pop-up series

POP-UP SERIES
TECHNICAL DOCUMENTATION
SUMMARY
1. Presentation of the Power Moller ® product range......................3
2. Presentation of «Pop-Up»...........................................................4-5
Structure
Operating principle
Bottom surface of load to be conveyed
General technical data
3. Transfer capacity..........................................................................6-9
Speed and rate of load transfer, zone by zone, in isolated singulation mode
Speed and rate of load transfer in train mode
4. Installation of the module.............................................................10-15
Assembly principle
Dimensions
Dimensions of circuit boards
5. POP-UP control...........................................................................16-20
Timing principal for controls
Control principle by PLC
Connection of circuit boards CBM-105 and CBR-305
Parameter settings
6.Element replacement....................................................................21-22
Replacement of free roller, belt and motorized roller (M1) for straight conveyor
Replacement of diverter wheel
Replacement of round belt for driving diverter wheels
7. Replacement parts.......................................................................23
Standard Pop-Up references
List of accessories
Replacement of round and ribbed belts for driving of diverter wheel
Annex 1 - Declaration of incorporation.................................................25
POP-UP SERIES
TECHNICAL DOCUMENTATION
2
Dated 21/07/2016
1 - PRESENTATION OF THE POWER MOLLER® PRODUCT RANGE
(ඔඍඋගක඗ඖඑඋ
උ ඗ උ
0඗ග඗කඑජඍඌක඗ඔඔඍකඛ
Standard circuit board
AC Induction
CB018
CB016
0඗ඌඝඔඍ
90° transfer
DC Brushless
HBR605
Ø50
CB016B
F-RAT-S
PM500 BS
(K)
150
PM500 BU
(KU)
150
PM500 BS-B
(KB)
150
CB030
CBM-105
CBR-305
45° transfer
CBM-105
External
circuit board
ZPA circuit board
HB510
Integrated
circuit board
Ø32
HB510B
Ø50
PM320 HS
(32HS)
HBK-608
LCX-901
50
CB018
Module circuit board
PM500 ME
PM500 XE
Ø50
HBR-605
CBM-105
CBR-305
POP-UP
PM500 FE
(50E)
300
CBM-105
HB510
PM500 FE-B
(50EB)
300
CB016B
HB510B
PM605 FE
(60E)
500
CBM-105
HB510
PM605 FE-B
(60EB)
500
CB016B
HB510B
PM605 KT
1000
CB030
HBK-608
50
LCX-901
300
LCX-901
500
LCX-901
Ø60,5
PM605 XE
(60XE)
Ø60,5
Corresponding circuit board
Max load to be conveyed
(60E)
Former part number
Mechanical brake version
POP-UP SERIES
TECHNICAL DOCUMENTATION
3
Dated 21/07/2016
2. PRESENTATION OF «POP-UP»
Itoh-Denki Pop-Up transfer modules use 24V DC Brushless Motorized Roller technology in a very compact «
cassette » structure. This makes it easy to integrate into both new and reconditioned conveyors. It can be used
on conveyor lines for order picking, distribution or on assembly lines to adapt to your logistics changes.
STRUCTURE
Size D, transfer left
Motorized roller
for diverter (M2)
Motorized roller
for lifting (M3)
Diverter wheel
Protective cover
l
Motorized roller for
straight conveyor (M1)
L
Free roller
Circuit boards
Ribbed belt
CBR-305
CBM-105
OPERATING PRINCIPLE
This diverter module works with three
brushless motorized rollers, at very low
voltage (24 V DC), without pneumatic or
other types of energy.
The transfer works using the up and down
PRYHPHQW RI WKH ZKHHO GHÀHFWRU 1R PRUH
than two motors function at any one time,
and don’t exceed 147W in nominal operation.
Rollers
Diverter wheels raised
Diverter wheels
Diverter wheels lowered
BOTTOM SURFACE OF LOAD TO BE CONVEYED
7KH³SRSXS´WUDQVIHUFDVVHWWHLVGHVLJQHGIRUÀDWERWWRPHGSDFNDJHVZLWKRXWHGJHVRUJURRYHV
POP-UP SERIES
TECHNICAL DOCUMENTATION
4
Dated 21/07/2016
GENERAL TECHNICAL DATA
Size
Width W (mm)
Dimension WxLxH (mm)
A
B
C
D
394
494
594
694
600
700
500x650
600x650
18
24
760
Length L (mm)
169
Height H (mm)
Frame width mini (mm)
Load dimensions WxL (mm)
400
500
Mini
Max.
300x300
300x650
400x650
Max load to be conveyed (Kg)
30
1XPEHURIGLYHUWHUZKHHOV
14
18
1XPEHURIWUDQVIHUIUHHUROOHUV
7
Transfer angle
45° (30° option)
Transfer direction
Right or left (to be specify on order)
Weight (Kg)
Protective cover
46
Protected as standard
Lower face
To be planned
To be planned
Level difference transfer wheel-roller (mm)
3
Zinc-coated steel
Frame
ø50mm / Zinc-coated steel
Roller
Cable length (mm)
50mm for M1 and 100 mm for M2 and M3
Connector
JST 9p male
Circuit board for straight
conveyor and diverter
CBM-105-FP1-EU1
Circuit board for lifting
CBR-305FP-B
313QRUPDOO\RSHQFRQWDFW9'&12
Proximity sensor
Power supply
Absorbed power
Dimensions (mm)
ø39,5
Material/hardness
Polyurethane 90ShA
Voltage
24VDC ± 10%
On motor start-up
192W max
1RPLQDO
147W max
Ambient temperature
Environment
Protection rating
0 to 40°C
Humidity
”UHODWLYHKXPLGLW\ZLWKRXWFRQGHQVDWLRQ
Vibration
”*
Motorized roller
IP54
IP20
Circuit board
Extension cable (motorized roller - circuit board)
Mounting support
24VDC supply unit
Accessories (Optional)
POP-UP SERIES
54
Straight conveyor: 60m/min max (adjustable)
Diverter 45° : 90m/min max (adjustable)
Speed
Diverter wheels
51
Upper face
Lateral faces
Motorized rollers
49
TECHNICAL DOCUMENTATION
5
Dated 21/07/2016
3. TRANSFER CAPACITY
SPEED AND RATE OF LOAD TRANSFER, ZONE BY ZONE, IN SINGULATION MODE
Plastic box
Diverter angle : 45°
Straight transfer speed : 60m/min
Divert transfer speed 45° : 90m/min
Load 600x390mm
5000
t1
Package throughput / hour
4000
t0
3000
5kg
30kg
2000
1000
t2
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
Transfer rate (%) = t1 x 100
t0
Load 450x370mm
5000
Transfer capacity depends on
dimension, bottom surface and material
of the transported load, as well as speed,
transfer mode, transfer rate...
These curves are given as a guide.
Package throughput / hour
4000
3000
5kg
30kg
2000
1000
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
Load 360x360mm
5000
Package throughput / hour
4000
3000
5kg
30kg
2000
1000
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
POP-UP SERIES
TECHNICAL DOCUMENTATION
6
Dated 21/07/2016
Load 600x390mm
t1
t0
5000
4000
Package throughput / hour
Cardboard box
Diverter angle : 45°
Straight transfer speed : 60m/min
Divert transfer speed 45° : 90m/min
3000
5kg
30kg
2000
1000
0
t2
0%
20%
40%
60%
80%
100%
Transfer rate (%)
Transfer rate (%) = t1 x 100
t0
Load 450x370mm
5000
Transfer capacity depends on
dimension, bottom surface and material
of the transported load, as well as speed,
transfer mode, transfer rate...
These curves are given as a guide.
Package throughput / hour
4000
3000
5kg
30kg
2000
1000
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
Load 360x360mm
5000
Package throughput / hour
4000
3000
5kg
30kg
2000
1000
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
POP-UP SERIES
TECHNICAL DOCUMENTATION
7
Dated 21/07/2016
SPEED AND RATE OF LOAD TRANSFER IN TRAIN MODE
Plastic box
Diverter angle : 45°
Straight transfer speed : 60m/min
Divert transfer speed 45° : 90m/min
Load 600x390mm
5000
t1
Package throughput / hour
4000
t0
3000
5kg
30kg
2000
1000
t2
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
Transfer rate (%) = t1 x 100
t0
Load 450x370mm
5000
Transfer capacity depends on
dimension, bottom surface and material
of the transported load, as well as speed,
transfer mode, transfer rate...
These curves are given as a guide.
