replace MDR for belt transfer.
Make sure the belt transfer unit position is right. (See the dimensional drawing, p.6-8)
Adjust the belt tension. (See the transfer belt replacement, p.16)
4. Follow steps 3 to 1 mentioned above to install
＊ Before replacing please turn off F-RAT-S and remove the motor cable of each MDR from the driver card.

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specifications
Transfer Load:
f-rat-s unit specifications: CB-016 □ /cbr-306f □ Specifications:
□ ＝ N (NPN in/out) or P (PNP in/out)
product weight:
Size and load weight are just guidance. (This may differ by conditions of transferred goods)
* Standard motor cable length : 1500mm
* Standard sensor wire length : 1000mm
Recommended size of transferred goods Maximum load weight

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Part Name
Part Number
1
Transfer Belt (flat belt)
TF10 L1630 W19
2
V-Ribbed Belt
3PJ336 (For pitch 100mm)
3PJ316 (For pitch 94mm) For size A
3
MDR for Belt Transfer
For size A: PM500FE (speed code: 277-D-024-JG-C150)
For size B: PM500FE (speed code: 392-D-024-JG-C150)
For size C: PM500FE (speed code: 492-D-024-JG-C150)
For size D: PM500FE (speed code: 592-D-024-JG-C150)
-Select speed from 17 (17m/min), 60 (60m/min) or 90 (90m/min)
＊ Note that it’s “PM500FC-90” for 90m/min type
4
MDR for Roller Transfer
PM500FE- speed code: 674-D-024-JW-C150-VG
-Select speed from 17 (17m/min), 60 (60m/min)or 90 (90m/min)
＊ Note that it’s “PM500FC-90” for 90m/min type.
5
Idler for transfer
IDR-50-674-JH-VG (for all types)
6
Driver card (Specify input and
output type NPN (N) or PNP (P))
CB-016 □ ( □ - N: NPN / P: PNP)
CBR-306F □ ( □ - N: NPN / P: PNP)
7
Idler wheel
F-RAT-SFL1
・ Cup square neck bolt M6 x 30mm
・ U nut M6
＊ For idler wheel installation. Need to be purchased with idler wheel.
Replacement Parts for f-rat-u225:
Transfer throughput: