ITOH DENKI POWER MOLLER 24 F-RAT-U225 User manual

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
www.itohdenki.com
Item
Size 6040, 6050,
9040, 9050
Size 6060, 6070, 6080,
9060, 9070, 9080
F-RAT-U225 Main unit, including
Carrier Wheel transfer side sensor (SN ･ S)
Roller transfer side sensor (SN ･ R)
1 unit
Hex bolt M8×15 ∕ Spring washer For installing
F-RAT-U225 main unit
4 sets
Driver card CB-016 □ *6
2 units
1 unit
Driver card CB-016 □ *6-CP2
-
2 units
Driver card (for Lifting ） CBR-306F □ *
1 unit
Power connector (WAGO 734-102)
3 units
4 units
Control connector (WAGO 733-105)
3 units
4 units
Cross-slotted screw/washer M4×15 / Hex nut M4
for mounting driver card
6 sets
8 sets
Please refer to HBR-605 user manual when HBR-605 is used for operation.
Before using, please read the operating instructions carefully to obtain the product knowledge, safety
information and to understand all of the caution items.
After reading the instructions, store the booklet in a designated location for readily accessing at any time.
When you open the crate, check that the model, specifications, voltage, etc. are correct
f-rat-u225
Specifications subject to change without notice
Operating Instructions
* Depending on the input/output type of F-RAT-U225, NPN (N) or PNP (P) signal input driver card is
included.
The crate contains the following items. Check that every item is included, and that the model,
specification, etc. are as you ordered.

table of contents
Specifications subject to change without notice
General Cautions
3-4
Product Designation
5
Structure
5
Power Supply
5
Dimensions
6-11
Installation/Operation
-Cautions during Transportation
-Cautions during Uncrating
-Cautions during Installation - Electrical
-Cautions during Installation - Main Unit
-Installation
-Precautions for Trial Run
11-20
Repair/Replacement
-Carrier Wheel Belt Tension Adjustment
-Carrier Wheel Replacement
-Replacement of a Idler, Roller Drive Belt, Roller MDR
21-26
Specifications
27-29
Troubleshooting
30-32
Appendix 1: CBR-306F □
33-35
Appendix 2: Maintenance
36
Appendix 3: Remaining Risks/MAP
37
Subject page
2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
www.itohdenki.com

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
www.itohdenki.com
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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Office Ph: 570-820-8811
Fax: [phone]
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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.

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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Model Example ： F-RAT-U225-60N-6050-V1
Transport speed 60m/min, NPN input/output type, Size 6050 （ L595mm×W495mm), Type V1
power supply
24V DC 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 (Size 6060, 6070,
6080, 9060, 9070, 9080 operates with 10A or higher) without fluctuation by load. In addition, the
power supply should not activate protection with peak current 20A, 1ms or below.
* Size 6060, 6070, 6080, 9060, 9070, 9080 operates with DC24V ・ 10A 240W
1. Speed
17 … 17m/min Low speed type (Carrier Wheel / Roller transfer : 17m/min)
60 … 60m/min standard type (Carrier Wheel / Roller transfer : 60m/min)
2. Signal type selection
N … NPN input/output
(NPN input/output driver card / Roller transfer side sensor, Carrier Wheel transfer side sensor included ）
P … PNP input/output
(PNP input/output driver card / Roller transfer side sensor, Carrier Wheel transfer side sensor included ）
3. Size
6040…L595mm×W395mm
6050…L595mm×W495mm
6060…L595mm×W595mm
6070…L595mm×W695mm
6080…L595mm×W795mm
4. Type
V1 (Applied only for model 6060 and 9060)
*Model 6060 and 9060 (V1 type) are obsolete in principle. If however the model 6060 or 9060 is absolutely
required, consult with ITOH DENKI representative to set the exceptional possibilities.
Product Designation
main unit:
f-rat-u225- (1) (2) - (3) - (4)
structure
9040…L895mm×W395mm
9050…L895mm×W495mm
9060…L895mm×W595mm
9070…L895mm×W695mm
9080…L895mm×W795mm

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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Dimensions
Main Unit:
Size 6040: L595mm×W395mm
Size 6050: L595mm×W495mm

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Office Ph: 570-820-8811
Fax: [phone]
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Main unit Dimensions:
Size 6060 … L595mm×W595mm
Size 6070 … L595mm×W695mm

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Office Ph: 570-820-8811
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Size 6080: L595mm×W795mm
Size 9040: L895mm×W395mm
Main unit Dimensions:

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Size 9050: L895mm×W495mm
Size 9060: L895mm×W595mm
Main unit Dimensions:

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Size 9070: L895mm×W695mm
Size 9080: L895mm×W795mm
Main unit Dimensions:

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Office Ph: 570-820-8811
Fax: [phone]
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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
-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
installation and operation
caution when transporting:
accessory dimensions:
CB-016 □ 6
This product contains precision components such as bearing and microchip. Use caution for avoiding
impacts by dropping or collision during transportation as impacts may cause damage of such components.
Caution for Unpacking:
Check for the following when opening the crate.
1. Abnormality 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 interrupters cause malfunction by sensing high
frequency component 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)
CB-016 □ 6-CP2
□ =N （ NPN input/output)
or P (PNP input/output)
for size 6060, 6070, 6080, 9060, 9070, 9080

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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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 UL60950-1) 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 the 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. Hold the bottom surface of F-RAT main unit. (F-
RAT mass Size 6040 approx 32kg) (Varies by size.)
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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Office Ph: 570-820-8811
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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.
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:
Attach the F-RAT by using the mounting holes (Refer to
Section 5-Dimension)
When using mounting stays, refer to the attachment
example shown below
Caution
Install the mounting stay by using F-RAT mounting holes (Refer to 5.
Dimensions) For mounting on the frame, use the mounting holes of the
mounting stay shown below. Mounting without using the mounting holes may
lead to unexpected accident or failure.

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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
For sizes 6040 ∕ 6050 ∕ 9040 ∕ 9050
F-RAT zone sensor is not included. User needs to provide it
For sizes 6060 ∕ 6070 ∕ 6080 ∕ 9060 ∕ 9070 ∕ 9080

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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Please refer to HBR-605 user manual when HBR-605 is used for operation
Installation
Wiring

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
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Caution
Make sure to turn OFF SW1#5. ON state does not allow external signal input and may lead to a failure.
SW5 must be set to "3" when using F-RAT-U225. Using with other than "3" may lead to a failure
For the detailed specification of CB-016 □ 6, please download the driver operating instruction manual
at itohdenki.com/tech-documents
For details of CBR-306F □ , refer to Appendix 1: CBR-306F □ Detail
Connector Wiring Common to CB-016
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 to the driver
card.
installation:
Driver Card Setting
For detail, refer to Appendix 1. CBR-306F □ Detail (p. 33)
1. M3 ： Set the driver card for lifting

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installation:
Driver Card Setting (continued)
*1 ： Rotation direction setting. When changing the setting, refer p.17-18 (Rotation direction setting)
*2 ： Speed setting. When changing the setting, refer p.18 (Speed setting)
2. Set M1: Driver card for Carrier Wheel, M4: Driver card for Carrier Wheel (In the case of
size 6060, 6070, 6080, 9060, 9070, 9080) and M2: Driver card for roller
Rotation Direction Setting
MDR rotation (F-RAT transfer) direction can be changed
by using the switch on the driver card or external switch.
(Or can be used in parallel)
MDR rotation direction is defined as CW or clockwise
direction when viewed from the cable side, and CCW or
counter-clockwise direction

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Speed Setting
installation:
Rotation Direction Setting (continued)
During operation, the rising time to the setting speed may vary depending on ambient
temperature. Perform running operation thoroughly.
Values described above may differ from the actual transfer speed depending on the
weight, material, bottom surface, and/or shape of trays, as well as ambient
temperature

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Driver card switch is assumed to be set in the initial setting ．
Use control equipment with its response time less than 20ms. Otherwise, abnormal operation may occur.
installation:
Control
Time Chart Example
Connector wiring example by using a PLC

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Caution
-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.
-When a load is on the Carrier Wheel, do not forcibly move the load. Carrier Wheel may break or cause
a failure.
-Before a trial run, make sure the wiring and driver card setting have been correctly made. Insufficient
check may lead to a damage and failure.
Is the wiring correct? Did you check that no loose connectors or wire breakages exist?
Before starting a trial run, check the following.
Checking the environment for permitting trial run
Precautions for a trial run
Confirm that Carrier Wheel transfer side sensor (SN ・ S) ON makes the Carrier Wheel lift up, or roller
transfer side sensor (SN ・ R) ON makes the roller lift up.
When both the Carrier Wheel transfer side sensor (SN ・ S) and roller transfer side sensor (SN ･ R) are OFF,
then perform the following operation and, confirm that roller transfer side sensor (SN ･ R) ON makes the
roller lift up.
Checking the Carrier Wheel transfer side sensor (SN ・ S) and roller transfer side sensor (SN ・ R)
M3: In the lifting driver card (CBR-306), is SW1#5 OFF and SW5 "3"?
Is the driver card setting correct? （ p16-17)
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.