Package throughput / hour
4000
3000
5kg
30kg
2000
1000
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
Load 360x360mm
5000
Package throughput / hour
4000
3000
5kg
30kg
2000
1000
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
POP-UP SERIES
TECHNICAL DOCUMENTATION
8
Dated 21/07/2016
Load 600x390mm
t1
t0
5000
4000
Package throughput / hour
Cardboard box
Diverter angle : 45°
Straight transfer speed : 60m/min
Divert transfer speed 45° : 90m/min
3000
5kg
30kg
2000
1000
0
t2
0%
20%
40%
60%
80%
100%
Transfer rate (%)
Load 450x370mm
Transfer rate (%) = t1 x 100
t0
5000
Transfer capacity depends on
dimension, bottom surface and material
of the transported load, as well as speed,
transfer mode, transfer rate...
These curves are given as a guide.
Package throughput / hour
4000
3000
5kg
30kg
2000
1000
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
Load 360x360mm
5000
Package throughput / hour
4000
3000
5kg
30kg
2000
1000
0
0%
20%
40%
60%
80%
100%
Transfer rate (%)
POP-UP SERIES
TECHNICAL DOCUMENTATION
9
Dated 21/07/2016
4. INSTALLATION OF THE MODULE
ASSEMBLY PRINCIPLE
Width (W)
7KHFDVVHWWHW\SHVWUXFWXUHLVLQVHUWHGEHWZHHQWKHFRQYH\RUIUDPHDQG¿[HGWRWZREUDFNHWVZLWKWKHDLGRI
four M8 screws.
Optional mounting supports are available on request.
Support
Diverter wheel
M1
Roller of
staright conveyor
51.5
114
44.5
3
4×2 - ̨10
Cassette mounting hole
44.5
Support optional
40
2×4-M8
Support mounting hole
44.5
671
M2
M3
Support
760
The level of the straight conveyor, before and after the “pop-up”, should be aligned with the straight conveyor roller.
7KHOHYHORIWKHDQJOHGFRQYH\RUVKRXOGEHDOLJQHGZLWKWKHGHÀHFWRUUROOHU
The lateral and lower parts of the transfer cassette
are unprotected against mechanical risks. Appropriate
protection should be applied depending on the
structure and environment in which it will be installed
and in accordance with local security regulations.
Integration of the “pop-up” transfer cassette should be designed in order to enable easy insertion/extraction for
maintenance purposes.
3 circuit board for the motorized rollers should be placed near the cassette with extension leads as required.
POP-UP SERIES
TECHNICAL DOCUMENTATION
10
Dated 21/07/2016
DIMENSIONS
Size A - Transfer to left
L 760
67
63
21
Proximity sensor
Mounting position
2-250
100
Output cable M2 for diverter
(100mm)
44.5
Mounting holes
(4 - Ø8,4mm)
Output cable M3 for lifting
(100mm)
44.5
100
Level difference
between wheels
and rollers 3
Mounting position 2-671
94x6(=564)
8
3
7-∅
∅5
169
0
Distance between level of
transfer and support
01,4
W 394
Output sensor cable
(50mm)
Distance inside the frame
Nominal width 400
Output cable M1 for
straight conveyor
(100mm)
M2
for diverter
M1 for
straight conveyor
M3 for lifting
Size A - Transfer to right
L 760
Output cable M2 for diverter
(100mm)
Mounting position
2-250
Output cable M1 for
straight conveyor
(100mm)
21
67
63
Output
sensor cable
(50mm)
Proximity sensor
94x6(=564)
100
38
7-∅
∅5
169
0
Level difference
between wheels
and rollers 3
Mounting position 2-671
Distance between level of
transfer and support
101,4
44.5
44.5
Distance inside the frame
Nominal width 400
Mounting holes
(4 - Ø8,4mm)
100
Ｗ394
Output cable M3 for lifting
(100mm)
M2
for diverter
POP-UP SERIES
M3 for lifting
M1 for
straight conveyor
TECHNICAL DOCUMENTATION
11
Dated 21/07/2016
Size B - Transfer to left
L 760
Output cable M1 for
straight conveyor
(100mm)
75
63
67
21
Proximity sensor
44.5
Mounting holes
(4 - Ø8,4mm)
Output cable M3 for lifting
(100mm)
44.5
100
Level difference
between wheels
