Pulseroller PDU-90 User manual

Thank you very much for purchasing PDU-90 product.
○Before operating the unit, please read this manual. These explained here are to help you use the unit
safe and correctly, and to prevent danger or injury to the users or other people.
○After reading these instructions, store the manual where it is always accessible by the user.
Please carefully unpack and inspect your order, taking care not to damage the original packaging.
Contents
■Safety Precautions --------------------------1~2
●WARNING ------------------------------------ 1
●CAUTION ------------------------------------- 2
■Precautions before Use ----------------------- 3
●Names of Parts ------------------------------ 3
●Accessory------------------------------------- 3
●Power Supply -------------------------------- 3
■External Dimensions --------------------------- 4
●Main Unit -------------------------------------- 4
●Accessory------------------------------------- 4
■Operation --------------------------------------4~5
●Basic Operation ----------------------------- 4
●Notes------------------------------------------- 5
■Setting ------------------------------------------5~6
●How to Set ------------------------------------ 5
●Notes------------------------------------------- 6
■Maintenance ----------------------------------7~9
●How to Replace a Belt --------------------- 7
●How to Replace PULSE ROLLER ---8~9
■Specification------------------------------------ 10
●Main Unit ------------------------------------ 10
●Parts List for Maintenance-------------- 10
Instruction Manual
PDU-90 (Pulse Diverter Unit - 90)
Issued date: June 8, 2016
Rev. 0

Safety Precautions
●Do not use the product in an explosive atmosphere, flammable gas atmosphere, corrosive atmosphere, a
place exposed to water splashes, or a place close to combustibles. It may cause an electric shock, injury
and/or fire.
●All work (e.g., installation, connection, operation, maintenance and failure diagnostics) must be done by a
qualified person. Failure to do so may cause a fire, electric shock and/or injury.
●Do not conduct such operations as move, installation, connection, and maintenance while the power is
on. Be sure to conduct such operations after turning off the power in order to be safe injury and/or
accident.
[General]
[Wiring]
[Adjustment / Installation]
●Never touch the power supply when installing PULSE ROLLER or Driver card. It may cause an electric
shock and/or injury.
●Do not touch the internal structure during operation to prevent entanglement and/or clamping accidents.
●Be sure to input instructions such as start/stop, after switching on the power. It may cause an injury
and/or accident due to unexpected start-up.
●If Driver card's protection function worked, remove the cause surely prior to release the function. Other-
wise, malfunction may occur and it will result in an accident, injury and/of breakage.
●If abnormal noises are being given out from the product, turn off the power switch and cut the power
supply immediately to avoid unpredictable accidents.
●Do not use the unit in any way beyond its specifications. It may cause an injury and/or breakage.
WARNING
●Be sure to check the specifications of the power supply (direct current), the voltage (DC24V±5%),
PULSE ROLLER and Driver card before wiring. Failure to do so may cause a fire, electric shock, injury
and breakage.
[Operation]
WARNING
CAUTION
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury and could
cause property damage.
Please strictly comply with the warnings and instructions
contained in this manual to prevent the risk of an accident,
breakage and/or malfunction of the product.

Safety Precautions
[General]
●Do not pull, bend or twist the cord with unnecessary force. There is a danger of a fire or electric shock
due to breakage.
●The DC power supply must be earthed. It may cause an electric shock in case of a breakdown or
electrical leakage.
●When connecting the control device such as PLC to Driver card, they should share a power supply. If the
power supplies are different, install a device like relay between a signal input of a Driver card and the
control device so as to transmit signals.
[Wiring]
[Adjustment / Installation]
[Maintenance]
●Replace with a new part immediately if you discovered damage of the product.
●Do not disassemble except for the parts that is specified in this manual.
●There is occasionally need to turn a part and make it go up and down by hand, for maintenance or repair.
Be careful not to get your fingers caught in the product.
●Be sure to turn off the power and leave the product for several minutes so as to discharge the electricity
in it prior to inspecting or repairing.
●Surely attach the parts such as a cover and screws after maintenance or repair.
●Never store or leave the product outdoors.
●Do not clime and/or overload on the product. It may cause an accident and/or breakage.
●Do not put a heavy load on the product or insert an object into an aperture. It may cause an accident
and/or breakage.
●Never modify the main unit of the product and Driver card. It may cause an accident, injury and/or
breakage.
●Do not splash the equipment with water. It may cause an electric shock, injury and/or breakage.
●Do not apply strong impact, such as dropping or striking the product. It may cause an accident and/ or
breakage.
●Take care not to touch the product immediately after operation. It can get very hot and there is a danger
that you may get burned and/or injured.
●Wear gloves as many metallic parts are used for the product when touching the products. Failure to do
so may cause an injury.
●Do not install the product in a place with large vibration.
●When using in a place with dust or water, surely take measures to keep the product’s performance
beforehand. The product is not provided with dust-proof and waterproof function.
2
CAUTION
●Install the product horizontally.
●Keep a sufficient working space around the unit for maintenance.
●Install the unit with the screws and tools designated by this manual.
●Always completely follow the necessary safety rules, about a place where the product is installed and the
device that uses.

Precautions before Use
[Names of Parts]
[Accessory]
[Power Supply]
●For further information, such as the method for selecting suitable power supply, please refer to
our separate-volume catalog or contact us.
●To ensure customer’s safety, we suggest using insulated power supply.
●Be sure to use a power supply which has sufficient power capacity and current capacity.
3
●Driver cards are required for the transporting and PULSE ROLLER for transport/lifting, respec-
tively.
●For more information on Driver card, please refer to our separate-volume catalog or contact
us.
●Use supplied bolts for the product mounting.
●Install the product with tightening torques according to each strength classification.
Snap pulley
Belt tensioner
Idler pulley
PULSE ROLLER for lifting
PULSE ROLLER
for transport
Label
Upper limit sensor
Lower limit sensor
Conveyor belt
Cover for conveyor belt

PULSE ROLLER for transport
--- PULSE ROLLER for lifting : STOP
PULSE ROLLER for transport : STOP
Lower limit sensor : OFF
Upper limit sensor : ON
[Main Unit]
4
• Please refer to Drawing for Approval for the external dimensions.
[Accessory and Driver card]
LOWER LIMIT POSITION
(STARTING POINT)
UP
DOWN
UPPER LIMIT POSITION
TRANSFER
--- PULSE ROLLER for lifting : STOP
PULSE ROLLER for transport : STOP
Lower limit sensor : ON
Upper limit sensor : OFF
--- PULSE ROLLER for lifting : Rotation in the CW direction
PULSE ROLLER for transport : STOP
Lower limit sensor : OFF
Upper limit sensor : OFF
--- PULSE ROLLER for lifting : STOP
PULSE ROLLER for transport : Rotation in the CW direction
Lower limit sensor : OFF
Upper limit sensor : ON
--- PULSE ROLLER for lifting : Rotation in the CCW direction
PULSE ROLLER for transport : STOP
Lower limit sensor : OFF
Upper limit sensor : OFF
[Basic Operation]
Operation
●The product is recommended being controlled the following basic flow by a control unit such as
PLC.
(See Fig. 1, 2)
PULSE ROLLER for lifting
• Please refer to our separate-volume catalog for the external dimensions.
Fig. 1
: CW
: CCW
This rotational direction is viewed from the
code side of PULSE ROLLER
External Dimensions

5
1. Put in the main unit from the under conveyor frames, then securely fasten it to the mounting
hole with supplied screws while supporting.
At this time, align the orientation of the pulley position and the direction of the main unit as
instructed by the drawing. In some cases, the main unit, conveyor, and interlocking roller belt
are possible to interfere one another.
2. Connect the PULSE ROLLERs for lifting/transport with Driver cards in which the programs
were already set.
Make sure that the cards are connected correctly. Failure to do so may lead to malfunction.
3. Connect the upper/lower limit sensors and Driver cards to the power supply and a PLC.
4. After installation, perform a test-run without loading to check whether it operates correctly.
[Notes]
●When an overrun occurs during rotation, PULSE ROLLER for lifting will turn around to its
original position.
At the operation resumption, the timing deviation may occur in ascent movement but it will be
eliminated in a short time. To prevent the deviation, Basic operation on Page 4 is recom-
mended.
●The product size at the upper limit position and the lower limit position might be different from
the size in this manual for reasons of the setting situation or control method.
Upper limit sensor Lower limit sensor
Setting
[How to set]
●Installation instructions
●Wiring method
Please refer to our separate-volume catalog for the details of the power supply method to the
Driver cards or the connection method to a PLC.

[Notes]
●Before installing the product make sure that a breaker of the appropriate capacity is installed.
●Before installing the power supply make sure the breaker and an emergency stop switch work
correctly.
●The installation of the power supply should be done in the predetermined method.
●When installing the product, be careful not to get things (e.g., cable) caught.
●When installing or performing a test run, be careful not to get your fingers and clothes caught
in the conveyor belt.
●Fasten the product firmly to the predetermined mounting holes.
6
Fig. 3
TRANSFER
DIRECTION Conveyor frame
Conveyor roller
PULSE ROLLER
for transport PULSE ROLLER
for lifting
Hole part for fixing
the main unit
lnterlocking pulley
TRANSFER
DIRECTION

