ITOH DENKI POWER MOLLER 24 Pop-D Divert User manual

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
www.itohdenki.com
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 the model, specifications, voltage, etc. are correct
Item
Quantity
Remarks
Pop-up Diverter main body
1 unit
with roller bottom sensor (SN ･ S) / roller
top sensor (SN ･ R ）
Hex bolt M8×20 ∕ Spring washer
4 sets
For installation of the Pop-up Diverter
main body
Driver card CB-016 □ *6
3
Power connector (WAGO 34-102)
3
Control connector (WAGO 733-105)
3
Cross-slotted screw/washer M4×15 / Hex
nut M4
6
For mounting driver card
Pop-D Divert
Specifications subject to change without notice
Operating Instructions
* Depending on the input/output type of Pop-up Diverter, the included driver card operates with
either NPN (N) or PNP (P) signal input
One type of driver, for lifting and transporting, are included. Do not change the setting of the
driver for lifting (with a green label) because it has been adjusted before factory shipping.
The crate contains the following items. Check that every item is included, and that the model,
specification, etc. are as you ordered.
When the tray or object is less than 350×350mm, move the tray along the branching side edge

table of contents
Specifications subject to change without notice
General Cautions
3-4
Product Designation
5
Structure
5
Power Supply
5
Dimensions
6-10
Installation/Operation
-Cautions during Transportation
-Cautions during Uncrating
-Cautions during Installation - Electrical
-Cautions during Installation - Main Unit
-Installation
-Cautions during Trial Operation
10-16
Repair/Replacement
-Replacement of a Free Roller, Roller Drive Belt, Straight MDR
-Replacement of a Diverting Roller
-Replacement/Installation of a Diverting Roller Round Belt
17-23
Specifications
24-26
Troubleshooting
27
Ref. 1: Maintenance
28
Ref. 2: Remaining Risks/MAP
29
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.

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
www.itohdenki.com
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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(1) Divert direction
L - Divert left
R - Divert right
(2) Divert angle
30D - 30 degrees
45D - 45 degrees
(3) Speed
60 - 60m/min
(4) Signal type selection
N - NPN input/output （ NPN input/output driver / up/down sensor included ）
P - PNP input/output （ PNP input/output driver / up/down sensor included ）
(5) Size
A - W394mm×L760mm
B - W494mm×L760mm
C - W594mm×L760mm
D - W694mm×L760mm
(6) Type
1
Model example: POP-D-L45D-60N-B1
Divert left 45 degrees, Transport speed 60m/min,
NPN input/output type, Size B (W500mm×L774mm), Type 1
Product Designation
main unit:
pop-d- (1) (2) - (3) (4) - (5) (6)
structure
power supply
24V DC Battery
Switching power supply (24V DC ・ 10A 240W)
Rectified power (With a rectifying capacitor, ripple rate 10% or below)
Supplied power must be a stabilized power supply of 24V DC, 10A or higher without fluctuation
by load. In addition, the power supply should not activate protection with peak current 20A,
1ms or below.

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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Dimensions
Size A:
W394mm×L760mm Divert Left
Size A:
W394mm×L760mm Divert Right

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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Dimensions
Size B:
W494mm×L760mm Divert Left
Size B:
W494mm×L760mm Divert Right

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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Dimensions
Size C:
W594mm×L760mm Divert Left
Size C:
W594mm×L760mm Divert Right

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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Dimensions
Size D:
W694mm×L760mm Divert Left
Size D:
W694mm×L760mm Divert Right

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
www.itohdenki.com
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
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:
CB-016 □ 6
□ =N （ NPN input/output ）
or P （ PNP input/output ）
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 the following when opening the crate.
1. Abnormality on the unit such as dent, concave mark, smear, corrosion (rust), etc.
2. Loose or missing screws. Please report to the supplier when you find abnormality.
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 type of incompatible ground fault interrupter causes malfunction by sensing high
frequency component of switching power supply as leak current.
Prohibiting Impacts
Appearance Check
Checking the Circuit breaker

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 5. Dimension P.5, P.6, P.7, P.8).
Incorrect direction (orientation) or using non-specified securing holes may cause unexpected accident
This product is not equipped with a 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 purpose.
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 if these wiring would 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 installation operation always by two persons
Use caution for motor cable or sensor cable not to be
pinched by other object.
Do not attach the driver card on the pop-up diverter
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

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
www.itohdenki.com
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 Pop-up Diverter by using the mounting holes (Refer to Section 5-Dimension)
When using mounting stays, refer to the attachment example shown below
Align the inbound C/V level with the roller surface of the Pop-up Diverter, and diverting C/V level with the
diverting roller surface (3mm above the roller surface).
Attachment reference example
C/V Transport Level (Height)