and rollers 3
Mounting position 2-671
94x6(=564)
8
3
7-∅
∅5
169
0
Distance between level of
transfer and support
101,4
Output cable M2 for diverter
(100mm)
Distance inside the frame
Nominal width 500
100
W 494
Mounting position
2-350
Output sensor cable
(50mm)
M2
for diverter
M1 for
straight conveyor
M3 for lifting
Size B - Transfer to right
L 760
Output cable M2 for diverter
(100mm)
Mounting position
2-350
8
3
7-∅
169
0
Level difference
between wheels
and rollers 3
94x6(=564)
100
∅5
75
63
21
Proximity sensor
Mounting position 2-671
Distance between level of
transfer and support
101,4
Ｗ 494
44.5
67
Output
sensor cable
(50mm)
Output cable M1 for
straight conveyor
(100mm)
44.5
Distance inside the frame
Nominal width 500
Mounting holes
(4 - Ø8,4mm)
100
Output cable M3 for lifting
(100mm)
M2
for diverter
POP-UP SERIES
M3 for lifting
M1 for
straight conveyor
TECHNICAL DOCUMENTATION
12
Dated 21/07/2016
Size C - Transfer to left
L 760
75
63
67
21
Proximity sensor
Output cable M1 for
straight conveyor
(100mm)
Distance inside the frame
Nominal width 600
132
W 594
Mounting position
2-450
Output sensor cable
(50mm)
44.5
Mounting holes
(4 - Ø8,4mm)
Output cable M3 for lifting
(100mm)
44.5
100
Level difference
between wheels
and rollers 3
Mounting position 2-671
94x6(=564)
38
∅5
7-∅
169
0
Distance between level of
transfer and support
101,4
Output cable M2 for diverter
(100mm)
M2
for diverter
M1 for
straight conveyor
Size C - Transfer to right
M3 for lifting
L 760
Output cable M2 for diverter
(100mm)
W 594
169
Distance between level of
transfer and support
101,4
8
3
7-∅
0
75
63
94x6(=564)
100
∅5
Level difference
between wheels
and rollers 3
21
Proximity sensor
Mounting position 2-671
44.5
67
Output
sensor cable
(50mm)
Output cable M1 for
straight conveyor
(100mm)
44.5
Distance inside the frame
Nominal width 600
Mounting holes
(4 - Ø8,4mm)
Mounting position
2-450
Output cable M3 for lifting
(100mm)
M2
for diverter
POP-UP SERIES
M3 for lifting
M1 for
straight conveyor
TECHNICAL DOCUMENTATION
13
Dated 21/07/2016
Size D - Transfer to left
L 760
75
67
63
21
Proximity sensor
Output cable M1 for
straight conveyor
(100mm)
Distance inside the frame
Nominal width 700
120
W 694
Mounting position
2-550
Output sensor cable
(50mm)
100
94x6(=564)
∅38
∅5
7-
169
0
Distance between level of
transfer and support
101,4
44.5
Mounting holes
(4 - Ø8,4mm)
Output cable M3 for lifting
(100mm)
Level difference
between wheels
and rollers 3
Output cable M2 for diverter
(100mm)
Mounting position 2-671
44.5
M2
for diverter
M1 for
straight conveyor
M3 for lifting
Size D - Transfer to right
L 760
Mounting holes
(4 - Ø8,4mm)
Output cable M2 for diverter
(100mm)
38
7-∅
75
169
0
Distance between level of
transfer and support
101,4
63
94x6(=564)
100
∅5
Proximity sensor
Level difference
between wheels
and rollers 3
21
Mounting position 2-671
44.5
67
Output
sensor cable
(50mm)
Output cable M1 for
straight conveyor
(100mm)
44.5
Distance inside the frame
Nominal width 700
W 694
Mounting position
2-550
120
Output cable M3 for lifting
(100mm)
M2
for diverter
POP-UP SERIES
M3 for lifting
TECHNICAL DOCUMENTATION
M1 for
straight conveyor
14
Dated 21/07/2016
CIRCUIT BOARD DIMENSIONS
78
38.5
47
4.5
4.5
0V
24V
3
23
23
3
5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN
40
7 8
ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. SV-BRK
6. N/P-OUT
VR1-ACC
VR2-DEC
4.5
52
18
78
18
9 0 1
90 1
456
47
SPEED
23
38.5
M3：昇降用
0V
24V
23
90 1
CBR-305
5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN
40
7 8
STATUS/ERR/PWR