[How to Replace a Belt]
Maintenance
(See Fig. 4,5)
7
1. Fasten the Lift table at the lower limit position.
2. Loosen a Tensioner of a conveyor belt unit.
3. Remove Fixing bolts of the conveyor belt unit.
4. Loosen Fixing bolts of a conveyor belt cover, and remove the cover.
5. Remove attached the belt and replace with a new one.
Belt does not have specified direction to attach, but be careful not to place upside down.
6. Set the belt at the predetermined position, then attach the conveyor belt cover.
Setting the belt in incorrect position might cause a breakage of the main unit.
(Recommended tightening torque for M4 screw: 1.48 Nm)
7. Attach the conveyor belt unit on the main unit.
(Be careful not to slacken the belt.)
(Recommended tightening torque for M6 screw: 10.8 Nm)
8. Adjust the belt tension by the tensioner.
(Recommended tightening torque for M6 screw: 5.2 Nm)
9. Verify that all the bolts, nuts, and belt are securely tightened and operate test-run to check
there is no abnormality.
Fig. 4
Tensioner
Fixing bolt for
Conveyor belt unit
Fixing bolt for
Conveyor belt cover
Fixing bolt for
Conveyor belt cover
(Measurement point to check belt tension)

Fig. 5
8
[How to Replace a PULSE ROLLER for transport] (See Fig. 6)
1. Follow the belt replacement procedures 1-3, then remove a conveyor belt unit.
2. Remove Fixing nuts for the PULSE ROLLER from the side of the main uint.
3. Push the Non-cable side shaft of the roller and pull out the roller.
4. Replace with a new one. Be careful not to pinch and damage the cable at this time.
5. Assemble the main unit in the reverse order to the belt replacement procedures 1-3.
(Recommended tightening torque for PULSE ROLLER fixing nut: 34.1 Nm)
(Recommended tightening torque for M6 screw: 10.8 Nm)
6. Verify that all the bolts, nuts, and belt are securely tightened and operate test-run to check
there is no abnormality.
PULSE ROLLER
for transport
Conveyor belt
PULSE ROLLER
for transport
Fixing nut
for PULSE ROLLER
PULSE ROLLER
for lifting
Fig. 6

(See Fig. 7)
1. Remove Fixing nuts for the PULSE ROLLER from the side of the main unit.
2. Insert a tool from a Maintenance space of the Lift table, and remove Fixing bolts for link rod.
3. Loosen a Fixing screw for sensor bracket on the side of the main unit, then remove the
bracket.
4. Fasten the Lift table at the upper limit position and replace the PULSE ROLLER with a new
one.
5. Assemble the main unit in the reverse order to the procedures 1-3.
(Recommended tightening torque for PULSE ROLLER Fixing nut: 34.1 Nm)
(Recommended tightening torque for M8 screw: 24.9 Nm)
(Recommended tightening torque for M6 screw: 10.8 Nm)
(Recommended tightening torque for M5 screw: 2.3 Nm)
6. Verify that all the bolts, nuts, and belt are securely tightened and operate test-run to check
there is no abnormality.
9
[How to Replace a PULSE ROLLER for lifting]
Maintenance
space
Lift table
Fixing screw for sensor bracket
Fixing bolt for link rod
Sensor bracket
Fig. 7

Specifications
*For details on PULSE ROLLER and Driver card, please refer to our separate-volume catalogs.
[Parts List for Maintenance]
●Conveyor belt --- L-350 W15 × L□□□□ × T1.4 (Made by NITTA Corporation)
●Ascent/descent detection sensor --- APM-B3A1 (Made by Azbil Corporation)
●PULSE ROLLER for lifting --- PR-HD-48-□□□-□ASAY 1 piece
●PULSE ROLLER for transport --- PR-HD-48-□□□-□□WSAA 1 piece
●Driver card --- Depends on your request
●When disposing of the product, entrust the work to an industrial waste disposal
contractor after the consignment contract.
10
[Main Unit]
Size
Overall width
Overall length
Overall height
Conveyor speed
Lifting stroke
Weight
Voltage
Operating ambient temperature
Operating ambient humidity
Installation site
DC24V
0～40 ℃ (No freezing)
Less than or equal to 90 %RH (No condensation)
Indoors
Please refer to your Drawing
for Approval.
■Contact information for Technical support
www.pulseroller.com
[email protected]
[email protected]
www.pulseroller.com/contact
The specifications of the products are subject to change for improvement without prior notice.
USA
Insight Automation, Inc.
2748 Circleport Dr. Erlanger,
KY 41018, USA
Phone : [phone]
Asia
Kyowa Manufacturing Co., Ltd.
570-10, Kubota-cho, Kasai-city,
Hyogo prefecture, 675-2364,
Japan
Phone : [phone]
Europe
Kyowa Europe., Ltd.
Opladener strasse 2, Halle 7, 42799,
Leichlingen Germany
Phone : [phone]
■Warranty
●The warranty period is 2(two) years from delivery of the product under proper installation and
handling. The warranty covers only the repair of the main body of the delivered product.