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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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.
Attach the power connector <CN1>, Control connector <CN2>, MDR connector <M1 for straight, M2 for
diversion, M3 for Lifting> to the driver card as shown below
Installation
Pop-up diverter zone sensor is not included. User needs to provide it.
Connection
Wiring

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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Caution
M3 ： For lifting has been set by the factory. Do not change setting. Changing by the user may cause a
failure.
For a detailed specification of CB-016 □ 6, please download the driver operating instruction manual at
itohdenki.com/tech-documents
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

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Speed Setting
Use control components with response time 20ms or shorter to avoid abnormal motion
installation:
Control
Example Time Chart when Diverting

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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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.
Example of Connector Wiring using a PLC
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.
1.
2.
installation:
Checking the environment for permitting trial run
Precautions for a trial run

Loosen the bolts on the shaft securing plate
and pull out the plate to remove.
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Office Ph: 570-820-8811
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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
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.
Tools needed: 8mm ・ 19mm spanners, flat-tip screw-driver, nipper
A roller without a power cable is a free roller.
To remove straight MDR, loosen the
attachment bracket on the power cable side
and remove the cable tie which secures the
MDR connector and cable.
Repair/replacement
Replacement of Free Rollers, Roller Link Belt, Straight MDR:
In order to avoid accident or damage during operations, confirm safety. The illustration used for repair and
inspection is size C, left diversion. Use caution for different shape when other size or right diversion is used.
（ Refer to Section 5-Dimensions ）
Safety Check Before Repairing/Replacing a Part
Part Repair/Replacement
When a damaged component is discovered, promptly replace 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 for being
caught or pinched by other parts and injured.
Component repair and confirmation after replacement
When component repair and replacement is completed, check the following before starting trial run.
(a) Roller link belt and diversion roller link belt are attached in the right groove.
(b) The removed cover is securely closed.
(c) All removed components and parts are attached.
1. Remove the shaft securing plate
2. Remove free rollers or straight MDR from the
end of the module.

2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: [phone]
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Tools Needed: 8mm ・ 19mm spanners, cross-tip screw-driver,
flat-tip screw-driver, nipper, 10mm socket wrench
Replacement of a Diverting Roller:
Replacement of Free Rollers, Roller Link Belt, Straight MDR:
Attach the straight MDR, and assemble free rollers from the straight MDR side toward the end of the module.
After assembling straight MDR, attach the MDR connector to the driver and secure the cable with general-
purpose cable-ties.
3. Replace and assemble free rollers, roller link belt, straight MDR.
Linking the straight MDR and free rollers - PJ316 (3PJ316)
Linking free rollers - PJ286 (2PJ286)
3-1. Engage the link belt on all rollers. Refer to the following
chart for groove position on which the link belt is attached.
3-2. Assemble free rollers one by one in the order of the
"shaft opposite from the VG roller" → "VG pulley side shaft".
4. Attach the shaft securing plate.
Loosen the bolts on the shaft securing
plate and pull out the plate to remove.
1. Remove the shaft securing plate

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Office Ph: 570-820-8811
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Replacement of a diverting roller:
Remove free rollers until those on both sides of the
diverting roller to be replaced can be removed.
A roller without a power cable is a free roller.
To remove a straight MDR, loosen the attachment
bracket on the power cable side and remove the
cable tie which secures the MDR connector and
cable.
2. Remove free roller or straight MDR from the end of
the module
3. Remove the roller cover of the diverting roller to
be replaced
Old nut may not be fully fastened.
Check the direction of the diverting roller when
assembling. (Fastening torque 5.4N ･ m)
Always use a new nut.
5. Replace the diverting roller
4. Remove the link belt (round belt) of the diverting
roller to be replaced
Use caution to avoid twisting the link belt.
6. Attach the link belt (round belt) around the
diverting roller

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Office Ph: 570-820-8811
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Replacement of a diverting roller:
Attach the straight MDR, and assemble free rollers from the straight MDR side toward the end of the module.
After assembling straight MDR, attach the MDR connector to the driver and secure the cable with general-
purpose cable-ties
8. Replace and assemble free rollers, roller link
belt, straight MDR
7. Attach the roller cover on the diverting roller
Linking the straight MDR and free rollers - PJ316 (3PJ316)
Linking free rollers PJ286 (2PJ286)
8-1. Engage the link belt on all rollers.
Refer to the following chart for groove position on which the
link belt is attached
8-2. Assemble free rollers one by one in the order of the
"shaft opposite from the VG roller" → "VG pulley side shaft".
9. Attach the shaft securing plate