1. SPEED L / H
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. N/P-OUT
VR1-ACC
901
2 3
VR2-DEC
SPEED
456
4.5
129
120
23
52
129
120
456
CBM-105
CBR-305
456
CBM-105
POP-UP SERIES
TECHNICAL DOCUMENTATION
15
Dated 21/07/2016
5. POP-UP CONTROL
TIMING PRINCIPAL FOR CONTROLS
SN･R
5
Sensor 4
Sensor 3
4
1
2
SN･S
3
Sensor 0
M1
C/V
M2
Sensor 6
Sensor 1
M3
Sensor 5
Sensor 2
TIMETABLE
༃
PLC
IN
Sensor 0
IN
Sensor 1
IN
Sensor 2
IN
Sensor 3
OUT
Motorized roller for
straight conveyor (M1)
OUT
Motorized roller for
diverter (M2)
OUT
Motorized
roller for
ůŝŌŝŶŐ
(M3)
༄
༅
༆
༇
RUN
DIR
IN
Proximity sensor
for diverter
in lower posiƟon SN-S
IN
Proximity sensor
for diverter
in upper posiƟon SN-R
Warning : ч 0,03s
Warning : ч 0,03s
:DUQLQJWKHWUDQVPLVVLRQWLPHIRUWKHVWRSVLJQDOVKRXOGEH¿[HGDWOHVVWKDQVHFRQGVIROORZLQJGHWHFWLRQRI
VHQVRU616DQG615
PRINCIPLE CONTROL BY PLC
POP-UP
Motorized roller for
straight conveyor M1
Motorized roller for
diverter M2
Motorized roller for
lifting M3
Straight conveyor
Sensor for diverter
can be operated
in lower position SN-S
when "ON"
Sensor for diverter
Diverter can be
operated when "ON" in upper position SN-R
POP-UP SERIES
OUT
M1
CBM-105
M2
CBM-105
OUT
OUT
TECHNICAL DOCUMENTATION
CBR-305
IN
CN2-1
Sensor 0
CN2-1
Sensor 1
CN2-1
M3
PLC
CN2-2
Signal «RUN» for
upstream conveyor
Signal «RUN» for
diverter
Sensor 2
Sensor 3
Sensor 4
Sensor 5
Sensor 6
Signal «RUN» for
straight conveyor
16
Dated 21/07/2016
CONNECTION OF CIRCUIT BOARDS CBM105 / CBR305
M1
M3
SN-S
SN-R
*
*2
7 8
78
23
456
VR2
3 4
7 8
VR1-ACC
VR2-DEC
ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. SV-BRK
6. N/P-OUT
78
78
SPEED L / H
4 5 6
901
LED1
LED2
ACC
2
CN1
*1 Sensor extension cable (not provided)
*2 Motorized roller extension cable (optional)
9 0 1
2 3
CBM-105
M2
1
0V
24V
SW2
CN2
CBM-105FP1-EU1
VR1
9 0 1
90 1
M3
456
SW1
SPEED
6
4 5 6
DEC
M3：昇降用
5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN
23
VR2
3 4
23
ACC
2
1
CN1
901
LED2
VR1
2 3
7 8
9 0 1
CBR-305F□-B
2 3
SPEED L / H
CN3
LED1
M1
CN3
CN2
CBM-105FP1-EU1
CBM-105
PM500FE series
Speed code 17
2
CN2
CN3
PM500FC series
Speed code 90
45
*11
*
456
*
M2
PM500FE series
2
DEC
SW1
CN1
SW2
Extension leads for the sensor and drive rollers should be placed in relation to the control panels, PLC, …
Max motor cable length must not exceed 3m (i.e. motor cable + optional extension cable)
D313YHUVLRQ&%0&%5
D131YHUVLRQ&%0&%5
&1
▶
▶
◀
◀
◀
&1
Pulse signal
Error signal
Speed variation (0~10V)
Direction of rotation
Start / Stop
Pulse signal
Error signal
◀
◀
Direction of rotation
Start / Stop
0 VDC
0 VDC
24 VDC
24 VDC
&1
POP-UP SERIES
▶
▶
TECHNICAL DOCUMENTATION
&1
17
Dated 21/07/2016
PARAMETERS SETTINGS
7 8
ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. SV-BRK
6. N/P-OUT
VR1-ACC
7 8
78
18
78
0V
24V
23
456
VR2 SW1
9 0 1
90 1
23
VR1
VR2-DEC
STATUS/ERR/PWR
1. SPEED L / H
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. N/P-OUT
0V
24V
5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN
SPEED
456
VR1-ACC
M3：昇降用
2 3
23
VR2-DEC
901
90 1
18
CBR-305FP-B
5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN
SPEED
456
CBM-105
Circuit board for M3
456
Circuit board for M1 and M2
SW2
VR1
VR2 SW1
SW2
Ɣ TRANSFER TO LEFT
Acceleration /
Deceleration
VR1
VR2
for straight conveyor
Output error
signal
SW1-3
1
SW1-1
ON
2
3
4
SW1-3
SW2
ON
901
78
1
2
3
4
5
SW1-3
VR1
SW1-6 / NPN
SW2
VR2
6
for lifting
1
2
3
4
5
OFF
SW1-6 / PNP
ON
6
901
23
M3
OFF
78
t2
456
for diverter
t0
23
t1
M2
VR2
SW1-2
OFF
5
OFF
VR1
Selection
fixed speed
456
M1
Direction of
rotation
Do not change.
Ɣ TRANSFER TO RIGHT
Acceleration /
Deceleration
VR1
VR2
for straight conveyor
Output error
signal
SW1-3
1
SW1-1
ON
2
3
4
SW1-3
SW2
ON
901
78
for diverter
1
2
3
4
5
SW1-6 / NPN
SW2
VR2
6
OFF
1
2
3
OFF
4
5
SW1-6 / PNP
ON
6
POP-UP SERIES
TECHNICAL DOCUMENTATION
18
901
23
M3
for lifting
78
t1
SW1-3
VR1
456
M2
VR2
23
t2
VR1
SW1-2
OFF
5
OFF
t0
Selection
fixed speed
456
M1
Direction of
rotation
Do not change.
Dated 21/07/2016
Change of direction of rotationPMdepending
on the transfer direction
500 FE (50E) - PM 605 FE (60E)
2
3
4
5
3
6
12 3 45
1
5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN
0V
24V
1 2
ON
SW1
Circuit boards characteristics
CBM-105 + PM500FE / FC
Power supply
CBR-305 + PM500FE
24 V DC ±10%
Nominal voltage
24 V DC
static
Intensity
0,03 A
nominal
2,9 A / 3,2 A
2,9 A
start-up
4,0 A
Connector 24V CN1
WRPP$:*a:$*2
Control connector CN2
WRPP$:*a:$*2
Cable dimension
Time difference between the ON signal and the
motor start
Less than 15ms
Fuse 6,3A
Electrical protection
Fuse7A
Diode against wiring fault
95°C for circuit board
Thermal protection
105°C for motor
Current Limiter
4,0A
Ambient temperature
0 to 40°C
Humidity
Lower than 90 % relative humidity without condensation
Atmosphere
1RFRUURVLYHJDV
Vibrations
/HVVWKDQ*
Installation
Inside
1$
Automatic stop function
After 10 pulses
CBM-105 + PM500FE / FC (M1 and M2)
Connector CN2
1
Start / Stop
RUN/
STOP
2
Rotation
direction
CW/CCW
DIR
3
Speed
variation
0-10V
4
Error mode
CBR305 + PM500FE (M3)
Start up and stop motorized roller
Input current 7.3mA at 24V
Start : close contact
Stop : open contact
Start up and stop motorized roller
Input current 13mA at 24V
Start : close contact
Stop : open contact
Reverse direction of rotation of motorized roller
Input current7.3mAat 24V
Reverse direction of rotation of motorized roller
Input current 13mA at 24V
Speed variation by external analog voltage 0-10V on
WHUPLQDORIFRQQHFWRU&1
Do not use
Output error signal (open collector)
ERROR Output 24V, 25mA maxi (adjust according to the control system with a resistance not included)
3URWHFWLRQZLWKUHVLVWDQFHRIȍ
5
Pulse
PULSE
POP-UP SERIES
2XWSXWSXOVHVLJQDO131VLJQDOE\RSHQFROOHFWRUVLJQDO131E\DQRSHQFROOHFWRUIRUDGMXVWLQJWKHRXWSXW
voltage to 24V maxi and 25mA maxi (with a resistance and external power supply not provided)
3URWHFWLRQZLWKDUHVLVWDQFHRIȍ
TECHNICAL DOCUMENTATION
19
Dated 21/07/2016
Setting of speed motorized roller for straight conveyor (M1) and motorized roller for
diverter (M2)
By SW1 and SW2 on circuit board CBM105-FP1-EU1
Do not change speed of motorized roller for lifting (M3)
SELECTION OF NOMINAL FIXED SPEED
6
6:21
7 8
6
5
5
4
7 8
6
3
1
SW2
2
3
4
5
6
5
2
2 3 4
1
+
2 3 4
+
9 0 1
9 0 1
SW2
SW1 (1 - OFF)
SW2
Code 60 (M1)
Code 90 (M2)
SW2
Code 60 (M1)
Code 90 (M2)
9
53,5
90,2
9
30,9
51,6
8
53,5
90,2
8
28,3
47,2
7
53,5
90,2
7
25,7
42,9
6
51,4
85,8
6
23,1
38,5
5
47,3
81,5
5
20,6
34,4
4
46,3
77,4
4
18
30,2
3
41,1
68,6
3
15,4
25,8
2
38,6
64,4
2
12,9
21,5
1
26
60,0
1
10,3
17,1
0
33,4
55,9
0
7,7
12,8
Connection and characteristic of sensors SN-R and SN-S
Model
GX-F12A-P (PANASONIC)
Supply voltage
12~24 VDC +10-15%
Absorbed power
”P$
Output signal
Power max : 100mA
Open collector
313QRUPDO\RSHQFRQWDFW12
Brown : 24VDC
Blue : 0VDC
Black : OUT
POP-UP SERIES
TECHNICAL DOCUMENTATION
20
Dated 21/07/2016
6. ELEMENTS REPLACEMENT
REPLACEMENT OF FREE ROLLER, BELT AND MOTORIZED ROLLER (M1) FOR STRAIGHT
CONVEYOR
Mounting
screws
Shaft fixation
plate
Loosen the screws and remove the plate that holds the
axles for the motorized and free rollers in place in order
to remove and change elements of the straight conveyor
Motorized roller
for straight conveyor
Ribbed belt
③
Spring shaft
Free roller
④
①
②
REPLACEMENT OF WHEEL DIVERTER
Wheel
,Q RUGHU WR FKDQJH WKH UROOHU ZKHHO ¿UVW UHPRYH WKH
motorized roller and/or free roller.
Cover
protection
Please read the installation and maintenance booklet for
full details.
Wheel
POP-UP SERIES
TECHNICAL DOCUMENTATION
1H[WUHPRYHWKHSURWHFWLYHFRYHUWRDFFHVVDQGUHSODFH
the worn roller wheel
21
Dated 21/07/2016
REPLACEMENT OF ROUND BELTS FOR DRIVING DIVERTER WHEELS
Cables
Motorized roller M1
Screw M8
Straight
conveyor
7RFKDQJHWKHEHOWV¿UVWUHPRYHWKHXSSHUSDUWRIWKH³SRSXS´
(straight conveyor), then remove the protective cover.
1H[WORRVHQWKHVFUHZDQGPRYHWKHGULYHUROOHUDQGRUIUHHUROOHU
to one side in order to change the round belts.
Cover protection
Please read the installation and maintenance booklet for full
details.
POP-UP SERIES
TECHNICAL DOCUMENTATION
22
Dated 21/07/2016
7. PRODUCT REFERENCES AND ACCESSOIRIES
REFERENCES FOR STANDARD POP-UP
Size
Evacuation left
Evacuation right
A
PUP-45L60P-A-F000
PUP-45R60P-A-F000
B
PUP-45L60P-B-F000
PUP-45R60P-B-F000
C
PUP-45L60P-C-F000
PUP-45R60P-C-F000
D
PUP-45L60P-D-F000
PUP-45R60P-D-F000
PUP – [ 1 ] [ 2 ] [ 3 ] [ 4 ] - [ 5 ] - [ 6] [ 7 ]
[ 1 ] DEVIATION ANGLE
45° … 45° (30° … 30° option)
[ 2 ] DIRECTION OF EVACUATION
L … Evacuation left
R … Evacuation right
[ 3 ] STRAIGHT CONVEYOR SPEED
60 ... Speed code 60 (60m/min)
[ 4 ] PROXIMITY SENSOR LOGIC
1131
3313
[ 5 ] SIZE
A … W 394 x L 760 mm
B … W 494 x L 760 mm
C … W 594 x L 760 mm
D … W 694 x L 760 mm
Example :
PUP-45L60P-B-F00
[ 6 ] TYPE OF MOTORIZED ROLLER
F ... PM500FE serie
(Angle 45°, evacuation left,
Speed code 60m/min, PNP, 494x760mm,
motorized roller PM500FE, index 0).
[ 7] INDEX VARIANT
0 ... STANDARD
1 ...
....
LIST OF ACCESSORIES
Optional mounting support
Size
A
Dimension
BF
A
Number of
support
Reference
400
250
2
PUP-SUP-A
B
500
350
2
PUP-SUP-B
C
600
450
2
PUP-SUP-C
D
700
550
2
PUP-SUP-D
POP-UP SERIES
TECHNICAL DOCUMENTATION
23
Dated 21/07/2016
24 VDC power supply
Reference
Input
CT-10-241
QT-20-241
380~480V
3 ph
QT-40-241
Output
Power
Start-up boost
24V-10A
240W
120%
24V-20A
480W
150%
24V-40A
960W
150%
- Very low inrush current.
- Can accomodate over current of 120 to 150% at startup (according to model)
Extension cable for motorized rollers (optional)
Male side
Cable length (mm)
Female side
Reference
600
ACE-CBM-B0600
1200
ACE-CBM-B1200
60 ±5
37
L
Max motor cable length must not exceed 3m (i.e. motor cable + optional extension cable)
Wear parts and frequency change
Round belt (1)
Diverter wheel (4)
Motorized roller
for straight conveyor
Ribbed belt (2)
Reference
Frequency*
MXP5-04/87F
L=260mm
5 millions
1
Round belt
2
3
Ribbed belt for
straight conveyor
3PJ316
4
Diverter wheel
POP-D-ROL
2PJ286
10 millions
5 millions
* The frequency of change in number of packages processed is given as an indication.
Ribbed belt (3)
List of components (excluding wear parts)
Motorized roller
Size A
Size B
Size C
Size D
M1 (straight conveyor)
30)(;3&1
30)(;3&1
30)(;3&1
30)(;3&1
M2 (diverter)
30)&;3'1
30)&;3'1
30)&;3'1
30)&;3'1
M3 (lifting)
30)(;3/1
30)(;3/1
30)(;3/1
30)(;3/1
Free roller
)5,';961
)5,';961
)5,';961
)5,';961
Circuit board of motorized rollers
PNP logic
M1 and M2
CBM-105FP1-EU1
M3
CBR-305FP-B
*;)$33$1$621,&
Proximity sensor SN-S and SN-R
POP-UP SERIES
TECHNICAL DOCUMENTATION
24
Dated 21/07/2016
ANNEX 1
DECLARATION OF INCORPORATION
in accordance with the EC Machinery Directive 2006/42/EC, Annex II B
The manufacturer:
,72+'(1.,&2/WG
1146-2 Asazuma-Cho, Kasai, Hyogo 679-0180 Japan
Distributed in Europe by :
,72+'(1.,(XURSH6$6
490 avenue des Jourdies - ZAE les Jourdies - BP 323
74807 St Pierre en Faucigny Cedex - France
hereby declares that the product series :
POP-UP
LVDQLQFRPSOHWHPDFKLQHDVGH¿QHGLQWKH(&0DFKLQHU\'LUHFWLYHDQGWKHUHIRUHGRHVQRWIXOO\PHHW
the requirements of this Directive. Commissioning is prohibited until the whole machine/system in
which it is incorporated is declared to be in compliance with the EC Machinery Directive
The health and safety requirements of Annex I have been applied. The special technical documents in
accordance with Annex VII have been drawn up (and, if appropriate, submitted to the competent authorities).
Person authorized to compile the technical documentation :
,72+'(1.,&2/WG
7RVKL\XNL7$&+,%$1$
1146-2 Asazuma-Cho, Kasai, Hyogo 679-0180 Japan
EC Directives applied :
• Machinery Directive 2006/42/EC
• European EMC Directive 2004/108/EC
• European RoHS Directive 2011/65/EU
6DLQW3LHUUHHQ)DXFLJQ\1RYHPEHU
K. TAMURA, Managing Director
POP-UP SERIES
TECHNICAL DOCUMENTATION
25
Dated 21/07/2016
ITOH DENKI EUROPE S.A.S.
ITOH DENKI
GREAT BRITAIN
ITOH DENKI
GERMANY
490 Av. des Jourdies
Z.A.E. les Jourdies
74800 St Pierre en Faucigny - France
Tél. : +33 (0)4 50 03 09 99
Fax : +33 (0)4 50 03 07 60
E-mail : info@itoh-denki.com
Suite 1 Trinity Space Centre
Waldorf Way
:DNH¿HOG:)'+8.
Tel : +44 (0)1924 366 539
Fax : +33 (0)4 50 03 07 60
E-mail : info@itoh-denki.com
1HXPH\HUVWUDEH
1h51%(5*'HXWVFKODQG
Tel : +49 911 25 26 - 200
Fax : +49 911 25 26 - 201
E-mail : info@itoh-denki.de
26
WWW.ITOH-DENKI.COM